SM D65ex PX WX 16 Komatsu PDF

SEN04887-09
BULLDOZER D65EX -16

D65PX -16
D65WX -16
D65EX- 80001
SERIAL NUMBERS D65PX- 80001 and up
D65WX- 80001
SEN04931-09
BULLDOZER
D65EX-16
D65PX-16
D65WX-16
Machine model Serial number

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
00 Index and foreword 00
100 Index
Composition of shop manual..................................................................................................................................2
Table of contents .....................................................................................................................................................4
D65EX, PX, WX-16 00-100 1

100 Index
SEN04931-09 Composition of shop manual
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04887-09
00 Index and foreword .................................................................................................................... SEN04923-09

100 Index .................................................................................................................................. SEN04931-09 q
200 Foreword and general information ..................................................................................... SEN04932-01
01 General ...................................................................................................................................... SEN04924-02

100 Specification and technical data......................................................................................... SEN04933-02 q
10 Structure, function and maintenance standard........................................................................... SEN04925-04

100 Engine and cooling system ................................................................................................ SEN04963-01 q
201 Power train, Part 1 ............................................................................................................. SEN04964-01 q
202 Power train, Part 2 ............................................................................................................. SEN04965-01
300 Undercarriage and frame ................................................................................................... SEN04966-02
401 Hydraulic system, Part 1 .................................................................................................... SEN04967-00
500 Work equipment................................................................................................................. SEN04970-01 q
600 Cab and its attachments .................................................................................................... SEN04971-02 q
700 Electrical system ................................................................................................................ SEN04972-02 q
20 Standard value table................................................................................................................... SEN04926-01

100 Standard service value table.............................................................................................. SEN05118-01
30 Testing and adjusting ................................................................................................................. SEN04927-04

101 Testing and adjusting, Part 1.............................................................................................. SEN05119-02
40 Troubleshooting.......................................................................................................................... SEN04928-03
100 Failure code table and fuse locations ................................................................................ SEN05029-01
200 General information on troubleshooting............................................................................. SEN05030-01
301 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN05031-00
00-100 2 D65EX, PX, WX-16

100 Index
Composition of shop manual SEN04931-09
305 Troubleshooting by failure code (Display of code), Part 5..................................................SEN05035-01

306 Troubleshooting by failure code (Display of code), Part 6..................................................SEN05036-01
400 Troubleshooting of electrical system (E-mode) ..................................................................SEN05037-01
500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN05038-00
600 Troubleshooting of engine (S-mode) ..................................................................................SEN05039-00
50 Disassembly and assembly ........................................................................................................SEN04929-04

100 General information on disassembly and assembly........................................................... SEN05110-01
200 Engine and cooling system ................................................................................................ SEN05111-01 q
300 Power train .........................................................................................................................SEN05112-02 q
400 Undercarriage and frame ................................................................................................... SEN05113-02
500 Hydraulic system ................................................................................................................SEN05114-00
600 Work equipment .................................................................................................................SEN05115-00
700 Cab and its attachments.....................................................................................................SEN05116-01
800 Electrical system ................................................................................................................SEN05117-00
80 Appendix.....................................................................................................................................SEN05040-00
100 Air conditioner ....................................................................................................................SEN05041-00
90 Diagrams and drawings ..............................................................................................................SEN04930-03

100 Hydraulic diagrams and drawings ......................................................................................SEN04934-01 q
200 Electrical diagrams and drawings.......................................................................................SEN04935-03 q
D65EX, PX, WX-16 00-100 3

100 Index
SEN04931-09 Table of contents
Table of contents 1
00 Index and foreword

100 Index ..........................................................................................................................................SEN04931-09
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information .............................................................................................SEN04932-01
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code ...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 General
100 Specification and technical data.................................................................................................SEN04933-02
Specification dimension drawing ................................................................................................................... 2
Specifications ................................................................................................................................................ 6
Weight table .................................................................................................................................................. 18
Table of fuel, coolant and lubricants.............................................................................................................. 22
10 Structure, function and maintenance standard

100 Engine and cooling system ........................................................................................................SEN04963-01
Engine mount ................................................................................................................................................ 3
Cooling system.............................................................................................................................................. 4
Cooling fan pump .......................................................................................................................................... 6
Cooling fan motor.......................................................................................................................................... 20
Coolant preheater (subextremely cold weather spec.).................................................................................. 26
201 Power train, Part 1 .....................................................................................................................SEN04964-01
Power train .................................................................................................................................................... 2
HSS system .................................................................................................................................................. 4
Overall view of power train unit ..................................................................................................................... 6
Power train hydraulic piping diagram ............................................................................................................ 10
Transmission, steering and brake control ..................................................................................................... 12
Damper ......................................................................................................................................................... 14
Universal joint................................................................................................................................................ 16
Torque converter and PTO ............................................................................................................................ 17
Transmission ................................................................................................................................................. 24
Transmission control valve............................................................................................................................ 42
ECMV............................................................................................................................................................ 46
Main relief and torque converter relief valve ................................................................................................. 54
Main relief and torque converter relief valve (subextremely cold weather spec.) ......................................... 56
Transmission lubrication relief valve ............................................................................................................. 58
202 Power train, Part 2 .....................................................................................................................SEN04965-01
Bevel gear shaft, HSS and brake.................................................................................................................. 2
Brake valve ................................................................................................................................................... 24
Final drive...................................................................................................................................................... 30
Final drive (Planetary gear installed inside of sprocket type) ........................................................................ 36
300 Undercarriage and frame ...........................................................................................................SEN04966-02
Main frame .................................................................................................................................................... 2
Suspension ................................................................................................................................................... 4
Track frame and idler cushion ....................................................................................................................... 14
Idler ............................................................................................................................................................... 18
00-100 4 D65EX, PX, WX-16

100 Index
Table of contents SEN04931-09
Idler (Without idler support automatic thrust adjustment) .............................................................................. 20

Carrier roller................................................................................................................................................... 26
Sprocket......................................................................................................................................................... 28
Track shoe ..................................................................................................................................................... 32
401 Hydraulic system, Part 1 ........................................................................................................... SEN04967-00
Work equipment hydraulic system layout drawing ........................................................................................ 2
Work equipment control................................................................................................................................. 6
Hydraulic tank and filter ................................................................................................................................. 8
Scavenging pump.......................................................................................................................................... 10
Power train and steering lubrication pump .................................................................................................... 11
HSS pump ..................................................................................................................................................... 12
HSS motor ..................................................................................................................................................... 31
Control valve.................................................................................................................................................. 2
CLSS ............................................................................................................................................................. 11
Function and operation of each valve............................................................................................................ 14
PPC valve (blade lift, blade tilt)...................................................................................................................... 2
PPC valve (ripper) ......................................................................................................................................... 8
Electric lever (steering).................................................................................................................................. 12
Quick drop valve............................................................................................................................................ 16
Work equipment lock solenoid valve ............................................................................................................. 18
Pitch selector solenoid valve ......................................................................................................................... 22
Hydraulic oil cooler bypass valve .................................................................................................................. 23
Accumulator................................................................................................................................................... 24
500 Work equipment ........................................................................................................................ SEN04970-01
Blade ............................................................................................................................................................. 2
Cutting edge and end bit ............................................................................................................................... 8
Ripper (Multi shank) ...................................................................................................................................... 10
Ripper (Single shank) .................................................................................................................................... 11
Hydraulic cylinder .......................................................................................................................................... 12
Piston valve ................................................................................................................................................... 15
600 Cab and its attachments............................................................................................................ SEN04971-02
Cab mount ..................................................................................................................................................... 2
Cab ................................................................................................................................................................ 3
Subextremely cold spec. cab (subextremely cold weather spec.)................................................................. 4
FRP canopy mount........................................................................................................................................ 5
FRP canopy................................................................................................................................................... 6
700 Electrical system ....................................................................................................................... SEN04972-02
Monitor system .............................................................................................................................................. 2
Engine control system ................................................................................................................................... 18
Cooling system control system...................................................................................................................... 21
Electronic steering control system................................................................................................................. 23
KOMTRAX system ........................................................................................................................................ 26
KOMTRAX terminal (for GPRS) .................................................................................................................... 28
System components ...................................................................................................................................... 29
Sensor ........................................................................................................................................................... 37
20 Standard value table

100 Standard service value table ..................................................................................................... SEN05118-01
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 4
30 Testing and adjusting

101 Testing and adjusting, Part 1 ..................................................................................................... SEN05119-02
Tools for testing, adjusting, and troubleshooting ........................................................................................... 2
D65EX, PX, WX-16 00-100 5

100 Index
Testing engine speed .................................................................................................................................... 5

Testing intake air pressure (boost pressure) ................................................................................................. 7
Testing exhaust temperature......................................................................................................................... 9
Testing exhaust gas color.............................................................................................................................. 11
Adjusting valve clearance ............................................................................................................................. 12
Testing compression pressure ...................................................................................................................... 14
Testing blow-by pressure .............................................................................................................................. 18
Testing engine oil pressure ........................................................................................................................... 19
Handling of fuel system devices.................................................................................................................... 20
Releasing residual pressure from fuel system .............................................................................................. 20
Testing fuel pressure ..................................................................................................................................... 21
Testing fuel return and leak amount .............................................................................................................. 26
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing fuel circuit for leakage....................................................................................................................... 29
Handling of reduced cylinder mode operation............................................................................................... 30
Handling of no injection cranking operation .................................................................................................. 30
Testing and adjusting air conditioner compressor belt tension...................................................................... 31
Replacing alternator belt ............................................................................................................................... 32
Adjusting fuel control dial and decelerator pedal .......................................................................................... 33
Handling controller high-voltage circuit ......................................................................................................... 34
102 Testing and adjusting, Part 2......................................................................................................SEN05120-02
Testing power train oil pressure .................................................................................................................... 3
Adjusting transmission output shaft speed sensor (replacement procedure) ............................................... 8
Simple test procedure for brake performance............................................................................................... 9
Adjusting brake pedal.................................................................................................................................... 10
Adjusting parking brake lever........................................................................................................................ 12
Emergency escape method when power train has trouble ........................................................................... 14
Adjusting clearance of idler ........................................................................................................................... 17
Adjusting clearance of idler (without idler support automatic thrust adjustment) .......................................... 18
Inspecting wear of sprocket .......................................................................................................................... 19
Testing and adjusting track shoe tension ...................................................................................................... 20
Testing and adjusting work equipment and HSS oil pressure ....................................................................... 21
Testing control circuit basic pressure ............................................................................................................ 24
Testing PPC valve output pressure ............................................................................................................... 25
Adjusting work equipment PPC valve play.................................................................................................... 27
Testing internal leakage of work equipment cylinder..................................................................................... 31
Bleeding air from work equipment cylinder ................................................................................................... 32
Releasing residual pressure from work equipment cylinder.......................................................................... 32
Checking parts which caused hydraulic drift of blade or ripper ..................................................................... 33
Adjusting work equipment lock lever............................................................................................................. 34
Adjusting work equipment lock lever (FRP canopy specification)................................................................. 35
Testing fan speed .......................................................................................................................................... 37
Testing fan circuit oil pressure....................................................................................................................... 38
Bleeding air from fan pump ........................................................................................................................... 39
Bleeding air from HSS pump......................................................................................................................... 40
Adjusting straight tiltdozer ............................................................................................................................. 41
Adjusting play of blade center ball ................................................................................................................ 43
Adjusting operator's cab................................................................................................................................ 44
Special functions of machine monitor (EMMS) ............................................................................................. 2
Handling of voltage circuit of engine controller ............................................................................................. 2
Adjustment method when controller has been replaced ............................................................................... 3
Preparation work for troubleshooting of electrical system............................................................................. 5
Inspection procedure of diode....................................................................................................................... 9
Pm-Clinic service .......................................................................................................................................... 10
00-100 6 D65EX, PX, WX-16

100 Index
40 Troubleshooting
100 Failure code table and fuse locations ........................................................................................ SEN05029-01
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 7
200General information on troubleshootingSEN05030-01

Points to remember when troubleshooting .................................................................................................... 2
How to proceed troubleshooting.................................................................................................................... 3
Checks before troubleshooting...................................................................................................................... 4
Classification and procedures for troubleshooting......................................................................................... 6
Symptom supposed to be failure and troubleshooting No............................................................................. 10
Information contained in troubleshooting table .............................................................................................. 12
Troubleshooting method for disconnecting wiring harness of pressure sensor system ................................ 14
Connector list and stereogram ...................................................................................................................... 16
Connection table for connector pin numbers................................................................................................. 30
T- branch box and T- branch adapter table ................................................................................................... 66
301 Troubleshooting by failure code (Display of code), Part 1......................................................... SEN05031-00
Failure code [1500L0] Transmission clutch: Abnormal.................................................................................. 3
Failure code [15SAL1] Forward clutch: Fill high ............................................................................................ 4
Failure code [15SALH] Forward clutch: Fill low............................................................................................. 6
Failure code [15SBL1] Reverse clutch: Fill high............................................................................................ 8
Failure code [15SBLH] Reverse clutch: Fill low............................................................................................. 10
Failure code [15SEL1] Speed 1st clutch: Fill high ......................................................................................... 12
Failure code [15SELH] Speed 1st clutch: Fill low .......................................................................................... 14
Failure code [15SFL1] Speed 2nd clutch: Fill high ........................................................................................ 16
Failure code [15SFLH] Speed 2nd clutch: Fill low ......................................................................................... 18
Failure code [15SGL1] Speed 3rd clutch: Fill high ........................................................................................ 20
Failure code [15SGLH] Speed 3rd clutch: Fill low ......................................................................................... 22
Failure code [15SJL1] L/U: Fill high............................................................................................................... 24
Failure code [15SJLH] L/U: Fill low ............................................................................................................... 26
Failure code [AB00MA] Battery Charge Abnormal ........................................................................................ 28
Failure code [B@BAZG] Eng Oil Press Low ................................................................................................. 30
Failure code [B@BCNS] Eng Water Overheat .............................................................................................. 30
Failure code [B@CENS] T/C Oil Overheat.................................................................................................... 31
Failure code [B@HANS] Hyd Oil Overheat ................................................................................................... 31
Failure code [CA111] ECM Critical Internal Failure ....................................................................................... 3
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 3
Failure code [CA122] Chg Air Press Sensor High Error................................................................................ 4
Failure code [CA123] Chg Air Press Sensor Low Error................................................................................. 6
Failure code [CA131] Throttle Sensor High Error.......................................................................................... 8
Failure code [CA132] Throttle Sensor Low Error........................................................................................... 10
Failure code [CA144] Coolant Temp Sens High Error ................................................................................... 12
Failure code [CA145] Coolant Temp Sens Low Error.................................................................................... 14
Failure code [CA153] Chg Air Temp Sensor High Error ................................................................................ 16
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................. 18
Failure code [CA155] Chg Air Temp High Speed Derate............................................................................... 20
Failure code [CA187] Sens Supply 2 Volt Low Error ..................................................................................... 22
Failure code [CA221] Ambient Press Sens High Error.................................................................................. 24
Failure code [CA222] Ambient Press Sens Low Error................................................................................... 26
Failure code [CA227] Sens Supply 2 Volt High Error .................................................................................... 28
Failure code [CA234] Eng Overspeed........................................................................................................... 28
Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................... 29
Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 30
Failure code [CA272] IMV/PCV1 Open Error ................................................................................................ 32
Failure code [CA281] Abnormal supply pump pressure balance .................................................................. 34
Failure code [CA322] Inj #1(L#1) Open/Short Error ...................................................................................... 36
D65EX, PX, WX-16 00-100 7

100 Index
Failure code [CA323] Inj #5(L#5) Open/Short Error...................................................................................... 38

303Troubleshooting by failure code (Display of code), Part 3 .............................................................SEN05033-01
Failure code [CA342] Calibration Code Incompatibility ................................................................................. 3
Failure code [CA351] Injectors Drive Circuit Error ........................................................................................ 3
Failure code [CA352] Sens Supply 1 Volt Low Error..................................................................................... 4
Failure code [CA386] Sens Supply 1 Volt High Error.................................................................................... 6
Failure code [CA428] Water in Fuel Sensor High Error ................................................................................ 8
Failure code [CA429] Water in Fuel Sensor Low Error ................................................................................. 10
Failure code [CA435] Eng Oil Press Sw Error .............................................................................................. 12
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 14
Failure code [CA442] Battery Voltage High Error.......................................................................................... 16
Failure code [CA449] Rail Press Very High Error ......................................................................................... 18
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 20
Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 22
Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................. 24
Failure code [CA553] Rail Press High Error.................................................................................................. 25
Failure code [CA559] Rail Press Low Error .................................................................................................. 26
Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 32
Failure code [CA757] All Continuous Data Lost Error................................................................................... 33
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 34
Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 37
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 38
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 40
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 42
Failure code [CA2265] Fuel Feed Pump Open Error .................................................................................... 44
Failure code [CA2266] Fuel Feed Pump Short Error .................................................................................... 46
Failure code [CA2311] IMV Solenoid Error ................................................................................................... 47
Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 48
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................................... 50
304 Troubleshooting by failure code (Display of code), Part 4 .........................................................SEN05034-01
Failure code [D110KB] Battery relay drive: Short circuit ............................................................................... 4
Failure code [D130KA] Neutral relay: Disconnection .................................................................................... 6
Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 8
Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 10
Failure code [D161KB] Back-up alarm relay: Short circuit ............................................................................ 12
Failure code [D862KA] GPS Antenna Open Circuit ...................................................................................... 14
Failure code [DAFRKR] CAN Disconnection ................................................................................................ 15
Failure code [DAFRMC] CAN Discon (Monitor Detected)............................................................................. 16
Failure code [DB2RKR] CAN Disconnection................................................................................................. 19
Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 24
Failure code [DBE1KK] Battery direct Source voltage reduction .................................................................. 26
Failure code [DBE2KK] Solenoid Source voltage reduction ......................................................................... 28
Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction .............................................................. 30
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction.................................................................. 32
Failure code [DBE9KQ] PT controller: Type select signal ............................................................................. 36
Failure code [DD12KA] Shift up Sw: Disconnection...................................................................................... 38
Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 40
Failure code [DD13KA] Shift down Sw: Disconnection ................................................................................. 42
Failure code [DD13KB] Shift down Sw: Short circuit..................................................................................... 44
Failure code [DD14KA] Parking lever Sw: Disconnection............................................................................. 46
Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 48
305 Troubleshooting by failure code (Display of code), Part 5 .........................................................SEN05035-01
00-100 8 D65EX, PX, WX-16

100 Index
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection.................................................................... 4

Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit ....................................................................... 6
Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection ........................................................................ 8
Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit............................................................................ 10
Failure code [DDNLKA] Weq lock Sw: Disconnection ................................................................................... 12
Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................... 14
Failure code [DGS1KX] Hyd oil temp sensor: Abnormal ............................................................................... 16
Failure code [DGT1KA] T/C oil temp sensor: Disconnection ......................................................................... 18
Failure code [DGT1KX] T/C oil temp sensor: Short circuit ............................................................................ 20
Failure code [DH21KA] Weq pressure sensor: Disconnection ...................................................................... 22
Failure code [DH21KB] Weq pressure sensor: Short circuit.......................................................................... 24
Failure code [DHT5KA] T/C pressure sensor: Disconnection ....................................................................... 26
Failure code [DHT5KB] T/C pressure sensor: Short circuit ........................................................................... 28
Failure code [DK10KA] Fuel control Dial: Disconnection .............................................................................. 30
Failure code [DK10KB] Fuel control Dial: Short circuit .................................................................................. 32
Failure code [DK30KA] ST lever 1: Disconnection ........................................................................................ 34
Failure code [DK30KB] ST lever 1: Short circuit............................................................................................ 36
Failure code [DK30KX] ST lever: Out of normal range.................................................................................. 38
Failure code [DK30KZ] ST lever: Disconnection or short circuit.................................................................... 38
Failure code [DK30L8] ST lever: Signal mismatch ........................................................................................ 39
Failure code [DK31KA] ST lever 2: Disconnection ........................................................................................ 40
Failure code [DK31KB] ST lever 2: Short circuit............................................................................................ 42
Failure code [DK40KA] Brake potentiometer: Disconnection ........................................................................ 44
Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................ 46
Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 48
Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 48
Failure code [DK55L8] FR lever: Signal mismatch........................................................................................ 49
Failure code [DK56KA] FR lever 1: Disconnection........................................................................................ 50
Failure code [DK56KB] FR lever 1: Short circuit ........................................................................................... 52
Failure code [DK57KA] FR lever 2: Disconnection........................................................................................ 54
Failure code [DKH1KA] Pitch angle sensor: Disconnection .......................................................................... 4
Failure code [DKH1KB] Pitch angle sensor: Short circuit.............................................................................. 6
Failure code [DLT3KA] T/M out-speed sensor: Disconnection ...................................................................... 8
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................. 9
Failure code [DW5AKA] Pitch selector Sol.: Disconnection .......................................................................... 10
Failure code [DW5AKB] Pitch selector Sol.: Short circuit.............................................................................. 11
Failure code [DW5AKY] Pitch selector Sol.: Short circuit.............................................................................. 12
Failure code [DW7BKA] Fan rev EPC: Disconnection .................................................................................. 14
Failure code [DW7BKB] Fan rev EPC: Short circuit ...................................................................................... 15
Failure code [DWN1KA] Hss EPC1: Disconnection ...................................................................................... 16
Failure code [DWN1KB] Hss EPC1: Short circuit.......................................................................................... 17
Failure code [DWN1KY] Hss EPC1: Short circuit.......................................................................................... 18
Failure code [DWN2KA] Hss EPC2: Disconnection ...................................................................................... 19
Failure code [DWN2KB] Hss EPC2: Short circuit.......................................................................................... 20
Failure code [DWN2KY] Hss EPC2: Short circuit.......................................................................................... 21
Failure code [DWN5KA] Fan pump solenoid: Disconnection ........................................................................ 22
Failure code [DWN5KB] Fan pump solenoid: Short circuit............................................................................ 23
Failure code [DWN5KY] Fan control solenoid: Short circuit .......................................................................... 24
Failure code [DXA0KA] TVC Sol.: Disconnection.......................................................................................... 26
Failure code [DXA0KB] TVC Sol.: Short circuit ............................................................................................. 27
Failure code [DXA0KY] TVC Sol.: Short circuit ............................................................................................. 28
Failure code [DXH1KA] Lock-up ECMV: Disconnection................................................................................ 29
Failure code [DXH1KB] Lock-up ECMV: Short circuit ................................................................................... 30
Failure code [DXH1KY] Lock-up ECMV: Short circuit ................................................................................... 32
Failure code [DXH4KA] 1st clutch ECMV: Disconnection ............................................................................. 34
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ................................................................................. 35
D65EX, PX, WX-16 00-100 9

100 Index
Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................................................. 36

Failure code [DXH5KA] 2nd clutch ECMV: Disconnection............................................................................ 37
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................................... 38
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................................... 39
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection............................................................................. 40
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 41
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit ................................................................................ 42
Failure code [DXH7KA] R clutch ECMV: Disconnection ............................................................................... 43
Failure code [DXH7KB] R clutch ECMV: Short circuit................................................................................... 44
Failure code [DXH7KY] R clutch ECMV: Short circuit................................................................................... 46
Failure code [DXH8KA] F clutch ECMV: Disconnection................................................................................ 48
Failure code [DXH8KB] F clutch ECMV: Short circuit ................................................................................... 49
Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................................... 50
Failure code [DXJ4KA] Weq lock Sol.: Disconnection .................................................................................. 52
Failure code [DXJ4KB] Weq lock Sol.: Short circuit ...................................................................................... 53
400 Troubleshooting of electrical system (E-mode)..........................................................................SEN05037-01
Before troubleshooting of electrical system .................................................................................................. 3
Information in troubleshooting table .............................................................................................................. 5
E-1 Engine does not start (starting motor does not turn) .............................................................................. 7
E-2 Preheater does not operate.................................................................................................................... 10
E-3 When starting switch is turned ON, machine monitor displays nothing .................................................. 16
E-4 When starting switch is turned ON (before starting engine), basic check item lights up ........................ 18
E-5 Precaution item lights up while engine is running................................................................................... 20
E-6 Emergency stop item lights up while engine is running.......................................................................... 22
E-7 Engine coolant temperature gauge does not indicate normally.............................................................. 24
E-8 Fuel gauge does not indicate properly ................................................................................................... 26
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 29
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 30
E-11 Contents of display by machine monitor are different from applicable machine................................... 31
E-12 Machine monitor does not display some items..................................................................................... 31
E-13 Function switch does not work ............................................................................................................. 31
E-14 Operation mode does not change ........................................................................................................ 32
E-15 Gearshift mode does not change ......................................................................................................... 32
E-16 Customize function does not operate normally .................................................................................... 33
E-17 Customize memory function does not operate normally ...................................................................... 33
E-18 Alarm buzzer does not sound or does not stop .................................................................................... 34
E-19 When starting switch is turned OFF, service meter is not displayed .................................................... 34
E-20 Machine monitor cannot be set in service mode .................................................................................. 34
E-21 Horn does not sound or does not stop ................................................................................................. 35
E-22 Back-up alarm does not sound or does not stop .................................................................................. 36
E-23 Head lamp or rear lamp does not light up ............................................................................................ 38
E-24 Windshield wiper does not operate ...................................................................................................... 42
E-25 Window washer does not operate ........................................................................................................ 56
E-26 KOMTRAX system does not operate correctly..................................................................................... 61
500 Troubleshooting of hydraulic and mechanical system (H-mode) ...............................................SEN05038-00
Failure mode and cause table....................................................................................................................... 2
Contents of troubleshooting table ................................................................................................................. 4
H-1 There is no travel power (no drawbar pull)............................................................................................. 5
H-2 Machine does not move (at 2nd or 3rd speed)....................................................................................... 6
H-3 Machine does not move at any gear speed ........................................................................................... 7
H-4 Machine travels only in one direction, forward or in reverse .................................................................. 8
H-5 When gear is shifted or travel direction is changed, large time lag is made .......................................... 9
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) ........................................... 10
H-7 Steering speed or power is low .............................................................................................................. 10
H- 8 Brake does not work.............................................................................................................................. 11
H-9 Overheat of power train oil ..................................................................................................................... 12
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor................... 13
H-11 All work equipment speeds are slow .................................................................................................... 13
00-100 10 D65EX, PX, WX-16

100 Index
H-12 Work equipment does not move ........................................................................................................... 14

H-13 Blade lift speed is slow or lacks power ................................................................................................. 14
H-14 Blade tilt speed is slow or lacks power ................................................................................................. 15
H-15 Ripper lift speed is slow or lacks power................................................................................................ 15
H-16 Excessive hydraulic drift of blade lift ..................................................................................................... 16
H-17 Excessive hydraulic drift of blade tilt..................................................................................................... 16
H-18 Excessive hydraulic drift of ripper lift..................................................................................................... 17
600 Troubleshooting of engine (S-mode) ......................................................................................... SEN05039-00
Method of using troubleshooting charts......................................................................................................... 3
S-1 Starting performance is poor. .................................................................................................................. 6
S-2 Engine does not start .............................................................................................................................. 7
S-3 Engine does not pick up smoothly .......................................................................................................... 10
S-4 Engine stops during operations .............................................................................................................. 11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ...................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) .................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive ............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)................................................... 18
S-12 Oil pressure drops................................................................................................................................. 19
S-13 Oil level rises (water, fuel in oil) ............................................................................................................ 20
S-14 Coolant temperature becomes too high (overheating).......................................................................... 21
S-15 Abnormal noise is made ....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
50 Disassembly and assembly

100 General information on disassembly and assembly.................................................................. SEN05110-01
How to read this manual................................................................................................................................ 2
Coating materials list ..................................................................................................................................... 4
Special tool list............................................................................................................................................... 7
Sketches of special tools ............................................................................................................................... 17
200 Engine and cooling system ........................................................................................................SEN05111-01
Removal and installation of fuel supply pump assembly ............................................................................... 2
Removal and installation of fuel injector assembly ........................................................................................ 7
Removal and installation of cylinder head assembly..................................................................................... 17
Removal and installation of radiator assembly .............................................................................................. 32
Removal and installation of aftercooler assembly ......................................................................................... 35
Removal and installation of hydraulic oil cooler assembly ............................................................................ 37
Removal and installation of power train oil cooler assembly ......................................................................... 39
Removal and installation of cooling fan drive assembly ................................................................................ 42
Removal and installation of cooling fan motor assembly............................................................................... 44
Removal and installation of main body of coolant preheater (subextremely cold weather spec) .................. 46
Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.)........................ 50
Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)................ 52
Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.) ............. 56
Removal and installation of damper assembly .............................................................................................. 65
Removal and installation of engine front oil seal ........................................................................................... 68
Removal and installation of engine rear oil seal ............................................................................................ 72
Removal and installation of engine hood assembly ...................................................................................... 80
Removal and installation of fuel tank assembly............................................................................................. 82
300 Power train ................................................................................................................................ SEN05112-02
Removal and installation of power train unit assembly.................................................................................. 2
Separation and connection of power train unit assembly .............................................................................. 6
Disassembly and assembly of PTO assembly............................................................................................... 11
Disassembly and assembly of torque converter assembly............................................................................ 16
Disassembly and assembly of transmission assembly.................................................................................. 27
D65EX, PX, WX-16 00-100 11

100 Index
Disassembly and assembly of HSS assembly .............................................................................................. 54

Removal and installation of final drive assembly .......................................................................................... 74
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)............. 76
Disassembly and assembly of final drive assembly ...................................................................................... 78
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type) ........ 86
400 Undercarriage and frame ...........................................................................................................SEN05113-02
Removal and installation of track frame assembly ........................................................................................ 2
Removal and installation of idler assembly ................................................................................................... 4
Removal and installation of idler assembly (Without idler support automatic thrust adjustment) ................. 6
Disassembly and assembly of idler assembly............................................................................................... 8
Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment) ............. 12
Removal and installation of recoil spring assembly ...................................................................................... 17
Disassembly and assembly of recoil spring assembly .................................................................................. 18
Removal and installation of track roller assembly ......................................................................................... 22
Disassembly and assembly of track roller assembly..................................................................................... 23
Removal and installation of carrier roller assembly....................................................................................... 27
Disassembly and assembly of carrier roller assembly .................................................................................. 28
Expansion and installation of track shoe assembly (Conventional type track shoe) ..................................... 31
Expansion and installation of track shoe assembly (PLUS type track shoe)................................................. 34
Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe) .............. 35
Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe).......................... 49
Field disassembly and assembly of one link (Conventional type track shoe) ............................................... 61
Field disassembly and assembly of one link (PLUS type track shoe)........................................................... 68
Removal and installation of pivot shaft assembly.......................................................................................... 73
Removal and installation of equalizer bar assembly ..................................................................................... 74
Disassembly and assembly of equalizer bar side bushing............................................................................ 76
500 Hydraulic system........................................................................................................................SEN05114-00
Removal and installation of hydraulic tank assembly.................................................................................... 2
Removal and installation of control valve assembly...................................................................................... 5
Disassembly and assembly of control valve assembly ................................................................................. 8
Disassembly and assembly of blade lift and tilt PPC valve assembly........................................................... 10
Disassembly and assembly of ripper PPC valve assembly .......................................................................... 11
Removal and installation of HSS and cooling fan pump assembly ............................................................... 12
Removal and installation of power train and lubrication pump assembly...................................................... 14
Removal and installation of scavenging pump assembly.............................................................................. 16
Removal and installation of HSS motor assembly ........................................................................................ 17
Disassembly and assembly of hydraulic cylinder assembly.......................................................................... 20
600 Work equipment .........................................................................................................................SEN05115-00
Removal and installation of blade assembly (ST-TPP dozer) ....................................................................... 2
Removal and installation of blade assembly (PAT dozer) ............................................................................. 5
Removal and installation of ripper assembly................................................................................................. 7
700 Cab and its attachments ............................................................................................................SEN05116-01
Removal and installation of ROPS cab assembly......................................................................................... 2
Removal and installation of FRP canopy (FRP canopy specification) .......................................................... 9
Removal and installation of floor frame assembly (FRP canopy specification)............................................. 10
Removal and installation of operator's cab glass (Stuck glass) .................................................................... 14
Removal and installation of air conditioner unit assembly ............................................................................ 20
Removal and installation of air conditioner compressor assembly ............................................................... 24
800 Electrical system ........................................................................................................................SEN05117-00
Removal and installation of monitor panel assembly .................................................................................... 2
Removal and installation of engine controller assembly ............................................................................... 4
Removal and installation of power train controller assembly ........................................................................ 6
Removal and installation of KOMTRAX terminal assembly .......................................................................... 8
80 Appendix
100 Air conditioner ............................................................................................................................SEN05041-00
Structure and function....................................................................................................................................... 4
00-100 12 D65EX, PX, WX-16

100 Index
Air conditioner component............................................................................................................................. 4

Configuration and function of refrigerating cycle ........................................................................................... 6
Outline of refrigerating cycle.......................................................................................................................... 7
Air conditioner unit......................................................................................................................................... 10
Control plate .................................................................................................................................................. 14
Compressor ................................................................................................................................................... 15
Condenser ..................................................................................................................................................... 16
Receiver drier ................................................................................................................................................ 17
Testing, adjusting and troubleshooting.............................................................................................................. 18
Caution about refrigerant............................................................................................................................... 18
Troubleshooting procedure............................................................................................................................ 19
Block diagram................................................................................................................................................ 20
Circuit diagram and arrangement of connector pins...................................................................................... 22
Detail of air conditioner unit ........................................................................................................................... 24
Parts and connectors arrangement ............................................................................................................... 26
Testing air leakage (duct) .............................................................................................................................. 32
Testing with self-diagnosis function ............................................................................................................... 34
Testing temperature control ........................................................................................................................... 37
Testing vent (mode) changeover ................................................................................................................... 39
Testing Recirc/Fresh changeover .................................................................................................................. 42
Testing inner sensor ...................................................................................................................................... 43
Testing evaporator temperature sensor......................................................................................................... 44
Testing sunlight sensor .................................................................................................................................. 47
Testing (dual) pressure switch for refrigerant ................................................................................................ 48
Testing relays and diodes .............................................................................................................................. 50
Troubleshooting chart 1 ................................................................................................................................. 52
Troubleshooting chart 2 ................................................................................................................................. 53
Troubleshooting for electrical system (E mode) ............................................................................................ 56
E-1 Power supply system (Air conditioner does not operate)..................................................................... 57
E-2 Compressor and refrigerant system (Air is not cooled)........................................................................ 60
E-3 Blower motor system (No air comes out or air flow is abnormal)......................................................... 63
E-4 Temperature cannot be controlled ....................................................................................................... 66
E-5 Vent (mode) cannot be changed over.................................................................................................. 68
E-6 Recirc/Fresh air cannot be changed over ............................................................................................ 70
Troubleshooting with gauge pressure............................................................................................................ 72
Connection of service tool ............................................................................................................................. 75
Precautions for connecting air conditioner piping.......................................................................................... 76
Handling of compressor oil ............................................................................................................................ 77
1. Control of compressor oil (Denso: ND-OIL8: For R134a)..................................................................... 77
2. Adding of compressor oil ...................................................................................................................... 77
3. Compressor replacement ..................................................................................................................... 78
4. Applying compressor oil for O-ring ....................................................................................................... 78
90 Diagrams and drawings

100 Hydraulic diagrams and drawings ............................................................................................. SEN04934-01
Power train hydraulic circuit diagram............................................................................................................. 3
Work equipment hydraulic circuit diagram..................................................................................................... 7
200 Electrical diagrams and drawings.............................................................................................. SEN04935-03
Electrical circuit diagram................................................................................................................................ 3
Electrical circuit diagram (sand terrain specification) .................................................................................... 41
Electrical circuit diagram (FRP canopy specification).................................................................................... 47
D65EX, PX, WX-16 00-100 13

SEN04931-09
D65EX-16, D65PX-16, D65WX-16 Bulldozer

Form No. SEN04931-09
©2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
00-100 14
SEN04932-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
00 Index and foreword 00
200 Foreword and general information

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
D65EX, PX, WX-16 00-200 1

SEN04932-01 Safety notice
Safety notice (Rev. 2008/08-a)1

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
00-200 2 D65EX, PX, WX-16

Safety notice SEN04932-01
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
D65EX, PX, WX-16 00-200 3

4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
00-200 4 D65EX, PX, WX-16

Safety notice SEN04932-01
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D65EX, PX, WX-16 00-200 5

8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
00-200 6 D65EX, PX, WX-16

How to read the shop manual SEN04932-01
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
80. Appendix
This section explains the equipments which cannot be included in the other sections. This section
explains the structure, function, testing, adjusting, and troubleshooting of the equipments.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
D65EX, PX, WX-16 00-200 7

SEN04932-01 How to read the shop manual
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
00-200 8 D65EX, PX, WX-16

Explanation of terms for maintenance standard SEN04932-01
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
D65EX, PX, WX-16 00-200 9

SEN04932-01 Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
00-200 10 D65EX, PX, WX-16

Handling of electric equipment and hydraulic component SEN04932-01
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D65EX, PX, WX-16 00-200 11

SEN04932-01 Handling of electric equipment and hydraulic component
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00-200 12 D65EX, PX, WX-16

3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
D65EX, PX, WX-16 00-200 13

2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00-200 14 D65EX, PX, WX-16

3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D65EX, PX, WX-16 00-200 15

4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00-200 16 D65EX, PX, WX-16

4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D65EX, PX, WX-16 00-200 17

Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00-200 18 D65EX, PX, WX-16

5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D65EX, PX, WX-16 00-200 19

SEN04932-01 Handling of connectors newly used for engines
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
00-200 20 D65EX, PX, WX-16

Handling of connectors newly used for engines SEN04932-01
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D65EX, PX, WX-16 00-200 21

SEN04932-01 Handling of connectors newly used for engines
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200 22 D65EX, PX, WX-16

How to read electric wire code SEN04932-01
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
tor tric appliance General wiring in extremely
tant low-volt-
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
D65EX, PX, WX-16 00-200 23

SEN04932-01 How to read electric wire code
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
00-200 24 D65EX, PX, WX-16

How to read electric wire code SEN04932-01
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
D65EX, PX, WX-16 00-200 25

SEN04932-01 Precautions when carrying out operation
Precautions when carrying out operation 1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
00-200 26 D65EX, PX, WX-16

Precautions when carrying out operation SEN04932-01
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D65EX, PX, WX-16 00-200 27

SEN04932-01 Precautions when carrying out operation
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
00-200 28 D65EX, PX, WX-16

Method of disassembling and connecting push-pull type coupler SEN04932-01
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D65EX, PX, WX-16 00-200 29

SEN04932-01 Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
00-200 30 D65EX, PX, WX-16

Method of disassembling and connecting push-pull type coupler SEN04932-01
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
D65EX, PX, WX-16 00-200 31

SEN04932-01 Standard tightening torque table
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
00-200 32 D65EX, PX, WX-16

Standard tightening torque table SEN04932-01
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
D65EX, PX, WX-16 00-200 33

SEN04932-01 Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
00-200 34 D65EX, PX, WX-16

Standard tightening torque table SEN04932-01
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
D65EX, PX, WX-16 00-200 35

SEN04932-01 Conversion table
Conversion table 1
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line
down from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-200 36 D65EX, PX, WX-16

Conversion table SEN04932-01
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D65EX, PX, WX-16 00-200 37

Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-200 38 D65EX, PX, WX-16

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D65EX, PX, WX-16 00-200 39

Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-200 40 D65EX, PX, WX-16

D65EX, PX, WX-16 00-200 41

SEN04932-01

©2009 KOMATSU
All Rights Reserved
00-200 42
SEN04933-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
01 General 1
100 Specification and technical data

Specification dimension drawing..................................................................................................................... 2
Specifications .................................................................................................................................................. 6
Weight table .................................................................................................................................................. 18
Table of fuel, coolant and lubricants.............................................................................................................. 22
D65EX, PX, WX-16 01-100 1

SEN04933-02 Specification dimension drawing
Specification dimension drawing 1
D65EX-16: With ROPS cab and air conditioner
D65EX-16 D65EX-16
Item Unit
Sigma dozer Power angle power tilt dozer
Machine weight kg 19,430 [19,750] 20,910 [21,230]
Engine model — Komatsu SAA6D114E-3 diesel engine
Engine rated output
• Net [ISO 9249/SAE J1349](*1) 153 {205}/1,950
kW{HP}/rpm
• Gross [SAE J1995](*2) 154.5 {207}/1,950
A Overall length mm 5,490 5,790
B Overall height (excluding antenna) mm 3,155 [3,160] 3,155 [3,160]
C Overall width mm 3,410 3,870
Travel speed Forward km/h 3.6/5.5/7.2/11.2
[1st/2nd/3rd (Low)/3rd] Reverse km/h 4.4/6.6/8.6/13.4
Track shoe
• Type — Single grouser Single grouser
• Width mm 510 560
Rear work equipment — Hitch Counterweight
Values in [ ] are shown for machine equipped with PLUS type track shoe.
*1: Indicates the value of minimum cooling fan speed.
*2: Indicates the value of the stand-alone engine (without cooling fan).
a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated output
measured of an independent engine. While, net denotes the value measured of an engine under the condition
essentially the same as that when it is installed on machine.
a Following shows the rated horsepower (net output power) at the maximum cooling fan speed.
139 kW {186 HP}/1,950 rpm
a Following shows the maximum gross value of the engine output power.
163.7 kW {219 HP}/1,950 rpm
01-100 2 D65EX, PX, WX-16

Specification dimension drawing SEN04933-02
D65EX-16: With FRP canopy
D65EX-16
Item Unit
Straight tilt dozer
Machine weight kg 18,630
Engine rated output
• Net [ISO 9249/SAE J1349](*1) 153 {205}/1,950
kW{HP}/rpm
• Gross [SAE J1995](*2) 154.5 {207}/1,950
A Overall length mm 5,330
B Overall height (excluding antenna) mm 3,125
C Overall width mm 3,415
Track shoe
• Type — Single grouser
• Width mm 510
Rear work equipment — Hitch
*1: Indicates the value of minimum cooling fan speed.
a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated output
measured of an independent engine. While, net denotes the value measured of an engine under the condition
essentially the same as that when it is installed on machine.
a Following shows the rated horsepower (net output power) at the maximum cooling fan speed.
139 kW {186 HP}/1,950 rpm
a Following shows the maximum gross value of the engine output power.
163.7 kW {219 HP}/1,950 rpm
D65EX, PX, WX-16 01-100 3

SEN04933-02 Specification dimension drawing
D65PX-16: With ROPS cab and air conditioner
D65PX-16 D65PX-16
Item Unit
Straight tilt dozer Power angle power tilt dozer
Engine rated output
• Net [ISO 9249/SAE J1349](*1) 153 {205}/1,950
kW{HP}/rpm
• Gross [SAE J1995](*2) 154.5 {207}/1,950
Track shoe
Type — Single grouser Single grouser
Width mm 915 760
Rear work equipment — Hitch Hitch
*1: Indicates the value of the minimum cooling fan speed.
a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated horsepower
measured of stand-alone engine. While, net denotes the value measured of an engine under the condition essentially
the same as that when it is installed on machine.
a The rated horsepower (net output power) at the maximum cooling fan speed is as follows.
139 kW {186 HP}/1,950 rpm
a The maximum gross value of the engine output is as follows.
163.7 kW {219 HP}/1,950 rpm
01-100 4 D65EX, PX, WX-16

Specification dimension drawing SEN04933-02
D65WX-16: With ROPS cab and air conditioner
D65WX-16 D65WX-16
Item Unit
Sigma dozer Power angle power tilt dozer
Engine rated output
• Net [ISO 9249/SAE J1349](*1) 153 {205}/1,950
kW{HP}/rpm
• Gross [SAE J1995](*2) 154.5 {207}/1,950
Track shoe
• Type — Single grouser Single grouser
• Width mm 760 760
Rear work equipment — Hitch Counterweight
*1: Indicates the value of the minimum cooling fan speed.
*2: Indicates the value of stand-alone the engine (without cooling fan).
a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated horsepower
measured of stand-alone engine. While, net denotes the value measured of an engine under the condition essentially
the same as that when it is installed on machine.
139 kW {186 HP}/1,950 rpm
163.7 kW {219 HP}/1,950 rpm
D65EX, PX, WX-16 01-100 5

SEN04933-02 Specifications
Specifications 1
D65EX-16
Machine model/type Power angle power Straight tilt dozer
Sigma dozer
tilt dozer (with FRP canopy)
Serial No. 80001 and up 80001 and up 80001 and up
Machine weight
• Stand-alone tractor with ROPS cab kg 17,230 [17,360] 18,140 [18,270] —
Weight
• Stand-alone tractor with FRP canopy kg — — 16,570

• With work equipment kg 19,430 [19,750] 20,910 [21,230] 18,630
• With work equipment and ripper kg (21,390) [(21,520)] (22,870) [(23,000)] —
Min. turning radius m — [Counter-rotation] — [Counter-rotation] — [Counter-rotation]
Gradeability deg. 30 30 30
Stability (front/rear/left/right) deg. 35 35 35
Forward 1st km/h 3.6 3.6 3.6
Forward 2nd km/h 5.5 5.5 5.5
Forward 3rd (Low) km/h 7.2 7.2 7.2
Travel speed
Forward 3rd km/h 11.2 11.2 11.2

Performance
Reverse 1st km/h 4.4 4.4 4.4

Reverse 2nd km/h 6.6 6.6 6.6
Reverse 3rd (Low) km/h 8.6 8.6 8.6
Reverse 3rd km/h 13.4 13.4 13.4
Stand-alone tractor with ROPS kPa 55.8 {0.57} 53.5 {0.55} —
cab {kg/cm2} [56.2 {0.57}] [53.8 {0.55}] —
Ground pressure
Stand-alone tractor with FRP kPa — — 53.4

canopy {kg/cm2} — — {0.55}
kPa 63.5 {0.65} 62.2 {0.63} 60.1
With work equipment
{kg/cm2} [63.9 {0.65}] [62.6 {0.64}] {0.61}
kPa (69.2 {0.71}) (67.4 {0.69}) —
With work equipment and ripper
{kg/cm2} [(69.6 {0.71})] [(67.8 {0.69})] —
Overall
Bare tractor mm 4,250 4,250 4,250

length
With work equipment mm 5,490 5,790 5,330

Overall
Bare tractor mm 2,390 2,610 2,390

width
With work equipment mm 3,410 3,870 3,415

Dimensions
To top of exhaust pipe mm 3,080 [3,085] 3,080 [3,085] 3,080

When ROPS cab is installed
Overall
height
mm 3,155 [3,160] 3,155 [3,160] —

(excluding antenna)
When ROPS canopy is installed mm 3,155 [3,160] 3,155 [3,160] —
When FRP canopy is installed mm — — 3,125
Track gauge mm 1,880 2,050 1,880
Length of track on ground mm 2,980 [2,970] 2,980 [2,970] 2,980
Track width (Standard track shoe) mm 510 560 510
Min. ground clearance mm 410 [415] 410 [415] 410
Values in ( ) are shown for reference.
01-100 6 D65EX, PX, WX-16

Specifications SEN04933-02
D65PX-16 D65WX-16
Power angle power Power angle power
Straight tilt dozer Sigma dozer
tilt dozer tilt dozer
80001 and up 80001 and up 80001 and up 80001 and up
19,000 [19,130] 19,000 [19,130] 17,980 [18,110] 19,010 [19,140]

— — — —
20,910 [21,230] 21,780 [22,120] 20,290 [20,610] 21,810 [22,130]
— — (22,250) [(22,380)] (23,770) [(23,900)]
— [Counter-rotation] – [Counter-rotation] – [Counter-rotation] – [Counter-rotation]
30 30 30 30
35 35 35 35
3.6 3.6 3.6 3.6
5.5 5.5 5.5 5.5
7.2 7.2 7.2 7.2
11.2 11.2 11.2 11.2
4.4 4.4 4.4 4.4
6.6 6.6 6.6 6.6
8.6 8.6 8.6 8.6
13.4 13.4 13.4 13.4
31.1 {0.32} 37.4 {0.38} 39.1 {0.40} 41.3 {0.42}
[31.3 {0.32}] [37.7 {0.38}] [39.3 {0.40}] [41.6 {0.42}]
— — — —
— — — —
34.5 {0.35} 43.3 {0.44} 44.5 {0.45} 47.8 {0.49}
[34.7 {0.35}] [43.6 {0.44}] [44.8 {0.46}] [48.1 {0.49}]
(48.3 {0.49}) (51.6 {0.53})
— —
[(48.6 {0.50})] [(51.9 {0.53})]
4,360 [4,370] 4,360 [4,370] 4,250 4,250
5,680 5,790 5,500 5,790
2,965 2,990 2,810 2,990
3,970 4,010 3,580 4,010

3,080 [3,085] 3,080 [3,085] 3,080 [3,085] 3,080 [3,085]
3,155 [3,160] 3,155 [3,160] 3,155 [3,160] 3,155 [3,160]
3,155 [3,160] 3,155 [3,160] 3,155 [3,160] 3,155 [3,160]

— — — —
2,050 2,230 2,050 2,230
3,285 [3,275] 3,285 [3,275] 2,980 [2,970] 2,980 [2,970]
915 760 760 760
410 [415] 410 [415] 410 [415] 410 [415]
D65EX, PX, WX-16 01-100 7

D65EX-16
Machine model/type Power angle power
Sigma dozer Straight tilt dozer
tilt dozer
Model SAA6D114E-3
4-cycle, water-cooled, in-line vertical, direct injection type,
Type
with turbocharger and air-cooled aftercooler
No. of cylinders – bore x stroke mm 6 – 114 x 135
Total piston displacement l {cc} 8.27 {8,270}
Rated horsepower
• Net (*1) 153{205}/1,950
[ISO 9249/SAE J1349] kW{HP}/rpm
• Gross (*2) 154.5{207}/1,950
Performance
[SAE J1995]
Engine
Max. torque (*2) Nm{kgm}/rpm 1,012{103}/1,450

Max. speed at no load rpm 2,070 ± 50
Min. speed at no load rpm 825 ± 25
Fuel consumption ratio at rated g/kWh
227 {169}
horsepower point {g/HPh}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 60 A
Battery (*3) 12 V, 112 Ah x 2 pieces
Type of radiator core Corrugated aluminum
Torque converter 3-element, 1-stage, 2-phase
Planetary gear, multiple disc, hydraulic,
Transmission gear pump pressure fed oil lubrication, 3 forward/reverse
gear speeds, manual electronic type
Power train
Bevel gear shaft Spiral bevel gear, gear pump pressure fed oil lubrication type
Differential planetary gear, hydraulic motor drive,
HSS
manual electronic, hydraulic type
HSS
unit
Wet, multiple disc, spring-boosted,

Brake
foot-operated, hydraulic type
1-stage spur gear/1-stage planetary gear reduction, splash
Final drive
lubrication type
Type of suspension Oscillation type, equlizer bar
Carrier roller 2 pieces on each side
Undercarriage
Track roller 7 pieces on each side

Track shoe
Width: 510 mm Width: 560 mm Width: 510 mm
• Assembly-type single grouser
Each side: 42 Each side: 42 Each side: 42
shoe
pieces pieces pieces
(PLUS type)
Pitch: 203.2 mm Pitch: 203.2 mm Pitch: 203.2 mm
*1:
Indicates the value of minimum cooling fan speed.
*2:
Indicates the value of the stand-alone engine (without cooling fan).
*3:
The battery capacity (Ah) is the 5-hour rate value.
a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the
rated horsepower measured in stand-alone engine. While, net denotes the value measured in
an engine under the condition essentially the same as that when it is installed on machine.
139 kW {186 HP}/1,950 rpm
163.7 kW {219 HP}/1,950 rpm
01-100 8 D65EX, PX, WX-16

D65PX-16 D65WX-16
SAA6D114E-3
4-cycle, water-cooled, in-line vertical, direct injection type,
with turbocharger and air-cooled aftercooler
6 – 114 x 135
8.27 {8,270}
153{205}/1,950
154.5{207}/1,950
1,012{103}/1,450
2,070±50
825±25
227 {169}
24 V, 7.5 kW
24 V, 60 A
12 V, 112 Ah x 2 pieces
Corrugated aluminum
3-element, 1-stage, 2-phase
Planetary gear, multiple disc, hydraulic,
gear pump pressure fed oil lubrication,
3 forward/reverse gear speeds, manual electronic type
Spiral bevel gear, gear pump pressure fed oil lubrication type
Differential planetary gear, hydraulic motor drive,
manual electronic, hydraulic type
Wet, multiple disc, spring-boosted,
foot-operated, hydraulic type
1-stage spur gear/1-stage planetary gear reduction,
splash lubrication type
Oscillation type, equlizer bar
2 pieces on each side
8 pieces on each side 7 pieces on each side
Width: 915 mm Width: 760 mm Width: 760 mm Width: 760 mm

Each side: 45 pieces Each side: 45 pieces Each side: 42 pieces Each side: 42 pieces
Pitch: 203.2 mm Pitch: 203.2 mm Pitch: 203.2 mm Pitch: 203.2 mm
D65EX, PX, WX-16 01-100 9

D65EX-16
Machine model/type Power angle Straight tilt dozer
Sigma dozer
power tilt dozer (with FRP canopy)
HSS pump
Variable displacement swash plate type piston pump,
Type
load sensing type
Theoretical delivery cm3/rev 112
Cooling fan pump
Hydraulic pump
Type Variable displacement swash plate type piston pump

Theoretical delivery cm /rev
3
30
Power train and steering
lubrication pump
Type Gear type (tandem)
3
43.7 x 2
Scavenging pump
Type Gear type
Hydraulic system

3
61.2
HSS motor
Hydraulic motor
Fixed displacement swash plate type piston motor,

Type
with brake valve
Motor capacity cm3/rev 90
Cooling fan motor
Type Fixed displacement swash plate type piston motor
Motor capacity cm /rev
3
28
3-spool type, 1 piece 3-spool type, 1 piece
Control valve
4-spool type, 1 piece 4-spool type, 1 piece

(machine with ripper) (machine with ripper)
Type and quantity
5-spool type, 1 piece —
(straight tilt power pitch dozer) —
(power angle power tilt dozer) —
Control method Hydraulic assist type Hydraulic assist type
Hydraulic tank Box type (external control valve type)
Hydraulic oil filter Tank return side
Oil cooler Corrugated aluminum
01-100 10 D65EX, PX, WX-16

D65PX-16 D65WX-16
Power angle power
Straight tilt dozer Power angle power tilt dozer Sigma dozer
tilt dozer
Variable displacement swash plate type piston pump,

load sensing type
112
Variable displacement swash plate type piston pump

30
Gear type (tandem)

43.7 x 2
Gear type
61.2
Fixed displacement swash plate type piston motor, with

brake valve
90
Fixed displacement swash plate type piston motor

28
3-spool type, 1 piece
(machine with ripper)
(straight tilt power pitch dozer)
(power angle power tilt dozer)
Hydraulic assist type
Box type (external control valve type)
Tank return side
Corrugated aluminum
D65EX, PX, WX-16 01-100 11

D65EX-16
Sigma dozer
Type Double acting piston — Double acting
Other than power angle power tilt
Lift cylinder
Cylinder bore mm 85 — 85
Piston rod diameter mm 60 — 60
Stroke mm 1,145 — 1,145
Max. distance between pins mm 1,695 — 1,695
dozer
Min. distance between pins mm 550 — 550

Type Double acting piston — Double acting
Tilt and pitch
Cylinder bore mm 125 — 125

cylinder
Piston rod diameter mm 70 — 70

Stroke mm 145 — 145
Max. distance between pins mm 1,222 — 1,222
Min. distance between pins mm 1,077 — 1,077
Type — Double acting piston —
Work equipment hydraulic system
Lift cylinder
Cylinder bore mm — 90 —
Piston rod diameter mm — 60 —
Stroke mm — 1,016 —
Max. distance between pins mm — 1,400 —
Power angle power tilt dozer
Min. distance between pins mm — 384 —

Tilt cylinder

Stroke mm — 160 —
Min. distance between pins mm — 1,040 —
Angle cylinder

Stroke mm — 550 —
Min. distance between pins mm — 997 —
Type Double acting piston
Ripper cylinder
Cylinder bore mm 125

Piston rod diameter mm 70
Stroke mm 330
Max. distance between pins mm 1,080
Min. distance between pins mm 750
01-100 12 D65EX, PX, WX-16

D65PX-16 D65WX-16
Double acting piston — Double acting piston —
85 — 85 —
60 — 60 —
1,075 — 1,145 —
1,975 — 1,695 —
900 — 550 —
Double acting piston — Double acting piston —
125 — 125 —
70 — 70 —
145 — 145 —
1,222 — 1,222 —
1,077 — 1,077 —
— Double acting piston — Double acting piston
— 90 — 90
— 60 — 60
— 1,016 — 1,016
— 1,400 — 1,400
— 384 — 384
— 130 — 130
— 70 — 70
— 160 — 160
— 1,200 — 1,200
— 1,040 — 1,040
— 110 — 110
— 65 — 65
— 550 — 550
— 1,547 — 1,547
— 997 — 997
— Double acting piston
— 125
— 70
— 330
— 1,080
— 750
D65EX, PX, WX-16 01-100 13

D65EX-16
Sigma dozer
Type Straight tilt dozer
Blade supporting method Left: brace, Right: tilt cylinder
Max. lift (above ground) mm 1,100 [1,105] — 1,100
Performance
Max. drop (below ground) mm 435 [430] — 435

Max. tilt mm 870 — 870
Blade edge angle variable range deg. ±7 — ±7
Dimensions
Blade width mm 3,415 — 3,415

Blade height mm 1,225 — 1,225
Tip angle of blade cutting edge deg. 55 — 55
Type Sigma dozer
Blade supporting method Left: brace, Right: tilt cylinder
Max. lift (above ground) mm 1,130 [1,135] — —
Performance
Max. drop (below ground) mm 505 [500] — —

Max. tilt mm 870 — —
Blade edge angle variable range deg. ±7 — —
Dimensions
Blade width mm 3,410 — —

Work equipment
Blade height mm 1,425 — —

Tip angle of blade cutting edge deg. 46 — —
Type Straight tilt power pitch dozer
Blade supporting method Left: tilt cylinder, Right: pitch cylinder
Performance

Dimensions

Type Sigma power pitch dozer
Blade supporting method Left: tilt cylinder, Right: pitch cylinder
Performance

Dimensions

01-100 14 D65EX, PX, WX-16

D65PX-16 D65WX-16
Straight tilt dozer
Left: brace, Right: tilt cylinder
1,125 [1,130] — —
540 [535] — —
890 — —
±7 — —
3,970 — —
1,100 — —
55 — —
Sigma dozer
Left: brace, Right: tilt cylinder
— 1,130 [1,135] —
— 505 [500] —
— 820 —
— ±7 —
— 3,580 —
— 1,425 —
— 46 —
Straight tilt power pitch dozer
Left: tilt cylinder, Right: pitch cylinder
1,125 [1,130] — —
540 [535] — —
890 — —
±7 — —
3,970 — —
1,100 — —
55 — —
Sigma power pitch dozer
Left: tilt cylinder, Right: pitch cylinder
— 1,130 [1,135] —
— 505 [500] —
— 820 —
— ±7 —
— 3,580 —
— 1,425 —
— 46 —
D65EX, PX, WX-16 01-100 15

D65EX-16
Sigma dozer
Type Power angle power tilt dozer
Blade supporting method Both sides: angle cylinder
Max. lift (above ground) mm — 1,165 [1,170] —
Performance
Max. drop (below ground) mm — 700 [695] —

Max. tilt mm — 500 —
Blade edge angle variable range deg. — 25 —
Tip angle of blade cutting edge deg. — ±3 —
Dimensions
Blade width mm — 3,870 —

Work equipment
Blade height mm — 1,235 —

Tip angle of blade cutting edge deg. — 55 —
Type Angle dozer
Blade supporting method Both sides: brace
Max. lift (above ground) mm 1,175 [1,180] — 1,175
Performance
Max. drop (below ground) mm 445 [440] — 445

Max. tilt mm 400 — 400
Blade edge angle variable range deg. 25 — 25
Dimensions
Blade width mm 3,970 — 3,970

Blade height mm 1,100 — 1,100
Tip angle of blade cutting edge deg. 55 — 55
Type Parallelogram —
Beam length mm 2,170 —
Ripper (Multi shank)
Number of shanks piece 3 —

Digging angle deg. 55 —
Performance
Digging depth 3-level variable —

Max. digging depth mm 590 [585] —
Max. lift mm 640 [645] —
Shank position (left/right) mm 950/950 —
Type Parallelogram —
Ripper (Single shank)
Beam length mm 2,170 —

Number of shanks piece 1 —
Digging angle deg. 55 —
Performance
Digging depth adjustment 3-stage variable —

Max. digging depth mm 590 [585] —
Max. lift above ground mm 640 [645] —
01-100 16 D65EX, PX, WX-16

D65PX-16 D65WX-16
Power angle power tilt dozer
Both sides: angle cylinder
— 1,165 [1,170] — 1,165 [1,170]
— 700 [695] — 700 [695]
— 520 — 520
— 25 — 25
— ±3 — ±3
— 4,010 — 4,010
— 1,235 — 1,235
— 55 — 55
Angle dozer
Both sides: brace
— —
— —
— —
— —
— —
— —
— —
— Parallelogram
— 2,170
— 3
— 55
— 3-level variable
— 590 [585]
— 640 [645]
— 950/950
— —
— —
— —
— —
— —
— —
— —
D65EX, PX, WX-16 01-100 17

SEN04933-02 Weight table
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
D65EX-16
Machine model/type D65EX-16 Straight tilt dozer D65PX-16 D65WX-16
(with FRP canopy)
Serial No. 80001 and up 80001 and up 80001 and up 80001 and up
Engine and damper assembly
960 960 960 960
(excluding coolant and oil)
• Engine assembly 870 870 870 870
• Damper assembly 32 32 32 32
• Engine-related parts (wiring, mount) 59 59 59 59
Universal joint 23 23 23 23
Cooling assembly (excluding coolant) 110 110 110 110
• Radiator assembly 18 18 18 18
• Aftercooler assembly 22 22 22 22
Hydraulic oil cooler (excluding oil) 4 4 4 4
Power train oil cooler (excluding oil) 9 9 9 9
Cooling fan pump 30 30 30 30
Cooling fan motor 13 13 13 13
Fuel tank (excluding fuel) 290 290 290 290
Power train unit assembly (excluding oil) 1,460 1,460 1,460 1,460
• Torque converter and PTO assembly 340 340 340 340
• Transmission assembly 370 370 370 370
• Transmission control valve assembly 26 26 26 26
• Main relief and torque
5 5 5 5
converter relief valve assembly
• HSS unit assembly 680 680 680 680
• Brake valve assembly 5 5 5 5
HSS motor 41 41 41 41
HSS pump 75 75 75 75
Power train and steering lubrication pump 14 14 14 14
Scavenging pump 5 5 5 5
Quick drop valve 7 7 7 7
Hydraulic tank (excluding oil) 85 85 85 85
Control valve
<3-spool valve> 45 45 45 45
<4-spool valve>
(Straight tilt dozer with ripper) 50 50 50 50
(Sigma dozer with ripper)
<5-spool valve>
(Straight tilt power pitch dozer)
55 55 55 55
(Sigma power pitch dozer)
(Power angle power tilt dozer)
Blade PPC valve
<Other than power angle power tilt dozer> 3 3 3 3
<Power angle power tilt dozer> 4 — 4 4
Ripper PPC valve 1 1 1 1
Steering electric lever 4 4 4 4
01-100 18 D65EX, PX, WX-16

Weight table SEN04933-02
Unit: kg
D65EX-16
(with FRP canopy)
Main frame assembly
<Other than power angle power tilt dozer> 2,710 2,710 2,710 2,710
<Power angle power tilt dozer> 2,870 2,870 3,060 3,060
Engine underguard 125 125 125 125
Transmission underguard 22 22 22 22
Final drive assembly (each side)
<Other than power angle tilt dozer with
825 755 *1 850 850
conventional type track shoe>
835 — 860 860
PLUS type track shoe>
<Power angle power tilt dozer with
850 — 850 850
<Power angle power tilt dozer with PLUS
860 — 860 860
type track shoe>
Sprocket teeth (each side)
<Conventional type track shoe> 8x9 8x9 8x9 8x9
<PLUS type track shoe> 9x9 — 9x9 9x9
Track frame assembly (each side)
1,580 1,580 1,730 1,600
1,640 — 1,790 1,690
PLUS type track shoe>
<Power angle power tilt dozer with
1,560 1,560 1,690 1,560
<Power angle power tilt dozer with PLUS
1,620 — 1,750 1,620
type track shoe>
• Track frame (each side)
<Power angle power tilt dozer> 660 660 710 660
• Idler assembly (each side) 200 200 200 200
• Idler cushion assembly (each side) 245 245 245 245
• Single flange track roller assembly (each
side)
53 x 5 53 x 5 53 x 6 53 x 5
<Conventional type track shoe>
56 x 5 — 56 x 6 56 x 5
<PLUS type track shoe>
• Double flange track roller assembly (each
side)
61 x 2 61 x 2 61 x 2 61 x 2
<Conventional type track shoe>
60 x 2 — 60 x 2 60 x 2
<PLUS type track shoe>
• Carrier roller assembly (each side)
<Conventional type track shoe> 35 x 2 35 x 2 35 x 2 35 x 2
<PLUS type track shoe> 39 x 2 — 39 x 2 39 x 2
• Center roller guard (each side)
<Conventional type track shoe> 29 29 29 29
<PLUS type track shoe> 29 — 57 29
• Full roller guard (each side)
<Conventional type track shoe> 61 61 73 61
<PLUS type track shoe> 69 — 82 69
*1 : Values *1 are shown for Planetary gear installed inside of sprocket
D65EX, PX, WX-16 01-100 19

SEN04933-02 Weight table
Unit: kg
D65EX-16
(with FRP canopy)
Track shoe assembly (each side)
<Single grouser shoe (510 mm)> 1,430 1,430 — —
<Swamp grouser shoe (940 mm)> — — 2,120 —
<Single grouser shoe (760 mm)> — — 1,880 1,755
<Single grouser shoe (915 mm)> — — 2,105 —
<Triple grouser shoe (510 mm)> 1,535 1,535 — —
<PLUS type single grouser shoe (510 mm)> 1,525 — — —
<PLUS type single grouser shoe (760 mm)> — — 1,985 1,850
<PLUS type single grouser shoe (915 mm)> — — 2,200 —
Pivot shaft (each side)
Equalizer bar
ROPS cab assembly
(including floor, operator seat and air 1,140 1,140 1,140 1,140
conditioner unit)
ROPS cab assembly with subextremely cold
weather spec.
1,207 1,207 — —
(including double window glass, floor,
operator's seat, and air conditioner)
ROPS canopy assembly
1,000 1,000 1,000 1,000
(including floor and operator seat mount)
Floor frame Ass'y (including operator seat
— 560 — —
and FRP canopy)
FRP canopy — 105 — —
Operator seat 59 59 59 —
Air conditioner unit 10 10 10 10
Compressor 7 7 7 7
Condenser 2 2 2 2
Receiver 1 1 1 1
Straight tilt dozer assembly 2,060 2,060 2,100 —
• Blade 1,200 1,200 1,250 —
• Straight frame (each side) 300 300 300 —
• Tilt cylinder assembly 62 62 62 —
Sigma dozer assembly 2,390 — — 2,500
• Blade 1,525 — — 1,585
• Straight frame (each side) 300 — — 325
• Tilt cylinder assembly 62 — — 62
01-100 20 D65EX, PX, WX-16

Weight table SEN04933-02
Unit: kg
D65EX-16
(with FRP canopy)
Straight tilt power pitch dozer assembly 2,110 — 2,160 —
• Blade 1,200 — 1,250 —
• Straight frame (each side) 300 — 300 —
• Tilt cylinder assembly 62 — 62 —
• Pitch cylinder assembly 62 — 62 —
Sigma power pitch dozer assembly 2,440 — — 2,550
• Blade 1,525 — — 1,585
• Straight frame (each side) 300 — — 325
• Tilt cylinder assembly 62 — — 62
• Pitch cylinder assembly 62 — — 62
Power angle power tilt dozer assembly 2,960 — 2,990 2,990
• Blade 1,510 — 1,540 1,540
• U-frame 1,110 — 1,110 1,110
• Tilt cylinder assembly 80 — 80 80
• Angle cylinder assembly 80 x 2 — 80 x 2 80 x 2
Angle dozer assembly 2,200 2,200 — —
• Blade 1,030 1,030 — —
• C-frame 850 850 — —
Lift cylinder assembly 85 x 2 85 x 2 85 x 2 85 x 2
Ripper assembly (Multi shank) 1,770 — — 1,770
Ripper cylinder assembly 70 — — 70
Ripper assembly (Single shank) 1,300 — — —
Ripper cylinder assembly 70 — — —
D65EX, PX, WX-16 01-100 21

SEN04933-02 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1
a For details of notes (Notes 1 and 2…) in the table, see Operation and Maintenance Manual.
01-100 22 D65EX, PX, WX-16

Table of fuel, coolant and lubricants SEN04933-02
q ASTM: American Society of Testing and Material
Unit: l
Supply point Specified capacity Refill capacity
Engine oil pan 33 28
Damper case 1.7 1.7
Idler (each of right and left) 0.25 0.25
Power train case 53 48
EX: 24 EX: 24
Final drive case
PX: 27 PX: 27
(each of right and left)
WX: 27 WX: 27
Hydraulic oil system 82 55
Cooling system (including sub-tank) 36 —
Cooling system (including sub-tank)
37 —
(subextremely cold weather spec.)
Fuel tank 415 —
Fuel tank for coolant preheat (subextremely
4 —
cold weather spec.)
D65EX, PX, WX-16 01-100 23

SEN04933-02

© 2012 KOMATSU
All Rights Reserved
01-100 24
SEN04963-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
10 Structure, function and

maintenance standard 10
100 Engine and cooling system

Engine mount.................................................................................................................................................. 3
Cooling system ............................................................................................................................................... 4
Cooling fan pump............................................................................................................................................ 6
Cooling fan motor.......................................................................................................................................... 20
Coolant preheater (subextremely cold weather spec.) ................................................................................. 26
D65EX, PX, WX-16 10-100 1

SEN04963-01
10-100 2 D65EX, PX, WX-16

Engine mount SEN04963-01
Engine mount 1
D65EX, PX, WX-16 10-100 3

SEN04963-01 Cooling system
Cooling system 1
1. Aftercooler inlet port hose 8. Cooling fan motor

2. Radiator inlet port hose 9. Drain valve
3. Reservoir tank 10. Aftercooler
4. Aftercooler outlet port hose 11. Radiator cap
5. Radiator outlet port hose 12. Radiator
6. Power train oil cooler 13. Hydraulic oil cooler bypass valve
7. Cooling fan 14. Hydraulic oil cooler
10-100 4 D65EX, PX, WX-16

Cooling system SEN04963-01
A: Power train oil cooler inlet port

B: Power train oil cooler outlet port
C: Hydraulic oil cooler inlet port
D: Hydraulic oil cooler outlet port
Specifications
Radiator Power train oil cooler Hydraulic oil cooler Aftercooler
Core type Corrugated aluminum PTO-OL Corrugated aluminum Corrugated aluminum
Fin pitch (mm) 8.0/2 — 8.0/2 8.0/2
Total heat dissipation

46.62 1.722 2.74 20.75
surface (m2)
Pressure valve cracking
88.3 ± 14.7
pressure — — —
{0.9 ± 0.15}
(kPa {kg/cm2})
Vacuum valve cracking
0 – 4.9
pressure — — —
{0 – 0.05}
(kPa {kg/cm2})
D65EX, PX, WX-16 10-100 5

SEN04963-01 Cooling fan pump
Cooling fan pump 1
Model: LPV30
P1: Pump discharge port 1. Servo valve

PCEPC: EPC output pressure pickup plug 2. EPC valve
PEPC: EPC valve basic pressure pickup plug 3. Self-pressure reducing valve
PR1: Self-pressure reducing valve output port 4. Air bleeder
PS: Pump suction port
T0: Drain port
T1: Drain plug
10-100 6 D65EX, PX, WX-16

Cooling fan pump SEN04963-01
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Valve
12. Spring
D65EX, PX, WX-16 10-100 7

Function Structure
q The pump converts the engine rotation and q Cylinder block (7) is supported to shaft (1) by
torque transmitted to its shaft to oil pressure spline (a), and shaft (1) is supported by the
and delivers pressurized oil corresponding to front and rear bearings.
the load. q The tip of piston (6) is a concave ball, and shoe
q It is possible to change the delivery by chang- (5) is caulked to it to form one unit. Piston (6)
ing the swash plate angle. and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A). It slides in
a circle pressing shoe (5) constantly to this sur-
face.
q Rocker cam (4) slides around ball retainer (11)
using it as fulcrum.
q Piston (6) performs relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q Cylinder block (7) carries out rotation relative
to valve plate (8) while sealing the pressurized
oil, and this surface ensures that the hydraulic
balance is maintained correctly.
q The oil inside each cylinder chamber of cylin-
der block (7) is suctioned and discharged
through valve plate (8).
10-100 8 D65EX, PX, WX-16

Operation
Operation of pump
q Cylinder block (7) rotates together with shaft q When center line (X) of rocker cam (4) is the
(1), and shoe (5) slides on flat surface (A). same as the axial direction of cylinder block (7)
q Tilting of rocker cam (4) around ball retainer [ s w a s h p l at e a n gl e = 0] , t he d i ff er e nc e
(11) changes inclination (a) of the center line between volumes (E) and (F) inside cylinder
(X) of rocker cam (4) and cylinder block (7) in block (7) is 0, so pump does not suck and dis-
the axial direction. charge, and no pumping is carried out. (Actu-
q Angle (a) is called the swash plate angle. ally, however, the swash plate angle is not set
q With the condition of center line (X) of rocker to 0)
cam (4) has swash plate angle (a) to axial q Swash plate angle (a) is in proportion to the
direction of cylinder block (7), flat surface (A) delivery.
functions as cam against shoe (5).
q Piston (6) slides inside cylinder block (7) and,
by this movement, a difference is made
between volumes (E) and (F) in cylinder block
(7). As a result, suction and discharge of oil by
(F) – (E) is carried out for each piston (6).
q Rotation of cylinder block (7) reduces the vol-
ume of chamber (E) and the oil is discharged
in this process. At the same time, the volume
of chamber (F) becomes larger and the oil is
sucked in this process. [In the figure, chamber
(F) is at the end of the suction stroke and
chamber (E) is at the end of the discharge
stroke.]
D65EX, PX, WX-16 10-100 9

Control of delivery
q The discharge amount is increased by the

increase of capacity difference of (E) and (F)
as swash plate angle (a) is increased. Swash
plate angle (a) is changed with servo piston
(10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight line movement is transmitted to
rocker cam (4), and rocker cam (4) supported
on ball retainer (11) starts oscillating around
ball retainer (11).
10-100 10 D65EX, PX, WX-16

Servo valve 1
P: EPC valve basic pressure

PE: Control piston pressure
PH: Pump discharge pressure
T: Drain
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D65EX, PX, WX-16 10-100 11

A: Drain side
B: Pump discharge pressure input side
C: EPC output pressure received
D: EPC output pressure
10-100 12 D65EX, PX, WX-16

Function Operation
q The servo valve controls the current input to q The output pressure of EPC valve is applied to
the EPC valve and the swash plate angle (a) of piston chamber (C) to push piston (6). Piston
the pump so that they will be related as shown (6) pushes spool (5) until it is balanced with the
in the diagram. spring.
q Then, the land (PE) of the servo piston pres-
sure passage is connected to the pump dis-
charge passage (PH) by the notch of spool (5)
and the discharge pressure is led to the servo
piston.
q The servo piston is raised by the rocker cam.
Then, the position feedback is applied and the
lever moves to compress the spring.
q If spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
shut off. The pressure in the servo piston
chamber lowers and the rocker cam returns
toward the maximum swash plate angle.
q These processes are repeated until the swash
q The relationship between the input current (i) plate is fixed to a position where the EPC out-
to the EPC valve and output pressure (F) of put is balanced with the spring force.
EPC valve is as follows. q The greater the EPC output pressure, the
smaller the swash plate angle. Conversely, the
smaller the EPC output pressure, the greater
the swash plate angle.
D65EX, PX, WX-16 10-100 13

Self-pressure reducing valve 1
P: From fan pump discharge port Cooling fan pump

P1: Fan pump inside pressure 1. Body
PR1: To PPC valve 2. Sequence valve
PS: To sequence valve 3. Spring
TS2: To fan pump drain
Self-pressure reducing valve
4. Valve (pressure reducing valve)
5. Spring (pressure reducing valve main)
6. Poppet
7. Spring (pressure reducing valve pilot)
8. Screw
9. Spring (safety valve)
10. Ball
10-100 14 D65EX, PX, WX-16

Function Operation
At engine stop (total low pressure)
q The self-pressure reducing valve reduces the

discharge pressure of the fan pump and sup-
plies it to the PPC valve, the EPC valve, etc. as
the control pressure.
q Since spring (7) pushes the poppet (6) against

the seat, the circuit between port (PR1) and
(TS2) is closed.
q Since spring (5) pushes valve (4) leftward, the
circuit between port (P) and (PR1) is open.
q Since spring (3) pushes valve (2) downward,
the circuit between ports (P) and (P1) is
closed.
D65EX, PX, WX-16 10-100 15

When load pressure (P1) is lower than output

pressure (PR1) of self-pressure reducing valve
q Spring (3) and pressure (PS) [0 MPa {0 kg/cm2}
when the engine is stopped] push valve (2) in
the direction to close the circuit between ports
(P) and (P1). However, inflow of the hydraulic
oil from port (P) balances the pressure at
[Pressure (P) C Spring (3) force + (area (d) x
pressure (PR))] and the valve adjusts the
opening from port (P) to port (P1) in order to
maintain pressure (P) at a level higher than
pressure (PS).
q When pressure (PR1) rises above set pres-
sure, poppet (6) opens and hydraulic oil flows
through the route, from port (PR1), through
hole (a) in spool (4), through poppet (6) open-
ing to the tank port (TS2).
q Therefore, differential pressure is generated
around (a) inside spool (4), and spool (4) is
moved to close the opening from port (P) to
port (PR1) area. Using the amount of opening
at this point, the valve decreases pressure (P)
to the constant pressure [set pressure] and
supplies it as pressure (PR1).
10-100 16 D65EX, PX, WX-16

At raise of load pressure (P1)

q In this case, load pressure (P1) of the fan
m o t o r i n c r e a s e s a n d p r e s s u r e ( P) a l s o
increases to [Pressure (P) > Spring (3) force +
((d) area x pressure (PR))] accompanying
increase in pump delivery. Thus, valve (2)
moves up to the stroke end.
q The amount of opening from ports (P) to (P1)
increases and the passage resistance is
reduced. As a result, engine horsepower loss
is reduced.
q When pressure (PR1) rises above set pres-
sure, poppet (6) opens and hydraulic oil flows
through the route, from port (PR1), through
hole (a) in spool (4), through poppet (6) open-
ing to the tank port (TS2).
q Therefore, differential pressure is generated
around (a) inside spool (4), and spool (4) is
moved to close the opening from port (P) to
port (PR1) area. Using the amount of opening
at this point, the valve decreases pressure (P)
to the constant pressure [set pressure] and
supplies it as pressure (PR1).
D65EX, PX, WX-16 10-100 17

In the case of abnormal high pressure

q If pressure (PR1) of the self-pressure reducing
valve goes abnormally high, ball (10) comes off
the seat resisting spring (9) force. This move of
ball (10) reduces pressure (PR1) by conduct-
ing the hydraulic oil from output port (PR1) to
(TS2). As a result, the equipment [PPC valve,
EPC valve, etc.], to which the oil pressure is
supplied, is protected from the abnormal high
pressure.
10-100 18 D65EX, PX, WX-16

D65EX, PX, WX-16 10-100 19

SEN04963-01 Cooling fan motor
Cooling fan motor 1
Model: LMF28
P: From fan pump Specifications

T: From cooler to tank Capacity (cc/rev) 28
TC: To tank
Rated speed (rpm) 1,850
Rated flow (l/min) 51.8
Check valve crack pressure
0.044 {0.45}
(MPa {kg/cm2})
10-100 20 D65EX, PX, WX-16

Cooling fan motor SEN04963-01
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool (for reversible valve)
6. Valve plate 12. Safety valve
Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit
Free length
Installed Installed Installed
x outside Free length
13 Spool return spring diameter
length load load Replace spring
if damaged or
44.84 x 12 33 58.8 N — 47.1 N deformed.
{6 kg} {4.8 kg}
1.96 N 1.57 N
14 Check valve spring 13.0 x 6.5 9.5
{0.2 kg}
—
{0.16 kg}
D65EX, PX, WX-16 10-100 21

Hydraulic motor portion 1
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The pressurized oil sent from the pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The pressurized oil sent to one side of cylin-
der block (5) pushes each piston (4) [2 or 3
pistons in total] to generate the force (F1)
[F1 = P x xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°) to
output shaft (1), the force is divided into com-
ponents (F2) and (F3).
q Among them, radial component (F3) respec-
tively generates torque (T = F3 x ri) against the
(Y-Y) line connecting the top dead center and
bottom dead center.
q The combined force of these torques [T = s
(F3 x ri)] rotates cylinder block (5) through the
piston (4).
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
10-100 22 D65EX, PX, WX-16

Suction valve 1
Function When stopped

q If the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor contin-
ues revolution because of the force of inertia,
however, the pressure on the outlet side of the
motor rises.
q When the oil stops flowing in from inlet port (P),
the suction valve sucks in the oil on the outlet
side and supplies it to port (MA) where there is
not sufficient oil to prevent cavitation.
Operation
When started
q When the engine is stopped and the input rota-

tion of the fan pump lowers to 0 rpm, the pres-
surized oil from the pump is not supplied to
port (P) any more. Since the pressurized oil is
not supplied to (MA) side of the motor, the
motor speed lowers gradually to stop.
q If the motor shaft is rotated by the force of iner-
tia while the oil flow to the port (P) is reducing,
the pressurized oil in port (T) on the outlet side
is sent by the suction valve (1) to the (MA) side
to prevent cavitation.
q If the pressurized oil from the pump is supplied

to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor,
the motor starts revolution. The pressurized oil
on the motor outlet (MB) side returns through
port (T) to the tank.
D65EX, PX, WX-16 10-100 23

Reversible valve 1
Operation
When ON/OFF solenoid is "de-energized" When ON/OFF solenoid is "energized"
q If ON/OFF solenoid (1) is "de-energized", the q If ON/OFF solenoid (1) is "energized", ON/OFF
pressurized oil from the pump is blocked by selector valve (2) is switched to allow the pres-
ON/OFF selector valve (2) and port (C) opens surized oil from the pump flow through port (C)
to the tank circuit. into spool chamber (D).
q Spool (3) is pushed by spring (4) to the right to q The pressurized oil in chamber (D) pushes
open motor port (MA). As a result, the pressur- valve spool (3) to the left resisting spring (4).
ized oil flows in to cause the positive rotation q As a result, motor port (MB) opens and pres-
(clockwise rotation) of the motor. surized oil flows in to cause reverse rotation
(counterclockwise rotation) of the motor.
10-100 24 D65EX, PX, WX-16

Safety valve 1
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q In this way, the safety valve prevents genera-
tion of an abnormal pressure in port (P).
D65EX, PX, WX-16 10-100 25

SEN04963-01 Coolant preheater (subextremely cold weather spec.)
Coolant preheater (subextremely cold weather spec.) 1
a subextremely cold weather specification machine only
1. Coolant preheater
2. Oil pan cover for coolant preheater
3. Exhaust duct for coolant preheater
4. Coolant preheater fuel tank
10-100 26 D65EX, PX, WX-16

Coolant preheater (subextremely cold weather spec.) SEN04963-01
Function
Subextremely cold weather specification machines
are equipped with coolant preheater (1) to warm up
engine coolant and engine oil when starting engine
at minus 25°C or low.
Coolant preheater includes fuel tank for coolant
preheater (4), exhaust duct (3) which leads the
exhaust heat of coolant preheater to engine oil pan,
oil pan cover(2) which transmits the exhaust heat to
engine oil pan.
1. Preheater timing chart

1) Normal ignition and normal combustion
2) When abnormal
D65EX, PX, WX-16 10-100 27

SEN04963-01 Coolant preheater (subextremely cold weather spec.)
3) Normal operation
10-100 28 D65EX, PX, WX-16

Coolant preheater (subextremely cold weather spec.) SEN04963-01
2. Electrical circuit diagram of preheater
D65EX, PX, WX-16 10-100 29

SEN04963-01

© 2012 KOMATSU
All Rights Reserved
10-100 30
SEN04964-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

201 Power train, Part 1

Power train...................................................................................................................................................... 2
HSS system .................................................................................................................................................... 4
Overall view of power train unit....................................................................................................................... 6
Power train hydraulic piping diagram............................................................................................................ 10
Transmission, steering and brake control ..................................................................................................... 12
Damper ......................................................................................................................................................... 14
Universal joint ............................................................................................................................................... 16
Torque converter and PTO............................................................................................................................ 17
Transmission................................................................................................................................................. 24
Transmission control valve............................................................................................................................ 42
ECMV............................................................................................................................................................ 46
Main relief and torque converter relief valve ................................................................................................. 54
Main relief and torque converter relief valve (subextremely cold weather spec.) ......................................... 56
Transmission lubrication relief valve ............................................................................................................. 58
D65EX, PX, WX-16 10-201 1

SEN04964-01 Power train
Power train 1
Outline
q The power generated by engine (1) has its tor- q The power transmitted to the bevel gear shaft
sional vibration dampened by damper (2), and is transmitted to HSS unit (10).
then passes through universal joint (3) and is HSS pump (4) is driven by PTO (5), and dis-
transmitted to torque converter (7). charged oil of the HSS pump drives HSS motor
q The power from the engine is transmitted (11).
through the oil by torque converter (7) to the The rotation of the pair of the HSS gears on
transmission input shaft in accordance with the the right and left is controlled by HSS motor
change in load. (11). The steering direction is controlled by
q Transmission (8) uses a combination of a plan- generating a difference in speed on the right
etary gear system and hydraulic clutches to and left.
reduce the speed and shift the gears (3 for- It is also possible to use the HSS mechanism
ward speeds and 3 reverse speeds). It con- to rotate the right and left sides in opposite
nects 2 sets of clutches selected according to directions to carry out counter-rotation.
the change in load and transmits the power to q Brake (12) built in HSS unit (10) is used for
bevel gear (9) from the bevel pinion at the rear braking the machine. Brake (12) is a wet, multi-
end of the transmission. ple disc clutch and spring boosted type.
The power sent from brake (12) is transmitted
to final drive (13).
q Final drive (13) consists of a single-stage spur
gear and a single-stage planetary gear sys-
tem. It reduces the speed and rotates sprocket
(14) to drive track shoe (15) and moves the
machine.
q Cooling fan motor (19) is rotated with the oil
discharged from cooling fan pump (6) driven
by PTO (5).
10-201 2 D65EX, PX, WX-16

Power train SEN04964-01
1. Engine 11. HSS motor

2. Damper 12. Brake
3. Universal joint 13. Final drive
4. HSS pump 14. Sprocket
5. PTO 15. Track shoe
6. Cooling fan pump 16. Power train pump
7. Torque converter 17. Steering lubrication pump
8. Transmission 18. Scavenging pump
9. Bevel gear 19. Cooling fan motor
10. HSS unit
D65EX, PX, WX-16 10-201 3

SEN04964-01 HSS system
HSS system 1
a HSS: Abbreviation for Hydrostatic Steering System
10-201 4 D65EX, PX, WX-16

HSS system SEN04964-01
1. Steering, directional, gear shift lever Outline

(PCCS lever) q The HSS system consists of control valve (4),
2. Power train controller HSS pump (6) and HSS motor (8). It turns the
3. Engine controller machine continuously without lowering the
4. Control valve traveling speed by making a difference in
5. EPC valve speed between both track shoes.
6. HSS pump q Power train controller (2) controls the rotating
7. Servo valve direction and the rotating speed of HSS motor
8. HSS motor (8) according to the tilting direction and angle
9. HSS circuit of steering, directional, gear shift lever (1) with
10. Engine EPC valve (5) of control valve (4).
11. Final drive HSS motor (8) acts on the planetary gear
12. Sprocket mechanism of the bevel gear shaft making a
13. Hydraulic tank difference in speed between both sprockets
(12) to turn the machine.
Input and output signals q Power train controller (2) senses the engine
a. Forward and reverse signals speed and the oil pressure at each part, and
b. Steering signal controls HSS pump (6) and control valve (4) so
c. Engine control information that engine (10) will not stall.
d. Work equipment oil pressure signal q The engine speed signal and other engine
e. CAN communication network control information are sent and received
through the CAN communication network
which connects engine controller (3) and
power train controller (2).
D65EX, PX, WX-16 10-201 5

SEN04964-01 Overall view of power train unit
Overall view of power train unit 1
10-201 6 D65EX, PX, WX-16

Overall view of power train unit SEN04964-01
1. HSS motor
2. Transmission
3. Transmission ECMV
4. Torque converter and PTO
5. Scavenging pump
6. Power train oil strainer
7. Power train pump
8. Lubrication pump
9. HSS pump
10. Cooling fan pump
11. Brake valve
12. HSS unit
13. Main relief valve
14. Power train filter relief valve (subextremely cold
weather spec.)
Outline
q The power train unit broadly consists of torque
converter and PTO (4), transmission (2), and
HSS unit (12). Therefore, after the power train
unit is removed, it can be divided into torque
converter and PTO (4), transmission (2), and
HSS unit (12).
q HSS unit (12) consists of the bevel gear unit,
bevel gear, HSS motor (1), planetary gear
mechanism and brake.
D65EX, PX, WX-16 10-201 7

SEN04964-01 Overall view of power train unit
*1: Shows other than the power angle power tilt dozer.
*2: Shows the power angle power tilt dozer.
10-201 8 D65EX, PX, WX-16

Overall view of power train unit SEN04964-01
Unit: mm
Standard Tolerance Standard Clearance
Clearance between steering case size Shaft Hole clearance limit
1 cover and bushing +0.096 +0.046 –0.096 –
204 +0.050 0 –0.004 Max. 0 Replace
2 Free height of rear mount rubber
43 41
D65EX, PX, WX-16 10-201 9

SEN04964-01 Power train hydraulic piping diagram
Power train hydraulic piping diagram 1
A: Transmission oil pressure pick-up port 1. HSS pump

B: Torque converter outlet oil pressure pick-up port 2. HSS motor
C: Torque converter inlet oil pressure pick-up port 3. Brake valve
D: Brake oil pressure pick-up port 4. Power train oil filter
5. Main relief, torque converter relief valve
6. Scavenging pump
7. Lubrication pump
8. Power train pump
9. Power train oil cooler
10. Central pressure detection port
10-201 10 D65EX, PX, WX-16

Power train hydraulic piping diagram SEN04964-01
D65EX, PX, WX-16 10-201 11

SEN04964-01 Transmission, steering and brake control
Transmission, steering and brake control 1
a PCCS: Abbreviation for Palm Command Control System
10-201 12 D65EX, PX, WX-16

Transmission, steering and brake control SEN04964-01
1. Decelerator pedal
2. Brake pedal
3. Parking brake lever
4. Steering, directional, gear shift lever (PCCS lever)
5. Fuel control dial
6. Parking brake limit switch
7. Brake valve
8. Power train controller
9. Cable
10. Transmission control valve
11. Rod
12. Brake pedal potentiometer
13. Decelerator pedal potentiometer
14. UP switch
15. DOWN switch
Outline
q The transmission, steering, and brake are con-
trolled with operation of steering, directional,
gear shift lever (PCCS lever) (4).
q Upon receiving the electric signal from steer-
ing, directional, gear shift lever (4), power train
controller (8) transmits the signal to the EPC
valve of the control valve according to the tilt-
ing angle of steering, directional, gear shift
lever (4) to change the oil flow of the HST
pump and thereby controls the HST motor.
q Brake pedal (2) operates brake valve (7) using
rod (11) to operate the brake.
q Parking brake lever (3) doubles as the parking
brake since it operates brake valve (7) using
cable (9).
q The safety mechanism employed does not
allow parking brake limit switch (6) to operate
unless parking brake lever (3) is set to the
"LOCK" position. In this case, therefore, the
engine does not start.
D65EX, PX, WX-16 10-201 13

SEN04964-01 Damper
Damper 1
10-201 14 D65EX, PX, WX-16

Damper SEN04964-01
Unit: mm

Standard size Tolerance Repair limit Repair by hard
1 Outside diameter of oil seal
contact surface of coupling 0 chrome plating or
85 –0.087 84.8 replace
Facial runout: Max 1.0 (at ø148.38), Radial runout: Max.: 1.5
— Facial and radial runout of
coupling
[When the damper shaft and transmission input shaft are rotated at Adjust
the same time.]
2. Breather Outline
3. Oil filler plug q The damper is a wet friction spring type.
4. Inspection plug Stopper angle: 4°
5. Drain plug Stopper torque: 2,685 Nm {274 kgm}
6. Damper case q The damper dampens the torsional vibration
7. Coupling caused by the engine torque fluctuation and
8. Shaft the impact torque generated when accelerat-
9. Bearing ing suddenly or carrying out heavy-duty opera-
10. Drive plate tion mode. In this way it acts to protect the
11. Friction plate torque converter, transmission, and other parts
12. Friction spring of the power train.
13. Stopper pin
14. Hub
15. Cover
D65EX, PX, WX-16 10-201 15

SEN04964-01 Universal joint
Universal joint 1
1. Spider
2. Yoke
10-201 16 D65EX, PX, WX-16

Torque converter and PTO SEN04964-01
Torque converter and PTO 1
a PTO: Abbreviation for Power Take Off
D65EX, PX, WX-16 10-201 17

SEN04964-01 Torque converter and PTO
10-201 18 D65EX, PX, WX-16

A: From transmission case Outline

(To power train and lubrication pump) q The torque converter is a 3-element, 1-stage,
B: To transmission case and 2-phase type, which is integral with the
(Drain) transmission.
C: From transmission case q Pump (15) is integrated with coupling (7), input
(To scavenging pump) shaft (8) and drive case (12), and rotated by
D: From transmission case the power from the engine.
(To torque converter) q Turbine (13) is integrated with transmission
E: Torque converter outlet pressure pick-up port input shaft (19), and rotated by the oil from
F: Torque converter inlet pressure pick-up port pump (15) as medium.
G: To oil cooler q Stator (14), which is installed to stator shaft
(16) through outer race (21) and free wheel
(20), is fixed to PTO case (11).
1. PTO lubrication tube q Each pump installed to the PTO case is driven
2. HSS pump and cooling fan pump mounting with the power transmitted from input shaft (8)
port to pump drive gears (26) and (28) through PTO
3. Torque converter oil temperature sensor idler gear (10).
mounting port
4. Torque converter oil pressure sensor mounting
port
5. Power train and steering lubrication pump
mounting port
6. Scavenging pump mounting port
7. Coupling
8. Input shaft
(PTO drive gear portion number of teeth: 62)
9. PTO idler gear shaft
10. PTO idler gear (number of teeth: 63)
11. PTO case
12. Drive case
13. Turbine
14. Stator
15. Pump
16. Stator shaft
17. Housing
18. Retainer
19. Transmission input shaft
20. Free wheel
21. Outer race
22. Boss
23. Lockup clutch disc
24. Lockup clutch piston
25. Lockup clutch housing
26. HSS pump, cooling fan pump, power train and
steering lubrication pump drive gear
(number of teeth: 53)
27. Sleeve
28. Scavenging pump drive gear
(number of teeth: 56)
29. Scavenging pump strainer
30. Power train strainer
D65EX, PX, WX-16 10-201 19

10-201 20 D65EX, PX, WX-16

Unit: mm
Standard size Tolerance Repair limit
Outside diameter of oil seal
1 contact surface of input coupling 0 Repair by hard
95 94.8
–0.087 chrome plating or
Inside diameter of retainer seal +0.040 replace
2 ring contact surface
140
0
140.5
Backlash between PTO drive
3 gear and PTO idler gear
0.17 – 0.46
Backlash of PTO idler gear and
HSS pump, cooling fan pump,
4 power train and steering
0.16 – 0.42
Replace
lubrication pump drive gear
Backlash between PTO drive
5 gear and scavenging pump drive 0.17 – 0.46
gear
Tolerance
Standard size
Shaft Hole
Fit tolerance of PTO Outside 0 –0.024
6 idler gear bearing 110
diameter –0.015 –0.049
Inside 0 0
diameter 60
–0.019 –0.015
Outside
diameter +0.035
Fit tolerance of HSS (On the 0
pump, cooling fan cover side) 0
120 —
pump, power train Outside –0.015
7 and steering diameter +0.022
lubrication pump (On the –0.013
drive gear bearing case side)
Inside +0.030 0
diameter 55
+0.011 –0.015
Outside 0 +0.030
Fit tolerance of diameter 72
–0.013 0
8 scavenging pump
drive gear bearing Inside +0.025 0
diameter 35
+0.009 –0.010
D65EX, PX, WX-16 10-201 21

Power transmitting route
When the lockup clutch is set to "DISENGAGED" When the lockup clutch is set to "ENGAGED"
Drive case (4) is disconnected from turbine (6) and Drive case (4) is connected to turbine (6) to perform
works as an ordinary torque converter. the lockup function.
The power from engine The power from engine
O O
Coupling (1) Coupling (1)
O O
Input shaft (2), clutch housing (3), Input shaft (2), clutch housing (3),
drive case (4) and pump (5) rotate together drive case (4) and pump (5) rotate together
O O
Oil is used as medium Lockup clutch (9)
O O
Turbine (6) and boss (7) Turbine (6) and boss (7)
O O
Transmission input shaft (8) Transmission input shaft (8)
10-201 22 D65EX, PX, WX-16

Oil flow
q The oil flows through the main relief valve and

its pressure is regulated to below the set pres-
sure at the torque converter relief valve. It then
flows into inlet port (A), goes through the oil
passages of housing (1) and retainer (2) and
then flows into pump (3).
q The oil is given centrifugal force by pump (3)
and flows in turbine (4) to transfer its energy to
turbine (4).
q The oil from turbine (4) is sent to stator (5) and
flows into pump (3) again. And part of the oil
flows through the space between turbine (4)
and stator (5) to outlet port (B). The oil is then
conducted to the oil cooler for cooling and
used for lubricating the transmission.
D65EX, PX, WX-16 10-201 23

SEN04964-01 Transmission
Transmission 1
10-201 24 D65EX, PX, WX-16

Transmission SEN04964-01
A: To steering control valve

B: Transmission lubrication oil pressure pick-up port
C: Main relief pressure pick-up port
D: From power train pump
E: From oil cooler
F: To torque converter
G: To PTO case (to scavenging pump)
H: From PTO case (drain)
J: To PTO case (to power train and steering lubrication pump)
K: From steering case
1. Transmission control valve

2. Transmission case
3. Main relief and torque converter relief valve
4. Transmission lubrication relief valve
5. Sleeve
D65EX, PX, WX-16 10-201 25

10-201 26 D65EX, PX, WX-16

1. Transmission input shaft

2. R sun gear (number of teeth: 26)
3. Tie bolt
4. R planetary pinion (number of teeth: 22)
5. R ring gear (number of teeth: 70)
6. Disc
7. Plate
8. F planetary pinion (number of teeth: 21)
9. 3rd planetary pinion (number of teeth: 28)
10. 3rd ring gear (number of internal teeth: 75)
11. 2nd planetary pinion (number of teeth: 23)
12. 2nd sun gear (number of teeth: 29)
13. 1st planetary pinion (number of teeth: 18)
14. 1st sun gear (number of teeth: 39)
15. Output shaft
(3rd sun gear number of teeth: 17)
16. Rear housing
17. 1st clutch piston
18. 1st carrier
19. 1st ring gear (number of internal teeth: 75)
20. 2nd clutch housing
21. 2nd clutch piston
22. 2nd carrier
23. 2nd ring gear (number of internal teeth: 75)
24. 3rd clutch housing
25. 3rd clutch piston
26. 3rd carrier
27. F and 3rd clutch housing
28. F sun gear (number of teeth: 34)
29. F ring gear (number of internal teeth: 76)
30. F clutch piston
31. F carrier
32. R and F clutch housing
33. R clutch piston
34. Return spring
35. R ring gear (hub) (number of internal teeth: 75)
36. R carrier
37. Front housing
D65EX, PX, WX-16 10-201 27

Outline
q The transmission uses a combination of the
planetary gear system and disc clutches to
shift the gears in "3-forward and 3-reverse
speeds".
q The transmission selects a single steering
direction and gear speed by hydraulically fixing
the planetary gear mechanism and 2 of the 5
sets of disc clutches by use of ECMV.
q The transmission transfers the power received
by the transmission input shaft to the output
shaft while changing the gear speed (forward
1st-3rd or reverse 1st-3rd) by any combination
of the F, R clutches and 3 speed clutches.
Number of plates and discs used

Number of
Clutch No. Number of discs
plates
R clutch 6 5
F clutch 8 7
3rd clutch 5 4
2nd clutch 5 4
1st clutch 5 4
Gear speeds and operated clutches

Reduction
Gear speed Operated clutches
ratio
Forward 1st F x 1st 2.020
Forward 2nd F x 2nd 1.388
Forward 3rd F x 3rd 0.674
Neutral (*1) —
Reverse 1st R x 1st 1.681
Reverse 2nd R x 2nd 1.155
Reverse 3rd R x 3rd 0.561
*1: Either of the 1st, 2nd or 3rd clutch is filled with oil at
low pressure.
10-201 28 D65EX, PX, WX-16

D65EX, PX, WX-16 10-201 29

10-201 30 D65EX, PX, WX-16

Unit: mm
Free length Free length
1 R clutch spring (5 pcs.) length load load
190.2 N 161.7 N
69.5 60.7 65.3
{19.4 kg} {16.5 kg}
95.2 N 81 N
2 F clutch spring (5 pcs.) 77.0 63.6
{9.7 kg}
72.4
{8.2 kg}
141.2 N 120.0 N
3 3rd clutch spring (5 pcs.) 59.0 44.6
{14.4 kg}
55.5
{12.2 kg}
141.2 N 120.0 N
4 2nd clutch spring (5 pcs.) 59.0 44.6
{14.4 kg}
55.5
{12.2 kg}
114.7 N 97.5 N
5 1st clutch spring (5 pcs.) 59.0 47.3
{11.7 kg}
55.5
{9.9 kg}
Total thickness of R clutch Standard size Tolerance Repair limit

6 assembly consisting of 5 discs
and 6 plates 36.2 ±0.33 32.2
Total thickness of F clutch
7 assembly consisting of 7 discs 49.4 ±0.39 43.8
and 8 plates
Total thickness of 3rd clutch
and 5 plates
Total thickness of 2nd clutch
and 5 plates
Total thickness of 1st clutch Replace
and 5 plates
11 Thickness of clutch disc 3.4 ±0.1 2.6
12 Thickness of clutch plate 3.2 ±0.1 2.9

–0.01
Wear on 3rd speed Width 4 3.6
–0.03
13 and 1st speed carrier
cover seal rings Thickness 5 ±0.15 4.85
Backlash between R, F, 3rd and
14 1st speed sun gears and 0.11 – 0.30
planetary pinion
Backlash between 2nd speed sun
15 gear and planetary pinion
0.12 – 0.33
Backlash of R planetary pinion
16 and ring gear
0.13 – 0.41
Backlash of F, 3rd and 1st
17 planetary pinion and ring gear
0.12 – 0.33
Backlash of 2nd planetary pinion
18 and ring gear
0.13 – 0.36
Backlash between R carrier and
19 internal teeth of ring gear
0.14 – 0.44
Backlash between F carrier and
0.14 – 0.38
Backlash between 1st carrier and
0.14 – 0.39
D65EX, PX, WX-16 10-201 31

Disc clutch
Structure When clutch is "DISENGAGED" (released)

q The disc clutch consists of piston (2), plates q As the oil from ECMV is stopped, piston (2) is
(3), discs (4), pin (5), return spring (6) etc. to fix pushed back rightward by return spring (6).
ring gear (1). q Plates (3) and discs (4) are free from the fric-
q Inside teeth of disc (4) are engaged with out- tional force and thus ring gear (1) is released.
side teeth of ring gear (1).
q Plate (3) is assembled to clutch housing (7)
with pin (5).
Operation
When clutch is "ENGAGED" (fixed) Oil passage in speed clutch
q The oil from ECMV passes through the oil pas- q When the steering, directional, gear shift lever
sage of clutch housing (7) and then sent with is set to the "NEUTRAL" position, the 1st, 2nd,
pressure to the back of piston (2) to push pis- or 3rd speed is selected.
ton (2) leftward. q The piston chamber of the clutch correspond-
q Piston (2) contacts plate (3) closely against ing to the selected gear speed is filled with oil
disc (4) to stop rotation of disc (4) by use of the by electronically controlling the hydraulic circuit
friction force generated between them. of each clutch.
q Since the internal teeth of disc (4) are engaged q When the steering, directional, gear shift lever
with the external teeth of ring gear (1), move of is shifted from the "NEUTRAL" position to the
ring gear (1) is stopped. "FORWARD" or "REVERSE" position, the
amount of oil from the pump must be sufficient
to fill up the piston chamber of the F clutch or R
clutch.
q When the gear speed is changed from "FOR-
WARD 1ST" to "FORWARD 2ND", only the
amount of oil enough to press-fitting the plate
and disc of the 2nd clutch is required since the
F clutch has been filled with the oil.
q The time lag in the gear shifting operation is
reduced by controlling the oil in the clutch cir-
cuit as explained above.
10-201 32 D65EX, PX, WX-16

D65EX, PX, WX-16 10-201 33


Forward 1st
10-201 34 D65EX, PX, WX-16

F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.
The power from torque converter
O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12) o o o O
O O
3rd ring gear (13)
O
2nd carrier (14)
O
O
2nd planetary pinion (15) o O
O O
2nd ring gear (16) O
O
1st carrier (17) O
O
O
1st planetary pinion (18)
O O
1st sun gear (20) 2nd sun gear (21)
O O O
Output shaft (22) i i i i
D65EX, PX, WX-16 10-201 35

Forward 2nd
10-201 36 D65EX, PX, WX-16

F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed hydraulically.
O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12) o O
O O
3rd ring gear (13)
O O
2nd carrier (14)
O O
2nd planetary pinion (15)
O O
2nd sun gear (21)
O O
Output shaft (22) i i
D65EX, PX, WX-16 10-201 37

Forward 3rd
10-201 38 D65EX, PX, WX-16

F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically.
O
Input shaft (1)
O
F sun gear (2)
O
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12)
O
Output shaft (22)
D65EX, PX, WX-16 10-201 39

Reverse 1st
10-201 40 D65EX, PX, WX-16

R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically.
O
Input shaft (1)
O
R sun gear (5)
O
R planetary pinion (6)
O
R ring gear(9)
(R carrier (8) is fixed with R ring gear (7)) =
Rotation direction of R ring gear (9) is
opposite to input shaft (1))
O
F carrier (10)
O
3rd carrier (11)
O
3rd planetary pinion (12) o o o O
O O
3rd ring gear (13)
O O
2nd carrier (14)
O O
2nd planetary pinion (15) o O
O O O
2nd ring gear (16)
O O O
1st carrier (17)
O O O
1st planetary pinion (18)
O O O
1st sun gear (20) 2nd sun gear (21)
O O O
Output shaft (22) i i i i
D65EX, PX, WX-16 10-201 41

SEN04964-01 Transmission control valve
Transmission control valve 1
10-201 42 D65EX, PX, WX-16

Transmission control valve SEN04964-01
A: Lockup clutch oil pressure pick-up port

B: R clutch oil pressure pick-up port
C: 3rd clutch oil pressure pick-up port
D: 1st clutch oil pressure pick-up port
E: F clutch oil pressure pick-up port
F: 2nd clutch oil pressure pick-up port
1. Lockup clutch ECMV

2. R clutch ECMV
3. 3rd clutch ECMV
4. 1st clutch ECMV
5. F clutch ECMV
6. 2nd clutch ECMV
7. Last chance filter
Operation table of ECMV

ECMV
F R 1st 2nd 3rd L/U
Gear speed
F1 Q Q Q
F2 Q Q Q
F3 Q Q Q
R1 Q Q Q
R2 Q Q Q
R3 Q Q Q
N (*1) (Q) (Q) (Q)
*1: Either of 1st, 2nd or 3rd clutch operates depending
on the preset value.
L/U: Indicates the lockup clutch ECMV.
D65EX, PX, WX-16 10-201 43

SEN04964-01 Transmission control valve
Outline
q The oil from the pump flows to the transmission case through the power train oil filter and then the flow
is divided to the one toward the main relief circuit and the other toward the clutch operating circuit.
q The oil, which has flown to the clutch operation circuit after being regulated at the main relief valve, then
flows through the last chance filter to operate the clutch, parking brake and main brake. The oil fed by
the main relief valve is supplied to the torque converter.
q At a gear shift, ECMV smoothly increases the clutch oil pressure responding to the command current
from the power train controller in order to alleviate the impacts resulting from the gear shift. And during
travel, the clutch oil pressure is kept at a constant level.
q Switching between the F and R as well as 1st, 2nd and 3rd clutch ECMVs supplies pressure-regulated
oil to the selected clutch to secure the desired speed.
q While traveling at the 1st, 2nd or 3rd speed, the lockup ECMV operates at a speed higher than the one
set on the transmission controller.
q 2 types of ECMVs are used. The following shows how to identify them as well as the difference between
them.
Printing on the Color for Fill switch
Pressure control Operated
nameplate identification (operating pressure:
valve clutches
(A) (B) MPa {kg/cm2})
Provided F, R, 1st, 2nd
L******* — No slit
(0.19 {2.0}) and 3rd
Provided
E******* Pink With slit L/U
(0.26 {2.7})
10-201 44 D65EX, PX, WX-16

Transmission control valve SEN04964-01
D65EX, PX, WX-16 10-201 45

SEN04964-01 ECMV
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve

For F, R, 1st, 2nd and 3rd clutches
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pick-up port
1. Fill switch connector

2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
10-201 46 D65EX, PX, WX-16

ECMV SEN04964-01
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q One proportional solenoid is mounted for each
and 1 fill switch. ECMV.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current from the power shown below according to the command cur-
train controller with the proportional solenoid, rent from the controller.
and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Therefore, modifying the amount
1. Outputs a signal (a fill signal) to the controller of the command current changes the thrust
to notify that filling is completed when the and turns on the operation of the pressure con-
clutch is filled with oil. trol valve for controlling the oil flow and oil
2. As long as oil pressure is needed for the pressure.
clutch, it keeps on transmitting the signals (fill
signals) to the controller to notify whether oil Current – Thrust characteristics of proportional
pressure is actually applied. solenoid
Thrust – Pressure characteristics of propor-

tional solenoid
Range A: Before shifting gear (when draining)

Range B: During filling
Range C: Pressure adjustment ECMV and fill switch
Range D: During filling (during triggering) q For each ECMV, 1 fill switch is installed.
Point E: Start of filling As the clutch is filled up, the fill switch is turned
Point F: Finish of filling "ON" by the pressure of the clutch. The oil
a The logic employed for the controller does not pressure is built up according to this signal.
recognize the filling is over even if the fill
switch is turned "ON" as long as the triggering
is taking place (range D).
D65EX, PX, WX-16 10-201 47

SEN04964-01 ECMV
Operation of ECMV Before shifting gear (when draining)

q The ECMV is controlled by the command cur- (Range A in chart)
rent from the controller to the proportional sole-
noid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
Also at this time, fill switch (5) is turned "OFF"
because oil pressure is not applied to oil pres-
Range A: Before shifting gear (when draining) sure detection valve (4).
Range B: During filling
Range C: Pressure adjustment
Range D: During filling (during triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic employed for the controller does not

recognize the filling is over even if the fill
switch is turned "ON" as long as the triggering
is taking place (range D).
10-201 48 D65EX, PX, WX-16

ECMV SEN04964-01
During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If current is supplied to proportional solenoid q If current is supplied to proportional solenoid

(1) when there is no oil in the clutch, the oil (1), the solenoid generates thrust in proportion
pressure force balanced with the solenoid to the current. This thrust of the solenoid is bal-
force is applied to chamber (B) and pushes anced with the sum of the thrust generated by
pressure control valve (3) to the left. As a the oil pressure in clutch port and the reaction
result, pump port (P) and clutch port (A) are force of pressure control valve spring (2), and
opened and oil starts filling the clutch. As the then the pressure is settled.
clutch is filled with oil, oil pressure detection
valve (4) operates to turn fill switch (5) "ON".
D65EX, PX, WX-16 10-201 49

SEN04964-01 ECMV
ECMV for lockup clutch

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pick-up port
1. Fill switch connector

2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
10-201 50 D65EX, PX, WX-16

ECMV SEN04964-01
Outline
q In addition to regulate the lockup clutch oil Operation
pressure, this valve is used to switch the When traveling in torque converter range
lockup clutch, too.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. In addition, it
prevents generation of peak torque in the
power train. As a result, it provides a comfort-
able ride for the operator and increases the
durability of the power train.
When changing from torque converter travel to

direct travel
q When traveling in torque converter range, cur-

rent is not supplied to proportional solenoid (1).
Since pressure control valve (3) drains the oil
from clutch port (A) through drain port (T), the
lockup clutch is "RELEASED".
Also at this time, fill switch (5) is turned "OFF"
because oil pressure force is not applied to oil
pressure detection valve (4).
D65EX, PX, WX-16 10-201 51

SEN04964-01 ECMV
When traveling in direct range

(torque converter travel to direct travel)
During filling Pressure regulation
q When traveling in direct (lockup) range, current q If current is supplied to proportional solenoid
is supplied to proportional solenoid (1), the oil (1), the solenoid generates thrust in proportion
pressure force balanced with the solenoid to the current. This thrust of the solenoid is bal-
force is applied to chamber (B) and pushes anced with the sum of the thrust generated by
pressure control valve (3) to the left. As a the oil pressure in clutch port and the reaction
result, pump port (P) and clutch port (A) are force of pressure control valve spring (2), and
opened and oil starts filling the clutch. As the then the pressure is settled.
clutch is filled with oil, oil pressure detection
valve (4) turns fill switch (5) "ON".
10-201 52 D65EX, PX, WX-16

ECMV SEN04964-01
D65EX, PX, WX-16 10-201 53

SEN04964-01 Main relief and torque converter relief valve
Main relief and torque converter relief valve 1
Unit: mm
Clearance between main relief size Shaft Hole clearance limit
1 valve and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 0 0.058
Clearance between torque
–0.035 +0.013 0.035 –
2 converter relief valve and valve 22 –0.045 0 0.058 0.078
body
Standard size Repair limit Replace
3 Main relief valve spring (outside) length load load
479.1 N 456 N
128 78.3 124.2
{48.9 kg} {46.5 kg}
365.5 N 347 N
4 Main relief valve spring (inside) 108 78.3
{37.3 kg}
104.8
{35.4 kg}
Torque converter relief valve 162.5 N 154 N
5 spring
50 41.5
{16.5 kg}
48.5
{15.7 kg}
6. Body A: Drain (torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pick-up port
P2: Torque converter relief oil pressure pick-up port
10-201 54 D65EX, PX, WX-16

Main relief and torque converter relief valve SEN04964-01
Outline Operation of main relief valve
Torque converter relief valve

q The torque converter relief valve maintains the
oil pressure in the torque converter inlet circuit
always below the set pressure in order to pro-
tect the torque converter from abnormally high
pressure.
Set pressure: 1.02 MPa {10.4 kg/cm2}
(cracking pressure)
Main relief valve

q The main relief valve maintains the hydraulic
circuit of the transmission, parking brake and
main brake at the set pressure. q The oil from the hydraulic pump flows to cham-
Set pressure: 3.58 MPa {36.5 kg/cm2} ber (F) through the filter, port (C) of the relief
(when engine is run at rated speed) valve and orifice (a) of main relief valve (1).
Operation
Operation of torque converter relief valve
q As the oil pressure in the circuit goes beyond

the set pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting reaction
force pushes main relief valve (1) leftward,
opening ports (C) and (E).
q The oil from the main relief valve is conducted Above operation conducts the oil from port (E)
to the torque converter through port (E) and, at to the torque converter.
the same time, also conducted to chamber (G)
through orifice (b) of torque converter relief
valve (3).
q As the oil pressure to the torque converter
rises beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting reaction force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As a result, the oil in port (E) is drained through
port (A).
D65EX, PX, WX-16 10-201 55

SEN04964-01 Main relief and torque converter relief valve (subextremely cold weather spec.)
Main relief and torque converter relief valve (subextremely cold weather
spec.) 1
a subextremely cold weather specification machine only
Unit: mm
Clearance between relief valve size Shaft Hole clearance limit
1 and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 0 0.058
2 Relief valve spring (outside) length load load
1,066 N 1,010 N
125 102.3 {108.8 kg} 123.8 {103.1 kg}
3. Body
4. Piston
5. Relief valve
A: From pump
B: To power line fillter
C: Drain
10-201 56 D65EX, PX, WX-16

Main relief and torque converter relief valve (subextremely cold weather spec.) SEN04964-01
Outline
q Power train filter relief valve always keeps the
oil pressure of power train filter inlet circuit
lower than set pressure to protect power train
filter from abnormal high pressure when start-
ing the engine at low temperature under sub-
extremely cold weather.
Set pressure: 4.07 MPa ± 0.2 MPa (41.5 kg/cm2 ± 2

kg/cm2) (cracking pressure)
Operation
Operation of power train filter valve
q The oil from power train pump flows to power

train filter of port (B) through port (A), at the
same time it flows to chamber (D) through
orifice (a).
q When the oil pressure in the port (B) flowing to

power train filter exceeds the set pressure, the
oil in chamber (D) pushes piston (4) and the
reaction force pushes relief valve (5) rightward.
This connects ports (E) and (C). Then, the oil
in port (E) is drained through port (A).
D65EX, PX, WX-16 10-201 57

SEN04964-01 Transmission lubrication relief valve
Transmission lubrication relief valve 1
Unit: mm
Transmission lubrication relief Free length Free length
1 valve spring
length load load Replace
26 23.7 12.0 N 25.2 11.4 N
{1.22 kg} {1.16 kg}
2. Piston Outline
3. Spring q The oil leaving the torque converter passes
4. Forward clutch housing through the oil cooler built in the radiator lower
tank. It then goes through the lubrication relief
A: From oil cooler valve and lubricates the transmission and
B: Drain PTO.
C: Drain q The transmission lubrication relief valve is
installed to the left side face of the forward
clutch housing. It maintains the lubricating oil
pressure below the set pressure.
Set pressure:
0.05 – 0.15 MPa {0.5 – 1.5 kg/cm2}
Cracking pressure: 0.29 MPa {3.0 kg/cm2}
10-201 58 D65EX, PX, WX-16

Transmission lubrication relief valve SEN04964-01
D65EX, PX, WX-16 10-201 59

SEN04964-01

© 2012 KOMATSU
All Rights Reserved
10-201 60
SEN04965-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up


Bevel gear shaft, HSS and brake.................................................................................................................... 2
Brake valve ................................................................................................................................................... 24
Final drive ..................................................................................................................................................... 30
Final drive (Planetary gear installed inside of sprocket type)........................................................................ 36
D65EX, PX, WX-16 10-202 1

SEN04965-01 Bevel gear shaft, HSS and brake
Bevel gear shaft, HSS and brake 1
a HSS: Abbreviation for Hydrostatic Steering System
A: To transmission case (to power train and steering lubrication pump)

B: Brake oil pressure pick-up port
10-202 2 D65EX, PX, WX-16

Bevel gear shaft, HSS and brake SEN04965-01
D65EX, PX, WX-16 10-202 3

10-202 4 D65EX, PX, WX-16

1. Brake valve
2. HSS motor
3. Output shaft
4. Brake spring (large)
5. Brake spring (small)
6. Spacer
7. Hub
8. Cage
9. Piston
10. Cover
11. Plate (one side: 4 pcs.)
12. Disc (one side: 5 pcs.)
13. Brake drum
14. Brake hub
15. Gear A (number of teeth: 38/55)
16. Cage
17. Gear B (number of teeth: 32)
18. Bevel gear shaft
19. Bevel gear (number of teeth: 34)
20. Bearing
21. Shaft
22. Gear C (number of teeth: 32)
23. Planetary pinion (number of teeth: 26)
24. Ring gear (number of teeth: 91)
25. Pinion shaft
26. Hub
27. Carrier
28. Gear D shaft
29. Gear D (number of teeth: 48)
30. HSS motor drive gear (number of teeth: 25)
31. Bevel pinion (number of teeth: 25)
32. Cage
D65EX, PX, WX-16 10-202 5

10-202 6 D65EX, PX, WX-16

Unit: mm
Replace
Thickness 5.0 ± 0.1 4.7
1 Brake plate
Strain — Max 0.15 0.3 Repair or replace
Thickness 5.2 ± 0.1 4.7 Replace

2 Brake disc
Strain — Max 0.25 0.4 Repair or replace
Total assembled thickness of 4
3 brake plates and 5 discs
46.0 ± 0.3 43.3
Standard clearance Clearance limit
Backlash between gear A and
4 gear B 0.06 – 0.65 — Replace
5 planetary pinion 0.14 – 0.35 —
Backlash between planetary
6 pinion and ring gear 0.15 – 0.38 —
If the starting torque is less than 9.8 Nm {1.0 kgm}, preload
Preload of taper roller bearing for adjustment must be done.
7 bevel gear shaft
Adjust
Starting torque after adjustment 10.3 – 14.7 Nm {1.05 – 1.50 kgm}
D65EX, PX, WX-16 10-202 7

10-202 8 D65EX, PX, WX-16

Unit: mm
1 gear D 0.09 – 0.64 —
Backlash between gear C and Replace
2 gear D
0.15 – 0.49 —
Backlash between gear D and
3 HSS motor drive gear
0.10 – 0.40 —
Backlash between bevel pinion
4 and bevel gear
0.20 – 0.28 — Adjust
D65EX, PX, WX-16 10-202 9

Outline
Bevel gear shaft Brake

q Bevel gear shaft converts power sideways at a q Brake is established to control the movement
right angle, which is transmitted from engine to of the machine, and is attached to brake hub
torque converter and transmission through (14).
mesh of bevel pinion (31) and bevel gear (19). q Brake adopts wet multiple disc type and
It also reduces the rotation speed. spring-boosted type, and it is hydraulic actu-
q Bevel gear shaft adopts spiral bevel gear at ated type which activates brake valve (1) by
bevel pinion (31) and bevel gear (19), and it the operation of brake pedal.
adopts splash lubrication with oil from scav- q It adopts forced lubrication which sends oil
enging pump and lubrication pump for lubrica- from scavenging pump and lubrication pump to
tion. cover (10) and cage (8) through passage
q Bevel gear shaft consists of bevel gear (19) inside steering case, and then to disc (12) and
which meshes with bevel pinion (31), bevel plate (11).
gear shaft (18) and bearing (20) which sup- q When the engine is stopped, back pressure of
ports bevel gear shaft and cage (16). brake piston (9) decreases even if the brake
pedal is not depressed. As a result, the brake
HSS is set to "operated" state. However, when the
q HSS is constructed from transfer area which engine is started, the parking brake lever must
transmits rotation of HSS motor (2) by turning it be set to "LOCK" state since the brake is
in reverse direction, and the planet area which "released" as the oil pressure within the circuit
adjusts inputs to ring gear (24) and gear A (15) increases when the engine is restarted.
and then outputs to carrier (27). q Brake is constructed from carrier (27), brake
It changes the turning direction of the machine hub (14) attached to hub (7), disc (12) meshed
by turning off the rotation of HSS motor (2), or with brake hub, plate (11) whose outside
by making it move in normal rotation or reverse perimeter is attached to brake drum (13) with
rotation. gear, piston (9) and springs (4) and (5) which
q The transfer unit employs a spur gear speed brings disc and plate together, and cage (8),
reduction mechanism and is lubricated with oil cover (10) and output shaft (3) which supports
splashed by the scavenging pump and lubrica- all of them.
tion pump. Brake drum (13) and cover (10) are fixed to the
q Planet area adopts forced lubrication with oil steering case.
from scavenging pump and lubrication pump Also, output shaft (3) is connected to the hub
for lubrication. (7) by spline and held by spacer (6) in the axial
q Transfer portion is constructed from HSS direction.
motor drive gear (30) connected with HSS
motor (2) with spline, gear D (29) meshed with
HSS motor drive gear, gear C (22) meshed
with gear D, gear B (17) attached to shaft (21),
gear A (15) retained on bevel gear shaft with
bearing, gear A (15) meshed with gear D (29)
and the case which supports them all.
q Planet area is constructed from gear A (15),
planetary pinion (23), pinion shaft (25), hub
(26) attached to bevel gear shaft (18) and ring
gear (24) with gear, and carrier (27) attached
to brake hub (14).
10-202 10 D65EX, PX, WX-16

D65EX, PX, WX-16 10-202 11

HSS operation
When steering is at "NEUTRAL" (straight travel)
Rotation direction of HSS motor

PCCS lever
steering operation Neutral Left turn Right turn
PCCS lever
Free, not Neutral Neutral
forward and reverse specified (*) Forward Reverse (*) Forward Reverse
switching operation
Rotation direction of
HSS motor
Stop Right Right Left Left Left Right
viewed from left
side of machine
*: Counter-rotation
10-202 12 D65EX, PX, WX-16

When the PCCS lever is steered to "NEUTRAL", HSS motor (7) is stopped.
The power from transmission
O
Bevel pinion (1)
O
Bevel gear (2)
O
Bevel gear shaft (3)
O
Hub (4)
O
Ring gear (5)
O
Planetary pinion (6)
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
D65EX, PX, WX-16 10-202 13

When steered to "LEFT TURN" (forward)
*A: Transmission output

*B: HSS motor output
*C: Combined output
*1. Transmission output speed

*2. HSS motor output speed
*3. Left bevel gear shaft output speed (*1 – *2)
*4. Right bevel gear shaft output speed (*1 + *2)
10-202 14 D65EX, PX, WX-16

If the PCCS lever is steered to "LEFT TURN" during forward travel, HSS motor (7) rotates clockwise viewed
from the left side of the machine body.
Power from transmission Power from HST motor (7)
(forward) (clockwise viewed from left
side of the machine)
O O
Bevel pinion (1) Drive gear (8)
O O
Bevel gear (2) Gear D (9) o O
O O O
Bevel gear shaft (3) Gear C (10)
O O O
Hub (4) Shaft (11)
O O O
Ring gear (5) Gear B (12)
O O O
Left gear A (13) Right gear A (13)
O (counterclockwise viewed from left (clockwise viewed from left
side of the machine) side of the machine)
O O O
Planetary pinion (6) i i i i i
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
D65EX, PX, WX-16 10-202 15

When steered to "LEFT TURN" (reverse)

*C: Combined output

*3. Left bevel gear shaft output speed (*1 – *2)
*4. Right bevel gear shaft output speed (*1 + *2)
10-202 16 D65EX, PX, WX-16

If PCCS lever is steered to "LEFT TURN" during reverse travel, HSS motor (7) rotates counterclockwise
viewed from the left side of the machine body.
(reverse) (counterclockwise viewed from left
side of the machine body)
O O
O O
O O O
O O O
Hub (4) Shaft (11)
O O O
O O O
O (clockwise viewed from left (counterclockwise viewed from left
side of the machine body) side of the machine body)
O O O
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
D65EX, PX, WX-16 10-202 17

When steered to "RIGHT TURN" (forward)

*C: Combined output

*3. Left bevel gear shaft output speed (*1 + *2)
*4. Right bevel gear shaft output speed (*1 – *2)
10-202 18 D65EX, PX, WX-16

If PCCS lever is steered to "RIGHT TURN" during forward travel, HSS motor (7) rotates counterclockwise
viewed from the left side of the machine body.
(forward) (counterclockwise viewed from left
O O
O O
O O O
O O O
Hub (4) Shaft (11)
O O O
O O O
O (clockwise viewed from left (counterclockwise viewed from left
O O O
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
D65EX, PX, WX-16 10-202 19

When steered to "RIGHT TURN" (reverse)

*C: Combined output

*3. Left bevel gear shaft output speed (*1 + *2)
*4. Right bevel gear shaft output speed (*1 – *2)
10-202 20 D65EX, PX, WX-16

If PCCS lever is steered to "RIGHT TURN" during reverse travel, HSS motor (7) rotates clockwise viewed
from the left side of the machine body.
(reverse) (clockwise viewed from left
O O
O O
O O O
O O O
Hub (4) Shaft (11)
O O O
O O O
O (counterclockwise viewed from left (clockwise viewed from left
O O O
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
D65EX, PX, WX-16 10-202 21

Brake operation
When brake is "released" When brake is "operated" (when brake pedal

"depressed"
q When the brake pedal is released, the brake

valve is at "NEUTRAL" position, and the back q When brake pedal is depressed, brake valve is
pressure port of piston (1) is filled with oil. switched and the oil of back pressure port of
q Rising of oil pressure makes piston (1) push piston (1) is drained.
down springs (2) and (3) and move towards left q By reducing the oil pressure of back pressure
direction, and releases disc (4) and plate (5). port, piston (1) moves to the right direction
q Power transmitted from bevel gear shaft via using reaction force of springs (2) and (3), and
HSS to brake hub (7) is transmitted from hub makes disc (4) and plate (5) crimped to brake
(8) to output shaft (9) and then to final drive. drum (6). Brake drum (6) is connected and
fixed to steering case.
q Power to brake hub (7), namely to output shaft
(9), is stopped by crimping disc (4) and plate
(5).
q By adjusting the depression power of the brake
pedal and controlling the oil pressure given to
piston (1), brake pedal can adjust the braking
power.
10-202 22 D65EX, PX, WX-16

D65EX, PX, WX-16 10-202 23

SEN04965-01 Brake valve
Brake valve 1
P: From power train pump Outline

T1: To steering case q Brake valve is located in the circuit between
T2: To steering case power train pump and brake piston within HSS
Br (R): To right brake unit, and is installed to the upper surface of
Br (L): To left brake HSS unit.
q Depressing the brake pedal actuates main
1. Parking brake valve brake valve (3) and setting the parking brake
2. Body lever to "LOCK" operates parking brake valve
3. Main brake valve (1).
4. Piston q Actuating each valve stops the oil flow to the
5. Shaft back pressure port of the brake piston and sets
6. Guide the brake "operated" state.
q In case of HSS, since brake is for braking
power control [not involved in steering opera-
tion], both left and right brake operate concur-
rently.
10-202 24 D65EX, PX, WX-16

Brake valve SEN04965-01
Unit: mm
size clearance limit
7 Clearance between main brake
valve and body
Shaft Hole
–0.020 +0.013 0.020 –
19 –0.030 0 0.043 0.07
Clearance between main brake –0.030 +0.015 0.030 –
8 valve and piston 9 –0.040 0 0.055 0.08
Clearance between parking brake –0.034 +0.013 0.034 –
9 valve and body 19 –0.043 0 0.056 0.08
10 Main brake modulating spring length load load
75.3 N 71.6 N
48 36 46.6
{7.68 kg} {7.3 kg}
157.9 N 150 N
11 Main brake valve return spring 52 38
{16.11 kg}
50.4
{15.3 kg}
16.7 N 15.7 N
12 Parking brake valve return spring 36.5 28.5
{1.7 kg}
35.4
{1.6 kg}
D65EX, PX, WX-16 10-202 25

Operation
When brake is "released" (brake pedal "RELEASED", parking brake lever "FREE")
q When the brake pedal is "released" [not

depressed], parking brake valve (1) opens port
(P) and chamber (A) by the reaction force of
return spring (2).
q Main brake valve (3) opens chamber (B) and
port (Br) by the reaction force of return spring
(4).
q The oil pressure from the power train pump is
regulated at the main relief valve, flows from
port (P) through chambers (A) and (B) and port
(Br) to the brake piston back pressure port.
q The brake piston moves to the left and com-
presses the brake spring to "RELEASE" the
brake.
q At this time, the oil pressure is balanced at
2.84 MPa {29.0 kg/cm 2}. Its measurement is
available at pressure detection port (Q).
10-202 26 D65EX, PX, WX-16

When brake is "operated" (brake pedal "DEPRESSED", parking beake lever "FREE")
q As the brake pedal is depressed, guide (5) and q The oil pressure behind port (Br) is determined
shaft (6) is pushed to the right. by the reaction force of return spring (4) of
q As shaft (6) is pushed, it compresses modulat- which the load varies in accordance with the
ing spring (7), and its reaction force moves brake pedal travel.
main brake valve (3) to the right. Then port (Br) q If the brake pedal stroke is small, the oil pres-
and chamber (B) close while port (Br) and port sure after port (Br) increases and the brake is
(T2) open. set to "semi-applied" state. And when the
q The oil from the power train pump enters stroke is large, the oil pressure decreases and
chamber (A) through port (P) and blocked by the brake is "applied".
chamber (B).
q A portion of the oil which had flown into the
brake piston back pressure port is drained
from port (Br) to port (T2). The other portion of
oil flows through port (Br) and orifice (a) to
chamber (D).
q When the oil behind port (Br) is drained to port
(T2) and the oil pressure is reduced, the oil in
chamber (D) pushes piston (8). Then the force
pushing main brake valve (3) to the right is
reduced, and main brake valve (3) moves to
the left by the reaction force of return spring
(4).
q Port (Br) and port (T2) are closed by the move-
ment of main brake valve (3) to the left, and the
oil pressure behind port (Br) is maintained not
to be further reduced.
q If the brake pedal is depressed further, the
operation described above is repeated until
main brake valve (3) reaches the stroke end,
setting the brake to fully "operated" state.
D65EX, PX, WX-16 10-202 27

When brake is set to "parking" (brake pedal "RELEASED", parking brake lever "LOCK")
q When the parking brake lever is set to "LOCK"

position, parking brake valve (1) is pulled to the
left. Then port (P) and chamber (A) are closed
while chamber (A) and chamber (C) are open.
q The oil from the power train pump is blocked
by port (P).
q The oil which had flown into the brake piston
back pressure port flows from port (Br) through
chambers (B), (A), and (C) and is drained
through port (T1).
q The oil pressure at the brake piston back pres-
sure port continues to be reduced because
parking brake valve (1) is held to the left. As a
result, the brake is fully set to "operated" and
this state is maintained.
q This condition is maintained while engine is
restarted.
10-202 28 D65EX, PX, WX-16

D65EX, PX, WX-16 10-202 29

SEN04965-01 Final drive
Final drive 1
Outline
q The final drive uses a single-stage spur gear
and a single-stage planetary gear reduction
system.
q The lubrication is the splash type utilizing the
gear rotation.
q The final drive can be removed and installed
as a single unit.
q Floating seal is installed to the rotating and
sliding portion of the sprocket to prevent entry
of dirt or sand from the outside and the lubrica-
tion oil leakage.
10-202 30 D65EX, PX, WX-16

Final drive SEN04965-01
a The figure shows D65EX-16.
1. Sun gear (number of teeth: 13) 9. Pinion (number of teeth: 21)

2. Carrier 10. Gear (number of teeth: 78)
3. Ring gear (number of teeth: 68) 11. Sprocket hub
4. Floating seal 12. Sprocket teeth
5. Cover 13. Hub
6. Pinion cover 14. Planetary pinion (number of teeth: 27)
7. Final drive case 15. Pinion shaft
8. Bearing cage
D65EX, PX, WX-16 10-202 31

10-202 32 D65EX, PX, WX-16

Unit: mm
Backlash between pinion and
1 gear 0.23 – 0.61 1.0
Backlash between sun gear and
2 planetary pinion
0.18 – 0.45 1.0
Backlash between planetary
3 pinion and ring gear
0.23 – 0.67 1.0
Outside diameter of oil seal Replace
4 contact surface of pinion (large) 0
80 –0.074 79.9
Outside diameter of oil seal 0
5 contact surface of pinion (small) 70 –0.074 69.9
Standard Tolerance Standard Interference

Interference between pinion shaft size Shaft Hole interference limit
6 and carrier +0.051 +0.030 0.002 –
56 0.002
+0.032 0 0.051
7 Axial clearance of pinion bearing 0 – 0.1
Adjust
Standard shim thickness for
8 pinion bearing cage
1.5
Projection of ball from pinion
9 cover
Replace
5.2 1.5
10 Amount
surface
of wear of sprocket tooth
317 299 Rebuild or replace
D65EX, PX, WX-16 10-202 33


10-202 34 D65EX, PX, WX-16

The power from HSS

O
Pinion (1)
O
Gear (2)
O
Sun gear (3)
O
Planetary pinion (4)
O
Pinion shaft (5)
O
Carrier (6)
O
Sprocket hub (7)
O
Sprocket teeth (8)
D65EX, PX, WX-16 10-202 35

SEN04965-01 Final drive (Planetary gear installed inside of sprocket type)
Final drive (Planetary gear installed inside of sprocket type) 1
Structure
q The final drive uses a single stage spur gear and single stage planetary gear reduction system.
q The lubrication is of splash type using the rotation of the gears.
q The final drive can be removed and installed in a single unit.
q A floating seal is installed to the rotating portion of the sprocket to prevent the entry of dirt or sand and to
prevent leakage of lubricating oil.
10-202 36 D65EX, PX, WX-16

Final drive (Planetary gear installed inside of sprocket type) SEN04965-01
1. Oil filler plug 11. Sun gear (number of teeth: 17)

2. Oil level plug 12. Gear hub
3. Drain plug 13. Carrier
4. Cover 14. Gear (number of teeth: 82)
5. Pinion cover 15. Ring gear (number of teeth: 73)
6. Pinion (number of teeth: 19) 16. Floating seal
7. Bearing cage 17. Shaft
8. Planetary gear shaft 18. Sprocket hub
9. Planetary gear (number of teeth: 27) 19. Sprocket teeth
10. Final drive case
D65EX, PX, WX-16 10-202 37

10-202 38 D65EX, PX, WX-16

Unit: mm
Standard clearance Allowable clearance
Backlash between pinion and
1 gear 0.23 to 0.70 1.0
Backlash between sun gear and
2 planetary gear
0.17 to 0.47 1.0
Backlash between planetary gear
3 and ring gear
0.20 to 0.66 1.0
Standard Replace
Tolerance Repair limit
Outside diameter of oil seal dimension
4 contact surface of pinion 0
80 79.9
-0.074
Standard Tolerance Standard Allowable
Interference between planetary dimension Shaft Hole interference interference
5 gear shaft and carrier +0.059 +0.035 0.002 to
84 0.002
+0.037 0 0.059
6 Axial clearance of pinion bearing 0 to 0.1
Adjust
Standard shim thickness of pinion
7 bearing cage
1.5
Standard dimension Repair limit
8 Pinion cover ball projection Replace
5.2 1.5
Build-up welding
9 Wear of sprocket teeth 317 299 for rebuilding or
replace
D65EX, PX, WX-16 10-202 39

10-202 40 D65EX, PX, WX-16

The power from HSS

O
Pinion (1)
O
Gear (2)
O
Gear hub (3)
O
Sun gear (4)
O
Planetary gear (5)
O
Planetary gear shaft (6)
O
Carrier (7)
O
Shaft (8)
O
Sprocket hub (9)
O
Sprocket teeth (10)
D65EX, PX, WX-16 10-202 41

SEN04965-01

©2011 KOMATSU
All Rights Reserved
10-202 42
SEN04966-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

300 Undercarriage and frame

Main frame ...................................................................................................................................................... 2
Suspension ..................................................................................................................................................... 4
Track frame and idler cushion....................................................................................................................... 14
Idler ............................................................................................................................................................... 18
Idler (Without idler support automatic thrust adjustment) ............................................................................. 20
Carrier roller .................................................................................................................................................. 26
Sprocket ........................................................................................................................................................ 28
Track shoe .................................................................................................................................................... 32
D65EX, PX, WX-16 10-300 1

SEN04966-02 Main frame
Main frame 1
a The figure shows other than the power angle power tilt dozer.
10-300 2 D65EX, PX, WX-16

Main frame SEN04966-02
Unit: mm
Clearance between cylinder yoke size clearance limit
Shaft Hole
1 and bushing
(large) –0.036 +0.207 0.156 –
85 –0.090 +0.120 0.297 0.5 Replace bushing
Clearance between cylinder yoke
–0.030 +0.174 0.130 –
2 and bushing 65
–0.076 +0.100 0.250
0.5
(small)
3. Frame assembly
4. Undercover
5. Engine mount
6. Power train unit mount
7. Cooling assembly mount
Outline
q Frame assembly (3) has a hull-frame structure,
on which the radiator guard, main frame, steer-
ing case, transmission underguard, fender and
cab mount are assembled into one unit.
D65EX, PX, WX-16 10-300 3

SEN04966-02 Suspension
Suspension 1
D65EX-16
10-300 4 D65EX, PX, WX-16

Suspension SEN04966-02
1. Equalizer bar Outline

2. Pivot shaft q Track frame (5) moves the front part of the
3. Side pin grease fitting track frame up and down around pivot shaft (2)
4. Center pin grease fitting in its rear side.
5. Track frame q Equalizer bar (1) vibrates around center pin (6)
6. Center pin and is connected to the right and left track
7. Side pin frames by side pin (7).
8. Seal
9. Bushing D65EX-16
10. Bushing Displacement at Upward 67.6
11. Seal center of equalizer
12. Bushing (large) bar side pin (mm) Downward 67.6
13. Oil filler plug
14. Bushing (small)
15. Cover
16. Seal
D65EX, PX, WX-16 10-300 5

Unit: mm
17 Clearance between pivot shaft
and bushing (large)
Shaft Hole
–0.145 +0.063 0.145 –
148 –0.208 0 0.271 1.0

and bushing (small) 105
–0.120
–0.174
+0.054
0
0.120 –
0.228 1.0 Replace bushing
19 Clearance between center pin

and bushing 70
–0.100
–0.146
+0.174
+0.100
0.200 –
0.320 0.5
20 Clearance
bushing
between side pin and
60
–0.030
–0.060
+0.010
–0.020
0.010 –
0.070 0.5
21 Press-fitting force of pivot shaft

bushing (large) 0.98 – 22.6 kN {0.1 – 2.3 tons}

bushing (small) 0.98 – 36.3 kN {0.1 – 3.7 tons} —
— Quantity
section
of oil in pivot shaft
4.5 l (power line oil: TO30)
10-300 6 D65EX, PX, WX-16

D65EX-16 (power angle power tilt dozer)

D65PX-16
D65WX-16
D65EX, PX, WX-16 10-300 7


8. Seal
9. Bushing D65EX-16 (PAT)
D65PX-16
10. Bushing D65WX-16
11. Seal
12. Bushing (large) Displacement at Upward 76.3
center of equalizer
13. Oil filler plug bar side pin (mm) Downward 76.3
14. Bushing (small)
15. Cover PAT: Power Angle power Tilt dozer
16. Seal
10-300 8 D65EX, PX, WX-16

Unit: mm
and bushing (large)
Shaft Hole
–0.145 +0.063 0.145 –
148 –0.208 0 0.271 1.0

–0.120
–0.174
+0.054
0
0.120 –

and bushing 70
–0.100
–0.146
+0.174
+0.100
0.200 –
0.320 0.5
20 Clearance
bushing
60
–0.030
–0.060
+0.010
–0.020
0.010 –
0.070 0.5


— Quantity
section
D65EX, PX, WX-16 10-300 9

D65PX-16 (Power angle power tilt dozer)

D65WX-16 (Power angle power tilt dozer)
10-300 10 D65EX, PX, WX-16


8. Seal
9. Bushing D65PX-16 (PAT)
D65WX-16 (PAT)
10. Bushing
11. Seal Displacement at Upward 65.9
12. Bushing (large) center of equalizer
bar side pin (mm) Downward 65.9
13. Oil filler plug
14. Bushing (small) PAT: Power Angle power Tilt dozer
15. Cover
16. Seal
D65EX, PX, WX-16 10-300 11

Unit: mm
and bushing (large)
Shaft Hole
–0.145 +0.063 0.145 –
148 –0.208 0 0.271 1.0

–0.120
–0.174
+0.054
0
0.120 –

and bushing 70
–0.100
–0.146
+0.174
+0.100
0.200 –
0.320 0.5
20 Clearance
bushing
60
–0.030
–0.060
+0.010
–0.020
0.010 –
0.070 0.5


— Quantity
section
10-300 12 D65EX, PX, WX-16

D65EX, PX, WX-16 10-300 13

SEN04966-02 Track frame and idler cushion
Track frame and idler cushion 1
D65EX-16
D65WX-16
*1: Shows the machine equipped with the conventional type track shoe.
*2: Shows the machine equipped with the PLUS type track shoe.
a PLUS: Abbreviation for Parallel Link Undercarriage System
10-300 14 D65EX, PX, WX-16

Track frame and idler cushion SEN04966-02
1. Idler 11. Recoil spring

2. Carrier roller (*3) 12. Wear ring
3. Track frame 13. U-packing
4. Sprocket teeth (*3) 14. Cabin
5. Track roller guard (*3) 15. Nut
6. Track roller (*3) 16. Lubricator
7. Center roller guard (*3) 17. Cylinder
8. Yoke 18. Bushing
9. Seal 19. Holder
10. Piston
*3: Exclusive parts are used for the machine equipped with the PLUS type track shoe.
a Using the parts for the machine equipped with the conventional type track shoe shortens the life of this
machine. The parts indicated with *3 must be exclusive ones.
Unit: mm
Check item Repair limit
20 Deformation of track frame Bend 7 (in length of 3,000) Repair
Distortion 3 (in length of 300)
Unclosed idler portion 5
Free length
21 Recoil spring diameter
193.2 kN 171.9 kN
723 x 239 580 705
{19,700 kg} {17,533 kg}
22 Clearance
bushing
between piston and Shaft Hole Replace bushing
–0.036 +0.270 0.097 –
90 1.0
–0.090 +0.061 0.360
23 Press-fitting force of idler yoke 392 kN {40 ton} Adjust
24 Height of track roller guard guide Rebuild or replace
27 16
— Quantity of grease 140 cc (Grease: G2-LI) —
Outline
q The idler cushion moves piston (10) back and
forth by filling or draining grease from lubrica-
tor (16) and adjusts tension of the track shoe.
Recoil spring (11) also dampens sudden shock
forced on idler (1).
Quantity
for one Flange type and arrangement
side
D65EX-16
7 pieces S, S, D, S, D, S, S
D65WX-16
S: single flange
D: double flange
D65EX, PX, WX-16 10-300 15

SEN04966-02 Track frame and idler cushion
D65PX-16
*1: Shows the machine equipped with the conventional type track shoe.
*2: Shows the machine equipped with the PLUS type track shoe.
10-300 16 D65EX, PX, WX-16

Track frame and idler cushion SEN04966-02
1. Idler 11. Recoil spring

2. Carrier roller (*3) 12. Wear ring
3. Track frame 13. U-packing
4. Sprocket teeth (*3) 14. Cabin
5. Track roller guard (*3) 15. Nut
6. Track roller (*3) 16. Lubricator
7. Center roller guard (*3) 17. Cylinder
8. Yoke 18. Bushing
9. Seal 19. Holder
10. Piston
*3: Exclusive parts are used for the machine equipped with the PLUS type track shoe.
a Using the parts for the machine equipped with the conventional type track shoe shortens the life of this
machine. The parts indicated with *3 must be exclusive ones.
Unit: mm
Check item Repair limit
20 Deformation of track frame Bend 7 (in length of 3,000) Repair
Distortion 3 (in length of 300)
Unclosed idler portion 5
Free length
21 Recoil spring diameter
193.2 kN 171.9 kN
723 x 239 580 705
{19,700 kg} {17,533 kg}
22 Clearance
bushing
between piston and Shaft Hole Replace bushing
–0.036 +0.270 0.097 –
90 1.0
–0.090 +0.061 0.360
23 Press-fitting force of idler yoke 392 kN {40 ton} Adjust
24 Height of track roller guard guide Rebuild or replace
27 16
— Quantity of grease 140 cc (Grease: G2-LI) —
Outline
q The idler cushion moves piston (10) back and
forth by filling or draining grease from lubrica-
tor (16) and adjusts tension of the track shoe.
Recoil spring (11) also dampens sudden shock
forced on idler (1).
Quantity
for one Flange type and arrangement
side
D65PX-16 8 pieces S, S, D, S, S, D, S, S
S: single flange
D: double flange
D65EX, PX, WX-16 10-300 17

SEN04966-02 Idler
Idler 1
10-300 18 D65EX, PX, WX-16

Idler SEN04966-02
Unit: mm
Outside diameter of protruding
1 portion 630 —
2 Outside diameter of tread 590 570
3 Depth of tread 20 30
Rebuild or replace
4 Thickness of tread 15 5
5 Width of tread 44.5 48.5
6 Overall width 190 —

Clearance between shaft and size Shaft Hole clearance limit
7 bushing –0.250 +0.142 0.242 –
65 —
–0.350 –0.008 0.492
Clearance between shaft and –0.250 +0.090 0.250 – Replace
8 support
64.7
–0.350 0 0.440
—
9 Axial play of idler
0.26 – 0.66 —
10 Clearance between guide plate

and side plate
0.9 —
Adjust shim or
replace plate
11 Standard shim thickness at side
plate installation part
4.0
D65EX, PX, WX-16 10-300 19

SEN04966-02 Idler (Without idler support automatic thrust adjustment)
Idler (Without idler support automatic thrust adjustment) 1
10-300 20 D65EX, PX, WX-16

Idler (Without idler support automatic thrust adjustment) SEN04966-02
Unit: mm
1 Outer diameter of projection
630 —
2 Outer diameter of tread 590 570
Build-up welding
3 Depth of tread 20 30
or replace
7
bushing –0.250 +0.142 0.242 –
65 —
–0.350 –0.008 0.492
Replace
Clearance between shaft and –0.250 +0.090 0.250 –
8 64.7 —
support –0.350 +0.090 0.440
9 Axial play of idler
0.26 – 0.66 —
Clearance between guide plate Build-up welding
10 2.0 —
and support or replace
Clearance between guide plate
11 1.0 —
and side plate Adjust shim or
Standard shim thickness at replace plate
12 4.0
side plate installation part
D65EX, PX, WX-16 10-300 21

SEN04966-02 Track roller
Track roller 1
For conventional type track shoe

Single flange type
Unit: mm
1 Outside diameter of flange
(outside) 240 —
Rebuild or replace
4 Width of flange (outside) 19.5 13.5
5 Width of tread 47 —

7 bushing –0.250 +0.143 0.243 –
65 —
–0.350 –0.007 0.493
Replace
8 Clearance
collar
between shaft and
64.7
–0.250
–0.350
–0.100
–0.150
0.100 –
0.250
—
9 Play of roller in axial direction
0.26 – 0.66 —
10-300 22 D65EX, PX, WX-16

Track roller SEN04966-02

Double flange type
Unit: mm
Outside diameter of flange
1 (outside) 240 —
2 (inside) 236 —
4 Thickness of tread 69 51 Rebuild or replace

6 Width of flange (inside) 19.5 13.5
7 Width of tread 47.7 —

9 bushing
65 –0.250 +0.143 0.243 – —
–0.350 –0.007 0.493
Replace
10 Clearance
collar
between shaft and 64.7 –0.250
–0.350
–0.100
–0.150
0.100 –
0.250
—
0.26 – 0.66 —
D65EX, PX, WX-16 10-300 23

SEN04966-02 Track roller
For PLUS type track shoe

Single flange type
Unit: mm
1 (outside) 250 —
Rebuild or replace
4 Width of flange (outside) 24 13.5
5 Width of tread 47 —

7 bushing –0.250 +0.143 0.243 –
65 —
–0.350 –0.007 0.493
Clearance between shaft and –0.250 –0.100 0.100 – Replace
8 collar
64.7
–0.350 –0.150 0.250
—
0.26 – 0.66 —
10-300 24 D65EX, PX, WX-16

Track roller SEN04966-02

Double flange type
Unit: mm
1 (outside) 240 —
2 (inside)
236 —
Rebuild or replace
6 Width of flange (inside) 19.5 13.5

9 bushing –0.250 +0.143 0.243 –
65 —
–0.350 –0.007 0.493
Replace
10 Clearance
collar
between shaft and
64.7
–0.250
–0.350
–0.100
–0.150
0.100 –
0.250
—
0.26 – 0.66 —
D65EX, PX, WX-16 10-300 25

SEN04966-02 Carrier roller
Carrier roller 1
Unit: mm
215 —

Rebuild or replace
3 Thickness of tread 37.5 26.5
5 Width of flange 21 15

6 support
61 –0.100 +0.300 0.100 – —
–0.200 0 0.500
Interference between shaft and size Shaft Hole interference limit Replace
7 seal guard +0.150 +0.030 0.100 –
61.5 —
+0.130 0 0.150
0 – 0.32 —
10-300 26 D65EX, PX, WX-16

Carrier roller SEN04966-02

Unit: mm
224 —

Rebuild or replace
3 Thickness of tread 37.5 25
5 Width of flange 21 15

6 support –0.100 +0.300 0.100 –
61 —
–0.200 0 0.500
Interference between shaft and size Shaft Hole interference limit Replace
7 seal guard
61.5 +0.150 +0.030 0.100 – —
+0.130 0 0.150
0 – 0.32 —
D65EX, PX, WX-16 10-300 27

SEN04966-02 Sprocket
Sprocket 1
Unit: mm
1 Width of tooth bottom
87 77 Rebuild or replace
2 Thickness of tooth bottom 26 17
10-300 28 D65EX, PX, WX-16

Sprocket SEN04966-02
Full-size drawing of sprocket tooth shape

a Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
D65EX, PX, WX-16 10-300 29

SEN04966-02 Sprocket

Unit: mm
1 Width of tooth bottom
87 78
Rebuild or replace
2 Thickness of tooth bottom 26 17
10-300 30 D65EX, PX, WX-16

Sprocket SEN04966-02
Full-size drawing of sprocket tooth shape

a Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
D65EX, PX, WX-16 10-300 31

SEN04966-02 Track shoe
Track shoe 1
Conventional type track shoe
*1. Single shoe

*2. Swamp shoe
a P portion shows the link of bushing press fitting end.
10-300 32 D65EX, PX, WX-16

Track shoe SEN04966-02
Unit: mm
1 Link pitch
203.45 206.45
Reverse
Standard size Reverse or replace
Light load Heavy load
2 Outside diameter of bushing
73 62.8 65.4
3 Thickness of bushing 13.9 3.7 6.3

4 Link height Repair or replace
132 119.5
Thickness of link (bushing press
5 fitted portion)
44.8 32.3 Replace
Tightening torque Retightening angle
a. (Nm {kgm}) (deg.)
Regular link
539 ± 49 {55 ± 5} 120 ± 10
6 Shoe bolt Retighten
Tightening torque Retightening angle Lower limit torque
b. (Nm {kgm}) (deg.) (Nm {kgm})
Master link 343 ± 39
180(0/–20) 784 {80}
{35 ± 4}
Tolerance Standard
Standard size interference
Interference between bushing Shaft Hole
7 and link +0.404 +0.074
66.5 0.230 – 0.404
+0.304 0
Interference between regular pin +0.435 +0.086
8 and link
44.4
+0.285 +0.024
0.199 – 0.411 Adjust or replace
Tolerance Standard
Standard size
Clearance between regular pin Shaft Hole clearance
9 and bushing +0.235 +0.915
44.6 0.180 – 0.830
+0.085 +0.415
D65EX, PX, WX-16 10-300 33

PLUS type track shoe

a P portion shows the link of bushing press fitting end.
10-300 34 D65EX, PX, WX-16

Unit: mm
1 Link pitch
203.45 206.45
Reverse
Standard size Reverse or replace
Light load Heavy load
2 Outside diameter of bushing
73 62.8 65.4
3 Thickness of bushing 13.9 3.7 6.3

4 Link height Repair or replace
132 119.5
Thickness of link
5 (bushing press-fitting portion)
44.8 32.3 Replace
Tightening torque Retightening angle
a. (Nm {kgm}) (deg.)
Regular link
539 ± 49 {55 ± 5} 120 ± 10
6 Shoe bolt Retighten
Tightening torque Retightening angle Lower limit torque
b. (Nm {kgm}) (deg.) (Nm {kgm})
Master link 343 ± 39
180(0/–20) 784 {80}
{35 ± 4}
Tolerance Standard
Standard size interference
Interference between regular pin Shaft Hole
7 and link +0.435 +0.086
44.4 0.199 – 0.411
+0.285 +0.024
Standard clearance Adjust or replace
One side Both side

8 Clearance between links
1.4 2.8
D65EX, PX, WX-16 10-300 35

Single shoe
Unit: mm
1 Height of grouser
65 25
Rebuild or replace
2 Thickness of grouser 77 37
Swamp shoe
Unit: mm
1 Height of grouser
109.5 94.5 Rebuild or replace
2 Thickness of grouser 20 5
10-300 36 D65EX, PX, WX-16

D65EX, PX, WX-16 10-300 37

SEN04966-02

©2011 KOMATSU
All Rights Reserved
10-300 38
SEN04967-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

401 Hydraulic system, Part 1

Work equipment hydraulic system layout drawing .......................................................................................... 2
Work equipment control .................................................................................................................................. 6
Hydraulic tank and filter .................................................................................................................................. 8
Scavenging pump ......................................................................................................................................... 10
Power train and steering lubrication pump.....................................................................................................11
HSS pump..................................................................................................................................................... 12
HSS motor .................................................................................................................................................... 31
D65EX, PX, WX-16 10-401 1

SEN04967-00 Work equipment hydraulic system layout drawing
Work equipment hydraulic system layout drawing 1
Straight tilt dozer (ST-T)

Sigma dozer (SGM)
Straight tilt power pitch dozer (ST-TPP)
Sigma power pitch dozer (SGM-PP)
Angle dozer (A)
a The figure shows the straight tilt power pitch dozer.
10-401 2 D65EX, PX, WX-16

Work equipment hydraulic system layout drawing SEN04967-00
1. Tilt cylinder (ST-T, SGM)

Pitch cylinder (ST-TPP, SGM-PP)
2. Quick drop valve
3. Cooling fan motor
4. Lift cylinder
5. Control valve
6. Work equipment lock solenoid valve (ST-TPP, SGM-PP)
7. Accumulator
8. Blade pitch selector solenoid valve
(ST-TPP, SGM-PP)
9. Blade PPC valve
10. Hydraulic tank
11. Ripper PPC valve (if equipped)
12. HSS motor
13. Ripper cylinder (if equipped)
14. Self-pressure reducing valve
16. HSS pump
17. Hydraulic oil cooler
18. Tilt cylinder (ST-TPP, SGM-PP)
19. Hydraulic oil cooler bypass valve
D65EX, PX, WX-16 10-401 3

SEN04967-00 Work equipment hydraulic system layout drawing
Power angle power tilt dozer (PAT)
10-401 4 D65EX, PX, WX-16

Work equipment hydraulic system layout drawing SEN04967-00
1.Tilt cylinder
2. Quick drop valve
3. Cooling fan motor
4. Lift cylinder
5. Control valve
6. Work equipment lock solenoid valve
7. Accumulator
8. Blade PPC valve
9. Hydraulic tank
11. HSS motor
12. Ripper cylinder (if equipped)
13. Self-pressure reducing valve
15. HSS pump
16. Hydraulic oil cooler
17. Hydraulic oil cooler bypass valve
18. Angle cylinder
D65EX, PX, WX-16 10-401 5

SEN04967-00 Work equipment control
Work equipment control 1
10-401 6 D65EX, PX, WX-16

Work equipment control SEN04967-00
1. Ripper control lever (if equipped)

2. Blade control lever
3. Work equipment lock lever
4. Blade PPC valve
6. Work equipment lock limit switch
7. PITCH switch (if equipped)
Outline
q The work equipment control system is a PPC
system that operates each spool of the control
valves by operating blade PPC valve (4) with
blade control lever (2) or operating ripper PPC
valve (5) with ripper control lever (1).
q Work equipment lock lever (3) is interlocked
with work equipment lock limit switch (6).
When work equipment lock lever (3) is set to
"FREE"position, work equipment lock limit
switch is turned "ON". Turning on of the lever
opens the work equipment control circuit and it
enables operating the work equipment.
q When blade control lever (2) is set to the
"FLOAT" position, the hydraulic detent of blade
PPC valve (4) works, and blade control lever
(2) is set to self-holding at the "FLOAT" posi-
tion.
q When work equipment lock lever (3) is set to
the "LOCK" position, the hydraulic detent of
blade PPC valve (4) is reset and blade control
lever (2) returns to the "HOLD" position by
itself.
q While the engine is stopped, the hydraulic
detent does not work even when blade control
lever (2) is set to the "FLOAT" position. Thus,
blade control lever (2) returns to "HOLD" posi-
tion by itself.
D65EX, PX, WX-16 10-401 7

SEN04967-00 Hydraulic tank and filter
Hydraulic tank and filter 1
1. Hydraulic tank Specifications

2. Sight gauge
3. Hydraulic oil temperature sensor Tank capacity (l) 80
4. Hydraulic filter element
Oil level in tank (l) 55
5. Spring
6. Bypass valve Bypass valve set pressure 147 ± 29.4
7. Oil filler cap (kPa {kg/cm2}) {1.5 ± 0.3}
8. Breather
9. Strainer
10. Drain plug
10-401 8 D65EX, PX, WX-16

Hydraulic tank and filter SEN04967-00
Breather 1
1. Nut
2. Cover
3. Filter element
4. Case
5. Valve assembly
6. Body
Prevention of negative pressure in tank

q The hydraulic tank is enclosed and pressur-
ized. When the oil level in the hydraulic tank
drops, negative pressure is generated in the
tank.
To prevent this negative pressure generation,
valve assembly (5) is opened to draw the
atmosphere to the tank.
(Intake valve set pressure:
1.96 ± 0.29 kPa {0.02 ± 0.003 kg/cm2})
Prevention of pressure buildup in tank

q When the hydraulic circuit is operating, the
pressure in the hydraulic tank increases as the
hydraulic cylinder operates and the oil level
and temperature increase in the tank.
If the pressure in the tank rises above the set
value, valve assembly (5) is pushed up to
release the pressure in the tank.
(Exhaust valve set pressure:
38.2 ± 5.69 kPa {0.39 ± 0.058 kg/cm2})
D65EX, PX, WX-16 10-401 9

SEN04967-00 Scavenging pump
Scavenging pump 1
Outline
q The scavenging pump is installed to the lower
part of the PTO case and is driven with the
power from the engine.
q The scavenging pump sucks oil collected in
the transmission case bottom through a
strainer and returns it to the steering case.
Specifications
Type Gear pump
Theoretical capacity (cc/rev) 61.2
Maximum delivery pressure
0.29{3.0}
(MPa {kg/cm2})
Maximum speed (rpm) 2,500
10-401 10 D65EX, PX, WX-16

Power train and steering lubrication pump SEN04967-00
Power train and steering lubrication pump 1
Model: SAL (2) 45 + 45
Unit: mm
Type Standard clearance Clearance limit
1 Side clearance
SAL(2)45 0.10 – 0.15 0.19
Clearance between plain bearing
2 inner diameter and gear shaft SAL(2)45 0.067 – 0.125 0.20 Replace
outer diameter
Type Standard size Tolerance Repair limit
3 Pin driving depth 0
SAL(2)45 12 —
–0.5
4 Rotating torque of spline shaft 5.8 – 13.8 Nm {0.6 – 1.4 kgm}
Speed Discharge Standard Delivery limit

Delivery Type (rpm)
pressure delivery (l/min) —
— Oil: SAE10W (MPa{kg/cm2}) (l/min)
Oil temperature: 45 – 55°C
SAL(2)45 3,000 2.9{30} 125 111
D65EX, PX, WX-16 10-401 11

SEN04967-00 HSS pump
HSS pump 1
Model: HPV95(112)
10-401 12 D65EX, PX, WX-16

HSS pump SEN04967-00
IM: PC mode selector current connector Outline

PA: Pump discharge port q This pump consists of a variable-displacement
PB: Pump pressure input port swash plate type piston pump, PC valve, LS
PC: Pump discharge pressure pickup port valve and EPC valve.
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PEPB: EPC source pressure pickup port
PEPC: EPC source pressure port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
D65EX, PX, WX-16 10-401 13

1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. PC valve
10-401 14 D65EX, PX, WX-16

Function Structure
q The pump converts the engine rotation trans- q Cylinder block (7) is supported to shaft (1) by
mitted to its shaft to oil pressure and delivers spline (12).
pressurized oil corresponding to the load. q Shaft (1) is supported by each bearing (13).
q It is possible to change the delivery by chang- q The end of piston (6) has a spherical hollow
ing the swash plate angle. and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Shoe (5) slides in circle being constantly
pushed against plane (A) of rocker cam (4).
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
cylinder block (7).
q Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylin-
der block (7) is suctioned and discharged
through valve plate (8).
D65EX, PX, WX-16 10-401 15

Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q Angle (a) is called the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q When center line (X) of rocker cam (4) has

swash plate angle (a) to axial direction of cylin-
der block (7), flat surface (A) functions as cam
to shoe (5).
q Piston (6) slides on the inside of cylinder block
(7), so a difference between volumes (E) and
(F) is created inside cylinder block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q The volume of chamber (F) grows larger and,
in this process, the oil is suctioned.
10-401 16 D65EX, PX, WX-16

Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Swash plate angle (a) is changed with servo
piston (10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the PC and the LS
valve.
q This straight line movement is transmitted to
rocker cam (4) through slider (14).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q The area receiving the pressure is different at
the left and right sides of servo piston (10), and
the receiving pressure at the small diameter
piston end is always connected with the main
pump discharge pressure (self pressure) (PP).
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The movement of servo piston (10) is con-
trolled by the relationship of the size of the
pressure (PP) at the small diameter piston end
and the pressure (PEN) at the large diameter
piston end, and the comparative size of the
ratio of the area receiving the pressure at the
small diameter piston end and large diameter
piston end.
D65EX, PX, WX-16 10-401 17

LS valve 1
PA: Pump port Function

PDP: Drain port q The LS (load sensing) valve detects the load
PLP: LS control pressure output port and controls the delivery.
PLS: LS pressure input port q This valve controls pump delivery (Q) accord-
PP: Pump port ing to differential pressure ( d PLS [= (PP) –
PPL: Control pressure input port (P LS) ] (c alle d LS differ ential pr ess ure)
PSIG: Drain port between pump delivery pressure (PP) and
control valve outlet port pressure (PLS).
1. Sleeve q Pump discharge pressure (PP), pressure
2. Piston (PLS) [called LS pressure] coming from the
3. Spool control valve output enter this valve.
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Locknut
10-401 18 D65EX, PX, WX-16

Operation
When control valve is at neutral position
q The LS valve is a three-way selector valve, q Pump discharge pressure (PP) is present in
with pressure (PLS) (LS pressure) from the the small diameter end of piston port (J).
inlet port of the control valve brought to spring q Because of the difference in area of servo pis-
chamber (B), and pump discharge pressure ton (10), it moves in the direction to make the
(PP) brought to port (H) of sleeve (1). swash plate angle smaller.
q Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump delivery pressure (self pressure) (PP)
determine the position of spool (3).
q Before the engine is started, servo piston (10)
is pressed to the left. (See right drawing)
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
is set to 0 MPa {0 kg/cm2}. (It is interconnected
to the drain circuit through the control valve
spool)
q Spool (3) is pushed to the right, and port (C)
and port (D) will be connected.
q Pump discharge pressure (PP) enters the
large diameter end of piston from port (K).
D65EX, PX, WX-16 10-401 19

Action for the direction of maximizing the pump delivery
q When the difference between pump discharge

pressure (PP) and LS pressure (PLS), namely
LS differential pressure (dPLS) becomes
smaller (for example, when opening area of
the control valve becomes larger and pump
delivery pressure (PP) drops), spool (3) is
pushed to the left by the combined force of LS
pressure (PLS) and the force of spring (4).
q When spool (3) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large piston diameter end
of servo piston (10) becomes drain pressure
(PT), and pump discharge pressure (PP)
always enters the small diameter end port (J),
so servo piston (10) is pushed to the left, and
moves the swash plate in the direction to make
the delivery larger.
10-401 20 D65EX, PX, WX-16

Action for the direction of minimizing the pump delivery
q When LS differential pressure (dPLS)

becomes larger [for example, when the area of
opening of the control valve becomes smaller
and pump pressure (PP) rises], pump pressure
(PP) pushes spool (3) to the right.
q When spool (3) moves, pump discharge pres-
sure (PP) flows from port (C) to port (D), and
from port (K), it enters the large piston diame-
ter end.
q Although main pump pressure (PP) is present
in the small diameter end port (J) of piston,
servo piston (10) is pushed to the right due to
the difference in area between the large and
small piston diameter ends of servo piston
(10). As a result, it moves in the direction to
make the swash plate angle smaller.
D65EX, PX, WX-16 10-401 21

When servo piston is balanced
q Let us take the area receiving the pressure at q Force of spring (4) is adjusted in such that the
the large diameter end of the piston as (A1), position of the balanced stop of this spool (3)
the area receiving the pressure at the small may be determined when (PP) – (PLS) = 1.9
diameter end as (A0), and the pressure flowing MPa {19 kg/cm2} at the median of the specified
into the large diameter end of the piston as value.
(PEN).
q If pump discharge pressure (PP) of the LS
valve and the combined force of spring (4) and
LS pressure (PLS) are balanced, and the rela-
tionship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (10) stops at that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (3) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q The relationship between the area receiving
the pressure on both ends of servo piston (10)
is (A0) : (A1) = 3 : 5, so the pressure applied to
both ends of the piston when it is balanced
becomes (PP) : (PEN) C 5 : 3.
10-401 22 D65EX, PX, WX-16

PC valve 1
PA: Pump port Function

PDP: Drain port q When the pump discharge pressure (PP) is
PM: Mode selector pressure pilot port high, the PC valve controls flow to a constant
PPL: Control pressure output port (to LS valve) level corresponding to the discharge pressure
independent of increase in stroke of the control
1. Plug valve.
2. Servo piston assembly q If the load during the operation becomes larger
3. Pin and the pump discharge pressure rises, it
4. Spool reduces the delivery from the pump.
5. Retainer q If the pump discharge pressure drops, it
6. Seat increases the delivery from the pump.
7. Seat q In this case, the relationship between pump
8. Plug discharge pressure (PP) and pump delivery
9. Cover (Q) may be represented like shown in the fig-
10. Wiring ure below if the relationship is expressed as
the parameter of current value (X) given to PC-
EPC valve solenoid.
q The controller counts the actual engine speed.
q At a low engine speed, the controller sends the
command current to PC-EPC valve solenoid to
reduce the pump delivery corresponding to the
engine speed.
D65EX, PX, WX-16 10-401 23

Operation
When the load on the actuator is small and the pump pressure (PP) is low
Action of PC-EPC valve solenoid (1)

q Command current (X) is being sent to PC-EPC
valve solenoid (1) from the pump controller.
q This command current (X) works on PC-EPC
valve and output the signal pressure to change
the force of pushing piston (2).
q Spool (3) stops at a position where the com-
bined force for pushing spool (3) is balanced
by the spring set pressure of spring (4) and
spring (5) and pump discharge pressure (PP).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
10-401 24 D65EX, PX, WX-16

Action of spring
q The load of spring (4) and spring (5) on the PC q If port (E) and port (G) of the LS valve are con-
valve is determined by the swash plate posi- nected, the pressure entering the large diame-
tion. ter end of the piston from port (J) becomes
q Spring load changes as servo piston (9) elon- drain pressure (PT), and servo piston (9)
gates and contracts spring (4) and spring (5). moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Spring (4) extends as servo piston (9) moves
q The load of spring (4) and spring (5) also and weakens the spring force.
changes according to the command current (X) q As the spring force is weakened, spool (3)
to the PC-EPC valve solenoid. moves to the right, the connecting between
q Port (C) of the PC valve is connected to port port (C) and port (D) is shut off and the pump
(E) of the LS valve. discharge pressure ports (B) and (C) are con-
q Pump pressure (PP) is applied to the small pis- nected.
ton diameter end of servo piston (9), port (A) q The pressure on port (C) rises and the pres-
and port (B). sure on the large diameter end of the piston
q As long as pump pressure (PP) is low, spool also rises. Thus, the leftward move of servo
(3) is on the left. piston (9) is stopped.
q Ports (C) and (D) are connected, and the pres- q The stop position for servo piston (9) [ = pump
sure entering the LS valve becomes drain delivery] is decided at the point where the force
pressure (PT). of spring (4) and the pushing force of PC-EPC
valve by solenoid and the pushing force cre-
ated by pressure (PP) acting on spool (3) are
in balance.
D65EX, PX, WX-16 10-401 25

When load on actuator is large and pump pressure is high
Outline
q When the load is large and pump discharge
pressure (PP) is high, the force pushing spool
(3) to the right becomes larger and spool (3)
moves to the position shown in the diagram
above.
q As shown in the diagram above, part of the
pressurized oil from port (B) flows out to port
(D) from port (C) through the LS valve, and the
pressure oil flowing from port (C) to the LS
valve becomes approximately half of pump dis-
charge pressure (PP).
10-401 26 D65EX, PX, WX-16

Operation
q When port (E) and port (G) of the LS valve are q If command current (X) sent to PC-EPC valve
connected, this pressure from port (J) enters solenoid (1) increases, the relationship
the large diameter end of servo piston (9), between pump discharge pressure (PP) and
stopping servo piston (9). pump delivery (Q) moves parallel in proportion
q If pump discharge pressure (PP) increases fur- to the pushing force of PC-EPC valve solenoid.
ther and spool (3) moves further to the right, q Because the pushing force of PC-EPC valve
pump discharge pressure (PP) flows to port solenoid (1) is added to the rightward pushing
(C) and acts to make the delivery the mini- force applied to spool (3) by the pump dis-
mum. charge pressure, the relationship between
q If servo piston (9) moves to the right, spring (4) pump discharge pressure (PP) and pump
and spring (5) contract and push back spool delivery (Q) moves from (A) to (B) in accor-
(3). dance with the increase of command current
q When spool (3) moves to the left, the openings (X).
of port (C) and port (D) become larger.
q The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q Stop position of servo piston (9) moves further
rightward compared when pump discharge
pressure (PP) is low.
q The relationship between pump discharge
pressure (PP) and pump delivery (Q) is as
shown in the following figure.
D65EX, PX, WX-16 10-401 27

PC-EPC valve 1
C: To PC valve
P: From pilot pump
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
10-401 28 D65EX, PX, WX-16

Function Operation
q The EPC valve consists of the proportional When the signal current 0 (coil de-energized)
solenoid portion and the hydraulic valve por-
tion.
q On receiving signal current (i) from the control-
ler, the EPC valve generates EPC output pres-
sure in proportion to the signal current and
outputs it to the PC valve.
q When there is no signal current flowing from

the controller to coil (2), coil (2) is de-ener-
gized.
q Spool (5) is pushed to the left by spring (4).
q Port (P) is closed and the pressurized oil from
the pilot pump does not flow to the PC valve.
q The oil from the PC valve is drained through
ports (C) and (T) to the tank.
D65EX, PX, WX-16 10-401 29

When the signal current minute (coil energized) When the signal current maximum
(coil energized)
q When a very small signal current flows to coil

(2), coil (2) is energized, and a propulsion force q As the signal current flows to coil (2), coil (2) is
is generated on the right side of plunger (7). energized.
q Rod (6) pushes spool (5) to the right, and pres- q When this happens, the signal current is at its
surized oil flows from port (P) to port (C). maximum, so the propulsion force of plunger
q Pressures on port (C) increases and the force (7) is also at its maximum.
to act on spool (5) surface and the spring load q Spool (5) is pushed toward the right side by rod
on spring (4) become larger than the propul- (6).
sion force of plunger (7). q Hydraulic oil from port (P) flows to port (C) with
q Spool (5) is pushed to the left, and port (P) is maximum flow rate. As the result, the circuit
shut off from port (C). pressure between the EPC and PC valves
q Port (C) and port (T) are connected. becomes maximum.
q Spool (5) moves in such that the thrust of q Since port (T) is closed, pressurized oil does
plunger (7) and pressure of port (C) + spring not flow to the tank.
load of spring (4) balance to each other.
q Circuit pressure between the EPC valve and
PC valve is controlled in proportion to the size
of the signal current.
10-401 30 D65EX, PX, WX-16

HSS motor SEN04967-00
HSS motor 1
Model: HMF95(90)
PA: From control valve Outline

PB: From control valve q This motor is composed of the fixed capacity
T2: To hydraulic tank swash plate type piston motor, flashing shuttle
valve, bypass valve and charge relief valve.
1. HSS motor
2. Counterbalance valve Specifications
3. Safety valve
4. Check valve Theoretical delivery (cc/rev) 81.79
Rated speed (rpm) 2,597

Rated output pressure
38.2 {390}
(MPa {kg/cm2})
D65EX, PX, WX-16 10-401 31

SEN04967-00 HSS motor
1. Output shaft 9. Counterbalance valve

2. Motor case 10. Safety valve
3. Thrust plate 11. Check valve
4. Piston 12. Sub bearing
5. Cylinder block 13. Spline
6. Valve plate 14. Shoe
7. End cover 15. Main bearing
8. Brake valve assembly
Unit: mm
Free length
x outside Installed Installed Free length Installed
16 Spool return spring diameter
length load load Replace spring
if damaged or
192 N 154 N deformed.
42.7 x 30.0 40.5 —
{19.6 kg} {15.7 kg}
1.27 N 0.98 N
17 Check valve spring 43 x 13.8 32.9
{0.13 kg}
—
{0.10 kg}
10-401 32 D65EX, PX, WX-16

Outline
q Pressurized oil sent from pump is converted to
rotating torque and is transmitted to output
shaft.
Structure
q Cylinder block (5) is supported by output shaft
(1) on spline (13), and output shaft (1) is sup-
ported by main bearing (15) and sub bearing
(12).
q The end of piston (4) has a concave ball
shape, and shoe (14) is caulked to it to form
one unit. Piston (4) and shoe (14) form a
spherical bearing.
cylinder block (5).
q Cylinder block (5) carries out rotation relative
to valve plate (6) while sealing the pressurized
oil.
q This surface ensures that the hydraulic bal-
ance is maintained correctly.
q The oil inside each cylinder chamber on the
rotating side [cylinder block] flows in and out of
the port area on the stationary side [valve
plate].
D65EX, PX, WX-16 10-401 33

Operation Rotation speed and torque control

Operation of motor q As flow (Q) from the HSS pump is increased,
q The pressurized oil sent from the pump enters motor speed (N) is heightened.
cylinder block (5) and pushes piston (4) from q Since the swash plate angle of the HSS motor
the back face. is fixed ((a) is constant), rotating torque (T) is
q In the case of the motor, the center line of plate proportional to pressure (P).
(3) is constantly tilted at a certain degree q Swash plate angle (a) is approx. 15°.
[swash plate angle (a)] to the axial direction of
cylinder block (5). Q = qN
q If we take the example of a piston (4), the oil (q = E – F)
pressure applied to the back face of the piston
generates the piston axial force (FO) as shown T = Pq/2x
in the figure below.
q With shoe (14), which is joined to piston (4) by Q: Total flow
the spherical surface, reaction force (FR) in a q: Flow per rotation
direction at right angles to flat surface (A) is N: Rotation speed
generated. The combined force of (FO) and P: Pressure
(FR) is (FP) and this becomes the force to T: Rotating torque
rotate cylinder block (5).
q Shaft (1), which is meshed to cylinder block (5)

by spline (13) transfers this rotating torque to
the output side.
q Cylinder block (5) rotates, and while the condi-
tion changes from volume (E) to volume (F),
pressurized oil from the pump flows into the
cylinder chamber, and pressure (P) is gener-
ated according to the load.
q On the other hand, when the condition goes
beyond volume (F) and changes to volume (E),
the oil is pushed out and returned to the pump.
10-401 34 D65EX, PX, WX-16

Brake valve operation

q The brake valve consists of check valve (11),
counterbalance valve (9), and safety valve
(10), and the circuit is configured as shown in
the following figure.
q The function and the operation of each compo-
nent is as given below.
D65EX, PX, WX-16 10-401 35

Counterbalance valve and check valve 1
Function q The pressurized oil at the side where the oil is

q When the steering is operated on a downhill being supplied flows from orifice (E1) of spool
slopes, the weight on the machine produces a (9) into chamber (S1). And when the pressure
force in the downward direction which makes in chamber (S1) becomes greater than the
the machine try to turn faster than the speed of spool switching pressure, spool (9) is pushed
the HSS motor. to the right.
q If the engine is run at low speed and the steer- q In this way, port (MB) and port (PB) are con-
ing is operated, the HSS motor will overrun, nected. As a result, the outlet port side of the
and this may cause an extremely dangerous HSS motor is opened and the HSS motor
condition. starts to run.
q To prevent this, this valve is installed to carry
out the steering in accordance with the engine
speed [pump discharge amount].
Operation when pressurized oil is supplied

q When the steering lever is operated, the pres-
surized oil from the control valve is supplied to
port (PA). It pushes open check valve (11a),
and flows from HSS motor inlet port (MA) to
HSS motor outlet port (MB).
q However, the outlet port side of the HSS motor
is closed with check valve (11b) and counter-
balance valve (9), so the pressure at the sup-
ply side increases.
10-401 36 D65EX, PX, WX-16

Action of brakes when operating steering on

downhill slopes
q When the steering is operated on a downhill
slopes, if the machine attempts to run away,
the HSS motor will rotate under no load, and
the oil pressure at the inlet port of the HSS
motor will drop. This drop in the pressure will
pass through orifice (E1), so the pressure in
chamber (S1) will also drop.
q If the pressure in chamber (S1) drops below
the spool switching pressure, spool (9) is
pushed to the left by spring (16) and outlet port
(MB) is throttled.
q The pressure on the outlet side increases to
generate rotational resistance on the HSS
motor. In this way, the machine runaway is pre-
vented.
q The spool moves to a position where the pres-
sure of the outlet side port (MB) is balanced
with the machine weight and the inlet side
pressure to throttle the outlet port circuit and
control the speed corresponding the pump
delivery.
D65EX, PX, WX-16 10-401 37

Safety valve 1
Function
q When the operation of the steering stops,
counterbalance valve (9) closes the circuit at
the inlet and outlet ports of the HSS motor.
q Since the inertial force keeps the HSS motor
running, the pressure on the outlet port of the
HSS motor becomes abnormally high, result-
ing in damaging the HSS motor and the piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the HSS motor to
protect the equipment from damage.
Operation
q When the operation of the steering is stopped, q If the pressure in chamber (E) [or chamber (F)]
the check valve of the counterbalance valve goes above the set pressure, x(D12 – D22)/4 x
(9) closes chamber (E) (or chamber (F)) in the pressure resulting from the difference in area
outlet port circuit, but the pressure at the outlet between (D1) and (D2) [or x (D3 2 – D1 2 )/4 x
port side continues to rise because of inertia. pressure resulting from the difference in area
between (D3) and (D1)] moves the poppet
rightward overcoming the spring force. Thus,
the oil flows to the circuit on the opposite side
chamber (F) [or chamber (E)].
10-401 38 D65EX, PX, WX-16

D65EX, PX, WX-16 10-401 39

SEN04967-00

©2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)
10-401 40
SEN04968-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up


Control valve ................................................................................................................................................... 2
CLSS..............................................................................................................................................................11
Function and operation of each valve ........................................................................................................... 14
D65EX, PX, WX-16 10-402 1

SEN04968-01 Control valve
Control valve 1
Outline
The control valves of the following 4 types are set.
q 4-spool valve (lift + tilt + angle + steering)
q 4-spool valve (lift + tilt + ripper + steering)
q 5-spool valve (lift + tilt + angle + ripper + steering)
[for power angle power tilt dozer]
q 5-spool valve (lift + tilt + pitch + ripper + steering)
[for straight tilt power pitch dozer]
[for sigma power pitch dozer]
As for outside view and sectional view, only the 5-spool valves (for straight tilt power pitch dozer and for
sigma power pitch dozer) are shown.
A1: To HSS motor

A2: To lift cylinder head
A3: To pitch cylinder bottom
A4: To angle cylinder bottom
A5: To ripper cylinder bottom
B1: To HSS motor
B2: To lift cylinder bottom
B3: To pitch cylinder head
B4: To angle cylinder head
B5: To ripper cylinder head
CA1: Connector (from controller)
CB1: Connector (from controller)
LS: To pump (port LS)
P: From pump
PA2: From blade PPC valve
PA5: From ripper PPC valve
PB2: From blade PPC valve
PB5: From ripper PPC valve
PEPC: From self-pressure reducing valve
PI: Pump pressure pickup port
PP: To pump LS valve
SI: Steering LS pressure pickup port
T: To tank
TS: To tank
10-402 2 D65EX, PX, WX-16

Control valve SEN04968-01
Outside view
D65EX, PX, WX-16 10-402 3

Sectional view
(1/5)
10-402 4 D65EX, PX, WX-16

1. Suction valve
2. Back pressure valve
3. Steering spool
4. Lift spool
5. Tilt spool
6. Pitch spool
7. Ripper spool
8. Cover (work equipment valve side)
9. Ripper valve
10. Pitch valve
11.Tilt valve
12. Lift valve
13. Block (pump port)
14. Steering valve
15. Cover (steering valve side)
Unit: mm
Free length x Installed Installed Free length Installed
16 Suction valve spring outside diameter length load load
46.8 x 7.5 40.6 5.49 N — 4.41 N
{0.56 kg} {0.45 kg}
67.7 N 54.1 N
17 Back pressure valve spring 67.7 x 20 42.5
{6.9 kg}
—
{5.52 kg}
5.10 N 4.12 N
18 Suction valve spring 39.2 x 4.45 33.5
{0.52 kg}
—
{0.42 kg} Replace spring if
Spool return spring 221 N 177 N damaged or
19 (steering)
45.7 x 28 43
{22.55 kg}
—
{18.0 kg} deformed.
Spool return spring 34.3 N 27.5 N
20 (lift ripper)
41.1 x 19.3 40.5
{3.5 kg}
—
{2.8 kg}
Spool return spring 108 N 86.3 N
21 (tilt pitch)
41.9 x 18.6 39
{11 kg}
—
{8.8 kg}
22 (lift)
37.3 x 19.4 17
{5.24 kg}
—
{4.19 kg}
23 (lift)
40.5 x 24.6 37.5
{8.3 kg}
—
{6.64 kg}
D65EX, PX, WX-16 10-402 5

(2/5)
10-402 6 D65EX, PX, WX-16

1. LS relief valve (for steering valve)

2. Pressure compensation valve R
3. Pressure compensation valve F
4. Pressure reducing valve (for work equipment valve)
5. Steering priority valve
6. Check valve (centralized safety valve)
R: Pressure reducing valve

F: Flow control valve
Unit: mm
Free length x Installed Installed Installed
Pressure compensation valve Free length
7 F
outside diameter length load load
9.81 N 7.85 N
36.2 x 5.3 32 —
{1 kg} {0.80 kg}
Pressure compensation valve 17.7 N 14.1 N
8 R spring
27.5 x 14.2 18
{1.8 kg}
—
{1.44 kg}
473 N 379 N
9 Steering priority valve spring 106.5 x 20 82
{48.2 kg}
—
{38.6 kg} Replace spring if
Pressure reducing valve 125 N 100 N damaged or
10 spring
51.6 x 10.5 44.5
{12.7 kg}
—
{10.2 kg} deformed.
11 F spring
30.85 x 5.2 27
{1.0 kg}
—
{0.80 kg}
12 R spring
31.9 x 14.4 21.5
{3.5 kg}
—
{2.8 kg}
13 R spring
33.4 x 14.4 21.5
{5.7 kg}
—
{4.56 kg}
3.92 N 3.14 N
14 Check valve spring 27.2 x 6.9 22
{0.4 kg}
—
{0.32 kg}
D65EX, PX, WX-16 10-402 7

(3/5)
10-402 8 D65EX, PX, WX-16

(4/5)
1. Unload valve
D65EX, PX, WX-16 10-402 9

(5/5)
1. Centralized safety valve (for work equipment valve)

2. Pressure release plug
3. Main relief valve (for work equipment valve)
10-402 10 D65EX, PX, WX-16

CLSS SEN04968-01
CLSS 1
a CLSS: Abbreviation for Closed center Load Sensing System
Outline of CLSS 1
Features Configuration
CLSS has the following features. q CLSS consists of the variable displacement
q Fine control performance free from influence of type piston pump, control valve and actuators.
load q The pump unit consists of the main pump,
q Control performance which enables digging fixed choke valve, PC valve and LS valve.
even in fine control mode
q Flow distribution decided by spool opening
area during compound operation
q Energy saved by variable pump control
D65EX, PX, WX-16 10-402 11

SEN04968-01 CLSS
Basic principle 1
Control of pump swash plate

q The pump swash plate (pump delivery) is con- q If the LS differential pressure (dPLS) lowers
trolled so that the LS differential pressure below the LS valve set pressure (when the
(dPLS) which is the differential pressure actuator load pressure is high), the pump
between pump discharge pressure (PP) and swash plate angle increases. If the LS differen-
control valve outlet LS pressure (PLS) (actua- tial pressure rises higher than the set pressure
tor load pressure) may become constant. (the actuator load pressure is low), the pump
[LS differential pressure (dPLS) = Pump dis- swash plate angle decreases.
charge pressure (PP) – LS pressure (PLS)]
[LS differential pressure (dPLS) and pump
swash plate
10-402 12 D65EX, PX, WX-16

CLSS SEN04968-01
Pressure compensation control
q The valve which balances the load (pressure in proportion to open area (S1) and (S2) of
compensation valve) is installed to the outlet each operated valve.
side of the control valve. When the actuators
are operated simultaneously, this valve keeps
the pressure difference between the upstream
(inlet) side of each valve spool and down-
stream (outlet) side (dP) constant, regardless
of the load (pressure). By this operation, the oil
flow from the pump is divided (compensated)
D65EX, PX, WX-16 10-402 13

SEN04968-01 Function and operation of each valve
Function and operation of each valve 1
Hydraulic circuit diagram and valve names 1
10-402 14 D65EX, PX, WX-16

Function and operation of each valve SEN04968-01
1. Unload valve
Set pressure: 3.4 MPa {35 kg/cm2}
3. Steering priority valve
4. Pressure reducing valve (for work equipment valve)
5. Pressure compensation valve
6. Suction valve
7. LS shuttle valve
8. LS relief valve (for steering valve)
9. Centralized safety valve (for work equipment valve)
10. Main relief valve (for work equipment valve)
11. Steering valve
12. Lift valve
13. Tilt valve
14. Pitch valve
15. Ripper valve
16. Back pressure valve
D65EX, PX, WX-16 10-402 15

Unload valve 1
When control valve is in neutral
PLS: LS circuit Function

PP: Pump circuit q When the control valve is in neutral, the valve
T: Tank circuit releases delivery (Q) for the pump minimum
swash plate angle into the tank circuit. At this
1. Sleeve time, pump discharge pressure (PP) is set to
2. Spring 3.4 MPa {35 kg/cm2} by spring (2) in the valve.
3. Spool [LS pressure (PLS) is 0 MPa {0 kg/cm2}]
Operation
q Pump discharge pressure (PP) is applied to
the right end of spool (3) and LS pressure
(PLS) is applied to the left end.
q While the control valve is in neutral, only pump
discharge pressure (PP) is applied and it is set
with only the spring load of spring (2) since LS
pressure (PLS) is 0 MPa {0 kg/cm2}.
q If pump discharge pressure (PP) increases to
the 3.4 MPa {35 kg/cm2} spring load of spring
(2), spool (3) moves to the left and pump circuit
(PP) is connected to the tank circuit (T)
through hole (a) of sleeve (1).
q Pump discharge pressure (PP) is set to
3.4 MPa {35 kg/cm2}.
10-402 16 D65EX, PX, WX-16

When control valve is set fine control
Function q If the differential pressure between pump dis-

q When the control valve is set fine control, if the charge pressure (PP) and LS pressure (PLS)
actuator demand flow is below the delivery at reaches 3.4 MPa {35 kg/cm 2 } spring load of
the pump minimum swash plate angle, pump spring (2), spool (3) moves to the left and
discharge pressure (PP) is set to LS pressure pump circuit (PP) is connected to the tank cir-
(PLS) + 3.4 MPa {35 kg/cm2}. If the differential cuit (T).
pressure between discharge pressure (PP) q The pump discharge pressure (PP) is set to
and LS pressure (PLS) reaches the 3.4 MPa pressure of 3.4 MPa {35 kg/cm2} + LS pressure
{35 kg/cm 2 } spring load of spring (2), the (PLS) and flow control differential pressure
unload valve opens and LS differential pres- ( d P L S ) a t b e l o w m i n i m um s wa s h p l a t e
sure (dPLS) becomes 3.4 MPa {35 kg/cm2}. becomes 3.4 MPa {35 kg/cm2}.
Operation
q When the actuators are controlled with flow of
below the pump minimum swash plate angle
[flow below (Q) min. in the figure at right], if the
control valve spool is changed, LS pressure
[PLS = Load pressure] is detected and applied
to the left end of spool (3).
q Since pump discharge pressure (PP)
increases to pass all of (Q) min. through the
narrow opening of the control valve spool, the
differential pressure between pump discharge
pressure (PP) and LS pressure (PLS)
increases.
D65EX, PX, WX-16 10-402 17

When control valve is operated
Function
q When the control valve is operated, if the actu-
ator demand flow exceeds the flow at the
pump minimum swash plate angle, the flow to
the tank circuit (T) is stopped and all of pump
delivery (Q) is supplied to the actuator circuit.
Operation
q If the control valve is operated far, LS pressure
(PLS) is generated and applied to the left end
of spool (3). At this time, LS differential pres-
sure (dPLS) not much different from pump dis-
charge pressure (PP), since the open area of
control valve spool is wide.
q Since the differential pressure between pump
discharge pressure (PP) and LS pressure
(PLS) does not reach the 3.4 MPa {35 kg/cm2}
spring load of spring (2), spool (3) is pushed to
the right by spring (2).
q Pump circuit (PP) is disconnected from tank
circuit (T) and all of pump delivery (Q) flows to
the actuator circuit.
10-402 18 D65EX, PX, WX-16

Main relief valve (steering and work equipment) 1
Centralized safety valve
Function
q If the oil pressure exceeds a set pressure, this
valve drains the oil into the tank. The maximum
pressure in the work equipment circuit is lim-
ited by this operation to protect the circuit.
Operation
q Since pilot poppet (3) opens, the pressure in

spring chamber (C) decreases and poppet (1)
moves to the right until it touches the end of
pilot poppet (3) and then oil is drained through
throttle (b) and the drilled hole.
q Port (A) is connected to the pump circuit and

port (B) is connected to the drain circuit. The
pressurized oil acts on diameter (d2) of main
valve (2) through diameter (d1) of main valve
(2) and the hole of poppet (1). Main valve (2) is
in contact with the sleeve because of the area
difference (d1 < d2).
q Since the pressure in spring chamber (C) is

lower than that in port (A), main valve (2)
opens and the oil flows from port (A) to (B) to
prevent abnormal pressure rise.
q If the pressure in port (A) reaches the set pres-

sure of spring (4), pilot poppet (3) opens and
the oil flows around pilot poppet (3) and then is
drained through drilled hole (a) and port (B).
D65EX, PX, WX-16 10-402 19

Steering priority valve 1
Compound operations
10-402 20 D65EX, PX, WX-16

a: Pump circuit
b: Steering pump circuit
c: Work equipment pump circuit
d: Spring chamber
e: Pressure chamber
1. Steering priority valve spool

2. Priority valve spring
3. Steering spool
4. Work equipment spool
Function
q If the steering valve and the work equipment
valve on the downstream side of the steering When pump swash plate does not reach maxi-
priority valve are operated at the same time, mum angle
priority is given to the flow of oil to the steering q When the maximum oil flow from the pump is
valve, and the rest of the oil discharged from greater than the sum of the flow demanded by
the pump goes to the work equipment valve. the steering valve and work equipment valve,
an amount of oil that matches the opening of
Operation steering spool (3) flows to the steering valve
q When steering spool (3) is operated and the oil and the amount of oil decided by the pump
flows, differential pressure occurs between pressure, load pressure and spool opening
pump discharge pressure (PP) and LS pres- area flows to the work equipment valve.
sure (PLS). Steering priority valve (1) is con-
trolled by this differential pressure, and at the When pump swash plate is at maximum angle
same time, the pump swash plate angle is con- q When the maximum flow of oil from the pump
trolled by (dPLS) [(PP) – (PLS)] = 1.96 MPa is smaller than the sum of the oil flow
{20 kg/cm2}, and the flow of oil to the steering demanded by the steering valve and work
valve is fixed. equipment valve.
q The (PP) pressure is applied to right end (e) of
priority valve spool (1) and the (PLS) pressure 1. When steering valve load Z work equipment
is applied to spring chamber (d) on the left valve load
side. Priority valve spool (1) is pushed to the q An amount of oil that matches the opening
right by spring (2). of steering spool (3) flows to the steering
q When the differential pressure between the valve, and the remaining oil flows to work
(PP) pressure and (PLS) pressure is below the equipment valve.
set pressure, the opening between chamber
(a) and chamber (b) becomes maximum. If the 2. When steering valve load > work equipment
differential pressure increases, spool (1) valve load
moves to the left to throttle the opening for the q Pump pressure (PP) is determined by the
steering and increase the opening for the work steering valve load, but in this condition, if
equipment. the downstream work equipment valve
q If work equipment spool (4) is operated while where the load is smaller is operated, the
steering spool (3) is operated, pump pressure differential pressure causes the oil to flow
(PP) momentarily drops. to the work equipment valve, so the pump
q The differential pressure between (PP) and pressure drops.
(PLS) decreases and priority valve (1) is q Steering priority valve (1) increases the
moved by the pressure in chamber (d) in the size of the opening to the steering, while
direction to throttle the opening to the [right]. at the same time reducing the size of the
q At the same time, (dPLS) becomes smaller, so opening to the work equipment in order to
the pump swash plate angle increases to sup- ensure the flow of oil to the steering.
ply an oil flow to make up the amount that the q In this condition, the flow of oil is divided in
pressures drops. proportion to the ratio of (PP) – (P1) differ-
ential pressure to (PP) – (P2) differential
pressure. The bigger (P1) – (P2) is, the
smaller the flow of oil to the steering sys-
tem becomes.
D65EX, PX, WX-16 10-402 21

Pressure reducing valve for work equipment 1
When work equipment valve is operated singly
a: Work equipment pump circuit Function

b: Orifice q This valve controls the pump circuit pressure
c: Spring chamber on the work equipment side to a maximum of
d: Valve pressure receiving chamber 28.1 MPa {287 kg/cm2} and secures the pump
e: Notch cir cui t pres sur e on the s teeri ng sid e at
f: Orifice 40.2 MPa {410 kg/cm2} during compound oper-
g: Pressure chamber ation (work equipment + steering).
h: Notch
i: Notch
PP: Pump circuit
T: Tank circuit
1. Pressure reducing valve

2. Poppet
3. Spring
4. Valve
5. Spring
6. Steering priority valve spool
7. Spring
10-402 22 D65EX, PX, WX-16

Operation
q If the work equipment valve (lift, tilt, angle, etc.)
is operated, pressurized oil (PP) in the pump
circuit flows through notch (e) and orifice (f) of
spool (6) to right end chamber (g) and pushes
spring (7) to the left, and notch open area (h)
becomes maximum. The pressurized oil is
supplied through notch (i) of valve (4) to work
equipment pump circuit (a).
q If the pressure in work equipment pump circuit
(a) reaches 28.1 MPa {287 kg/cm2} set pres-
sure of pressure reducing valve (1), poppet (2)
pushes spring (3) to the right to release the
pressurized oil in spring chamber (c) into tank
circuit (T). Accordingly, the pressurized oil in
pressure chamber (d) flows through orifice (b)
and spring chamber (c) to tank circuit (T). A
pressure difference is generated between
pressure chamber (d) and spring chamber (c)
and then valve (4) moves to the right to close
notch (i). As a result, pump circuit (PP) and
work equipment pump circuit (a) are discon-
nected.
q Even if the steering is operated and the pump
c ir cu it pr es su re in cr ea se s to 40.2 MP a
{410 kg/cm2}, the work equipment pump circuit
pressure does not exceed 28.1 MPa {287 kg/
cm2}.
D65EX, PX, WX-16 10-402 23

Pressure compensation valve 1
10-402 24 D65EX, PX, WX-16

Function Suction valve 1
q When the load pressure of an actuator is lower Function

than the other actuator and the oil flow is about
q This valve prevents generation of negative
start increasing during compound operation,
pressure in the cylinder circuit.
the pressure compensation valve compen-
sates for the pressure. [At this time, the load
Operation
pressure on the other actuator side (upper
side) in the compound operation is higher than
the actuator on this side (lower side).]
Operation
q Load pressure (Ab) on the other actuator side
(upper side) increases during compound oper-
ation, the flow in the actuator circuit (Aa) on
this side (lower side) starts increasing.
q In this case, LS pressure (PLS) of the other
actuator acts on spring chamber (PLS1) and
pushes pressure reducing valve (1) and flow
control valve (2) to the left.
q Flow control valve (2) throttles the open area
between pump circuit (PP) and spool upstream q Port (A) is connected to the cylinder circuit and
(PPA) to generate a pressure loss between port (B) is connected to the drain circuit. If load
(PP) and (PPA). is applied to port (A), main poppet (1) opens
q Flow control valve (2) and pressure reducing because of the area difference between (d1)
valve (1) are balanced at a position where the and (d2) and then the oil flows through port (B)
pressure difference between (PA) and (PLS) to port (A) to prevent generation of negative
applied to both sides of pressure reducing pressure.
valve (1) is the same as the pressure loss
between (PP) and (PPA) at the front and rear
of flow control valve (2).
q The pressure differences between upstream
pressure (PPA) and downstream pressure (PA)
of both spools operated for compound opera-
tion become the same and the pump delivery
is divided in proportion to the open area of
notch (a) of each spool.
D65EX, PX, WX-16 10-402 25

Suction safety valve 1
Function
q When an impact is applied to the cylinder and
abnormal pressure is generated, this valve
releases the abnormal pressure to protect the
cylinder and other hydraulic devices.
q If negative pressure is generated in the cylin-
der circuit, this valve functions as a suction
valve.
Operation as safety valve
q Since pilot poppet (4) opens, the pressure in

chamber (C) drops and poppet (3) moves to
the right. Poppet (3) is seated to the end of
pilot poppet (4) and the oil is drained through
throttle (b) and chamber (D).
q Port (A) is connected to the cylinder circuit and

port (B) is connected to the drain circuit. The
hydraulic pressure in port (A) passes through
the hole of poppet (3) and port (C), and safety
valve (2) is seated to the left side because of
the relationship of (d2) < (d3). The relationship
between the sectional diameters (sectional
areas) is (d4) > (d1) > (d3) > (d2).
q Since the pressure in chamber (C) is lower

than that in port (A), safety valve (2) moves to
the right and the oil flows from port (A) to port
(B) to prevent abnormal pressure generation.
q Even if abnormal pressure is generated, suc-
tion valve (1) having large sectional area does
not operate since (d1) < (d4).
q If abnormal pressure is generated in port (A)

and it reaches the set pressure of spring (5),
pilot poppet (4) opens and the oil in chamber
(C) is drained through chamber (D) and periph-
ery (a) of suction valve (1).
10-402 26 D65EX, PX, WX-16

Operation as suction valve
q If negative pressure is generated in the cylin-

der circuit, the pressures in port (A) and cham-
ber (C) become negative since those are
connected to each other. Since the tank pres-
sure of port (B) is applied to port (E), the
hydraulic pressure on suction valv e ( 1)
increases by the area difference between (d4)
and (d3) and moves suction valve (1) to the
right against the reaction force of spring (6). As
a result, the oil flows through port (B) to port
(A) to prevent negative pressure generation in
port (A).
D65EX, PX, WX-16 10-402 27

10-402 28 D65EX, PX, WX-16

LS shuttle valve 1
a: LS bypass orifice (steering) Operation

b: LS bypass orifice (work equipment side) q Circuit pressure (PLS) on the steering side
presses ball shuttle valve (2) to the right and is
1. LS shuttle valve led to upper output port (PLS). [When steering
2. Ball shuttle valve is operated singly or together with another
actuator and steering (PLS) > work equipment
Function PLS)]
q This valve releases residual LS pressure q Pressurized oil (PLS) on the steering side
(PLS). flows through orifice (a) to the tank circuit.
q This valve lowers the increasing speed of LS q The pressure in the PLS circuit on the work
pressure (PLS) and generates a pressure loss equipment side presses ball shuttle valve (2) to
in the throttle between (P) and (LS) of the pres- the left and is led to upper (PLS) output port.
sure compensation valve with the discarded [When work equipment is operated singly or
throttled flow to lower the effective LS differen- together with another actuator and work equip-
tial pressure to increase the stability. ment (PLS) > steering (PLS)]
q This valve selects and outputs the higher one q Pressurized oil (PLS) on the work equipment
of LS pressure on the steering side or on the side flows through orifice (b) to the tank circuit.
work equipment side.
D65EX, PX, WX-16 10-402 29

Operations of steering LS relief valve and main relief valve
a: Pump primary circuit 1. Steering spool

b: Pump secondary circuit 2. Steering LS relief valve
c: LS circuit 3. Main relief valve
4. HSS motor
5. Priority valve spool
6. Priority valve spring
7. Unload valve
10-402 30 D65EX, PX, WX-16

Function
q It sets the maximum pressure when the HSS
motor is operated.
q The pump LS valve senses the differential
pressure (PP) – (PLS) generated by the opera-
tion of the LS relief valve and reduces the
pump swash plate angle. The pump delivery is
balanced at the minimum point. As a result, the
relief flow decreases.
q The main relief valve cuts the peak pressure
generated by a sudden outside load (e.g.,
operation of the LS relief valve) which the
pump swash plate control cannot follow.
Operation
q If steering spool (1) is moved and HSS motor
drive pressure (4) increases, steering LS relief
valve (2) operates and the oil in pump circuit
(b) is drained. As a result, the pressure differ-
ence between pump circuit (b) and LS circuit
(c) increases.
q For the same reason, if the pressure in LS cir-
cuit (c) decreases, priority valve spool (5)
moves to the left against spring (6) to throttle
the open area between pump primary circuit
(a) and secondary circuit (b), and the pressure
difference between (a) and (b) increases.
q The pump LS valve senses LS differential
pressure (PP) – (PLS) generated by LS relief
valve (2) and reduces the pump swash plate
angle. The pump swash plate is balanced at
the minimum delivery point when LS differen-
tial pressure X 2.0 MPa {20 kg/cm 2 }. (See
"Control of pump swash plate")
q When the pump swash plate is at the minimum
angle (minimum flow position), if pump circuit
pressure (PP) – LS circuit pressure (PLS) X
3.4 MPa {35 kg/cm2}, unload valve (7) operates
to relieve the excessive oil to balance the
swash plate.
LS relief valve set pressure

37.2 {379}
(MPa {kg/cm2})
Main relief valve set pressure
40.2 {410}
(MPa {kg/cm2})
D65EX, PX, WX-16 10-402 31

Operation of work equipment relief valve
1. Work equipment spool

2. Pressure reducing valve
3. Main relief valve (work equipment)
4. Main relief valve (steering)
5. Pressure reducing valve spool
6. Unload valve
10-402 32 D65EX, PX, WX-16

Function
q This valve sets the maximum pressure when
the work equipment operates.
q The pump LS valve senses differential pres-
sure (PP1) – (PP2) C (PLS) generated by the
operation of the reducing valve and relief pres-
sure on the work equipment side, and reduces
the pump swash plate angle. The pump deliv-
ery is balanced at the minimum point. As a
result, the relief flow decreases.
Operation
q If work equipment spool (1) is moved and work
equipment operating pressure (PP2)
increases, pressure reducing valve (2) oper-
ates and pressure reducing valve spool (5)
closes to reduce the opening between (PP1)
and (PP2) (1.1 mm2). Work equipment pump
circuit pressure (PP2) becomes 28.1 MPa {287
kg/cm 2 } of the pressure reducing valve set
pressure.
q Work equipment operating pressure (PP2) is
decided by the pressure reducing valve set
pressure and (PP1) is decided by the pressure
reducing valve set pressure + unload valve set
pressure since excessive oil is drained through
the unload valve.
q The work equipment relief valve cuts the peak
pressure generated by a sudden outside load
(e.g., operation of the pressure reducing valve)
which the pump swash plate control cannot fol-
low.
Pressure reducing valve set

28.1 {287}
pressure (MPa {kg/cm2})
Relief valve set pressure
30.1 {307}
(MPa {kg/cm2})
Unload valve set pressure
3.4 {35}
(MPa {kg/cm2})
D65EX, PX, WX-16 10-402 33

Introduction of LS pressure 1
Steering valve
Function q Since pressure reducing valve (3) moves to

q The LS pressure means the actuator load the left at the same time, pump discharge pres-
pressure on the control valve outlet side. sure (PP) led through orifice (c) is led into LS
q In the work equipment valve, actually, pump circuit (PLS) while it is pressure-reduced by
discharge pressure (PP) is reduced by pres- the pressure loss of throttle (d) and further led
sure reducing valve (3) of the pressure com- to spring chamber (PLS1).
pensation valve to the level of actuator circuit q LS circuit (PLS) is connected to tank circuit (T)
pressure (A) and then introduced into LS cir- through LS bypass plug (4).
cuit (PLS). Orifice (c) is made in piston (5) q The areas on both sides of pressure reducing
between pump circuit (PP) and pressure valve (3) are the same (SA) = (SLS), and actu-
reducing valve (3), and it works as a damper. ator circuit pressure (PA) = (A) is applied to the
(SA) side and reduced pump discharge pres-
Operation sure (PP) is applied to the opposite (SLS) side.
q If spool (1) is operated, pump discharge pres- q Pressure reducing valve (3) is balanced at a
sure (PP) flows through flow control valve (2), position where actuator circuit pressure (PA)
spool notch (a) and bridge passage (b) to actu- and the pressure in spring chamber (PLS1) are
ator circuit (A). the same, and pump discharge pressure (PP)
reduced by notch (d) is led as actuator circuit
pressure (A) to LS circuit (PLS).
10-402 34 D65EX, PX, WX-16

Work equipment valve (lift, tilt, angle, ripper)
When blade is lifted "RAISE"
Operation
q If spool (1) is operated, pump discharge pres- q Pressure reducing valve (3) is balanced at a
sure (PP) flows through flow control valve (2), position where actuator circuit pressure (PA)
spool notch (a) and bridge passage (b) to actu- and the pressure in spring chamber (PLS1) are
ator circuit (A). the same, and pump discharge pressure (PP)
q Since pressure reducing valve (3) moves to reduced by notch (d) is led as actuator circuit
the right at the same time, pump discharge pressure (A) to LS circuit (PLS).
pressure (PP) led through passage (c) is led
into LS circuit (PLS) while it is pressure-
reduced by the pressure loss of notch (d) and
further led to spring chamber (PLS1).
q LS circuit (PLS) is connected to tank circuit (T)
through LS bypass plug (4).
q The areas on both sides of pressure reducing
valve (3) are the same (SA) = (SLS), and actu-
ator circuit pressure (PA) = (A) is applied to the
(SA) side and reduced pump discharge pres-
sure (PP) is applied to the opposite (SLS) side.
D65EX, PX, WX-16 10-402 35

When blade is operated in "FLOAT" position
Operation
q When the lift valve is in the "FLOAT" position,
the cylinder port and drain port (T) are con-
nected and no load is applied.
q Even while the lift valve is in the "FLOAT" posi-
tion, the pump circuit and the cylinder circuit
are separated so that the other work equip-
ment control valves (e.g., tilt, angle) can be
operated.
q If the work equipment control lever is set in the
"FLOAT" position, spool (1) is set to the maxi-
mum stroke position, port (B) is connected to
port (A) through bridge passage (b), and port
(A) is connected to (T) circuit.
q If the blade is loaded, it moves in either direc-
tion.
q While the work equipment control lever is in
the "FLOAT" position, part (a) of spool (1) is
closed. Accordingly, another work equipment
valve (e.g., tilt, angle) is operated, the pump
pressure increases and compound operation
becomes possible.
10-402 36 D65EX, PX, WX-16

Back pressure valve 1
Function Operation
q When the steering is operated or stopped, the q The steering circuit drain pressure is increased
steering drain circuit pressure is increased to with back pressure valve (1) and spring (2).
improve the effect of suction valve (3) and pre-
vent cavitation in the HSS motor.
D65EX, PX, WX-16 10-402 37

SEN04968-01

©2010 KOMATSU
All Rights Reserved
10-402 38
SEN04969-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up


PPC valve (blade lift, blade tilt) ....................................................................................................................... 2
PPC valve (ripper)........................................................................................................................................... 8
Electric lever (steering) ................................................................................................................................. 12
Quick drop valve ........................................................................................................................................... 16
Work equipment lock solenoid valve............................................................................................................. 18
Pitch selector solenoid valve......................................................................................................................... 22
Hydraulic oil cooler bypass valve .................................................................................................................. 23
Accumulator .................................................................................................................................................. 24
D65EX, PX, WX-16 10-403 1

SEN04969-00 PPC valve (blade lift, blade tilt)
PPC valve (blade lift, blade tilt) 1
a PPC: Abbreviation for Proportional Pressure Control
10-403 2 D65EX, PX, WX-16

PPC valve (blade lift, blade tilt) SEN04969-00
P: From self-pressure reducing valve 1. Disc

P1: To blade lift valve (port PA3) 2. Plate
P2: To blade lift valve (port PB3) 3. Body
P3: To blade tilt valve (port PA2)
P4: To blade tilt valve (port PB2)
T: To hydraulic tank
D65EX, PX, WX-16 10-403 3

Operation
When in neutral
For blade lift For blade tilt
q Ports (PA3) and (PB3) of the blade lift control q Ports (PA2) and (PB2) of the blade tilt control
valve and ports (P1) and (P2) of the PPC valve valve and ports (P3) and (P4) of the PPC valve
are connected to drain chamber (D) through are connected to drain chamber (D) through
fine control hole (f) of spool (1). fine control hole (f) of spool (1).
10-403 4 D65EX, PX, WX-16

During fine control

(neutral o fine control)
q In this way, the control valve spool moves to a
position where the pressure of chamber (PA3)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.
q When piston (4) is pushed by disc (5), retainer

(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q Fine control hole (f) is shut off from drain
chamber (D) and almost simultaneously it is
connected to pump pressure chamber (PP).
The pilot pressure oil passes through fine con-
trol hole (f) and is conducted from port (P1) to
port (PA3).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1). The relation
between the positions of spool (1) and body
(10) [fine control hole (f) is at the midpoint
between drain chamber (D) and pump pres-
sure chamber (PP)] does not change until
retainer (9) contacts spool (1).
q Metering spring (2) is compressed in propor-
tion to the strokes of the control lever. Thus,
the pressure at port (P1) increases in propor-
tion to the strokes of the control lever.
D65EX, PX, WX-16 10-403 5

During fine control During full stroke

(when control lever is returned)
q When disc (5) pushes down piston (4) and

q When disc (5) starts to be returned, spool (1) is retainer (9) pushes down spool (1), fine control
pushed up by the force of centering spring (3) hole (f) is shut off from drain chamber (D) and
and the pressure at port (P1). is connected to pump pressure chamber (PP).
q Because of this, fine control hole (f) is con- q The pilot pressure oil passed through fine con-
nected to drain chamber (D), and the pressur- trol hole (f), is taken from port (P1) to chamber
ized oil at port (P1) is released. (PA3), and pushes the control valve spool.
q If the pressure at port (P1) goes down too far, q The return oil from chamber (PB3) passes from
spool (1) is pushed down by metering spring port (P2) through fine control hole (f'), and then
(2). Fine control hole (f) is shut off from drain flows to drain chamber (D).
chamber (D), and almost simultaneously, it is
Pump pressure is supplied until the pressure at
port (P1) recovers to a pressure equivalent to
the position of the lever.
q When the control valve spool returns, the oil at
drain chamber (D) flows from fine control hole
(f') in the valve on the side that is not moving.
Oil passed through port (P2) is taken to cham-
ber (PB3), and fills the chamber.
10-403 6 D65EX, PX, WX-16

When blade is operated in "FLOAT" position When "FLOAT" position of blade is released
q When piston (4) at port (P1) "LOWER" side is q When disc (5) is returned from the "FLOAT"
pushed by disc (5) and moves down, ball (11) position, it is pushed down by a force greater
contacts protrusion (a) of the piston during the than the hydraulic force in chamber (E).
stroke. [Detent starts to act] q As a result, chamber (E) is shut off from pas-
q When piston (4) is pushed in, ball (11) pushes sage (d) and is connected to the drain cham-
up collar (12), which is being held by detent ber. Therefore, the oil pressure inside chamber
spring (13). While pushing up collar (12), it (E) is los t, and the "F LOAT " position is
escapes to the outside and passes over protru- released.
sion (a) of the piston.
q Piston (4') on the opposite side is pushed up
by spring (14).
q The oil inside chamber (F) passes through (b)
and (c), and flows to chamber (E), and piston
(4') follows disc (5). Passage (d) is connected
to port (P1), so more or less the same pres-
sure is applied as is applied to port (P1).
q Chamber (E) is normally connected to drain
chamber (D), but if ball (11) passes over pro-
trusion (a) of the piston, passage (d) and
chamber (E) which were shut off, are con-
nected and the pressure oil flows.
q At the same time, the control valve also moves
to "FLOAT" position and the circuit is set to the
"FLOAT" condition.
q Piston (4') is being pushed up by the oil pres-
sure inside chamber (E), so even if the lever is
released, it is held at the "FLOAT" position.
D65EX, PX, WX-16 10-403 7

SEN04969-00 PPC valve (ripper)
PPC valve (ripper) 1

(if equipped)
a PPC: Abbreviation for Proportional Pressure Control
10-403 8 D65EX, PX, WX-16

PPC valve (ripper) SEN04969-00
P: From self-pressure reducing valve

P1: To ripper valve (port PA4)
P2: To ripper valve (port PB4)
T: To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
Unit: mm
Free length
x outside Installed Installed Free length Installed
7 Centering spring diameter
length load load Replace spring if
damaged or
125 N 100 N deformed.
33.9 x 15.3 28.4 {12.7 kg} — {10.2 kg}
16.7 N 13.3 N
8 Metering spring 22.7 x 8.10 22.0 {1.70 kg} — {1.36 kg}
D65EX, PX, WX-16 10-403 9

SEN04969-00 PPC valve (ripper)
Operation
When in neutral q The relation between the positions of spool (1)

and body (8) [fine control hole (f) is at the mid-
point between drain chamber (D) and pump
pressure chamber (PP)] does not change until
retainer (7) contacts spool (1).
q Metering spring (2) is compressed in propor-
tion to the strokes of the control lever. Thus,
the pressure at port (P1) increases in propor-
tion to the strokes of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force
of the return spring of the control valve spool
are balanced.
q Ports (A) and (B) of the control valve and ports

(P1) and (P2) of the PPC valve are connected
to drain chamber (D) via fine control hole (f) in
spool (1).
During fine control

(neutral o fine control)
q As piston (4) is pushed by lever (5), retainer (7)
is pushed too. At the same time, spool (1) is
also pushed down via metering spring (2).
q Fine control hole (f) is shut off from drain
chamber (D) and almost simultaneously it is
The pilot pressure oil passes through fine con-
trol hole (f) and is conducted from port (P1) to
port (A).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1).
10-403 10 D65EX, PX, WX-16

PPC valve (ripper) SEN04969-00
During fine control During full stroke

(when control lever is returned)
q When lever (5) pushes down piston (4) and

q When lever (5) starts to be returned, spool (1) retainer (7) pushes down spool (1), fine control
is pushed up by the force of centering spring hole (f) is shut off from drain chamber (D) and
(3) and the pressure at port (P1). Because of is connected to pump pressure chamber (PP).
this, fine control hole (f) is connected to drain q The pilot pressure oil passes through fine con-
chamber (D), and the pressurized oil at port trol hole (f), is taken from port (P1) to chamber
(P1) is released. (A), and pushes the control valve spool.
q If the pressure at port (P1) goes down too far, q The return oil from chamber (B) passes from
spool (1) is pushed down by metering spring port (P2) through fine control hole (f'), and then
(2). Fine control hole (f) is shut off from drain flows to drain chamber (D).
chamber (D), and almost simultaneously, it is
Pump pressure is supplied until the pressure at
port (P1) recovers to a pressure equivalent to
the position of the lever.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
D65EX, PX, WX-16 10-403 11

SEN04969-00 Electric lever (steering)
Electric lever (steering) 1
1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
10-403 12 D65EX, PX, WX-16

Electric lever (steering) SEN04969-00
Function
Operating effort characteristics

Operation for forward and reverse travel Operation for left and right steering
q The control lever is held at 3 positions: "FOR- q Free return

WARD", "NEUTRAL" and "REVERSE".
D65EX, PX, WX-16 10-403 13

SEN04969-00 Electric lever (steering)
Output voltage characteristics

q The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
q The operating angle (stroke) of the control
levers is detected with potentiometers and it is
output to the transmission, steering controller
as signal voltage.
q A potentiometer is installed in each of longitu-
dinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the fig-
ure at right.
10-403 14 D65EX, PX, WX-16

Electric lever (steering) SEN04969-00
D65EX, PX, WX-16 10-403 15

SEN04969-00 Quick drop valve
Quick drop valve 1
CB1: To right lift cylinder bottom 1. Plug

CB2: To left lift cylinder bottom 2. Piston
CH1: To right lift cylinder head 3. Retainer
CH2: To left lift cylinder head 4. Valve
VB: From control valve, blade "LOWER" 5. Body
VH: From control valve, blade "RAISE" 6. Plug
7. Plug
8. Plug with operating orifice
10-403 16 D65EX, PX, WX-16

Quick drop valve SEN04969-00
Unit: mm
Free length x Installed
outside Installed load Free length Installed load
9 Piston spring
diameter
length
Replace spring if
25.5 N 20.4 N
27.3 x 12 20 — damaged or
{2.6 kg} {2.08 kg}
deformed.
46.1 N 36.9 N
10 Valve spring 53.24 x 34.8 18
{4.7 kg}
—
{3.76 kg}
52.5 N 42.0 N
11 Valve spring 26.35 x 23 25
{5.35 kg}
—
{4.28 kg}
Outline While lowering blade

q The quick drop valve is installed between con-
trol valve and lift cylinder. When blade control
lever is set in "LOWER" position, the quick
drop valve prevents a vacuum on cylinder bot-
tom side and shortens time lag in starting dig-
ging.
q The blade "lowering" speed is mostly decided
by the pump discharge. However, it can be
heightened by installing the quick drop valve.
Operation
Start of lowering blade
q The pressurized oil pushed out of cylinder

head side flows through ports (CH1) and (CH2)
to port (VH). At this time, the oil flow rate is
reduced by orifice (a) and pressure difference
is made before and after the orifice.
q If oil pressure in ports (CH1) and (CH2) rises
higher than the reaction force of springs (1)
and (2), valve (3) and piston (4) move to the
right.
q A part of the pressurized oil which has been
flowing from ports (CH1) and (CH2) to port
(VH) opens valve (3) and flows into ports (VB),
q If the blade control lever is set in "LOWER" (CH1) and (CH2), and then merges with the
position, pressurized oil from the control valve pressurized oil from control valve and flows
flows into port (VB) and further flows through into cylinder bottom side.
ports (CB1) and (CB2) to the cylinder bottom q The blade lowering speed is increased by the
and pushes the cylinder piston to the left. quantity of oil flowing into cylinder bottom side
q The pressurized oil in the cylinder head side is and prevents on the bottom side being vac-
pushed out by the cylinder piston into ports uum.
(CH1) and (CH2), and flows through port (VH)
and control valve into the hydraulic tank.
D65EX, PX, WX-16 10-403 17

SEN04969-00 Work equipment lock solenoid valve
Work equipment lock solenoid valve 1

Sigma dozer (SGM)
Angle dozer (A)
10-403 18 D65EX, PX, WX-16

Work equipment lock solenoid valve SEN04969-00
P: From cooling fan pump (from self-pressure

reducing valve)
P1: To PPC valve
P2: To control valve PEPC port
ACC: To accumulator
T: From blade PPC valve T port
T1: To hydraulic tank
1. Solenoid
2. Accumulator check valve
3. Block
Outline
q The work equipment lock solenoid valve is
installed to the work equipment control circuit
between the self-pressure reducing valve and
PPC valve.
q If the work equipment lock lever is set in the
"FREE" position, the work equipment lock limit
switch operates and the work equipment lock
solenoid valve opens the work equipment con-
trol circuit so that the operator can operate the
work equipment.
Operation
q Solenoid (1) is "energized" by the electric sig-
nal and operates the spool to open ports (P)
and (P1) and the source pressure is supplied
to the PPC valve.
D65EX, PX, WX-16 10-403 19

SEN04969-00 Work equipment lock solenoid valve

10-403 20 D65EX, PX, WX-16

Work equipment lock solenoid valve SEN04969-00
P: From cooling fan pump (from self-pressure

reducing valve)
P1: To PPC valve
P2: To control valve PEPC port
P4: To control valve PA3 port
A1: From blade PPC valve P4 port
A2: To control valve PA4 port
B1: From blade PPC valve P3 port
B2: To control valve PB4 port
ACC: To accumulator
T: From blade PPC valve T port
T1: To hydraulic tank
T2: To control valve PB3 port
PS: To pitch selector solenoid valve P port
AS: To pitch selector solenoid valve A port
BS: To pitch selector solenoid valve B port
TS: To pitch selector solenoid valve T port
1. Solenoid
2. Accumulator check valve
3. Block
Outline
q The work equipment lock solenoid valve is
installed to the work equipment control circuit
between the self-pressure reducing valve and
PPC valve.
q If the work equipment lock lever is set in the
"FREE" position, the work equipment lock limit
switch operates and the work equipment lock
solenoid valve opens the work equipment con-
trol circuit so that the operator can operate the
work equipment.
Operation
q Solenoid (1) is "energized" by the electric sig-
nal and operates the spool to open ports (P)
and (P1) and the source pressure is supplied
to the PPC valve.
D65EX, PX, WX-16 10-403 21

SEN04969-00 Pitch selector solenoid valve
Pitch selector solenoid valve 1

P: From work equipment lock solenoid valve PS Outline

port q The pitch selector solenoid valve is installed to
A: From work equipment lock solenoid valve AS the tilt circuit between the blade PPC valve and
port control valve.
B: From work equipment lock solenoid valve BS q Solenoid (2) is "energized" to connect the tilt
port and pitch pilot circuits while the PITCH switch
T: From work equipment lock solenoid valve TS on the blade control lever head is depressed.
port
1. Block
2. Solenoid
10-403 22 D65EX, PX, WX-16

Hydraulic oil cooler bypass valve SEN04969-00
Hydraulic oil cooler bypass valve 1
M: From cooling fan motor Outline

C: From hydraulic oil cooler outlet q This valve is installed on the oil cooler outlet
T: To hydraulic tank side and pushes open poppet (2) to return the
oil to the hydraulic tank directly when the pres-
1. Block s ur e o f t he oi l fl o wi n g to th e o i l c o o l er
2. Poppet increases abnormally.
3. Spring
4. Plug
Specified value
Cracking pressure 0.78 ± 0.05
(MPa {kg/cm2}) {8 ± 0.5}
D65EX, PX, WX-16 10-403 23

SEN04969-00 Accumulator
Accumulator 1
(for PPC circuit)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
q The accumulator is installed between the self-
pressure reducing valve and PPC valve. When
the engine is stopped with the work equipment
raised, the operator can send pilot oil pressure
to the control valve to have the work equip-
ment lower with its own weight by using nitro-
gen gas pressure in the accumulator.
Specifications
Gas used Nitrogen gas
Amount of gas (cc) 300
Charged pressure 1.18 {12}

(MPa {kg/cm2}) (at 80°C)
Max. pressure used
6.86 {70}
(MPa {kg/cm2})
10-403 24 D65EX, PX, WX-16

Accumulator SEN04969-00
D65EX, PX, WX-16 10-403 25

SEN04969-00

©2009 KOMATSU
All Rights Reserved
10-403 26
SEN04970-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
10 Structure, operation and

500 Work equipment

Blade............................................................................................................................................................... 2
Cutting edge and end bit................................................................................................................................. 8
Ripper (Multi shank)...................................................................................................................................... 10
Ripper (Single shank) ....................................................................................................................................11
Hydraulic cylinder.......................................................................................................................................... 12
Piston valve................................................................................................................................................... 15
D65EX, PX, WX-16 10-500 1

500 Work equipment
SEN04970-01 Blade
Blade 1

Sigma dozer (SGM)
*1: Shows the sigma dozer.
1. Cutting edge
2. Center brace
3. End bit
4. Straight frame
5. Trunnion
6. Blade
7. Left side: Brace (ST-T, SGM)
Tilt cylinder (ST-TPP, SGM-PP)
Right side: Tilt cylinder (ST-T, SGM)
Pitch cylinder (ST-TPP, SGM-PP)
10-500 2 D65EX, PX, WX-16

500 Work equipment
Blade SEN04970-01
Unit: mm
Spherical clearance between size Shaft Hole clearance limit Adjust shim or
1 trunnion and cap replace
–0.1 +1.5
S140 0.1 – 2.0 5.0
–0.5 0
Clearance between brace –0.2 +0.2
2 mounting pin and bracket
50
–0.4 0
0.2 – 0.6 2.0
Replace
3 Clearance between brace
mounting pin and brace
50 –0.2
–0.4
+0.2
0
0.2 – 0.6 2.0
4 Spherical clearance between

bracket and brace
S90 (shaft)
S91 (hole)
–0.1
–0.3
+1.0
0
1.1 – 2.3 2.0 Adjust shim or
replace
bearing and bushing
S90 –0.1
–0.5
+0.5
0
0.1 – 1.0 2.0
6 Clearance between frame

mounting pin and bracket
55 0
–0.3
+0.6
+0.2
0.2 – 0.9 2.0
7 Clearance between frame

mounting pin and bearing
55 0
–0.3
+0.5
+0.2
0.2 – 0.8 2.0 Replace
8 Clearance between center brace

mounting pin and bracket
50 –0.2
–0.4
+0.2
0
0.2 – 0.6 2.0
9 Clearance between center brace

50 –0.2
–0.4
+0.2
0
0.2 – 0.6 2.0

bracket and center brace
S90 (shaft)
S91 (hole)
–0.1
–0.3
+1.0
0
1.1 – 2.3 2.0 Adjust shim or
replace
D65EX, PX, WX-16 10-500 3

500 Work equipment
SEN04970-01 Blade
1. Tilt cylinder
2. Cutting edge
3. End bit
4. Pitch rod
5. Blade
6. Angle cylinder
7. U-frame
8. Trunnion
10-500 4 D65EX, PX, WX-16

500 Work equipment
Blade SEN04970-01
Unit: mm
Spherical clearance between size Shaft Hole clearance limit Adjust shim or
1 trunnion and cap replace
–0.1 +1.5
S140 0.1 – 2.0 5.0
–0.5 0
Clearance between angle cylinder –0.025 +0.3 0.125 –
2 bottom pin and U-frame bracket
50
–0.064 +0.1 0.364
1.0
Replace
Clearance between angle cylinder –0.025 +0.3 0.125 –
3 head pin and blade bracket
50
–0.064 +0.1 0.364
1.0
Clearance between U-frame center –0.25 +0.5 0.25 – Adjust shim or
4 spherical surface and blade cap
S177.5
–0.75 0 1.25
5.0
replace
Clearance between pitch rod pin –0.030 +0.004 0.011 –
5 and bushing
60
–0.076 –0.019 0.080
0.5
Clearance between tilt cylinder –0.025 +0.3 0.125 –
6 bottom pin and U-frame bracket
50
–0.064 +0.1 0.364
1.0 Replace
Clearance between tilt cylinder –0.025 +0.3 0.125 –
7 head pin and blade bracket
50
–0.064 +0.1 0.364
1.0
Standard shim thickness between
Adjust shim or
8 U-frame center spherical surface 8.0 replace
and blade cap
D65EX, PX, WX-16 10-500 5

500 Work equipment
SEN04970-01 Blade
Angle dozer (A)
1. Center shaft
2. Cutting edge
3. C-frame
4. End bit
5. Trunnion
6. Joint
7. Blade
8. Arm
9. Brace
10-500 6 D65EX, PX, WX-16

500 Work equipment
Blade SEN04970-01
Unit: mm
Spherical clearance between size Shaft Hole clearance limit
1 trunnion and cap –0.1 +1.5
S140 0.1 – 2.0 8.0
–0.5 0
Clearance between arm mounting –0.6 +1.5
2 pin and bracket (large)
100
-1.0 +1.0
1.6 – 2.5 3.5
3 Clearance between arm mounting

pin and bracket (small)
80 –0.6
–1.0
+1.5
+1.0
1.6 – 2.5 3.5

mounting pin and arm bracket
50 –0.3
–0.6
+0.7
0
0.3 – 1.3 2.0

50 –0.3
–0.6
+0.2
0
0.3 – 0.8 2.0

mounting pin and joint
50 0
–0.3
+0.2
0
0 – 0.5 2.0 Replace

mounting pin and bearing
50 0
–0.3
+0.5
0
0 – 0.8 2.0
8 Clearance between joint mounting

pin and bracket
50 –0.1
–0.3
+0.3
0
0.1 – 0.6 2.0
9 Clearance between joint mounting

pin and joint
50 –0.1
–0.3
+0.2
0
0.1 – 0.5 2.0
10 Clearance
and frame
between center shaft 79.5 (shaft)
80 (hole)
–0.2
–0.5
+0.5
–0.5
0.2 – 1.5 2.0
Clearance between center shaft –0.1 +0.3
11 mounting pin and bracket 55
–0.3 0
0.1 – 0.6 2.0
12 Clearance between center shaft

mounting pin and center shaft
55 (shaft)
60 (hole)
–0.1
–0.3
+0.5
+0.1
5.2 – 5.8 7.0
D65EX, PX, WX-16 10-500 7

500 Work equipment
SEN04970-01 Cutting edge and end bit
Cutting edge and end bit 1
10-500 8 D65EX, PX, WX-16

500 Work equipment
Cutting edge and end bit SEN04970-01
Unit: mm
ST-T(EX)
ST-TPP(EX) 242 187
ST-T(PX)
ST-TPP(PX) 204 187
End bit height
1 (outside) SGM(EX,WX)
SGM-PP(EX,WX) 225 198
A(EX) 242 187
PAT(EX,PX,WX) 242 187

ST-T(EX)
ST-TPP(EX) 330 300
ST-T(PX)
ST-TPP(PX) 325 300
SGM(EX,WX) Replace
2 Width of end bit SGM-PP(EX,WX) 511 440
A(EX) 330 300

ST-T(EX)
ST-TPP(EX) 204 187
ST-T(PX)
ST-TPP(PX) 204 187
End bit height SGM(EX,WX)
3 (inside) SGM-PP(EX,WX) 205 198
A(EX) 204 187

ST-T(EX)
ST-TPP(EX) 102 85
Cutting edge ST-T(PX)

ST-TPP(PX) 102 85
height
SGM(EX,WX)
4 (from center of bolt SGM-PP(EX,WX)
102 85 Replace or reverse
mounting hole to
end face) A(EX) 102 85
ST-T(EX)
ST-TPP(EX) 392 – 530 Nm {40 – 54 kgm}
ST-T(PX)
ST-TPP(PX) 392 – 530 Nm {40 – 54 kgm}
Tightening torque
SGM(EX,WX)
5 of end bit and SGM-PP(EX,WX) 392 – 530 Nm {40 – 54 kgm} Retighten
cutting edge
A(EX) 392 – 490 Nm {40 – 50 kgm}
PAT(EX,PX,WX) 392 – 530 Nm {40 – 54 kgm}
ST-T: Shows values for straight tilt dozer.

ST-TPP: Shows values for straight tilt power pitch dozer.
SGM: Shows values for sigma dozer.
SGM-PP: Shows values for sigma power pitch dozer.
PAT: Shows values for power angle power tilt dozer.
A: Shows values for angle dozer.
D65EX, PX, WX-16 10-500 9

500 Work equipment
SEN04970-01 Ripper (Multi shank)
Ripper (Multi shank) 1
(if equipped)
D65EX-16, D65WX-16
Unit: mm
Clearance between pin and size Shaft Hole clearance limit
1 bushing –0.030 +0.299 0.199 –
56 1.0
–0.076 +0.169 0.375 Replace
2 Wear of point
222 152
3. Bracket
4. Upper link
5. Ripper cylinder
6. Beam
7. Shank
8. Point
9. Lower link
10-500 10 D65EX, PX, WX-16

500 Work equipment
Ripper (Single shank) SEN04970-01
Ripper (Single shank) 1
(if equipped)
D65EX-16, D65WX-16
Unit: mm
Clearance between pin and size Shaft Hole clearance limit
1 bushing –0.030 +0.299 0.199 –
56 1.0
–0.076 +0.169 0.375 Replace
2 Wear of point
222 152
3. Bracket
4. Upper link
5. Ripper cylinder
6. Beam
7. Shank
8. Point
9. Lower link
D65EX, PX, WX-16 10-500 11

500 Work equipment
SEN04970-01 Hydraulic cylinder
Hydraulic cylinder 1
Lift cylinder
D65EX-16, D65WX-16
(for other than power angle power tilt dozer)
D65PX-16
D65EX-16, D65PX-16, D65WX-16

(for power angle power tilt dozer)
10-500 12 D65EX, PX, WX-16

500 Work equipment
Hydraulic cylinder SEN04970-01
Tilt cylinder
Pitch cylinder
Tilt cylinder
Angle cylinder
D65EX, PX, WX-16 10-500 13

500 Work equipment
SEN04970-01 Hydraulic cylinder
Ripper cylinder
D65EX-16, D65WX-16
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
–0.030 +0.151 0.036 –
Lift 60 0.527
–0.076 +0.006 0.227
Lift –0.030 +0.151 0.036 –
60 0.527
(PAT) –0.076 +0.006 0.227
Clearance between Tilt –0.030 +0.259 0.093 –
1 piston rod and bushing 70 0.635 Replace bushing
Pitch –0.076 +0.063 0.335
Tilt –0.030 +0.259 0.093 –
70 0.635
(PAT) –0.076 +0.063 0.335
Angle –0.030 +0.250 0.085 –
65 0.626
(PAT) –0.076 +0.055 0.326
–0.030 +0.259 0.093 –
Ripper 70 0.635
–0.076 +0.063 0.335
Spherical clearance
–0.2 +0.3 Adjust shim or
between piston rod and Lift S85 0.2 – 0.5 1.0
trunnion –0.3 0 replace
Clearance between
cylinder rod support Lift 50 –0.025 +0.003 0.010 – 1.0 Replace bushing
(PAT) –0.064 –0.015 0.067
shaft and bushing
Spherical clearance
Tilt S90 (shaft) –0.1 +1.0 Adjust shim or
between piston rod and 0.2 – 0.5 2.0
2 Pitch S91 (hole) –0.3 0 replace
bracket
Clearance between
Tilt –0.025 +0.039 0.025 –
cylinder rod support 50 1.0
shaft and bushing (PAT) –0.064 0 0.103
Angle –0.025 +0.039 0.025 –
Clearance between (PAT) 50 –0.064 0 0.103 1.0
cylinder rod support
shaft and bushing –0.030 +0.174 0.130 –
Ripper 75 –0.076 +0.100 0.250 1.0
–0.100 +0.116 0.100 –
Clearance between Lift 55 1.0
–0.174 0 0.290
cylinder boss and Replace pin and
bushing Lift –0.100 +0.118 0.100 –
55 1.0 bushing
(PAT) –0.174 0 0.292
Tilt –0.200 +0.142 0.280 –
50 1.0
Pitch –0.400 +0.080 0.542
3
Tilt –0.025 +0.039 0.025 –
Clearance between 50 1.0
(PAT) –0.064 0 0.103
cylinder bottom support
shaft and bushing Angle –0.025 +0.039 0.025 –
50 1.0
(PAT) –0.064 0 0.103
–0.030 +0.174 0.130 –
Ripper 75 1.0
–0.076 +0.100 0.250
PAT: Shows values for power angle power tilt dozer.
10-500 14 D65EX, PX, WX-16

500 Work equipment
Piston valve SEN04970-01
Piston valve 1
For lift cylinder

Outline
q The piston valve is installed to the piston of the
lift cylinder.
q When the piston rod is at the stroke end, oil
from the pump is released to the port on the
opposite side to lower the oil pressure applied
to the piston.
Oil is also released to the port on the opposite
side before the piston rod reaches the stroke
end to lower the surge pressure and reduce
the shock made when the piston rod reaches
the stroke end.
Operation
Piston valve "closed" Piston valve "opened"
q The pressurized oil from the pump acts on pis- q Slider (5) touches cylinder bottom (b) and
ton (3) and piston valve (1). stops moving before piston rod (4) reaches the
Then, piston valve (1) is pushed to the right to stroke end.
seal tapered part (a) of piston valve seat (2). q Slider (5) touches the end of piston valve (1),
As a result, the oil pressure in the cylinder and then only piston (3) continues moving.
rises to move piston (3) to the right. q The pressurized oil which has been stopped by
piston valve (1) is released through piston
valve seat (2) to the bottom side, thus the oil
pressure in the cylinder lowers.
D65EX, PX, WX-16 10-500 15

500 Work equipment
SEN04970-01 Piston valve
For angle cylinder

Outline
q The piston valve is installed to the piston of the
angle cylinder.
q When the piston rod is at the stroke end, pres-
surized oil from the pump is released to the
port on the opposite side to lower the oil pres-
sure applied to the piston.
Operation
Piston valve "closed" Piston valve "opened"
q The pressurized oil from the pump pushes pis- q Slider (6) touches cylinder bottom (b) and
ton (2) open against the force of spring (4) and stops moving before piston rod (1) reaches the
flows to chamber (A). stroke end.
q The pressurized oil fills chamber (A) and q Slider (6) touches the end of piston valve (5),
pushes piston valve (5) to the right to seal the and then only piston (3) continues moving.
tapered part of piston valve seat (a). q The pressurized oil which has been stopped in
q As a result, the oil pressure in the cylinder chamber (A) by piston valve (5) is released
rises and piston (3) moves to the right. through piston valve seat (a) to the bottom
side, thus the oil pressure in the cylinder low-
ers.
10-500 16 D65EX, PX, WX-16

500 Work equipment
Piston valve SEN04970-01
D65EX, PX, WX-16 10-500 17

SEN04970-01

© 2012 KOMATSU
All Rights Reserved
10-500 18
SEN04971-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

600 Cab and its attachments

Cab mount ...................................................................................................................................................... 2
Cab ................................................................................................................................................................. 3
Subextremely cold spec. cab (subextremely cold weather spec.) .................................................................. 4
FRP canopy mount ......................................................................................................................................... 5
FRP canopy .................................................................................................................................................... 6
D65EX, PX, WX-16 10-600 1

SEN04971-02 Cab mount
Cab mount 1
1. Damper mount (front) Outline

2. Damper mount (rear) q Mounts are installed at two places in front and
at two places in the rear to secure the floor
frame and cab.
q An oil-filled damper mount is used to absorb
the vibration.
10-600 2 D65EX, PX, WX-16

Cab SEN04971-02
Cab 1
a ROPS: Abbreviation for RollOver Protective Structure
1. Front window
2. Front wiper
3. Door
4. Radio antenna
5. Rear wiper
6. ROPS cab
D65EX, PX, WX-16 10-600 3

SEN04971-02 Subextremely cold spec. cab (subextremely cold weather spec.)
Subextremely cold spec. cab (subextremely cold weather spec.) 1
(if equipped)
a ROPS: Abbreviation for RollOver Protective Structure
1. Front window
2. Front wiper
3. Door
4. Radio antenna
5. Rear wiper
6. ROPS cab
Outline
q The window is a double glass window.
q Window washer is not equipped to.
10-600 4 D65EX, PX, WX-16

FRP canopy mount SEN04971-02
FRP canopy mount 1
1. Damper mount Outline

q Mounts are installed at two places in front and
at two places in the rear to secure the floor
frame and cab.
q An oil-filled damper mount is used to absorb
the vibration.
D65EX, PX, WX-16 10-600 5

SEN04971-02 FRP canopy
FRP canopy 1
1. Roof
2. Bracket
3. Pole
10-600 6 D65EX, PX, WX-16

FRP canopy SEN04971-02
D65EX, PX, WX-16 10-600 7

SEN04971-02

© 2012 KOMATSU
All Rights Reserved
10-600 8
SEN04972-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
10 Structure, operation and

700 Electrical system

Monitor system................................................................................................................................................ 2
Engine control system................................................................................................................................... 18
Cooling system control system ..................................................................................................................... 21
Electronic steering control system ................................................................................................................ 23
KOMTRAX system........................................................................................................................................ 26
KOMTRAX terminal (for GPRS).................................................................................................................... 28
System components ..................................................................................................................................... 29
Sensor........................................................................................................................................................... 37
D65EX, PX, WX-16 10-700 1

SEN04972-02 Monitor system
Monitor system 1
1. Machine monitor Outline

2. Battery q The monitor system keeps the operator
3. Power train controller informed of all machine functions, by monitor-
4. Engine controller ing the machine conditions using the sensors
5. Air conditioner controller and switches installed in various parts of the
6. KOMTRAX terminal machine and processing them instantly to dis-
7. Sensors, switches play on the machine monitor.
The contents displayed on the machine moni-
Input and output signals tor falls into the following types:
a. Power supply 1. Alarm buzzer when any abnormality
b. CAN signal occurs in the machine
c. Sensor and switch signals 2. Machine status display (including engine
coolant temperature, power train oil tem-
perature, hydraulic oil temperature and
fuel level, etc.)
3. Action code and failure code
4. Current values and voltage values dis-
played on the sensors and solenoids, etc.
q The switches on the machine monitor controls

the machine.
10-700 2 D65EX, PX, WX-16

Monitor system SEN04972-02
Processing on machine monitor (common to all specifications)
Display of machine monitor

Contents and conditions of processing Method Flow of signals
1. Display of direction of travel and gear speed
• Based on the information from the power train controller, F1, R3, etc. CAN signal
are transmitted to the machine monitor in CAN signal.
2. Display of gauge such as fuel level, engine coolant temperature, etc.
• The controller converts the sensor signals into gauge numbers and CAN signal
sends them to the machine monitor by CAN signal.
3. Display of failure
• If the machine failure occurs, the controller transmits the corresponding Sensors and solenoids
failure code to the machine monitor in CAN signal. O
• Depending on the content of failure, the controller transmits information Controller
whether the alarm buzzer should be sounded. O
• The following information is displayed on the machine monitor: Machine monitor
1) In the normal state
CAN signal
• Action code (3-digit code)
• Failure code (6-digit code)
2) In the abnormality record display mode
• Failure code (6-digit code)
• Service meter hours when the failure occurred for the first time
• Service meter hours when it occurred the last time
• Frequency of occurrence
Display of monitoring
1. Display of sensors, solenoids and communicating state of CAN signal
• The monitoring system transmits the item No.and equipment status to Sensors
the machine monitor in CAN signal.
CAN signal O
• The machine monitor displays the items and values. Controller
O
2. Items are selected by using the function switch. CAN signal Machine monitor
Other items
1. Monitoring
2. Abnormality record
3. Maintenance record
4. Maintenance mode change
5. Phone number entry
6. Default
7. Adjustment — —
8. PM clinic
9. Cylinder cut-out
10. No injection
11. Fuel consumption
12. KOMTRAX settings
13. Service message
a For details of the operating method, see "Special functions of monitor panel (EMMS)" in "Testing and
adjusting".
D65EX, PX, WX-16 10-700 3

Machine monitor 1
Outline Precautions on the machine monitor display

q The machine monitor provides monitor display q The LCD panel may have black points (points
function, mode selection function and switch which are not lighted) and bright points (points
function of the electrical equipment etc. Also it which do not go off) for the reason of its char-
provides an alarm buzzer. acteristics. It is not failure occurrence as long
q The machine monitor has a CPU (Central Pro- as the number of black or bright spots are 10
cessing Unit) in it to process, display, and out- or less.
put the information. q Battery voltage may suddenly drop at engine-
q The machine monitor consists of display and start due to ambient temperature or the condi-
switches: the display is of LCD type, and the tion of the battery. In this case, the machine
switches are of flat sheet switch. monitor may go off for a moment. However,
q If an error occurs in the machine monitor itself, this phenomenon is not a failure.
controller or wiring circuit between monitor and q Continuous operation of the machine monitor
controller, the monitor does not display prop- may display blue bright spots on the screen
erly. with black background. It, however, is not fail-
ure occurrence on the monitor.
Blue points can never be a problem as the
screen has blue or white background. (White in
the LCD is made up of red, green and blue.)
10-700 4 D65EX, PX, WX-16

Input and output signals

070-18P(1) [CN-CM01]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Constant power supply (24 V) Input 10 NC —
2 Constant power supply (24 V) Input 11 Charge level Input
3 GND (constant power supply) — 12 GND (machine analog signal) —
4 GND (constant power supply) — 13 Lamp switch Input
5 Wake-up Input/output 14 Starting switch ACC signal Input
6 NC — 15 Starting switch C signal Input
7 NC — 16 Preheating Input
8 Hydraulic oil temperature Input 17 NC —
9 Fuel level Input 18 NC —
070-12P(1) [CN-CM02]
signal signal
1 NC — 7 NC —
2 NC — 8 CAN terminal signal —
3 NC — 9 CAN_H Input/output
4 Air cleaner clogging sensor Input 10 CAN_L Input/output
5 NC — 11 NC —
6 NC — 12 NC —
070-18P(2) [CN-CM03]
Pin No. Signal name signal Pin No. Signal name signal
1 RS232C CD for communication terminal Input 10 NC —
2 RS232C RXD for communication terminal Input 11 NC —
3 RS232C SG for communication terminal — 12 GND (communication terminal power supply) —
4 GND (communication terminal control signal) — 13 NC —
5 Communication terminal selection signal Input 14 NC —
6 NC — 15 NC —
7 For communication terminal, RS232C TXD Output 16 NC —
8 For communication terminal, RS232C DTR Output 17 NC —
9 For communication terminal, RS232C DSR Input 18 Communication terminal power supply (12 V) Output
070-12P(2) [CN-CM04]
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
signal signal
1 NC — 7 NC —
2 NC — 8 NC —
3 NC — 9 NC —
4 NC — 10 NC —
5 NC — 11 NC —
6 NC — 12 NC —
B60-8P [CN-CM05]
signal signal
1 Camera power supply (8 V) Output 5 GND (Camera power supply) —
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1) —
D65EX, PX, WX-16 10-700 5

Display 1
A: Check before starting screen

q If troubles that turn monitors (13) – (15) ON occur after the starting switch is turned "ON", the corre-
sponding monitors are displayed from the left top in the order of the occurrence time.
q If trouble of monitors (13) – (15) occur during working, the corresponding monitors are displayed in large
size for 2 seconds and then displayed in small size.
q If power train oil temperature or hydraulic oil temperature rises while any monitoring item is displayed at
the center portion (multi gauge portion), monitor (3b) alone is displayed.
B: Standard screen
C: Maintenance interval warning screen
10-700 6 D65EX, PX, WX-16

Display
No. Display item Description Remarks
classification
Temperature Background • Indicates the corresponding
Range
(°C) color temperature range.
W1 105 Red • If the temperature goes beyond 105°C,
W2 102 Red the alarm buzzer is sounded.
1a Gauge (*1) • When the background color is white,
Engine coolant W3 100 Blue warming-up run of the engine must be
temperature W4 85 Blue done.
W5 60 Blue
W6 30 Blue
1b Caution See the "Background color" of the gauge.
Background • Indicates the corresponding range of
Range Quantity (l)
color the remaining fuel level.
F1 376 Blue
F2 297 Blue
2a Gauge (*1) F3 219 Blue
Fuel level
F4 140 Blue
F5 100 Blue
F6 61 Blue
2b Caution See the "Background color" of the gauge.
Range
M1 130 Red • If the temperature goes beyond 130°C,
M2 120 Red the alarm buzzer is sounded.
3a-1 Gauge (*1) • When the background color is white,
Power train oil M3 118 Blue warming-up run of the hydraulic
temperature M4 90 Blue equipment must be done.
(Press switch F2 to switch the display of
M5 50 Blue gauge.)
M6 0 Blue
3b-1 Caution See the "Background color" of the gauge.
Range
M1 105 Red • If the temperature goes beyond 105°C,
M2 102 Red the alarm buzzer is sounded.
3a-2 Gauge (*1) • When the background color is white,
Hydraulic oil M3 98 Blue warming-up run of the hydraulic
temperature M4 70 Blue equipment must be done.
(Press switch F2 to switch the display of
M5 20 Blue gauge.)
M6 0 Blue
Background • Indicates the corresponding speed
Range Speed (km/h)
color range.
M1 15 Blue (Press switch F2 to switch the display of
3a-3 Gauge (*1) gauge.)
M2 10 Blue
Travel speed
M3 5 Blue
M4 0 Blue
*1: If the gauge signal is not received due to disconnection of CAN communication line, the gauge pointer is out of the
screen.
D65EX, PX, WX-16 10-700 7

Display
classification
Pressure Background • Indicates the corresponding pressure
Range
(MPa) color range.
M2 40 Blue gauge.)
3a-4 Gauge (*1)
HSS pump oil M3 30 Blue
pressure M4 20 Blue
M5 10 Blue
M6 0 Blue
Background • Indicates the corresponding voltage
Range Voltage (V)
color range.
M2 30 Blue gauge.)
3a-5 Gauge (*1) M3 25 Blue
Battery voltage
M4 20 Blue
M5 17 Blue
M6 0 Blue
Rotation • Indicates the corresponding rotation
Background
Range speed speed range.
color
(n/min) (Press switch F2 to switch the display of
M1 3,000 Blue gauge.)
3a-6 Gauge M2 2,500 Blue
(*1)
Engine speed M3 2,000 Blue
M4 1,500 Blue
M5 1,000 Blue
M6 500 Blue
Traction Background • Indicates the corresponding traction
Range
force (W) color force range.
M1 1.0 Blue (Press switch F2 to switch the display of
M2 0.8 Blue gauge.)
3a-7 Gauge (*1) M3 0.6 Blue
Traction force
M4 0.4 Blue
M5 0.2 Blue
M6 0 Blue
Segment Load level • Displays the mean of the load level in 10
Light to levels on a second-by-second basis.
4 ECO gauge Green 1–8 (It is displayed when "ON" is selected for
medium
Orange 9,10 Heavy the "Default (setting of ECO display)".)
• Counts the engine operation hours

(when power is generated by the
Service meter 00000 h – 99999 h alternator).
(Press switch F4 to switch to the clock
5 display.)
• 12-hour display (AM/PM) • Displays the time.

Clock (Press switch F4 to switch to the service
• 24-hour display
meter display)
*1: If the gauge signal is not received due to disconnection of CAN communication line, the gauge pointer is out of the
screen.
10-700 8 D65EX, PX, WX-16

Display
classification
• Displays the present gear speed and
6 Gear speed display
gear shift mode.
Background (KOMTRAX-equipped machine)
State
color • Displays the state of messages.
7 Message
Green There is unread message. (Background color goes out when there
Blue There is unsent message. is no message)
Operation P: Heavy-duty operation
8 • Displays the operation mode.
mode E: Low-fuel consumption operation
Light ON: ON • Indicates the operating state of the air
9 Air conditioner
Light OFF: OFF conditioner and air blower.
Ambient • Displays the operating state of
Pilot Monitor light ON duration
temperature preheating.
(seconds)
(°C)
10 Preheating -3 – -10 5 – 15
-10 – -20 15 – 32
-20 – -30 32 – 45
Fan in reverse Light ON: Cooling fan in reverse rotation • Displays the rotating state of the
11
rotation Light OFF: Cooling fan in normal rotation cooling fan.
Reverse slow Light ON: ON (decelerates reverse travel) • Displays the operating state of reverse
12
mode Light OFF: OFF slow mode.
(*2) Light ON: When abnormal (water settles • The monitor is lit if any abnormality is
13 Water in the water separator) detected while the starting switch is at
separator Light OFF: When normal "ON" position.
Light ON: Defective battery charge
• The monitor is lit if any abnormality is
(*2) (charge voltage is below
14 detected while the engine is in
Caution Charge level specified value)
operation.
Light Off: Normal state
• If any abnormality is detected while the
(*2) Light ON: Abnormal state (below the
engine is in operation, the monitor lamp
15 Engine oil specified pressure)
is lit and the alarm buzzer is sounded at
pressure Light OFF: Normal state
the same time.
Light ON: Lock • Displays the operating state of the
16 Parking brake
Light OFF: Free parking brake lever.
Pilot
Work Light ON: Lock • Displays the operating state of the work
17
equipment lock Light OFF: Free equipment lock lever.
Background • The display switches as course of
State
color maintenance time.
There is a maintenance item • When the starting switch is turned "ON"
Maintenance position, the lamp is lit if the monitor
18 Caution Yellow which is 30 hours or less left
interval lamp turning-on requirements are met.
before next maintenance.
There is a maintenance The lamp goes out in 30 seconds.
Red
overdue item.
*2: These items are included in the check before starting. After the staring switch is turned "ON", the monitor is lit for 2
seconds, and switching to the standard screen if no abnormality is detected.
D65EX, PX, WX-16 10-700 9

Switch part 1
For the air conditioner specification
No. Name Function Operation

Operation mode
P: Heavy-duty operation
1 selector switch Switches the engine operation mode.
E: Low-fuel consumption operation
[Numeric keypad: 1]
Gear shift mode Automatic gear shift mode
2 selector switch Switches the gear shift mode. I O
[Numeric keypad: 2] Manual gear shift mode
Customize switch • The screen allows setting the operation
3 Displays the customize mode screen.
[Numeric keypad: 3] mode and the reverse slow mode.
Buzzer cancel Stops the alarm buzzer. • The alarm buzzer stops.
4 switch (Some alarm buzzer does not stop even if • If any abnormality is detected again, the
[Numeric keypad: 4] the switch is pressed.) alarm buzzer is sounded.
5 [Numeric keypad: 5]
Customize memory
Saves and calls of data to and from the
6 switch • This switch allows data store up to 5.
memory.
[Numeric keypad: 6]
Fan switch • The fan speed increases concurrently with
7a (Increase) Adjusts the fan speed of the air conditioner the switching to the air conditioner control
[Numeric keypad: 7] in 6 levels. screen.
(Low, Middle 1, Middle 2, Middle 3, Middle • The fan speed decreases concurrently with
Fan switch 4, High)
7b the switching to the air conditioner control
(Decrease)
screen.
Temperature control • The set temperature rises concurrently with
8a switch (Raise) Controls the temperature in the cab. the switching to the air conditioner control
[Numeric keypad: 8] (18.0°C – 32.0°C: Allows controlling the screen.
Temperature control temperature in 0.5°C steps between • The set temperature lowers concurrently
8b switch (Lower) 18.0°C – 32.0°C.) with the switching to the air conditioner
[Numeric keypad: 0] control screen.
10-700 10 D65EX, PX, WX-16


• In parallel with the switching to the air
(*1) Operates the air conditioner and air blower conditioner control screen, switching of the
9 Auto switch in automatic operation mode. fan speed, vent and FRESH/RECIRC takes
[Numeric keypad: 9] AUTO light ON: Auto run place automatically according to the set
temperature.
• The air conditioner control screen appears.
Turns the air conditioner ON/OFF. Pressing this switch again to switch ON to
(*2)
10 AC ON light ON: Manual operation OFF and vice versa.
Air conditioner switch
Light OFF: Stop
OFF io ON
FRESH/RECIRC Pressing this switch again causes
11 Changes the FRESH/RECIRC. switching between FRESH and RECIRC.
selector switch
FRESH io RECIRC
Selects the air vent mode from 5 types. Pressing this switch again switches the
1. Front and rear vent mode.
2. Front and rear-foot • In the auto mode, vent modes 4 and 5 are
12 Vent selector switch not selectable.
3. Foot
4. Foot and defroster o1o2o3o4o5o
5. Defroster I O
i i i i i
Turns the fan and air conditioner OFF. • Operation of the fan and air conditioner is
13 OFF switch
Light OFF: OFF stopped.
14a Guidance icon
a See "Guidance icon and function switch."
14b Function switch
*1: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at "High". In this case, the fan speed remains
the same even if the set temperature is reached.
*2: When the fan is not in operation, the air conditioner is not operated even if the switch is pressed.
D65EX, PX, WX-16 10-700 11

For the non air conditioner specification

Operation mode
P: Heavy-duty operation
1 selector switch Switches the engine operation mode.
E: Low-fuel consumption operation
[Numeric keypad: 1]
Gear shift mode Automatic gear shift mode
2 selector switch Switches the gear shift mode. I O
[Numeric keypad: 2] Manual gear shift mode
Customize switch • This screen allows setting the operation
3 Displays the customize mode screen.
[Numeric keypad: 3] mode and the reverse slow mode.
Stops the alarm buzzer. • The alarm buzzer stops.
Buzzer cancel switch
4 (Some alarm buzzer does not stop even if • If any abnormality is detected again, the
[Numeric keypad: 4]
the switch is pressed.) alarm buzzer is sounded.
5 [Numeric keypad: 5] — —
Customize memory
6 switch Saves and calls data to and from memory. • This switch allows data store up to 5.
[Numeric keypad: 6]
10-700 12 D65EX, PX, WX-16

D65EX, PX, WX-16 10-700 13

Guidance icon and function switch

q Functions of the function switch depend on the guidance icon displayed above the switch.
q No function is available if no guidance icon appears above the function switch.
q The following is the list of guidance icons and the functions displayed above the function switches.
Guidance
Function switch Item Function
icon
1 Clear Clears selected/displayed item.
Moves selection down one page.
2 Move selection
(To the top page from the bottom page.)
F1 3 Set Sets function.
Starts function.
4 Start
(Used for starting measurement of split fuel consumption.)
Stops function.
5 Stop
(Used for stopping measurement of split fuel consumption.)
1 Selecting multi gauge Selects the display item of the multi gauge.
Moves selection up one page.
2 Move selection
(To the bottom page from the top page.)
F2
3 Clear Clears selected/displayed item.
Sets selected item back to default.
4 Default
(Used for screen adjustment.)
Switches to camera image.
1 Camera image
(machines equipped with camera)
Moves selection down one item.
F3 2 Move selection (To the top item from the bottom item.)
Cancels hold function in the monitoring.
Moves selection to the left.
3 Move selection
(To the rightmost item from the leftmost item.)
10-700 14 D65EX, PX, WX-16

Guidance
Function switch Item Function
icon
Switching clock/
1 Switches clock/service meter display.
service meter
Moves selection up one item.
F4 2 Move selection (To the bottom item from the top item.)
Starts hold function in the monitoring.
Moves selection to the right.
3 Move selection
(To the leftmost item from the rightmost item.)
Selecting maintenance
1 Selects maintenance screen.
screen
F5
2 Return Returns to the previous screen or condition.
Selecting user mode
1 Selects user mode screen.
screen
F6
2 Fix Fixes selected/displayed item.
D65EX, PX, WX-16 10-700 15

Operator mode function 1
q When the standard screen is displayed, display and setting of these functions are available from the
operator's switch operations.
Display and setting of some functions require special operation of the switch.
q Items available in the operator mode are as follows:
Category Display order (*2)
Item
(*1) W X Y Z
Display of KOMATSU logo 1 1 1 1
Display of inputting password 2 — — —
Display of check before starting 3 2 2 2
Display of warning after check before starting — — 3 —
A
Display of overdue maintenance — — — 3
Display of preset confirmation 4 3 4 4
Display of standard screen 5 4 5 5
Display of end screen
Selection of operation mode
Selection of gear shift mode
Operation of customize
Operation of customize memory
Operation to stop alarm buzzer
Operation of air conditioner
Selection of multi gauge
Operation to display camera mode (machines equipped with camera)
B
Operation to display clock/service meter
Check of maintenance information
Setting and display of user mode
• Utility Screen Select
• Multi Gauge Select
• Screen Adjustment
• Clock Adjustment
• Language
• User Message (including KOMTRAX messages for user)
• Fan Reverse Mode
Display of caution monitor
C
Display of action code and failure code
Function of checking display of LCD (Liquid Crystal Display)
D Function of checking service meter
Function of changing maintenance password
*1: The items available in the operator mode fall into the following categories.
A: The items displayed from turning "ON" of the starting switch up to switching to the standard screen and the item
displayed after the starting switch is turned "OFF"
B: The items displayed when the machine monitor switch is operated
C: The items displayed when the requirements are met
D: The items that require special switch operation to display
*2: The sequence of display from turning "ON" of the starting switch up to switching to the standard screen varies
depending on the setting and conditions of the machine as described below.
W: When the engine start lock is effective
X: When the engine start lock is ineffective
Y: When a trouble is detected in any of the check before starting items
Z: When a maintenance overdue item is detected
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Spe-
cial functions of machine monitor" in "Testing and adjusting".
a For how to set the engine start lock on/off, see "Password setting/cancel manual".
10-700 16 D65EX, PX, WX-16

Service mode function 1
q When the standard screen is displayed, display and setting of these functions are available by the ser-
viceman's special operations of the switch.
This mode is used for special setting, testing, adjusting or troubleshooting.
q Items available in the service mode are as follows:
Monitoring
Mechanical Systems
Abnormality Record Electrical Systems
Air-conditioning System
Maintenance Record
Maintenance Mode Change
Phone Number Entry
Key-on Mode
Unit
Default Maintenance Password
Camera
ECO Display
Adjustment
PM CLINIC
Cylinder Cut-Out
No Injection
Fuel Consumption
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem S/N
Service Message
a For how to operate the service mode functions, see "Special functions of machine monitor" in "Testing
and adjusting".
D65EX, PX, WX-16 10-700 17

SEN04972-02 Engine control system
Engine control system 1
10-700 18 D65EX, PX, WX-16

Engine control system SEN04972-02
1. Battery
2. Starting switch
3. Engine controller
5. Machine monitor
6. Fuel control dial
7. Decelerator pedal
8. Parking limit switch
9. Parking brake lever
10. Work equipment lock limit switch
11. Work equipment lock lever
12. Electric lever
13. Steering, directional, gear shift lever (PCCS lever)
14. Neutral safety relay
15. Engine
16. Starting motor
17. Engine speed sensor
18. Coolant temperature sensor
19. Engine oil pressure switch
20. Injector
21. Fuel supply pump valve

a. Battery power source
b. Engine start signal
c. Neutral safety relay signal
d. Starting switch ACC signal
e. Parking brake signal
f. Work equipment lock signal
g. Neutral signal
h. No.1 throttle signal (fuel control dial signal)
i. No.2 throttle signal (decelerator pedal signal)
j. No.3 throttle signal (controller control signal)
k. Controller power supply
l. Engine speed signal
m. Coolant temperature signal
n. Engine oil pressure signal
o. Sensor signal
p. Monitor display signal
D65EX, PX, WX-16 10-700 19

SEN04972-02 Engine control system
Engine start mechanism Engine stop mechanism

q The power train controller controls the neutral q Setting the starting switch to "OFF" turns off
safety relation operation in such that the the starting switch ACC signal to the engine
engine is not started unless both the parking controller.
brake lever and work equipment lock lever are q The engine controller stops supplying fuel to
set to "LOCK" and the steering, directional, the engine to stop the engine.
gear shift lever is set to "NEUTRAL".
Engine speed control mechanism

q The engine controller receives the No.1 throttle
signal (fuel dial signal), No.2 throttle signal
(decelerator pedal signal) and No.3 throttle sig-
nal (controller control signal) from the power
train controller. The engine controller selects
the lowest command signal among the above
three to control the fuel supply pump and injec-
tor.
The No.3 throttle signal has the following
types:
1) Auto-decelerator (F3, R3)
The auto-decelerator is the function of
lowering the engine speed temporarily
when the travel direction is changed from
F3 or R3.
(Above is intended to protect the transmis-
sion clutch.)
2) Momentary engine speed-up (directional

change on downhill)
When travel direction is changed while
running down a hill, this function increases
the minimum engine speed momentarily
depending on the given conditions of the
machine.
(This function secures safety by prevent-
ing slipping down of the machine body.)
q The power train controller calculates a proper

engine speed based on the information from
the auto-decelerator and momentary engine
speed-up, and transmits it to the engine con-
troller as the No.3 throttle signal.
q The information from the engine controller is
owned jointly by the other controllers and
transmitted so that the relationship between
the engine and chassis will be optimized.
10-700 20 D65EX, PX, WX-16

Cooling system control system SEN04972-02
Cooling system control system 1
1. Battery Input and output signals

2. Battery relay a. Controller power supply
3. Power train controller b. Power train oil temperature signal
4. Engine controller c. Hydraulic oil temperature signal
5. Machine monitor d. Engine speed signal
6. Cooling fan motor e. Coolant temperature signal
7. Cooling fan pump f. CAN signal
8. Power train oil temperature sensor g. Pump control signal
9. Hydraulic oil temperature sensor h. Fan reverse signal
10. Engine
11. Engine speed sensor
12. Coolant temperature sensor
D65EX, PX, WX-16 10-700 21

SEN04972-02 Cooling system control system
Outline Selection of fan rotation mode

q The power train controller monitors the cool- q When the starting switch is set to "ON" and the
ant, power train oil and hydraulic oil tempera- engine is stopped, selecting the "fan reverse
tures and controls the fan speed according to mode" in the "user menu" of the machine mon-
those temperatures. itor allows setting the fan rotation mode.
Fan rotation mode includes;
Function 1) Forward rotation mode
Fan speed control 2) Cleaning mode
q The power train controller selects the maxi- According to the selected mode, the power
mum target fan speed obtained from the cool- train controller operates the reverse solenoid
ant, power train oil, and hydraulic oil valve of the cooling fan motor to change the
temperatures and outputs it as the pump con- rotational direction of the fan.
trol signal to the cooling fan pump.
q The cooling fan pump changes its swash plate 1) Forward rotation mode
angle to control its oil discharge for the cooling In this mode, the reverse solenoid valve
fan motor. does not operate and the fan rotates for-
ward. The fan speed varies with the tem-
perature sensor signal.
This mode is selected normally.
2) Cleaning mode
In this mode, the fan rotates in reverse at
high speed to blow off dirt from the radia-
tor fins, regardless of the temperature
sensor signals.
If this mode is used periodically, the clean-
ing interval of the radiator fins can be
expanded.
As long as the "cleaning mode" is turned
on, setting the steering, directional, gear
shift lever to "FORWARD" or "REVERSE"
does not start the machine operation. This
arrangement is intended for protecting the
radiator.
Set the starting switch to "OFF" once and
then set it to "ON" again to restore the
"forward rotation mode".
Interlock for changing rotation mode

q If the rotation direction of the fan is changed
while the fan is rotating, the fan drive circuit is
broken.
q In order to protect the fan drive circuit, this sys-
tem ignores the signal generated from select-
ing the "fan reverse mode" in the "user menu"
of the machine as long as the engine is run. In
this case, the machine monitor displays
"Denied" and the fan does not rotate reverse.
10-700 22 D65EX, PX, WX-16

Electronic steering control system SEN04972-02
Electronic steering control system 1
1. Machine monitor 8. Engine

2. Steering, directional, gear shift lever 9. Torque converter
(PCCS lever) 10. Transmission
3. Engine controller 11. Transmission control valve
4. Power train controller 12. HSS unit
5. Engine speed sensor 13. Control valve
6. Torque converter oil pressure sensor 13a. Steering control valve
7. Transmission output speed sensor 14. HSS motor
D65EX, PX, WX-16 10-700 23

SEN04972-02 Electronic steering control system
Gear shift mode function 1
Outline Screen display

q There are the auto gear shift mode and manual q The gear shift mode is displayed on the gear
gear shift mode in the gear shift mode. These speed display of the machine monitor as
modes are changed to each other each time shown below.
gear shift mode switch (1) is pressed.
Auto gear shift mode
Auto gear shift mode

1. Currently used gear speed
q If a load is applied, the gear is shifted down
2. "AUTO" mark representing the auto gear shift
automatically. And if the load is reduced, the
mode
gear is automatically shifted up to the set max-
3. The symbol representing the auto gear shift
imum gear speed.
mode
q This mode excels in the fuel consumption and
4. Preset (gear speed at start) and maximum gear
working efficiency since the torque converter
speed during travel
locks up according to the given load, enabling
to select the set maximum gear speed auto-
Manual gear shift mode
matically.

q If a load is applied, the gear is shifted down
automatically. However, reducing the load
does not automatic induce the shift up.
Gear shift operation

q Pressing UP switch (1) or DOWN switch (2) of
the steering, directional, gear shift lever
enables the gear shift operation and specifying
a preset speed.
1. Currently used gear speed

2. "MAN" mark representing the manual gear shift
mode
3. The symbol representing the manual gear shift
mode
4. Preset (gear speed at start)
10-700 24 D65EX, PX, WX-16

Electronic steering control system SEN04972-02
Setting preset with shift switch operation at Shifting speed range by operating shift switch
NEUTRAL when traveling
q Set the preset (gear speed at start) and the q While the machine is traveling, operating UP
maximum gear speed during travel (for only switch and DOWN switch allows changing the
the auto gear shift mode) with the gear shift maximum gear speed when the auto gear shift
switches in neutral. mode is turned on and changing the gear
speed currently used when the manual gear
Auto gear shift mode shift mode is turned on.
Setting the preset (gear speed at start) and the
maximum gear speed during travel Auto gear shift mode
Changing maximum gear speed during travel
During The maximum gear speed can be set to
forward travel
F1–F3.
reverse travel
R1–R3.
Each time operator presses this switch,
UP switch the maximum gear speed is sequentially
increased to the next higher range.
DOWN switch the maximum gear speed is sequentially
decreased to the next lower range.

Changing the currently used gear speed during
travel
Setting the preset (gear speed at start) forward travel
F1–F3.
reverse travel
R1–R3.
UP switch the maximum gear speed is sequentially
increased to the next higher range.
DOWN switch the maximum gear speed is sequentially
decreased to the next lower range.
Gear speed at start or travel direction change

on a slope
q In order to secure safety, this function may
switch an uphill travel started at 3rd speed
(Low) "3L" to 2nd speed "2" depending on the
a Turning the starting switch to "ON" sets the given condition of the machine.
preset to "F1–R1" of the automatic gear shift q When travel direction is changed while the
mode. machine is running a downhill, this function
a When the gear shift mode is changed, "F1–R1" may start the travel at 1st speed "1" and
is selected as the initial state. increase the engine minimum speed momen-
tarily in order to secure safety under the given
condition of the machine.
D65EX, PX, WX-16 10-700 25

SEN04972-02 KOMTRAX system
KOMTRAX system 1
q The KOMTRAX system consists of the

KOMTRAX terminal, communication antenna,
machine monitor and GPS antenna.
q This system sends various information of the
machine via wireless communication. It allows
operators of the KOMTRAX to obtain the
machine information from the office and to pro-
vide various services with the customers.
q Information transmittable from the KOMTRAX

system includes the following.
1. Operation map
2. Service meter
3. Location information
4. Error history
and others.
a To provide the services, you need to make an
arrangement for starting the KOMTRAX ser-
vice separately.
10-700 26 D65EX, PX, WX-16

KOMTRAX system SEN04972-02
KOMTRAX terminal 1
Model: TH300
q The KOMTRAX system uses satellite communication technology.
1. Communication antenna connection Input and output signals

2. Machine harness connection (AMP-14P) AMP-14P [CN-CK01]
3. Machine harness connection (AMP-10P) Input/Output
Pin No. Signal name
signal
Outline A1 Power supply (12 V) Input
q The KOMTRAX terminal sends various A2 NC —
machine information based on the network sig- A3 NC —
nals and input signals obtained through the A4 Switching of power supply voltage Output
machine monitor, as well as GPS position A5 NC —
d a ta , v ia w i r e l e s s c o m m u n ic a t i o n . T h e A6 NC —
KOMTRAX terminal can transmit information A7 GND —
via the communication antenna. A8 GND —
q Conditions of the KOMTRAX terminal can be A9 NC —
checked with the "Display of KOMTRAX set- A10 NC —
ting" in the service mode of the machine moni- A11 NC —
tor. A12 NC —
q Use of KOMTRAX terminal must be limited to A13 NC —
the countries where such communication is A14 NC —
allowed.
AMP-10P [CN-CK02]
Pin No. Signal name Input/Output
signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND Input
B6 RS232C DSR Output
B7 NC —
B8 NC —
B9 NC —
B10 NC —
D65EX, PX, WX-16 10-700 27

SEN04972-02 KOMTRAX terminal (for GPRS)
KOMTRAX terminal (for GPRS) 1
Model: TC530
q The KOMTRAX system uses Terrestrial transmission.
1. Communication antenna connection Input and output signals

2. Machine harness connection (AMP-14P) AMP-14P [CN-CK01]
3. Machine harness connection (AMP-10P) Input/Output
Pin No. Signal name
signal
Outline A1 Power supply output (5 V) Output
q The KOMTRAX terminal sends various A2 GND
machine information based on the network sig- A3 RS232C (extend) RXD Output
nals and input signals obtained through the A4 RS232C (extend) RXD Input
machine monitor, as well as GPS position A5 ON/OFF contact input 3 (low side) Input
d a ta , v ia w i r e l e s s c o m m u n ic a t i o n . T h e A6 ON/OFF contact input 6 (low side, Input
startable by terminal)
KOMTRAX terminal can transmit information
A7 ON/OFF contact input 2 (low side) Input
via the communication antenna.
A8 ON/OFF contact input 1 (low side) Input
q Conditions of the KOMTRAX terminal can be
A9 ON/OFF output 0 Output
checked with the "Display of KOMTRAX set-
A10 CAN Input/Output
ting" in the service mode of the machine moni-
A11 CAN Input/Output
tor.
A12 ON/OFF contact input 5 (high side) Input
q Use of KOMTRAX terminal must be limited to
A13 ON/OFF contact input 4 (high side) Input
the countries where such communication is
Outside input/output to cancel sleep
allowed. A14 Input/Output
mode
A15 Busy lamp output Output
A16 Analog input 3 (0 to 5 V) Input
AMP-10P [CN-CK02]
Input/Output
Pin No. Signal name
signal
B1 GND
B2 GND
B3 ACC signal input (high side) Input
B4 Analog input 2 (0 to 30 V) Input
B6 Power supply input (10 to 30 V) Input
B7 Power supply input (10 to 30 V) Input
B8 Output of prohibition of starting engine Output
B9 Inspection mode switch signal (low Input

side)
Inspection mode switch signal (low
B10 side) Input
B11 ON/OFF contact input 0 (high side) Input
10-700 28 D65EX, PX, WX-16

System components SEN04972-02
System components 1
Engine controller

q The following is the list of the symbols used for signal classification in the input/output signal chart.
A: Power supply
B: Input
C: Ground/shield/return
D: Output
E: Communication
DTP06-4P [CN-CE03]
Signal
Pin No. Signal name classification
1 GND C
2 GND C
3 Constant power supply (+24 V) A
4 Constant power supply (+24 V) A
D65EX, PX, WX-16 10-700 29

SEN04972-02 System components
DRC26-60P [CN-CE01]
Pin Signal name Signal Pin Signal name Signal
No. classification No. classification
1 Fuel electrical lift pump (+) D 31 NC —
2 Inlet metering valve (+) D 32 Inlet metering valve (–) C
3 Atmospheric pressure sensor B 33 Atmospheric pressure sensor power supply (+5V) A
4 NC — 34 NC —
5 NC — 35 NC —
6 CAN_L E 36 NC —
7 NC — 37 Sensor power supply (+5 V) A
8 CAN_H E 38 Sensor GND C
9 NC — 39 NC —
10 NC — 40 NC —
11 Fuel electrical lift pump (–) C 41 NC —
12 NC — 42 NC —
13 NC — 43 NC —
14 Water-in-fuel sensor (+) B 44 Boost pressure sensor B
15 Coolant temperature sensor B 45 Injector #1 (+) D
16 Crank shaft angle sensor power supply (+5V) A 46 Injector #5 (+) D
17 Engine oil pressure switch B 47 Sensor GND C
18 NC — 48 Crankshaft angle sensor GND C
19 NC — 49 NC —
20 NC — 50 NC —
21 NC — 51 Injector #2 (–) C
22 NC — 52 Injector #3 (–) C
23 Boost temperature sensor B 53 Injector #1 (–) C
24 NC — 54 Injector #2 (+) D
25 Common rail pressure sensor B 55 Injector #3 (+) D
26 Camshaft speed sensor (+) B 56 Injector #4 (+) D
27 Crankshaft angle sensor (+) B 57 Injector #6 (+) D
28 NC — 58 Injector #4 (–) C
29 NC — 59 Injector #6 (–) C
30 NC — 60 Injector #5 (–) C
DRC26-50P [CN-CE02]
Pin Signal Pin Signal
No. Signal name classification No. Signal name classification
1 NC — 26 NC —
2 NC — 27 NC —
3 NC — 28 NC —
4 NC — 29 NC —
5 NC — 30 NC —
6 NC — 31 NC —
7 NC — 32 NC —
8 NC — 33 NC —
9 Decelerator potentiometer signal B 34 NC —
10 NC — 35 NC —
11 NC — 36 NC —
12 NC — 37 NC —
13 NC — 38 NC —
14 NC — 39 Starting switch ACC signal B
15 NC — 40 Intake air heater drive signal D
16 NC — 41 NC —
17 NC — 42 NC —
18 NC — 43 NC —
19 NC — 44 NC —
20 NC — 45 NC —
21 NC — 46 CAN_H E
Decelerator potentiometer power supply
22 (+5 V) A 47 CAN_L E
23 Decelerator potentiometer (–) C 48 NC —
24 NC — 49 Engine power supply relay drive signal D
25 NC — 50 NC —
10-700 30 D65EX, PX, WX-16

Power train controller
D65EX, PX, WX-16 10-700 31


DRC26-24P [CN-STC1]
Pin Input/Output Pin Input/Output
Signal name Signal name
No. signal No. signal
1 Fuel control dial Input 13 Directional lever position meter 3 Input
2 Steering lever potentiometer 1 Input 14 Hydraulic oil pressure sensor Input
3 Brake pedal potentiometer Input 15 Alternator R signal Input
4 GND (signal) — 16 Sensor power supply (+24 V) Output
5 NC — 17 Starting switch C signal Input
6 NC — 18 DOWN switch (NO) Input
7 Directional lever position meter 4 Input 19 Steering lever potentiometer 2 Input
8 Pitch angle sensor Input 20 Torque converter oil pressure sensor Input
9 Torque converter oil temperature sensor Input 21 GND (analog) —
10 GND (signal) — 22 Sensor power supply (+5 V) Output
11 Air compressor drive signal Input 23 NC —
12 UP switch (NC) Input 24 DOWN switch (NC) Input
DRC26-40P(A) [CN-STC2]
Pin Signal name Input/Output Pin Signal name Input/Output
1 NC — 21 NC —
2 Left tilt oil pressure switch Input 22 CAN0_L Input/output
3 Blade lower oil pressure sensor Input 23 CAN1_L Input/output
4 RS232C RXD Input 24 Service connector signal Input
5 Parking brake limit switch (NC) Input 25 Transmission R clutch fill switch Input
6 Work equipment lock limit switch (NC) Input 26 NC —
7 NC — 27 Blade control lever lower switch (NC) Input
8 Neutral safety relay Output 28 NC —
9 NC — 29 GND (Pulse) —
10 NC — 30 Transmission output speed sensor Input
11 NC — 31 NC —
12 NC — 32 CAN0_H Input/output
13 Blade raise oil pressure switch Input 33 CAN1_H Input/output
14 RS232C TXD Output 34 RS232C GND —
15 Parking brake limit switch (NO) Input 35 Transmission F clutch fill switch Input
16 Work equipment lock limit switch (NO) Input 36 Torque converter lockup clutch fill switch Input
17 NC — 37 Blade control lever lower switch (NO) Input
18 Backup alarm relay Output 38 Right tilt oil pressure switch Input
19 Beacon lamp relay Output 39 NC —
20 NC — 40 NC —
DRC26-40P(B) [CN-STC3]
Pin Signal name Input/Output Pin Signal name Input/Output
1 Power supply (Controller) Input 21 GND (Power supply) —
2 Power supply (Solenoid) Input 22 Power supply (Solenoid) Input
3 GND (Solenoid, common) Input 23 GND (Solenoid, common) —
4 For activating battery relay Output 24 Starting switch ACC signal Input
5 NC — 25 HSS left EPC valve Output
6 Transmission 1st clutch ECMV Output 26 Transmission 3rd clutch ECMV Output
7 HSS pump TVC solenoid Output 27 Transmission F clutch ECMV Output
8 Work equipment lock solenoid Output 28 Pitch selecting solenoid Output
9 UP switch (NO) Input 29 Transmission 2nd clutch fill switch Input
10 Blade control lever upper switch (NO) Input 30 NC —
11 Power supply (Controller) Input 31 GND (Power supply) —
12 Power supply (Solenoid) Input 32 GND (Power supply) —
13 GND (Solenoid, common) Input 33 GND (Power supply) —
14 Starting switch ACC signal Input 34 Sensor power supply 2 (+5 V) Output
15 NC — 35 HSS right EPC valve Output
16 Transmission 2nd clutch ECMV Output 36 Fan pump solenoid Output
17 Torque converter lockup clutch ECMV Output 37 Transmission R clutch ECMV Output
18 Cooling fan reverse solenoid Output 38 NC —
19 Transmission 1st clutch fill switch Input 39 Transmission 3rd clutch fill switch Input
20 Blade control lever upper switch (NC) Input 40 NC —
10-700 32 D65EX, PX, WX-16

Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Coolant temperature sensor
1. Connector
2. Sensor
3. O-ring
D65EX, PX, WX-16 10-700 33

Crankshaft angle sensor (Ne sensor)
1. Connector
2. Sensor
3. O-ring
Boost pressure, temperature sensor
1. Connector
2. Sensor
3. O-ring
10-700 34 D65EX, PX, WX-16

Fuel control dial
1. Knob Function
2. Dial q The fuel control dial is installed to the left side
3. Spring of the operator's seat.
4. Ball q If knob (1) is turned, the shaft of potentiometer
5. Potentiometer (5) is turned to change the resistance of the
6. Connector variable resistor and send a throttle signal to
the engine controller.
q The hatched areas in the following graph is the
abnormality detection areas. In those areas,
the engine speed is reduced to a half.
D65EX, PX, WX-16 10-700 35

Decelerator pedal potentiometer

Brake pedal potentiometer
1. Element Output characteristics

2. Contact
3. Shaft
4. Connector
Function
q The decelerator pedal potentiometer is
installed at the bottom of the front part of the
floor and directly connected to the decelerator
pedal.
q The brake pedal potentiometer is installed at
the bottom of the front part of the floor and
directly connected to the brake pedal.
q Potentiometer shaft (3) starts rotation when the
pedal is operated. It outputs the signal voltage
after converting the power supply voltage to
signal voltage according to the angle of pedal
operation based on the resistance value of the
variable resistor.
10-700 36 D65EX, PX, WX-16

Sensor SEN04972-02
Sensor 1
Power train oil temperature sensor

Hydraulic oil temperature sensor
1. Connector 2. Plug 3. Thermistor
Function
q The power train oil temperature sensor is installed on the left side face block of the torque converter and
the hydraulic oil temperature sensor is installed in the hydraulic tank.
q This sensor senses the oil temperature and converts it into an electric signal and then outputs that sig-
nal.
Hydraulic oil pressure sensor
1. O-ring Output characteristics

2. Sensor
3. Connector
Function
q This sensor is installed in the discharge side
block of the HSS pump.
q This sensor detects pressure of hydraulic oil. It
converts the pressure to an electric signal and
then outputs that signal.
D65EX, PX, WX-16 10-700 37

SEN04972-02 Sensor
Torque converter oil pressure sensor
1. O-ring Output characteristics

2. Sensor
3. Connector
Function
q This sensor is installed on the left side block of
the torque converter.
q This sensor detects the torque converter oil
pressure. It converts the pressure to an electric
signal and then outputs that signal.
10-700 38 D65EX, PX, WX-16

Sensor SEN04972-02
Transmission output speed sensor
1. Pole piece 4. Magnet 7. Connector

2. Magnet wire 5. Housing
3. Bobbin 6. Grommet
Function
q This sensor is installed on the bevel gear area situated in the rear side of the steering case.
q These sensors detect the gear shift speed. It converts speed to the corresponding pulse signals and
then outputs the signals.
Pitch angle sensor
1. Body 4. Ring
2. Tube 5. Wire
3. Tube 6. Connector
Function
q This sensor is installed in the engine room on the right side of the machine body.
q There are multiple electrodes and oil in this sensor. The changes of the oil level made by inclination of
the machine are sensed by the differences in electrostatic capacity between the electrodes, and then
those differences are converted into voltage signals.
D65EX, PX, WX-16 10-700 39

SEN04972-02 Sensor
Fuel level sensor
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
Function
q This sensor is installed on the front of the fuel tank.
q This sensor senses the fuel level and converts it into an electric signal and then outputs that signal.
q The float moves up and down according to the fuel level.
q The movement of the float operates the variable resistor through the arm.
10-700 40 D65EX, PX, WX-16

Sensor SEN04972-02
Water-in-fuel sensor
1. Connector 3. Sensor
2. Tube 4. O-ring
Function
q This sensor is installed in the cup of the fuel pre-filter.
q This sensor outputs the signal upon sensing water in fuel.
D65EX, PX, WX-16 10-700 41

SEN04972-02 Sensor
Air cleaner clogging sensor (sand terrain specification)
1. Adapter
2. Hood
3. Indicator
4. Connector
Function
q The air cleaner clogging sensor is installed to
the air cleaner outlet. If the air cleaner is
clogged and the pressure reaches the speci-
fied level (negative pressure), caution lamp on
the machine monitor lights up to output a warn-
ing.
10-700 42 D65EX, PX, WX-16

Sensor SEN04972-02
D65EX, PX, WX-16 10-700 43

SEN04972-02

© 2012 KOMATSU
All Rights Reserved
10-700 44
SEN05118-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
20 Standard value table 20
100 Standard service value table

Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 4
D65EX, PX, WX-16 20-100 1

SEN05118-01 Standard service value table for engine
Standard service value table for engine 1
Machine model D65EX, PX, WX-16

Engine SAA6D114E-3
Standard value for
Check item Measurement conditions Unit Permissible value
new machine
High idle 2,070 ± 50 2,070 ± 50
Rotation speed Low idle rpm 825 ± 25 825 ± 25
Rated speed 1,950 —
Air boost pressure
kPa 151 – 177 120
(boost pressure) At rated horsepower
{mmHg} {1,130 – 1,330} {900}
(Aftercooler outlet)
At sudden acceleration (LooHi) Bosch Max. 2.5 3.5
Exhaust gas color
At high idle index Max. 1.0 2.0
Exhaust temperature Whole speed range
°C Max. 600 Max. 650
(Turbine inlet temperature) (Ambient temperature 20°C)
Intake valve 0.305 0.152 – 0.559
Valve clearance (Normal temperature) mm
Exhaust valve 0.559 0.381 – 0.813
Oil temperature: 40 – 60°C
MPa Min. 2.6 2.1
Compression pressure (SAE30 or SAE15W-40)
{kg/cm2} {Min. 26.5} {21.4}
(Engine speed: Min. 170 rpm)
(SAE30 or SAE15W-40)
kPa Max. 1.96 Max. 2.94
Blow-by pressure (Coolant temperature: Operating range)
{mmH2O} {Max. 200} {Max. 300}
At rated horsepower
(Coolant temperature: Operating range)
When torque converter is stalling 0.34 – 0.59 0.21

MPa
Oil pressure (SAE30 or SAE15W-40) {3.5 – 6.0} {2.1}
{kg/cm2}
At low idle Min. 0.15 0.08
(SAE30 or SAE15W-40) {Min. 1.5} {0.8}
Oil temperature Whole speed range (Inside oil pan) °C 80 – 110 Min. 120
Alternator –
crankshaft pul- Auto-tensioner —
Deflection when ley
pressed with finger Air condi-
Belt tension mm
force of approx. 98 N tioner com-
{approx. 10 kg} pressor – 15 – 18 —
crankshaft pul-
ley
20-100 2 D65EX, PX, WX-16

Standard service value table for engine SEN05118-01
D65EX, PX, WX-16 20-100 3

SEN05118-01 Standard service value table for chassis
Standard service value table for chassis 1
Machine model D65EX, WX-16

Classification
Standard
Permissible
Check item Measurement conditions Unit value for new
value
machine
• Coolant temperature: Within operating range

Decelerator pedal • Power train oil temperature: Within operating 1,000 ± 25 1,000 ± 25
Engine speed
speed range
• Hydraulic oil temperature: Within operating range
rpm
• Engine: High idle
Torque converter • Operation mode: P-mode 1,770 ± 100 1,650
stall speed • Decelerator pedal speed: Press pedal.
• Torque converter stall speed: F3
Forward and Neutral o Forward 30 ± 10 30 ± 10
reverse Neutral o Reverse 30 ± 10 30 ± 10
• Stop engine.
PCCS 40 ± 15 40 ± 15
lever
• Center of lever Neutral o Left
knob. (Play: Max. 3) (Play: Max. 3)
Steering
40 ± 15 40 ± 15
Neutral o Right
(Play: Max. 3) (Play: Max. 3)
Stroke of control lever and pedal
• Stop engine.
Decelerator pedal 55 ± 11 55 ± 11
• Center of pedal.
• Engine: Low idle mm
Brake pedal All stroke 68 ± 11 68 ± 11
• Center of pedal.
• Straight tilt Neutral o Raise or Lower 63 ± 10 63 ± 10

Blade control lever
dozer Neutral o Float 88 ± 13 88 ± 13

• Sigma dozer • Engine: Low idle
• Hydraulic oil tem- Neutral o Left or Right tilt 53 ± 8 53 ± 8
perature: 45 – 55°C Neutral o Raise or Lower 51 ± 10 51 ± 10
• Center of lever Neutral o Float 77 ± 13 77 ± 13
Power angle
knob.
power tilt dozer Neutral o Left or Right tilt 57 ± 8 57 ± 8
Neutral o Left or Right angle ° (degree) 15 ± 3 15 ± 3
• Engine: Low idle
• Hydraulic oil tem-
Ripper control lever
perature: 45 – 55°C Neutral o Raise or Lower mm 54 ± 8 54 ± 8
(If equipped)
• Center of lever
knob.
Neutral o Forward or 46.1 ± 19.6 46.1 ± 19.6
Operating effort of control
Forward and Reverse {4.7 ± 2.0} {4.7 ± 2.0}

lever and pedal
reverse Forward or Reverse o Neu- 46.1 ± 19.6 46.1 ± 19.6

• Stop engine. tral {4.7 ± 2.0} {4.7 ± 2.0}
PCCS N
• Center of lever
lever {kg} 24.5 ± 9.8 24.5 ± 9.8
knob. Neutral o Left
{2.5 ± 1.0} {2.5 ± 1.0}
Steering
24.5 ± 9.8 24.5 ± 9.8
Neutral o Right
{2.5 ± 1.0} {2.5 ± 1.0}
20-100 4 D65EX, PX, WX-16

Standard service value table for chassis SEN05118-01
D65PX-16
Standard value
Permissible
for new
value
machine
1,000 ± 25 1,000 ± 25
1,770 ± 100 1,650
30 ± 10 30 ± 10
30 ± 10 30 ± 10
40 ± 15 40 ± 15
40 ± 15 40 ± 15
55 ± 11 55 ± 11
68 ± 11 68 ± 11
63 ± 10 63 ± 10
88 ± 13 88 ± 13
53 ± 8 53 ± 8
51 ± 10 51 ± 10
77 ± 13 77 ± 13
57 ± 8 57 ± 8
15 ± 3 15 ± 3
— —
46.1 ± 19.6 46.1 ± 19.6

{4.7 ± 2.0} {4.7 ± 2.0}
46.1 ± 19.6 46.1 ± 19.6
{4.7 ± 2.0} {4.7 ± 2.0}
24.5 ± 9.8 24.5 ± 9.8
{2.5 ± 1.0} {2.5 ± 1.0}
24.5 ± 9.8 24.5 ± 9.8
{2.5 ± 1.0} {2.5 ± 1.0}
D65EX, PX, WX-16 20-100 5


Classification
Standard
Permissible
value
machine
• Engine: Low idle 62.7 ± 19.6 62.7 ± 19.6

Decelerator pedal
• Center of pedal. {6.4 ± 2.0} {6.4 ± 2.0}
• Engine: Low idle 392 ± 39 510
Brake pedal
• Center of pedal. {40 ± 4.0} {52}
29.4 ± 9.8 29.4 ± 9.8
Neutral o Raise or Lower
Operating effort of control lever and pedal
{3.0 ± 1.0} {3.0 ± 1.0}

• Straight tilt
74.5 ± 19.6 74.5 ± 19.6
dozer Neutral o Float
N {7.6 ± 2.0} {7.6 ± 2.0}
• Sigma dozer
{kg}
Blade control lever
25.5 ± 9.8 25.5 ± 9.8

• Engine: Low idle Neutral o Left or Right tilt
• Hydraulic oil tem- {2.6 ± 1.0} {2.6 ± 1.0}
perature: 45 – 29.4 ± 9.8 29.4 ± 9.8
Neutral o Raise or Lower
55°C {3.0 ± 1.0} {3.0 ± 1.0}
• Center of lever 74.5 ± 19.6 74.5 ± 19.6
knob. Neutral o Float
Power angle {7.6 ± 2.0} {7.6 ± 2.0}
power tilt dozer 25.5 ± 9.8 25.5 ± 9.8
Neutral o Left or Right tilt
{2.6 ± 1.0} {2.6 ± 1.0}
Neutral o Nm 3.9 ± 1.0 3.9 ± 1.0
Left or Right angle {kgm} {0.4 ± 0.1} {0.4 ± 0.1}
• Engine: Low idle 25.5 ± 9.8 25.5 ± 9.8
Neutral o Raise
Ripper control lever • Hydraulic oil tempera- N {2.6 ± 1.0} {2.6 ± 1.0}
(If equipped) ture: 45 – 55°C {kg} 25.5 ± 9.8 25.5 ± 9.8
• Center of lever knob. Neutral o Lower
{2.6 ± 1.0} {2.6 ± 1.0}
Engine: 0.03 – 0.49 0.03 – 0.49
Torque converter Low idle {0.3 – 5.0} {0.3 – 5.0}
inlet pressure Engine: Max. 0.98 Max. 0.98
High idle {Max. 10} {Max. 10}
Engine: 0.02 – 0.29 0.02 – 0.29
Torque converter Low idle {0.2 – 3.0} {0.2 – 3.0}
outlet pressure Engine: 0.39 – 0.89 0.39 – 0.89
High idle {4.0 – 9.0} {4.0 – 9.0}
Engine: 3.3 ± 0.2 Min. 3.01
Power train oil pressure
Transmission Low idle {33.7 ± 2.0} {Min. 30.7}

main relief pressure Engine: 3.45 ± 0.2 Min. 3.17
• Power train oil temper- High idle {35.3 ± 2.0} {Min. 32.3}
MPa
ature: Within operating
Engine: {kg/cm2} 1.42 ± 0.15 1.42 ± 0.15
Torque converter range
Low idle {14.5 ± 1.5} {14.5 ± 1.5}
lock-up clutch pres-
sure Engine: 1.42 ± 0.15 1.42 ± 0.15
High idle {14.5 ± 1.5} {14.5 ± 1.5}
Engine: 2.89 ± 0.15 Min. 2.60
F clutch pressure Engine: 2.89 ± 0.15 Min. 2.60
High idle {29.5 ± 1.5} {Min. 26.5}
Engine: 3.28 ± 0.15 Min. 2.99
R clutch pressure Engine: 3.28 ± 0.15 Min. 2.99
High idle {33.5 ± 1.5} {Min. 30.5}
20-100 6 D65EX, PX, WX-16

D65PX-16
Standard value
Permissible
for new
value
machine
62.7 ± 19.6 62.7 ± 19.6

{6.4 ± 2.0} {6.4 ± 2.0}
392 ± 39 510
{40 ± 4.0} {52}
29.4 ± 9.8 29.4 ± 9.8
{3.0 ± 1.0} {3.0 ± 1.0}
74.5 ± 19.6 74.5 ± 19.6
{7.6 ± 2.0} {7.6 ± 2.0}
25.5 ± 9.8 25.5 ± 9.8
{2.6 ± 1.0} {2.6 ± 1.0}
29.4 ± 9.8 29.4 ± 9.8
{3.0 ± 1.0} {3.0 ± 1.0}
74.5 ± 19.6 74.5 ± 19.6
{7.6 ± 2.0} {7.6 ± 2.0}
25.5 ± 9.8 25.5 ± 9.8
{2.6 ± 1.0} {2.6 ± 1.0}
3.9 ± 1.0 3.9 ± 1.0
{0.4 ± 0.1} {0.4 ± 0.1}
— —
— —
0.03 – 0.49 0.03 – 0.49

{0.3 – 5.0} {0.3 – 5.0}
Max. 0.98 Max. 0.98
{Max. 10} {Max. 10}
0.02 – 0.29 0.02 – 0.29
{0.2 – 3.0} {0.2 – 3.0}
0.39 – 0.89 0.39 – 0.89
{4.0 – 9.0} {4.0 – 9.0}
3.3 ± 0.2 Min. 3.01
{33.7 ± 2.0} {Min. 30.7}
3.45 ± 0.2 Min. 3.17
{35.3 ± 2.0} {Min. 32.3}
1.42 ± 0.15 1.42 ± 0.15
{14.5 ± 1.5} {14.5 ± 1.5}
1.42 ± 0.15 1.42 ± 0.15
{14.5 ± 1.5} {14.5 ± 1.5}
2.89 ± 0.15 Min. 2.60
{29.5 ± 1.5} {Min. 26.5}
2.89 ± 0.15 Min. 2.60
{29.5 ± 1.5} {Min. 26.5}
3.28 ± 0.15 Min. 2.99
{33.5 ± 1.5} {Min. 30.5}
3.28 ± 0.15 Min. 2.99
{33.5 ± 1.5} {Min. 30.5}
D65EX, PX, WX-16 20-100 7


Classification
Standard
Permissible
value
machine
Engine: 3.23 ± 0.15 Min. 2.94

1st clutch pressure Engine: 3.23 ± 0.15 Min. 2.94
High idle {33.0 ± 1.5} {Min. 30.0}
Engine: 24.5 ± 0.15 Min. 2.16
Transmission Low idle {25.0 ± 1.5 {Min. 22.0}
Power train oil pressure
2nd clutch pressure Engine: 24.5 ± 0.15 Min. 2.16

High idle {25.0 ± 1.5 {Min. 22.0}
• Power train oil tempera- Engine: 3.28 ± 0.15 Min. 2.99
Transmission ture: Within operating Low idle {33.5 ± 1.5} {Min. 20.5}
3rd clutch pressure range Engine: 3.28 ± 0.15 Min. 2.99
MPa
High idle {33.5 ± 1.5} {Min. 20.5}
{kg/cm2}
Transmission
Engine: 0.05 – 0.25 0.05 – 0.25
lubricating oil pressure
High idle {0.5 – 2.5} {0.5 – 2.5}
(For reference)
Engine: 2.55 – 2.94 2.55 – 2.94
Low idle {26 – 30} {26 – 30}
Brake pressure
Engine: 2.55 – 2.94 2.55 – 2.94
High idle {26 – 30} {26 – 30}
37.1 – 40.1 Min. 34.8
HSS pressure
Relief pressure
• Hydraulic oil temperature: 45 – 55°C {379 – 409} {Min. 355}
LS pressure • Engine: High idle 35.2 – 38.1 Min. 32.8
(Load sensing pressure) {359 – 389} {Min. 335}
F1 3.6 ± 0.2 3.6 ± 0.2
• Flat road F2 5.5 ± 0.3 5.5 ± 0.3
Power train performance
• Coolant temperature: Within operating

range F3L 7.2 ± 0.4 7.2 ± 0.4
• Power train oil temperature: Within F3 11.2 ± 0.6 11.2 ± 0.6
Travel speed operating range km/h
• Engine: High idle R1 4.4 ± 0.3 4.4 ± 0.3
• Before measuring, run machine 10 – R2 6.6 ± 0.3 6.6 ± 0.3
30 m.
• Measuring distance: 20 m R3L 8.6 ± 0.4 8.6 ± 0.4
R3 13.4 ± 0.7 13.4 ± 0.7
Work equipment oil pressure
• Hydraulic oil tempera- Engine: 3.23 – 4.9 3.23 – 4.9

Unload pressure ture: 45 – 55°C High idle {33 – 50} {33 – 50}
• Unload pressure: Set
all equipment in neutral.
• Relief pressure: Set tilt Engine: MPa Min. 28.4 Min. 27.4
or ripper cylinder to Low idle {kg/cm2} {Min. 290} {Min. 280}
Blade tilt relief pressure stroke end.
• LS pressure: Set tilt or
ripper cylinder to stroke Engine: 29.4 – 32.8 Min. 28.4
end. High idle {300 – 335} {Min. 290}
20-100 8 D65EX, PX, WX-16

D65PX-16
Standard value
Permissible
for new
value
machine
3.23 ± 0.15 Min. 2.94

{33.0 ± 1.5} {Min. 30.0}
3.23 ± 0.15 Min. 2.94
{33.0 ± 1.5} {Min. 30.0}
24.5 ± 0.15 Min. 2.16
{25.0 ± 1.5 {Min. 22.0}
24.5 ± 0.15 Min. 2.16
{25.0 ± 1.5 {Min. 22.0}
3.28 ± 0.15 Min. 2.99
{23.5 ± 1.5 {Min. 30.5}
3.28 ± 0.15 Min. 2.99
{23.5 ± 1.5 {Min. 30.5}
0.05 – 0.25 0.05 – 0.25

{0.5 – 2.5} {0.5 – 2.5}
2.55 – 2.94 2.55 – 2.94

{26 – 30} {26 – 30}
2.55 – 2.94 2.55 – 2.94
{26 – 30} {26 – 30}
37.1 – 40.1 Min. 34.8
{379 – 409} {Min. 355}
35.2 – 38.1 Min. 32.8
{359 – 389} {Min. 335}
3.6 ± 0.2 3.6 ± 0.2
5.5 ± 0.3 5.5 ± 0.3
7.2 ± 0.4 7.2 ± 0.4
11.2 ± 0.6 11.2 ± 0.6
4.4 ± 0.3 4.4 ± 0.3
6.6 ± 0.3 6.6 ± 0.3
8.6 ± 0.4 8.6 ± 0.4
13.4 ± 0.7 13.4 ± 0.7
3.23 – 4.9 3.23 – 4.9

{33 – 50} {33 – 50}
Min. 28.4 Min. 27.4

{Min. 290} {Min. 280}
29.4 – 32.8 Min. 28.4

{300 – 335} {Min. 290}
D65EX, PX, WX-16 20-100 9


Classification
Standard
Permissible
value
machine
• Hydraulic oil temperature: 45 – Engine: Min. 2.84 Min. 27.4

Ripper lift relief pres- 55°C Low idle {Min. 290} {Min. 280}
Work equipment oil pressure
sure • Unload pressure: Set all equip- Engine: 29.4 – 32.8 Min. 28.4
ment in neutral. High idle {300 – 335} {Min. 290}
• Relief pressure: Set cylinder to Engine: Min. 26.5 Min. 25.5
LS pressure stroke end. Low idle {Min. 270} {Min. 260}
(Load sensing pres- LS pressure: Set cylinder to MPa
sure) Engine: {kg/cm2} 27.4 – 30.9 Min. 26.5
stroke end.
High idle {280 – 315} {Min. 270}
Control circuit main
3.97 ± 0.29 3.97 ± 0.29
pressure
• Hydraulic oil temperature: 45 – 55°C {40.5 ± 3.0} {40.5 ± 3.0}
(HSS, PPC, fan)
PPC valve output pres- 3.19 – 4.17 3.19 – 4.17
sure {32.5 – 42.5} {32.5 – 42.5}
a See figure A Straight tilt dozer
2.5 ± 0.3 3.1
• Hydraulic oil tempera- Sigma dozer
Raise
ture: 45 – 55°C Power angle
• Apply no load to blade. 2.5 ± 0.3 3.1
power tilt dozer
Blade lift • Between ground level
Straight tilt dozer
and rising end of blade 1.9 ± 0.2 2.3
Sigma dozer
• Engine: High idle Lower
Power angle
1.6 ± 0.2 2.0
power tilt dozer
a See figure B Straight tilt dozer
1.6 ± 0.3 2.1
• Hydraulic oil tempera- Left Sigma dozer
ture: 45 – 55°C tilt Power angle
• Apply no load to blade. 1.7 ± 0.3 2.2
power tilt dozer
Blade tilt • Between left tilt end
Straight tilt dozer
and right tilt end 1.6 ± 0.3 2.1
Right Sigma dozer
tilt Power angle
Work equipment speed
1.7 ± 0.3 2.2

power tilt dozer
Work equipment
a See figure C
• Hydraulic oil tempera- Left angle 4.0 ± 0.5 5.0
Second
ture: 45 – 55°C
Blade angle • Apply no load to blade.
• Between left angle end
and right angle end Right angle 4.0 ± 0.5 5.0
a See figure D
• Hydraulic oil tempera- Raise 1.5 ± 0.5 2.5
ture: 45 – 55°C
Ripper lift • Apply no load to ripper.
(If equipped) • Between ground level
and rising end of rip- Lower 1.5 ± 0.5 2.5
per.
a See figure E
• Hydraulic oil tempera- Pitch in 1.6 ± 0.3 2.1
ture: 45 – 55°C
Pitch speed
• Apply no load to blade.
(If equipped)
• Pitch in – pitch back
• Engine: High idle Pitch back 1.6 ± 0.3 2.1
20-100 10 D65EX, PX, WX-16

D65PX-16
Standard value
Permissible
for new
value
machine
— —
— —
— —
— —
Min. 26.5 Min. 26.5
{Min. 270} {Min. 270}
27.4 – 30.9 Min. 26.5
{280 – 315} {Min. 270}
3.97 ± 0.29 3.97 ± 0.29

{40.5 ± 3.0} {40.5 ± 3.0}
3.19 – 4.17 3.19 – 4.17

{32.5 – 42.5} {32.5 – 42.5}
2.4 ± 0.3 3.0
2.5 ± 0.3 3.1
1.7 ± 0.2 2.1
1.6 ± 0.2 2.0
1.6 ± 0.3 2.1
1.7 ± 0.3 2.2
1.6 ± 0.3 2.1
1.7 ± 0.3 2.2
4.0 ± 0.5 5.0
4.0 ± 0.5 5.0
— —
— —
1.6 ± 0.3 2.1
1.6 ± 0.3 2.1
D65EX, PX, WX-16 20-100 11


Classification
Standard value
Permissible
Check item Measurement conditions Unit for new
value
machine
• Hydraulic oil temperature: 45 – 55°C

• Move lever to stroke end.
Time lag
• Lower blade from max. rising position and

Blade Second Max. 1.0 Max. 1.5
measure time after blade comes in contact
with ground until idler is lifted.
• High idle
a See figure F
Hydraulic drift of
Work equipment
• Hydraulic oil temperature: 45 – 55°C Max. 35 Max. 35

lifted blade
• Stop engine.
a See figure G
Hydraulic drift
• Hydraulic oil temperature: 45 – Left tilt Max. 70 Max. 70

Hydraulic drift of 55°C mm/
machine when • Stop engine. 5 min
blade is titled • Hydraulic drift of tip of blade cut-
ting edge Right tilt Max. 70 Max. 70
a See figure H
Hydraulic drift of
• Hydraulic oil temperature: 45 – 55°C Max. 35 Max. 35
lifted ripper
• Stop engine.
Work equipment
Blade tilt
Leakage from
• Engine: High idle 5 20

cylinder
cylinder
• Hydraulic oil temperature: 45 – 55°C

cc/min
• Relieve cylinder and measure leakage for 1
Ripper lift minute. 5 20
cylinder
• Engine: Low idle

• Coolant temperature, Min.
600 ± 50 500
• Hydraulic oil power train oil tem- speed
temperature: perature: Max. 80°C
Cooling fan
Fan speed 45 – 55°C rpm

• Fan: Normal
rotation • Engine: High idle
Max.
• Fan 100% speed speed 1,700 (+100/0) 1,600
mode
• Hydraulic oil temperature: 45 – 55°C MPa 14.2 – 17.2 13.2

Fan pump pressure
• Fan: Normal rotation {kg/cm2} {145 – 175} {135}
20-100 12 D65EX, PX, WX-16

D65PX-16
Standard value
Permissible
for new
value
machine
Max. 1.0 Max. 1.5
Max. 35 Max. 35
Max. 70 Max. 70
Max. 70 Max. 70
— —
5 20
5 20
600 ± 50 500
1,700 (+100/0) 1,600
14.2 – 17.2 13.2

{145 – 175} {135}
D65EX, PX, WX-16 20-100 13

Illustrations related to standard value table
Figure A Figure D
Figure B Figure E
Figure C Figure F
20-100 14 D65EX, PX, WX-16

Figure G
Figure H
D65EX, PX, WX-16 20-100 15

SEN05118-01
D65EX, PX, WX-16 Bulldozer

©2010 KOMATSU
All Rights Reserved
20-100 16
SEN05119-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
30 Testing and adjusting 30
101 Testing and adjusting, Part 1

Tools for testing, adjusting, and troubleshooting............................................................................................. 2
Testing engine speed ...................................................................................................................................... 5
Testing intake air pressure (boost pressure) ................................................................................................... 7
Testing exhaust temperature........................................................................................................................... 9
Testing exhaust gas color ..............................................................................................................................11
Adjusting valve clearance ............................................................................................................................. 12
Testing compression pressure ...................................................................................................................... 14
Testing blow-by pressure .............................................................................................................................. 18
Testing engine oil pressure ........................................................................................................................... 19
Handling of fuel system devices ................................................................................................................... 20
Releasing residual pressure from fuel system .............................................................................................. 20
Testing fuel pressure..................................................................................................................................... 21
Testing fuel return and leak amount.............................................................................................................. 26
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing fuel circuit for leakage....................................................................................................................... 29
Handling of reduced cylinder mode operation .............................................................................................. 30
Handling of no injection cranking operation .................................................................................................. 30
Testing and adjusting air conditioner compressor belt tension ..................................................................... 31
Replacing alternator belt ............................................................................................................................... 32
Adjusting fuel control dial and decelerator pedal .......................................................................................... 33
Handling controller high-voltage circuit ......................................................................................................... 34
D65EX, PX, WX-16 30-101 1

SEN05119-02 Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting 1
Quantity
Testing or adjusting Sym-
Part No. Part name Remarks
item bol
Air boost pressure

A 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost pressure)
Water temperature, oil
temperature and exhaust B 799-101-1502 Digital temperature gauge 1 –99.9 – 1,299°C
temperature
1 799-201-9001 Handy smoke checker 1
Exhaust gas color C Commercial Bosch index: 0 – 9
2 Smoke meter 1
item
1 795-799-1131 Gear 1
Valve clearance D Commercial
2 Clearance gauge 1
item
1 795-799-6700 Puller 1
2 795-502-1590 Gauge assembly 1
Compression pressure E 3 795-790-6110 Adapter 1 For 114E-3
4 6754-11-3130 Gasket 1
5 795-799-8150 Remover 1
1 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH20}
Blow-by pressure F 795-790-3300

2 or Blow-by tool 1
799-201-1511
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Engine oil pressure G
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
6732-81-3170 Adapter 1 10 x 1.0 mm o R1/8
3
6215-81-9710 O-ring 1
1 *As common as G1
790-261-1204 Digital hydraulic tester 1
6732-81-3170 Adapter 1 10 x 1.0 mm o R1/8
2
6215-81-9710 O-ring 1
3 799-401-2320 Gauge 1 *As common as G2
Fuel pressure H 4 795-790-6210 M10 computer check fitting 1

795-790-1500 1 (0 – 30 inHg)
5 or Vacuum gauge
799-201-1201 1 –107 – 0 kPa {–800 – 0 mmHg}
6 795-790-4900 Adapter kit 1
7 795-790-5010 Fitting 1
8 795-790-1150 Pressure gauge 1 (0 – 75 inHg)
1 795-790-4800 Hose kit 1
Quantity of fuel return 2 795-790-6700 Adapter 1
J
and leakage Commercial
4 Measuring cylinder 1
item
30-101 2 D65EX, PX, WX-16

Tools for testing, adjusting, and troubleshooting SEN05119-02
Quantity
item bol

1 *As common as G1
Power train oil pressure K 2 799-401-2320 Gauge 1 *As common as G2
799-101-5220 Nipple (10 x 1.25 mm) 1
3
07002-11023 O-ring 1
19M-06-32820 Switch assembly 1
1
14X-06-52930 Wiring harness 1
Emergency escape 7824-66-6430 Prolix resistance 1

2
method when L 7827-10-1520 Prolix resistance 1
power train has trouble 3 790-190-1601 Pump assembly 1
799-101-5220 Nipple (10 x 1.25 mm) 1
4 *As common as K3
07002-11023 O-ring 1
1 Digital hydraulic *As common as G1
Work equipment and 790-261-1204 1
M tester
HSS oil pressure
799-101-5220 Nipple (10 x 1.25 mm) 1
2 *As common as K3
07002-11023 O-ring 1
Control circuit 1 *As common as G1
N 790-261-1204 Digital hydraulic tester 1
basic pressure
2 799-401-3100 Adapter (size 02) 1
PPC valve output 1 *As common as G1
O 790-261-1204 Digital hydraulic tester 1
pressure
2 799-401-3100 Adapter (size 02) 1
Internal leakage of work Commercial
P Measuring cylinder 1
equipment cylinder item
Fan motor speed Q 799-205-2200 Tachometer 1
1 *As common as G1
Fan pump circuit
R 2 799-401-3400 Adapter (size 05) 1
pressure
799-101-5220 Nipple (10 x 1.25 mm) 1
3 *As common as K3
07002-11023 O-ring 1
79A-264-0021 0 – 294 N {0 – 30 kg} 1
Operating effort S
79A-264-0091 0 – 490 N {0 – 50 kg} 1
Stroke and Commercial
T Scale 1
hydraulic drift item
Commercial
Work equipment speed U Stopwatch 1
item
Commercial
Voltage and resistance V Tester 1
item
799-601-7400 T-adapter assembly 1 AMP40 connector
799-601-7500 T-adapter assembly 1 AMP070 connector
Troubleshooting sensors 799-601-9000 T-adapter assembly 2 DT, HD30 connector
—
and wiring harnesses 799-601-9300 T-adapter assembly 1 DRC26-24, 40-pin
799-601-7360 Adapter 1 Relay (5-pin)
799-601-7370 Adapter 1 Relay (6-pin)
D65EX, PX, WX-16 30-101 3

SEN05119-02 Tools for testing, adjusting, and troubleshooting
Quantity
item bol
799-601-4101 T-adapter assembly 1 Engine-related connector

799-601-4130 • T-adapter 1 Ne sensor, CAM sensor
799-601-9020 • Socket 1 Pump actuator
799-601-4140 • T-adapter 1 Ambient pressure sensor
Boost pressure and temperature sen-
799-601-4230 • Socket 1
sor
Troubleshooting sensors
and wiring harnesses 799-601-4190 • Socket 1 Common rail pressure sensor
— 799-601-4160 • T-adapter 1 Oil pressure sensor
795-799-5530 • Socket 1 Coolant temperature sensor
799-601-4260 • T-adapter 1 Controller (4-pole)
Removal and installation
of engine coolant 795T-981-1010 Socket 1 19mm (width across flats) deep socket
temperature sensor
30-101 4 D65EX, PX, WX-16

Testing engine speed SEN05119-02
Testing engine speed 1 2. Measuring low idle speed
k
1) Start the engine and set the fuel control
Stop the machine on level ground, lower dial in the low idle (MIN) position.
the work equipment to the ground, stop the 2) Set the PCCS lever, blade control lever,
engine, and set the parking brake lever and and ripper control lever in neutral and
work equipment lock lever in the lock posi- measure the engine speed.
tion. a The parking brake lever and work
a Measure the engine speed under the following equipment lock lever may be kept in
conditions. the LOCK position.
q Engine coolant temperature: Within oper-
ating range 3. Measuring high idle speed
q Power train oil temperature: Within operat- 1) Start the engine and set the fuel control
ing range dial in the high idle (MAX) position.
q Hydraulic oil temperature: Within operat- 2) Set the PCCS lever, blade control lever,
ing range and ripper control lever in neutral and
q Working mode: P mode measure the engine speed.
q Gearshift mode: Either Auto or Manual a The parking brake lever and work
equipment lock lever may be kept in
1. Preparation work the LOCK position.
Measure the engine speed with the Adjustment
function in the service mode of the machine 4. Measuring decelerator pedal speed
monitor. 1) Start the engine and set the fuel control
a For the operating method of the machine dial in the high idle (MAX) position.
monitor, see Special functions of machine 2) Set the PCCS lever, blade control lever,
monitor (EMMS). and ripper control lever in neutral, press
q Measuring low idle speed, high idle speed, the decelerator pedal to the stroke end,
decelerator pedal speed, torque con- and measure the engine speed.
verter stall speed, and torque converter a The parking brake lever and work
stall speed + work equipment relief speed equipment lock lever may be kept in
(full stall speed): the LOCK position.
q Adjustment code: 0530 (Stall mode)
a When stalling the torque converter for 5. Measuring torque converter stall speed
a purpose other than measuring the a Relieve the work equipment frequently
engine speed, be sure to use this during measurement to keep the hydraulic
adjustment code, too. oil temperature above 50°C.
If the hydraulic oil temperature lowers
below 40°C, the fan speed fluctuates and
t h e a c c u r a t e s ta l l s p e e d c a n n o t b e
obtained.
1) Start the engine and set the fuel control
dial in the low idle (MIN) position.
2) Operate the shiftup (UP) switch of the
PCCS lever and set the preset mode dis-
play section to [F3-R3].
a The preset mode display section (at
the right bottom of the screen) can be
set to [F3-R3] only while the Adjust-
ment function is selected.
3) While pressing the brake pedal securely,
set the parking brake lever in the free
position and set the direction of PCCS
lever in the forward position.
a Before going to the next step, check
that [F3] is displayed in the gear
speed display section (at the right
bottom of the screen).
a Keep the steering system in neutral.
D65EX, PX, WX-16 30-101 5

SEN05119-02 Testing engine speed
4) Press the decelerator pedal and set the

fuel control dial in the high idle (MAX)
position.
5) Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
k Keep pressing the brake pedal
securely and keep your right foot on
the decelerator pedal for safety until
the work is finished.
6) Just after the power train oil temperature
gauge (T/C TEMPERATURE) indicates
118 – 120°C, return the direction of PCCS
lever to neutral.
a The top of the green range of the
power train oil temperature gauge
indicates about 118 – 120°C.
7) Repeat above steps 3) – 6) 3 times.
8) Perform steps 3) – 5) again and measure
the engine speed about 5 seconds after
the power train oil temperature gauge (T/C
TEMPERATURE) indicates 118 – 120°C.
a Immediately after finishing measure-
ment, return the direction of PCCS
lever to neutral and lower the power
train oil temperature with the engine
at high idle.
30-101 6 D65EX, PX, WX-16

Testing intake air pressure (boost pressure) SEN05119-02
Testing intake air pressure (boost

pressure) 1
a Testing instruments for intake air pressure

(boost pressure)
Symbol Part No. Part name
799-201-2202 Boost gauge kit
A
799-401-2220 Hose
k Stop the machine on level ground, lower

the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock posi-
tion.
k Be careful not to touch any hot part of the
engine when removing or installing the 4. Run the engine at a medium or higher speed
measuring tools. and drain the oil from the test hose.
a Measure the intake air pressure (boost pres- a Insert the connecting parts of the gauge
sure) under the following conditions. and hose about a half and open the self-
q Engine coolant temperature: Within oper- seal on the hose side repeatedly, and the
ating range oil will be drained.
q Power train oil temperature: Within operat- a If Pm kit (A) is available, you may drain
ing range the oil by using the oil draining coupling
q Hydraulic oil temperature: Within operat- (790-261-1130) in that kit.
ing range a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
1. Open the top left side engine cover.
2. Remove intake air pressure pickup plug (1) 5. Turn the starting switch ON and set the
from the air intake connector. machine monitor to Adjustment function of the
service mode.
a For the operating method, see “Special
functions of machine monitor (EMMS)”.
3. Install nipple [1] of boost gauge kit A and con-

nect gauge [2].
D65EX, PX, WX-16 30-101 7

SEN05119-02 Testing intake air pressure (boost pressure)
6. While running the engine at high idle, stall the

torque converter and measure the intake air
pressure (boost pressure).
a For the procedure for stalling the torque
converter, see Measuring engine speed.
a Normally, the intake air pressure (boost
pressure) should be measured while the
engine is operated at the rated output. In
the field, however, an approximate value
can be obtained by stalling the torque con-
verter.
7. After finishing measurement, remove the mea-

suring instruments and return the removed
parts.
a The boost pressure can also be checked
with the “PM clinic” function in the Service
mode of the machine monitor.
a For the operation procedure, see “Special
a Since the boost pressure displayed on the
machine monitor is an absolute pressure
value (including the atmospheric pres-
sure), measure the atmospheric pressure
simultaneously and calculate its difference
from the displayed boost pressure to
obtain the actual boost pressure.
q Example
If the value measured by the monitor is
247 kPa; 247 kPa – 101 kPa (Atmospheric
pressure) = 146 kPa (Actual boost pres-
sure)
30-101 8 D65EX, PX, WX-16

Testing exhaust temperature SEN05119-02
Testing exhaust temperature 1 2. Install sensor [1] of digital thermometer B and

connect them to thermometer B.
a Testing instruments for exhaust temperature a Clamp the wiring harness of the digital
Symbol Part No. Part name thermometer so that it will not touch a hot
part during measurement.
B 799-101-1502 Digital thermometer

tion.
k Install and remove the measuring instru-
ments after the exhaust manifold is cooled.
a Measure the exhaust temperature under the
following conditions.
q Engine coolant temperature: Within oper-
ating range
q Power train oil temperature: Within operat-
ing range
q Hydraulic oil temperature: Within operat-
ing range
1. Open the right engine side cover and remove

heat insulation cover (1) and exhaust gas tem-
perature pickup plug (2).
3. When measuring maximum exhaust tempera-

ture for troubleshooting
Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the thermometer.
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
q Corrected value [°C] = Measured
value + 2 × (20 – Outside air tempera-
ture)
D65EX, PX, WX-16 30-101 9

SEN05119-02 Testing exhaust temperature
4. Procedure for measuring exhaust temperature 7) Return the decelerator pedal slowly to stall
periodically for preventive maintenance (Pm the torque converter and relieve the blade
clinic) tilt system to raise the exhaust tempera-
a If the torque converter is stalled simply, ture to about 450°C (Condition (a) in the
the torque converter oil is overheated figure) with the engine at high idle.
before the exhaust temperature is stabi-
lized. Accordingly, measure according to k Keep pressing the brake pedal
the following procedure. securely and keep your right foot
1) Turn the starting switch ON and set the on the decelerator pedal for safety
machine monitor to Adjustment function of until the work is finished.
the service mode.
a For the operating method, see “Spe-
cial functions of machine monitor
(EMMS)”.
8) Under the condition of step 7), stop reliev-

ing the blade tilt system and lower the
exhaust temperature by only stalling the
torque converter (Condition (b) in the fig-
2) Start the engine and set the fuel control ure).
dial in the low idle (MIN) position. a If the exhaust temperature does not
3) Operate the shiftup (UP) switch of the lower but rises, set the temperature
PCCS lever and set the preset mode dis- high in step 7).
play section to [F3-R3]. 9) After the exhaust temperature is lowered
a The preset mode display section (at and stabilized, measure the exhaust tem-
the right bottom of the screen) can be perature (Condition (c) in the figure).
set to [F3-R3] only while the Adjust- k Just after the power train oil tem-
ment function is selected. perature (T/C TEMPERATURE)
4) Set the work equipment lock lever in the reaches about 120°C, return the
free position and operate the blade control direction of PCCS lever to neutral
lever to set the blade tilt cylinder to the and lower the power train oil tem-
maximum extend. perature with the engine at high
5) While pressing the brake pedal securely, idle.
set the parking brake lever in the free a The border between the green range
position and set the direction of PCCS and red range of the power train oil
lever in the forward position. temperature gauge indicates about
a Before going to the next step, check 120°C.
that [F3] is displayed in the gear
speed display section (at the right 5. After finishing measurement, remove the mea-
bottom of the screen). suring instruments and return the removed
a Keep the steering system in neutral. parts.
6) Press the decelerator pedal and set the
fuel control dial in the high idle (MAX)
position.
30-101 10 D65EX, PX, WX-16

Testing exhaust gas color SEN05119-02
Testing exhaust gas color 1 2. Measuring with smoke meter C2

1) Insert probe [1] of smoke meter C2 in the
a Testing instruments for exhaust gas color outlet of exhaust pipe and fix it to the
Symbol Part No. Part name exhaust pipe with a clip.
1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available

tion.
k Be careful not to touch any hot part of the
engine when removing or installing the
measuring tools.
a If an air source and an electric power source
are not available in the field, use handy smoke
2) Connect the probe hose, receptacle of the
checker C1. When recording official data, use accelerator switch, and air hose to smoke
smoke meter C2. meter C2.
a Measure the exhaust gas color under the fol- a Limit the supplied air pressure to 1.5
lowing condition. MPa {15 kg/cm²}.
q Engine coolant temperature: Within oper- 3) Connect the power cable to a receptacle
ating range of AC 100 V.
a Before connecting the cable, check
1. Measuring with handy smoke checker C1 that the power switch of the smoke
1) Stick a sheet of filter paper to smoke meter is turned OFF.
checker C1. 4) Loosen the cap nut of the suction pump
2) Insert the exhaust gas intake pipe in and fit the filter paper.
exhaust pipe. a Fit the filter paper securely so that the
3) Start the engine. exhaust gas will not leak.
4) Accelerate the engine suddenly or run it at 5) Turn power switch of smoke meter C2 ON.
high idle and operate the handle of smoke
checker C1 so that the filter paper will
absorb the exhaust gas.
6) Start the engine.

7) Accelerate the engine suddenly or run it at
high idle and press the accelerator switch
of smoke meter C2 and collect the
5) Remove the filter paper and compare it exhaust gas into the filter paper.
with the attached scale. 8) Place the contaminated filter paper on the
6) After finishing measurement, remove the clean filter paper (at least 10 sheets) in the
measuring instrument and return the filter paper holder and read the indicated
removed parts. value.
9) After finishing measurement, remove the
measuring instrument and return the
removed parts.
D65EX, PX, WX-16 30-101 11

SEN05119-02 Adjusting valve clearance
Adjusting valve clearance 1 4. Set the No.1 cylinder to the compression top
dead center.
a Adjusting instrument for valve clearance 1) Remove cap (5) of flywheel housing,
Symbol Part No. Part name insert gear D1 to rotate forward.
1 795-799-1131 Gear
D Commercial
2 Clearance gauge
item

tion.
1. Remove and install the engine hood assembly
and muffler assembly. For detail, see Disas-
sembly and assembly, “Removal and installa-
tion of cylinder head assembly”.
2. Disconnect breather tube (1) and blow-by tube 2) Align the TDC stamp line (a) of the front
(2) and remove cylinder head cover (3). [*1] gear cover and supply pump gear stamp
line (b).
a The No.1 cylinder comes to the com-
pression top dead center position.
3. Remove cap (4) of the front gear cover.
5. While the No.1 cylinder is at the compression

top dead center, adjust the clearance of valve
marked with q in the valve arrangement figure.
30-101 12 D65EX, PX, WX-16

Adjusting valve clearance SEN05119-02
6. Adjust the valve clearance in the following pro- 5) While the No. 6 cylinder is at the compres-
cedure. sion top dead center, adjust the clearance
1) Insert clearance gauge D2 into the clear- of valves marked with Q in the valve
ance between rocker lever (6) and cross- arrangement figure.
head (7). a Procedure for the adjustment is as
2) Loosen locknut (8) and adjust valve clear- same as 1) – 3).
ance with adjustment screw (9).
a With the clearance gauge inserted, 7. After finishing adjustment, reinstall the removed
turn the adjustment screw so that you parts.
can move clearance gauge D2 lightly.
3) Fix adjustment screw (9) and tighten lock- [*1]
nut (8). 3 Cylinder head cover mounting bolt:
3 Locknut: 12 ± 2 Nm {1.2 ± 0.2 kgm}
24 ± 4 Nm {2.4 ± 0.4 kgm}
a After tightening the locknut, check the
valve clearance again.
4) After finishing the adjustment of all valves

marked with q, turn the crankshaft 360°
forward and align stamp line (c) of the
front gear cover and stamp line (b) of sup-
ply pump gear.
a The No.6 cylinder comes to the com-
pression top dead center position.
D65EX, PX, WX-16 30-101 13

SEN05119-02 Testing compression pressure
Testing compression pressure 1
a Testing instruments for compression pressure

1 795-799-6700 Puller
2 795-502-1590 Gauge assembly
E 3 795-790-6110 Adapter
4 6754-11-3130 Gasket
5 795-799-8150 Remover

5. Loosen injector harness terminal nuts (7) and
tion.
k
disconnect the terminal from the injector.
When measuring the compression pres-
sure, take care not to burn yourself on the
6. Set the cylinder to be inspected to the com-
exhaust manifold, muffler, etc. or get
pression top dead center.
caught in a rotating part.
a Refer to “Adjusting valve clearance”.
a Measure the compression pressure after the
engine is warmed up.
7. Remove rocker arm assembly (8).
(Engine oil temperature: 40 – 60°C)
8. Remove crossheads (9).
1. Remove and install the engine hood assembly
and muffler assembly. For detail, see Disas-
sembly and assembly, “Removal and installa-
tion of cylinder head assembly”.
2. Disconnect breather tube (1) and blow-by tube

(2) and remove cylinder head cover (3).
3. Disconnect injector harness (4). (3 places)
a Make notes of the installation positions

and hole shapes of (a) and (b) sections.
(So that the removed parts can be rein-
stalled to their original positions later.)
4. Disconnect fuel high-pressure pipe (5).

a Before disconnecting pipes No.1, 3, and 5,
disconnect harness connector (6) from the
block.
30-101 14 D65EX, PX, WX-16

Testing compression pressure SEN05119-02
9. Remove retainer (10) to dismount inlet connec- 12. Install gasket E4 to the top of adapter E3 and
tor (11). insert adapter into mounting section of the
k Remove the dusts around the inlet con- injector.
nector thoroughly in advance to pre-
vent them from entering the cylinder
head hole or the inlet connector during
the removal operations.
q Use remover E5 to remove the inlet con-
nectors.
13. Fix adapter E3 with holder (13).

a Tighten bolts (12) diagonally so that the
upper surface of holder (13) becomes par-
allel to the upper surface of the cylinder
head.
q Maximum angle limit: 2.4°
10. Unscrew bolt (12) to remove holder (13). 3 Bolt:
1st time: 10 ± 2.0 Nm {1.0 ± 0.2 kgm}
2nd time: 41 ± 4.0 Nm {4.1 ± 0.4 kgm}
14. Connect gauge assembly E2 to adapter E3.

a Leakage can be prevented by applying a
little amount of engine oil to the fitting
faces of the adapter and gauge.
11. Remove injector (14) with puller E1.

a Do not ply the upper part of the injector to
remove it without using puller E1.
15. Install rocker arm assembly (8).

3 Rocker arm assembly mounting bolts:
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
16. Install crossheads (9).
17. Adjust valve clearance.

a Refer to “Adjusting valve clearance”.
D65EX, PX, WX-16 30-101 15

SEN05119-02 Testing compression pressure
18. Turn the starting switch to the ON position and 6) Tighten bolts (12) to the specified torque.
set the machine monitor in the service mode. a Tighten bolts diagonally so that the
q Select 09 “Cylinder cutout mode opera- upper surface of holder (13) becomes
tion” and set all the cylinders in the cylin- parallel to the upper surface of the
der cutout mode. cylinder head.
a Depress “F6” and check background (a) of q Maximum angle limit: 2.4°
the cylinder No. If the background is white, 3 Bolt: 10 ± 2.0 Nm {1.0 ± 0.2 kgm}
the corresponding cylinder is set in the
cylinder cutout mode. 7) Tighten inlet connector (11) to the speci-
a For the operation procedure, see “Special fied torque.
functions of machine monitor (EMMS)”. 3 Retainer (10):
k If all the cylinders are not set in the cyl- 41 ± 4 Nm {4.1 ± 0.4 kgm}
inder cutout mode, the engine starts Apply the caulking compound (e)
during testing and that is dangerous. (hatched section) to retainer (10) and
Accordingly, be sure to set in the cylin- the cylinder head.
der cutout mode. 2 Caulking compound:
GE TOSHIBA SILICON TOSSEAL 381
19. Crank the engine with the starting motor and

measure the compression pressure.
a Read the pressure when the gauge
pointer is stabilized.
a Check the engine speed with the monitor.
20. When the checking is completed, remove the

instruments and reinstall the removed parts.
a Install the injector and the inlet connector
according to the following procedure.
1) Coat the O-ring of injector (14) and the
mounting hole on the head with engine oil
(EO15W-40).
2) Assemble holder (13) on injector (14) then
insert the assembly into the cylinder head
with the fuel inlet hole of injector (14) on
the intake manifold side. a Rocker arm assembly
3) Tighten bolt (12) by three or four threads 1) Tighten the mounting bolt after checking
with hands. that the ball portion of adjustment screw is
well seated in the push rod socket.
3 Bolts: 65 ± 5 Nm {6.6 ± 0.5 kgm}
4) Coat the O-ring of inlet connector (11) and
the mounting hole on the head with engine
oil (EO15W-40). 2) After installing the rocker arm assembly,
5) Install inlet connector (11) temporarily with adjust the valve clearance referring to
retainer (10). “Adjusting valve clearance”.
3 Retainer:
14.7 ± 5.0 Nm {1.5 ± 0.5 kgm}
30-101 16 D65EX, PX, WX-16

Testing compression pressure SEN05119-02
a Fuel high-pressure piping

When assembling the pipe, tighten the mount-
ing nuts in the injector side first, then tighten
nuts in the common rail side.
3 Nuts: 37 ± 4 Nm {3.8 ± 0.4 kgm}
a Tightening torque of the injector harness termi-
nal nut
3 Nut: 1.25 ± 0.25 Nm {0.13 ± 0.03 kgm}
a When installing, secure clearance between
injector wiring harnesses (15), rocker arm (16)
and rocker housing (17) so that they will not
interfere with each other.
q Clearance (f): Min. 3 mm
q Clearance (g): Min. 3 mm
a Tightening torque of the head cover mounting

nuts
3 Nut: 11.8 ± 1.96 Nm {1.2 ± 0.2 kgm}
D65EX, PX, WX-16 30-101 17

SEN05119-02 Testing blow-by pressure
Testing blow-by pressure 1
a Testing instrument for blow-by pressure

1 799-201-1504 Blow-by checker
F 795-790-3300
2 or Blow-by tool
799-201-1511

tion.
a Measure the blow-by pressure under the fol-
5. Measure the blow-by pressure while the
lowing condition.
engine is running at high idle and the torque
q Coolant temperature: Within operating
converter is stalling.
range
converter, see “Measuring engine speed”.
ing range
a Normally, the blow-by pressure should be
q Power train oil temperature: Within operat-
measured while the engine is operated at
ing range
the rated output. In the field, however, an
approximate value can be obtained by
1. Open the left side cover (1) of engine hood and
stalling the torque converter.
remove side cover (2).
a If it is impossible to run the engine at the
rated output or stall the torque converter,
measure while the engine is running at
high idle.
The value obtained in this case is about
80% of the blow-by pressure at the rated
output.
a The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, premature deterioration or con-
tamination of oil, etc. which are related to
the abnormal blow-by pressure.
2. Remove the mounting clamp of blow-by hose

(3) on the engine side and pull out the hose to
the left outer side of the engine.
3. Install blow-by tool F2 to blow-by hose (3).
4. Install hose [1] of blow-by checker F1 to blow-

by tool F2 and connect them to gauge [2].

suring instrument and reinstall the removed
parts.
30-101 18 D65EX, PX, WX-16

Testing engine oil pressure SEN05119-02
Testing engine oil pressure 1 3. Install adapter G3 and nipple [1] of hydraulic
tester G1 to the plug installation portion and
a Testing instruments for engine oil pressure connect to gauge G2.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
G 2 799-401-2320 Gauge: 1 MPa {10 kg/cm2}
6732-81-3170 Adapter (10 x 1.0 mm o R1/8)
3
6215-81-9710 O-ring

tion.
a Measure the engine oil pressure under the fol-
lowing condition.
4. Start the engine and measure the engine oil
q Coolant temperature: Within operating
pressure when the engine is running at low idle
range
and when the torque converter is stalling.
1. Open left side cover (1) of engine hood and
converter, see “Measuring engine speed”.
remove side cover (2).

2. Remove oil pressure inspection plug (3).
parts.
D65EX, PX, WX-16 30-101 19

SEN05119-02 Handling of fuel system devices
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-

The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit: Fuel pre-filter – Lift pump
eign matter enters this system, it can cause a – Fuel main filter – Fuel supply pump
trouble. High-pressure circuit: Fuel supply pump –
When testing and maintaining the fuel system, Common rail – Fuel injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use Komatsu genuine fuel filter car- a Before the fuel circuit is tested and its parts are
tridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. ping the engine until the residual pressure
If a filter other than the genuine one is used, in the fuel circuit is released. (Do not start
the fuel system may have a trouble. Accord- the work just after stopping the engine
ingly, never use such a filter. since there is residual pressure.)
30-101 20 D65EX, PX, WX-16

Testing fuel pressure SEN05119-02
Testing fuel pressure 1 2. Testing fuel negative pressure circuit pres-

sure (fuel supply connector)
a Testing tools for fuel pressure 1) Remove fuel pressure pickup plug (3)
Symbol Part No. Part name from the fuel supply connector.
1
Adapter
6732-81-3170
2 (10 x 1.0 mm o PT1/8)
6215-81-9710 O-ring
3 799-401-2320 Gauge: 1 MPa {10 kg/cm2}
H 4 795-790-6210 M10 computer check fitting
795-790-1500
5 or Vacuum gauge
799-201-1201
6 795-790-4900 Adapter kit
7 795-790-5010 Fitting
8 795-790-1150 Pressure gauge 2) Connect M10 computer check fitting H4 to
vacuum gauge H5.
tion.
a Tests only the fuel pressure in negative pres-
sure circuit from fuel supply connector to lift
pump inlet, and in low-pressure circuit from lift
pump to fuel main filter and supply pump.
k Since the pressure in the high-pressure cir-
cuit from fuel supply pump to common rail
and fuel injector is very high, it cannot be
measured.
1. Open left side cover (1) of engine hood and

remove side cover (2). 3) Run the engine at high idle and test the
fuel negative pressure circuit pressure.
a If the fuel negative pressure circuit
pressure is in the following range, it is
normal.
q Standard value of fuel negative pres-
sure circuit pressure (fuel supply con-
nector):
–27.1 – 0 kPa {–203 – 0 mmHg}
4) After finishing testing, remove the testing

tools and return the removed parts.
3 Fuel pressure pickup plug:
20 – 22 Nm {2.0 – 2.2 kgm}
D65EX, PX, WX-16 30-101 21

SEN05119-02 Testing fuel pressure
3. Testing fuel negative pressure circuit pres-

sure (supply pump section)
1) Disconnect intake hose (4) from the
engine.
a Make a mark at the hose end of the
tube to indicate the original connec-
tion point.
8) Start the engine and measure the fuel

negative pressure circuit pressure at high
idle.
a If the fuel negative pressure circuit
pressure is in the following standard
range, it is normal.
q Standard fuel negative pressure cir-
2) Disconnect fuel tube (5) from supply pump cuit pressure (supply pump section):
(6). –33.9 – 0 kPa {–254 – 0 mmHg}
3) Remove fitting (7) installed to supply
pump (6). 9) After finishing testing, remove the testing
3 Fitting (7):
24 ± 4 Nm {2.4 ± 0.4 kgm}
q When assembling, replace fuel tube
(5) with new one.
3 Intake hose clamp:
10.5 ± 0.5 Nm {107 ± 5 kgcm}
4) Install hose assembly [1] of adapter kit H6

to fitting H7 and install them to supply
pump (6).
3 Fitting H7:
24 ± 4 Nm {2.4 ± 0.4 kgm}
5) Connect fuel tube (5) again.
6) Connect fuel vacuum gauge H5 to hose
assembly [1].
7) Install intake hose (4).
10.5 ± 0.5 Nm {107 ± 5 kgcm}
30-101 22 D65EX, PX, WX-16

4. Testing fuel low-pressure circuit pressure

(fuel filter inlet side)
1) Remove fuel pressure pickup plug (8)
from the fuel main filter inlet side.

20 – 22 Nm {2.0 – 2.2 kgm}
2) Install adapter H2 and nipple [1] of
hydraulic tester H1 to plug hole, and con- 5. Testing fuel low-pressure circuit pressure
nect hydraulic tester H3. (fuel filter outlet side)
1) Remove fuel pressure pickup plug (9)
from the fuel main filter outlet side.
3) Measure fuel low-pressure circuit pres-

sure when cranking the engine.
a If the fuel low-pressure circuit pres- 2) Install adapter H2 and nipple [1] of
sure (at the fuel filter inlet side) is in hydraulic tester H1 to plug hole, and con-
the following range, it is normal. nect hydraulic tester H3.
q Standard value of fuel low-pressure
circuit pressure (fuel filter inlet side):
Min. 0.14 MPa {1.4 kg/cm2}
k For protection of the starting
motor, do not continue cranking
for 30 seconds or more.
D65EX, PX, WX-16 30-101 23

SEN05119-02 Testing fuel pressure
3) Run the engine at high idle and measure 2) Install adapter H2 and nipple [1] of
the fuel low-pressure circuit pressure. hydraulic tester H1 to plug hole, and con-
a If the fuel low-pressure circuit pres- nect hydraulic tester H3.
sure (at the fuel filter outlet side) is in
the following range, it is normal.
q Standard value of fuel low-pressure
circuit pressure (fuel filter outlet side):
Min. 0.48 MPa {Min. 4.9 kg/cm2}
3) Run the engine at high idle and measure

the fuel filter front and rear differential
pressure.
q Fuel filter front and rear differential
4) After finishing testing, remove the testing pressure =
tools and return the removed parts. Fuel filter inlet pressure – Fuel filter
3 Fuel pressure pickup plug: outlet pressure
20 – 22 Nm {2.0 – 2.2 kgm} a If the fuel filter front and rear differen-
tial pressure is in the following range,
6. Testing fuel filter front and rear differential it is normal.
pressure q Standard value of fuel filter front and
1) Remove fuel pressure pickup plug (8) rear differential pressure:
from the fuel main filter inlet side and fuel Max. 0.14 MPa {Max. 1.4 kg/cm2}
pressure pickup plug (9) from the outlet a If the drop exceeds the standard
side. value, clogging of the fuel filter is sus-
pected.

20 – 22 Nm {2.0 – 2.2 kgm}
30-101 24 D65EX, PX, WX-16

7. Testing fuel lift pump outlet pressure (sup- a If the fuel lift pump outlet pressure is not in
ply pump section) the standard range, perform the following
1) The testing position is the same as that for checks.
fuel negative circuit pressure and only q Check that fuel is in the fuel lift pump.
gauge H8 of the testing tool is different. q If fuel is not in the fuel lift pump just
after the fuel filter is replaced or a fuel
system part is removed and returned,
operate the fuel lift pump 3 – 4 times
with the starting switch to bleed air
from the fuel circuit and fill the pump
with fuel and then measure the outlet
pressure again.
q If the fuel lift pump outlet pressure is
not in the standard range while fuel is
in the fuel lift pump, remove check
valve (13) of engine controller cooling
plate (12) and check to see if the
valve is seized.
2) Turn the starting switch ON, operate fuel

lift pump (10), and measure the fuel lift
pump outlet pressure.
Reference: Fuel lift pump (10) is installed
to cooling plate (12) on the back side of
engine controller (11).

measuring instruments and return the
removed parts.
3 Fitting (7):
24 ± 4 Nm {2.4 ± 0.4 kgm}
q When assembling, replace fuel tube
(5) with new one
a The fuel lift pump operates for 30 seconds 10.5 ± 0.5 Nm {107 ± 5 kgcm}
after the starting switch is turned ON and
then stops. Measure the pressure while
the pump is operating.
a If the fuel lift pump outlet pressure is in the
following standard range, it is normal.
q Standard fuel lift pump outlet pressure
(supply pump section):
Min. 34 kPa {10.0 in Hg}
D65EX, PX, WX-16 30-101 25

SEN05119-02 Testing fuel return and leak amount
Testing fuel return and leak 3) Connect hose kit J1 on supply pump side,
amount 1
and insert the tip into measuring cylinder
J4.
a Testing tools for leakage from pressure limiter 4) Connect adapter J2 to fuel return connec-
and return rate from injector tor side, and block fuel leak.
Symbol Part No. Part name 5) Run the engine at low idle and test the
return rate from the supply pump.
1 795-790-4800 Hose kit
a If the return rate from the supply
2 795-790-6700 Adapter pump is in the following range, it is
J
Commercial normal.
4 Measuring cylinder
item
Low idle Max. 300 cc/30 sec.
1. Testing supply pump return rate Cranking Max. 200 cc/30 sec.
1) Remove air conditioner compressor (4)
and its bracket together. k When the engine cannot run, you
a For the removal procedure, see Dis- may test it by cranking the engine
assembly and assembly, “Removal with the starting motor. To protect
and installation of fuel supply pump the starting motor, do not continu-
assembly”. ously crank the engine 30 seconds
or more.
2) Remove tube installation bolt, and discon- 6) After finishing testing, remove the testing
nect return tube (1). tools and return the removed parts.
3 Joint bolt (M14):
36 ± 5 Nm {3.7 ± 0.5 kgm}
30-101 26 D65EX, PX, WX-16

Testing fuel return and leak amount SEN05119-02
2. Testing leakage from pressure limiter 3. Testing return rate from injector
a When displaying failure code [CA559] or 1) Remove return tube (3) of the injector.
[CA2249], implement troubleshooting
beforehand.
1) Remove return tube (2) of the pressure
limiter.
2) Connect hose kit J1 on cylinder head side,

and insert the tip into measuring cylinder
J4.
3) Connect adapter J2 to return tube joint
2) Connect hose kit J1 on pressure limiter connector on cylinder block side, and
side, and insert the tip into measuring cyl- block fuel leak.
inder J4. 4) Run the engine at low idle and test the
3) Connect adapter J2 to return tube joint return rate from the injector.
connector on cylinder block side, and a If the return rate from the injector is in
block fuel leak. the following range, it is normal.
4) Run the engine at low idle and test the
Low idle Max. 300 cc/45 sec.
return rate from the pressure limiter.
a If the leakage from the pressure lim- Cranking Max. 100 cc/30 sec.
iter is in the following range, it is nor-
mal. k When the engine cannot run, you
may test it by cranking the engine
Low idle Below 30 drops/min. with the starting motor. To protect
the starting motor, do not continu-
ously crank the engine for 30 sec-
onds or more.

3 Joint bolt: 5) After finishing testing, remove the testing
24 ± 4 Nm {2.4 ± 0.4 kgm} tools and return the removed parts.
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
D65EX, PX, WX-16 30-101 27

SEN05119-02 Bleeding air from fuel circuit
Bleeding air from fuel circuit 1 2. Fill up the fuel tank with fuel.
a Bleed the air by electric lift pump as follows if 3. Turn the starting switch ON.
the engine has run out of fuel or the fuel circuit q The lift pump is operated for 30 seconds
equipment has been removed and installed. automatically.
k Do not turn the starting switch to start
1. The installation procedures for fuel main filter position.
(1) and fuel pre-filter (2) after their removal,
installation or replacement are as follows. 4. Return the starting switch to OFF position, and
keep it for 10 seconds.
5. Repeat the above 3 and 4 operation 4 times.
6. Crank the engine with the starting motor and

start the engine.
a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 2.
a If the engine is run when there is still air in
the fuel circuit, fuel circuit errors (CA559,
CA2249) may occur. In this case, start the
1) Do not fill fuel into fuel main filter (1). engine after the procedure above, and
2) Fill up fuel into fuel pre-filter (2). continue to drive the engine for about 3
q When filling, use clean fuel and be minutes at low idle. When air is bleed from
careful not to let dirt get in. fuel circuit, engine speed is stabilized and
q Add fuel through inlet port (a) areas error display will disappear.
(8 places) of the filter.
Area (b) is the outlet port (clean side)

after the fuel has been filtered, so
never add fuel from here.
3) Apply a thin coat of oil on the packing sur-

face of the filter and install it to filter head
until it touches the sealing surface, then
tighten 3/4 rotation. (For the procedure to
replace fuel filter cartridge, see the Opera-
tion and Maintenance Manual.)
30-101 28 D65EX, PX, WX-16

Testing fuel circuit for leakage SEN05119-02
Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
k
leakage.
Very high pressure is generated in the high- a Inspect the high-pressure circuit parts
pressure circuit of the fuel system. If fuel concentration on the areas coated with the
leaks while the engine is running, it is dan- color checker, for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its components, inspect it for fuel leakage a If any fuel leakage is not detected, inspec-
according to the following procedure. tion is completed.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Inspect the fuel piping and the devices for fuel

leakage.
a Inspect the high-pressure circuit parts
concentration on the areas coated with the
color checker, for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
6. Run the engine at high idle.

leakage.
8. Run the engine at high idle to apply load to the

engine.
a Relieve by tilting the blade or raising the
ripper.
D65EX, PX, WX-16 30-101 29

SEN05119-02 Handling of reduced cylinder mode operation
Handling of reduced cylinder Handling of no injection cranking

mode operation 1 operation 1
a Reduced cylinder mode operation means to a No injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
When a cylinder is selected for the reduced a Use the no-injection cranking function for only
cylinder mode operation, if the engine speed the above purposes while the engine is
and output do not change from the normal mounted on the machine.
operation (all-cylinder operation), that cylinder a To implement no injection cranking operation,
has 1 or more defects. see “Special functions of machine monitor
The possible defects are as follows. (EMMS)”.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring, and cylinder
liner
q Defective valve mechanism
(Moving valve system)
q Defect in electrical system
2. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a The reduced cylinder mode operation is
carried out by using the special functions
of machine monitor.
a For the operation method, see Testing and
adjusting, “Special functions of machine
monitor”.
30-101 30 D65EX, PX, WX-16

Testing and adjusting air conditioner compressor belt tension SEN05119-02
Testing and adjusting air Adjusting

conditioner compressor belt a If the deflection is out of range, adjust it
tension 1
k Stop the machine on level ground, lower 1. Loosen 4 compressor bracket mounting bolts
the work equipment to the ground, stop the (1).
work equipment lock lever in the lock posi- 2. Loosen locknut (2), turn adjustment nut (3) and
tion. adjust the belt tension.
Testing
q Press the intermediate point between air con- 3. After adjusting the belt tension to the standard
ditioner pulley and drive pulley with a finger value, tighten locknut (2), then tighten 4 com-
and measure deflection (a). pressor bracket mounting bolts (1).
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Defection (a): 15 – 18 mm
D65EX, PX, WX-16 30-101 31

SEN05119-02 Replacing alternator belt
Replacing alternator belt 1
a The auto-tensioner is provided for the alterna-

tor belt. Thus, testing and adjustment of the
belt is usually not necessary.
a Disconnect air conditioner compressor belt
before replacing the alternator belt.

tion.
1. Open engine hood right cover (1) and remove

side cover (2). 3. Replace the alternator belt (4).
q Check each pulley for breakage and
crack.
2. Insert a wrench [1] to the portion (A) (width

across flats T12.7 mm) of the tensioner
assembly (3), and rotate it to the opposite to
the winding-up direction to decrease the alter-
nator belt (4) tension.
k Make sure that the wrench [1] is
secured at the portion (A) of the ten-
sioner assembly (3) before rotating it.
(The spring of the tensioner assembly
(3) is strong. If the wrench [1] is loosely
inserted, the wrench [1] may acciden-
tally come off while being rotated and it
is extremely dangerous.)
k After removing the alternator belt (4),
return the tensioner assembly (3)
slowly with care.
k Be careful not to get your fingers
caught between the pulley and alterna-
tor belt (4) during work.
30-101 32 D65EX, PX, WX-16

Adjusting fuel control dial and decelerator pedal SEN05119-02
Adjusting fuel control dial and decelerator pedal 1

tion.
1. Outline of fuel control system

q The following signals are inputted as rota-
tion command signals to the engine con-
troller.
q Decelerator pedal potentiometer sig-
nal
q 3rd throttle signal
q The engine controller controls the fuel
control system of the engine (CRI system) [1] Fuel control dial
according to the lowest engine speed sig- [2] Engine controller
nal among those input signals. [3] Power train controller
q Adjust the deceleration slow speed by [4] Decelerator pedal
adjusting the decelerator pedal stopper [5] Decelerator potentiometer
bolt. [6] Engine (CRI system)
[7] 3rd throttle signal
D65EX, PX, WX-16 30-101 33

SEN05119-02 Handling controller high-voltage circuit
2. Preparation work Handling controller high-voltage

Test the engine speed with the "Adjustment" circuit 1
function in the service mode of the machine
monitor. 1. Disconnection or connection of the connector
q Adjustment code: 0530 (Stall mode) between the engine controller and engine must
a For the operating method, see "Special be done after turning off the starting switch.
functions of machine monitor (EMMS)".
2. It is prohibited to start the engine when T-
adapter is inserted or connected, for trouble-
shooting purpose, to the connector between
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
3. Adjusting decelerator pedal speed

With the fuel control dial in the high idle posi-
tion (MAX), press decelerator pedal (1) to stop-
per bolt (2) and check that the decelerator
pedal speed is normal.
q Decelerator pedal speed: 1,000 ± 25 rpm
a If the decelerator pedal speed is abnor-
mal, adjust installed dimension (a) of stop-
per bolt (2).
q Standard installed dimension (a) of stop-
per bolt: 22.0 mm
4. Adjusting high idle speed

With the fuel control dial in the high idle posi-
tion (MAX), release decelerator pedal (1) and
check that the high idle speed is normal.
q High idle speed: 2,100 ± 50 rpm
a If the high idle speed is abnormal, adjust it
q When the engine speed is above 2,000
rpm:
Lower the engine speed below 1,950 rpm
temporarily with stopper bolt (3) to elimi-
nate the play of the decelerator pedal, and
then adjust the engine speed to the high
idle.
q When the engine speed is below 2,000
rpm:
Adjust the engine speed to the high idle
speed with stopper bolt (3).
q Standard installed dimension (b) of stop-
per bolt: 28.0 mm
5. Work after adjustment

After finishing all adjustment, return the
removed parts.
30-101 34 D65EX, PX, WX-16

Handling controller high-voltage circuit SEN05119-02
D65EX, PX, WX-16 30-101 35

SEN05119-02

©2011 KOMATSU
All Rights Reserved
30-101 36
SEN05120-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Testing power train oil pressure ...................................................................................................................... 3
Adjusting transmission output shaft speed sensor (replacement procedure) ................................................. 8
Simple test procedure for brake performance................................................................................................. 9
Adjusting brake pedal ................................................................................................................................... 10
Adjusting parking brake lever........................................................................................................................ 12
Emergency escape method when power train has trouble ........................................................................... 14
Adjusting clearance of idler........................................................................................................................... 17
Adjusting clearance of idler (without idler support automatic thrust adjustment) .......................................... 18
Inspecting wear of sprocket .......................................................................................................................... 19
Testing and adjusting track shoe tension ...................................................................................................... 20
Testing and adjusting work equipment and HSS oil pressure ....................................................................... 21
Testing control circuit basic pressure ............................................................................................................ 24
Testing PPC valve output pressure............................................................................................................... 25
Adjusting work equipment PPC valve play ................................................................................................... 27
Testing internal leakage of work equipment cylinder .................................................................................... 31
Bleeding air from work equipment cylinder ................................................................................................... 32
Releasing residual pressure from work equipment cylinder ......................................................................... 32
Checking parts which caused hydraulic drift of blade or ripper..................................................................... 33
Adjusting work equipment lock lever............................................................................................................. 34
Adjusting work equipment lock lever (FRP canopy specification)................................................................. 35
Testing fan speed.......................................................................................................................................... 37
Testing fan circuit oil pressure....................................................................................................................... 38
Bleeding air from fan pump........................................................................................................................... 39
D65EX, PX, WX-16 30-102 1

SEN05120-02
Bleeding air from HSS pump......................................................................................................................... 40

Adjusting straight tiltdozer ............................................................................................................................. 41
Adjusting play of blade center ball ................................................................................................................ 43
Adjusting operator’s cab................................................................................................................................ 44
30-102 2 D65EX, PX, WX-16

Testing power train oil pressure SEN05120-02
Testing power train oil pressure 1
a Testing tools for power train oil pressure

1
Hydraulic tester
K 2 799-401-2320
(1 MPa {10 kg/cm2})
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
k Stop the machine on a level place, lower

the work equipment to the ground, and set
the parking brake lever and work equip-
ment lock lever in the lock position. 1. Measuring brake pressure (BR)
a Measure the power train oil pressure under the 1) Remove oil pressure pickup plug (1) and
following condition. attach nipple K3, and connect oil pressure
q Power train oil temperature: Within operat- gauge [1] of hydraulic tester K1.
ing range a Use an oil pressure gauge of 6 MPa
a The centralized power train oil pressure pickup {60 kg/cm2}.
ports are installed inside the inspection cover
(1) on the right side of the operator cab.
2) Run the engine and set the parking brake

lever in free position.
a List of oil pressure measuring points and 3) Measure the oil pressure while the engine
gauges to be used. is running at low idle and high idle.
a Check that the oil pressure lowers to
Gauge 0 when the brake pedal is depressed
No. Stamp Oil pressure reading
(MPa {kg/cm2}) or the parking brake lever is set in the
1 BR Brake pressure 6.0 {60} lock position.
Torque converter inlet
2 IN 2.5 {25}
pressure
Torque converter outlet
3 OUT 1.0 {10}
pressure
Transmission main relief
4 MAIN 6.0 {60}
pressure
D65EX, PX, WX-16 30-102 3

SEN05120-02 Testing power train oil pressure
4) After finishing measurement, remove the 3. Measuring torque converter outlet pressure
measuring instrument and reinstall the (OUT)
removed parts. 1) Remove oil pressure pickup plug (3) and
attach nipple K3, and connect hydraulic
2. Measuring torque converter inlet pressure tester K1.
(IN) a Use an oil pressure gauge of 1 MPa
1) Remove oil pressure pickup plug (2) and {10 kg/cm2}.
attach nipple K3, and connect oil pressure
gauge [1] of hydraulic tester K1.
a Use an oil pressure gauge of 2.5 MPa
{25 kg/cm2}.
2) Run the engine and set the PCCS lever in

the full neutral position.
3) Measure the oil pressure while the engine
is running at low idle and high idle.

measuring instrument and reinstall the
removed parts.

removed parts.
30-102 4 D65EX, PX, WX-16

4. Measuring transmission main relief pres- 5. Measuring clutch pressure

sure (MAIN) q Remove the operator seat assembly and
1) Remove oil pressure pickup plug (4) and measure the clutch pressure from the top
attach nipple K3, and connect oil pressure of the floor frame.
gauge [1] of hydraulic tester K1. a List of oil pressure measuring points and
a Use an oil pressure gauge of 6 MPa gauges to be used.
{60 kg/cm2}.
Gauge
No. Measuring point
(MPa {kg/cm2})
Transmission forward clutch
5 6 {60}
pressure
Transmission reverse clutch
6 6 {60}
pressure
Transmission 1st clutch
7 6 {60}
pressure
Transmission 2nd clutch
8 6 {60}
pressure
Transmission 3rd clutch
9 6 {60}
pressure
Torque converter lockup
10 2.5 {25}
clutch pressure


removed parts.
D65EX, PX, WX-16 30-102 5

SEN05120-02 Testing power train oil pressure
1) Measuring transmission forward clutch k Since the torque converter is

pressure stalled, keep pressing the brake
1] Remove oil pressure pickup plug (5) pedal securely.
and attach nipple K3, and connect oil k Do not run the engine at high idle
pressure gauge [1] of hydraulic tester while measuring.
K1. 5] After finishing measurement, remove
a Use an oil pressure gauge of 6 the measuring instrument and rein-
MPa {60 kg/cm2}. stall the removed parts.
2] Run the engine and set the parking 4) Measuring transmission 2nd clutch pres-
brake lever in free position. sure
3] With the brake pedal depressed, set 1] Remove oil pressure pickup plug (8)
the PCCS lever in the “forward” and and attach nipple K3, and connect oil
3rd gear speed position. pressure gauge [1] of hydraulic tester
4] Measure the oil pressure while the K1.
engine is running at high idle. a Use an oil pressure gauge of 6
k Since the torque converter is MPa {60 kg/cm2}.
stalled, keep pressing the brake 2] Run the engine and set the parking
pedal securely. brake lever in free position.
5] After finishing measurement, remove 3] With the brake pedal depressed, set
the measuring instrument and rein- the PCCS lever in the “forward” and
stall the removed parts. 2nd gear speed position.
2) Measuring transmission reverse clutch 4] Measure the oil pressure while the
pressure engine is running at low idle.
1] Remove oil pressure pickup plug (6) k Since the torque converter is
and attach nipple K3, and connect oil stalled, keep pressing the brake
pressure gauge [1] of hydraulic tester pedal securely.
K1. k Do not run the engine at high idle
a Use an oil pressure gauge of 6 while measuring.
MPa {60 kg/cm2}. 5] After finishing measurement, remove
2] Run the engine and set the parking the measuring instrument and rein-
brake lever in free position. stall the removed parts.
3] With the brake pedal depressed, set 5) Measuring transmission 3rd clutch pres-
the PCCS lever in the “forward” and sure
3rd gear speed position. 1] Remove oil pressure pickup plug (9)
4] Measure the oil pressure while the and attach nipple K3, and connect oil
engine is running at high idle. pressure gauge [1] of hydraulic tester
k Since the torque converter is K1.
stalled, keep pressing the brake a Use an oil pressure gauge of 6
pedal securely. MPa {60 kg/cm2}.
5] After finishing measurement, remove 2] Run the engine and set the parking
the measuring instrument and rein- brake lever in free position.
stall the removed parts. 3] With the brake pedal depressed, set
3) Measuring transmission 1st clutch pres- the PCCS lever in the “forward” and
sure 3rd gear speed position.
1] Remove oil pressure pickup plug (7) 4] Measure the oil pressure while the
and attach nipple K3, and connect oil engine is running at low idle.
pressure gauge [1] of hydraulic tester k Since the torque converter is
K1. stalled, keep pressing the brake
a Use an oil pressure gauge of 6 pedal securely.
MPa {60 kg/cm2}. k Do not run the engine at high idle
2] Run the engine and set the parking while measuring.
brake lever in free position. 5] After finishing measurement, remove
3] With the brake pedal depressed, set the measuring instrument and rein-
the PCCS lever in the “forward” and stall the removed parts.
1st gear speed position.
4] Measure the oil pressure while the
engine is running at low idle.
30-102 6 D65EX, PX, WX-16

6) Measuring torque converter lockup clutch 3] Set the gearshift mode and preset
pressure range as follows with the gearshift
1] Remove oil pressure pickup plug (10) mode selector switch and shiftup or
and attach nipple K3, and connect oil shiftdown switch.
pressure gauge [1] of hydraulic tester q Gearshift mode:
K1. Auto gearshift (Dozing)
a Use an oil pressure gauge of 2.5 q Preset range: F1-R1
MPa {25 kg/cm2}. 4] Set the machine monitor to Monitor-
2] Start the engine and raise the ing function of the service mode.
machine with the blade and ripper to q Monitoring code:
a height where you can run the track 31520 T/M Fill Sw Input 2
shoe idle. a For the operating method, see
k After raising the machine, set the “Special functions of machine
work equipment lock lever in the monitor (EMMS)”.
LOCK position.
5] Set the PCCS lever in the reverse

position to run the track shoe idle.
k Take care not to get caught in a
rotating part of the track shoe dur-
ing measurement.
a Keep the steering system in neu-
tral.
6] While running the engine at high idle,
when L/U Fill Sw in the monitoring
item is turned ON, measure the
lockup clutch pressure.
7] After finishing measurement, remove
the measuring instruments and return
the removed parts.
D65EX, PX, WX-16 30-102 7

SEN05120-02 Adjusting transmission output shaft speed sensor (replacement procedure)
Adjusting transmission output 3. Assembly procedure for sensor assembly

shaft speed sensor (replacement 1) Install sensor (3) to bracket (4).
3 Locknut (5):
procedure) 1
39.2 – 49.1 Nm {4 – 5 kgm}
k Stop the machine on level ground, lower a Installed dimension of sensor:
the work equipment to the ground, stop the Dimension (L) measured
engine, and set the parking brake lever and at removal ± 0.2 mm
work equipment lock lever in the LOCK 2) Pull out the sensor (3) connector through
position. the flange hole of bracket (4) and insert it
1. Remove the cover of the main frame rear, then in connector assembly (6). (Push in the
remove transmission speed sensor assembly connector securely until it clicks.)
(1) from steering case (2). 3) Install connector assembly (6) to bracket
a Before adjusting the transmission output (4).
shaft speed sensor, remove it and check 3 Bolt (7):
that its tip is free from steel chips and 4.9 – 6.9 Nm {0.5 – 0.7 kgm}
flaws, and then reinstall it. 4) Install sensor assembly (1) to steering
case (2).
2 O-ring: Grease (G2-LI)
q Standard clearance between bevel
gear and sensor end
(x): 0.84 – 1.76 mm
5) After finishing adjustment, return the
removed parts.
6) Start the engine, set the machine monitor
to the “Monitoring” function display in the
service mode, and check that the trans-
mission speed is displayed normally.
a Monitoring code:
31400 (T/M Out Speed)
a For the operation procedure, see
“Special functions of machine monitor
2. Measure installation dimension (L) of removed (EMMS)”.
sensor (3). a To rotate the transmission output
a When replacing the sensor, be sure to shaft, travel actually or travel with no
measure dimension (L). load.
30-102 8 D65EX, PX, WX-16

Simple test procedure for brake performance SEN05120-02
Simple test procedure for brake 6. Return the decelerator pedal slowly and check
performance 1
that the machine does not start when the
engine speed reaches the high idle level.
k Stop the machine on a level place, lower k Since the torque converter is stalled,
the work equipment to the ground, and set keep pressing the brake pedal securely
the parking brake lever and work equip- and keep your right foot on the deceler-
ment lock lever in the lock position. ator pedal for safety until the work is
a Carry out the simple performance test of the finished.
brake under the following condition.
q Power train oil temperature:
Within operating range
1. Set the blade and ripper in the travel position

on a level place.
2. Run the engine and set the parking brake lever

in the FREE position.
3. Set the gearshift mode and preset range as fol-

lows with the gearshift mode selector switch
and shiftup or shiftdown switch.
q Gearshift mode: Manual gearshift
q Preset range: F2-R2
4. With the engine at low idle and the brake pedal

depressed securely, set the direction of PCCS
lever in the forward position.
k If this test is carried out in the 1st gear
position, the brake will be overloaded.
Accordingly, be sure to carry out in the
2nd gear speed.
a Check that [F2] is displayed in the gear
speed display section.
a Keep the steering system in neutral.
5. Press the decelerator pedal and set the fuel

control dial in the high idle (MAX) position.
D65EX, PX, WX-16 30-102 9

SEN05120-02 Adjusting brake pedal
Adjusting brake pedal 1

tion.
a Tighten the locknuts of the rods and cables
securely, and bend the cotter pins securely.
1. Adjust the stroke (a) of brake pedal (1) with the
installation dimension (b) of bumper (2).
q Pedal stroke (a): 68 mm
q Installation dimension (b) of bumper:
23 mm
2. Adjust installation dimension (c) of rod (3) on

the valve side, then connect to brake valve
lever (4).
q Rod installation dimension (c): 938 mm
a Fully screw in joint (5) to the valve side.
3. Adjust installation dimension (d) of rod (6) on

the pedal side, then connect to brake pedal (1).
q Rod installation dimension (d): 175 mm
4. Lightly push rod (3) on the valve side toward

the rear of the machine, and turn only joint (7)
to connect rods (3) and (6).
a Push rod (3) with a force of about 9.8 –
19.6 N {1 – 2 kg}.
3 Joint: 34.3 – 58.8 Nm {3.5 – 6.0 kgm}
30-102 10 D65EX, PX, WX-16

Adjusting brake pedal SEN05120-02
5. With brake pedal (1) released, adjust its play

with dimension (e) between the pins of rod
assembly (8).
q Play of pedal: 3 – 8 mm (center of pedal)
q Dimension (e) between pins of rod assem-
bly: 1,143 mm
a Adjust by turning joints (5) and (7) in the
same direction at the same time.
6. With brake pedal (1) released, check that

brake pedal (1) is in contact with damper (2).
7. Checking brake oil pressure

Oil pressure
Remarks
MPa {kg/cm2}
Brake Engine at full
Min. 2.55 {Min. 26}
released throttle
Brake applied 0
8. After adjusting the pedal, turn the starting

switch to the ON position, set the machine
monitor to “ADJUSTMENT” function in the ser-
vice mode, and perform adjustment.
a Adjustment code: 0005
(Brake pedal potentiometer initial correc-
tion)
a For the operating method, see “Special
D65EX, PX, WX-16 30-102 11

SEN05120-02 Adjusting parking brake lever
Adjusting parking brake lever 1
k Stop the machine on level ground, lower 3. Checking brake oil pressure
the work equipment to the ground, stop the Check that the brake oil pressure is as follows
engine, and set the parking brake lever and when the parking brake lever is set in free and
work equipment lock lever in the lock posi- lock positions.
tion. a For the method of measuring the brake oil
1. Assembling and installing lever assembly pressure, see “Measuring power train oil
1) Assemble lever assembly (1) and adjust pressure”.
the operation of limit switch (2). q Lock position: 0,
a When assembling the lever assembly, Free position: Specified pressure
disconnect the parking brake cable
from the lever.
q When lever is pulled up: OFF, low-
ered: ON
q Operation stroke of limit switch: 3 mm
2) Install lever assembly (1).
2. Adjusting installation length of parking

brake cable
1) Connect parking brake cable (3) to the
lever side and valve side, and adjust
installation dimensions (a) and (b).
q Cable installation dimension (a):
148.5 mm
q Cable installation dimension (b):
166 mm
2) Operate parking brake lever (4) between
the free and lock positions, and adjust rod
end (6) so that spool stroke (h) of brake
valve (5) is normal.
q Spool stroke (h): 13.3 mm
30-102 12 D65EX, PX, WX-16

Adjusting parking brake lever SEN05120-02
4. Checking limit switch

1) Turn the starting switch ON and set the
machine monitor to Monitoring function of
the service mode.
a Monitoring code:
40905 T/M Sw Input 1
a For the operating method, see “Spe-
(EMMS)”.
2) Check that the limit switch signal is input

normally when parking brake lever (4) is
set in the FREE position and LOCK posi-
tion.
q FREE position:
Travel lock NC OFF, Travel lock NO
ON
q LOCK position:
Travel lock NC ON, Travel lock NO
OFF
D65EX, PX, WX-16 30-102 13

SEN05120-02 Emergency escape method when power train has trouble
Emergency escape method when 2) Open the battery cover of the machine left
power train has trouble 1
and connect wiring harness [2] to connec-
tor PL1 (1).
a Devices used for emergency escape a The male housing and female hous-
Symbol Part No. Part name ing of connector PL1 are fixed with
screws.
19M-06-32820 Switch assembly
1 a Connect the wiring harness to both
14X-06-52930 Wiring harness male side and female side of connec-
7824-66-6430 Prolix resistance tor PL1.
2
L 7827-10-1520 Prolix resistance
3 790-190-1601 Pump assembly
799-101-5220 Nipple (10 x 1.25 mm)
4
07002-11023 O-ring
1. Emergency escape method by the switch

box (Use L1)
a If the machine cannot be moved because
of a trouble in the electric system of the
power train control unit (travel direction,
gear speed, steering), carry out the emer-
gency escape according to the following
procedure.
a The engine must be able to start during 3) Remove the cover (2) on the front of the
implementing this procedure. left console box.
a If the engine cannot be started, see
“Emergency escape method with brake
releasing device”.
1) Connect switch assembly [1] and L2 to
wiring harness [2] of emergency escape
device L1.
k To prevent the machine from start-
ing suddenly, set all the gear speed
switches of switch assembly [1] to
OFF position and the direction
switch in P position.
30-102 14 D65EX, PX, WX-16

Emergency escape method when power train has trouble SEN05120-02
4) Disconnect neutral safety relay NSF (3) 5) Run the engine and set the parking brake
and connect pins [3] and [5] of the connec- lever in free position.
tor on the wiring harness side (female). 6) Operate switch assembly [1] and move
k If the engine is started by this the machine to a safe place.
method, the neutral safety function a The electrical circuit of the gear
does not work. Accordingly, before speed switches is configured so that
starting the engine, set the parking the switch on the lower gear speed is
brake lever in lock position and set operated first.
the PCCS lever in full neutral posi- k Take care that the L.H. and R.H.
tion. steering directions are opposite
k Start the engine by this method when reverse.
only in an emergency. If the engine
does not start in other cases, be
sure to carry out troubleshooting
and repair the trouble.
7) After moving the machine, remove the

instruments used and return the removed
parts.
a Check that the seal at the joint of con-
nector PL1 is not projected or
removed and then tighten the screws
to the specified torque.
3 Screw of connector PL1:
2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
D65EX, PX, WX-16 30-102 15

SEN05120-02 Emergency escape method when power train has trouble
2. Emergency escape method with brake 3) Remove inspection plug for brake oil pres-
releasing device (Use L3) sure which is located within the inspection
a If the engine cannot be started and the cover on the right outer side of the opera-
parking brake cannot be released, carry tor cab.
out the emergency escape according to 4) Install nipple L4 and connect hose [2] of
the following procedure. pump assembly L3.
a Operate after putting a block, etc. on the
crawler as a lock so that machine cannot
move on a downhill slope.
1) Assemble pump assembly L3.
2) Install volume pump [1] of pump assembly
L3 to the left outside of the operator cab.
5) Turn the starting switch on and set the

parking brake lever in free position.
6) Operate the vacuum pump to raise the
brake releasing oil pressure to the initial
pressure.
q Initial pressure: Approx. 2.74 MPa
{Approx. 28 kg/cm2}
a Since an accumulator is installed in
the circuit, the handle must be oper-
ated 30 – 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure low-
ers gradually because of internal
leakage and the brake is applied
again about 1 minute after. Therefore,
work immediately.
a If the brake releasing pressure lowers
to about 1.57 MPa {16 kg/cm 2 }, the
brake is applied. In this case, operate
the volume pump again to raise the
brake releasing pressure to the initial
pressure.
8) When disconnecting the hose after finish-
ing the work, loosen the screw slowly and
do not stand in the spouting direction of
the oil.
30-102 16 D65EX, PX, WX-16

Adjusting clearance of idler SEN05120-02
Adjusting clearance of idler 1
a If the lateral guide plates of the idler have worn

excessively and the idler ran out slants, adjust
the clearance of the idler according to the fol-
lowing procedure.
tion.
Adjustment procedure
1) Drive the machine 1 – 2 m on flat ground,
then measure clearance (a) between the
track frame and guide plate (4 places; left,
right, inner and outer sides).
2) If clearance (a) is larger than 4 mm,
loosen bolt (1) and reduce shim (2).
q Standard clearance (a) on each side:
0.5 – 1.0 mm
q Shim thickness: 1.0 mm
D65EX, PX, WX-16 30-102 17

SEN05120-02 Adjusting clearance of idler (without idler support automatic thrust adjustment)
Adjusting clearance of idler (without idler support automatic thrust

adjustment) 1
a If the lateral guide plates of the idler have worn

excessively and the idler ran out slants, adjust
the clearance of the idler according to the fol-
lowing procedure.
tion.
Adjustment procedure
1) Drive the machine 1 – 2 m on flat ground,
then measure clearance (a) between the
track frame and guide plate (4 places; left,
right, inner and outer sides).
2) If clearance (a) is larger than 4 mm,
loosen bolt (1) and reduce shim (2).
q Standard clearance (a) on each side:
0.5 – 1.0 mm
q Shim thickness: 1.0 mm
30-102 18 D65EX, PX, WX-16

Inspecting wear of sprocket SEN05120-02
Inspecting wear of sprocket 1
a Use the “Full-scale dimensions drawing of

sprocket profile” in the topic “Sprocket” in the
chapter “Structure, function and maintenance
standard” as a gauge for measuring wear of
the sprocket.
a Make a copy of the “Full-scale dimensions
drawing of sprocket profile” on a transparent
paper or sheet and apply it directly to the
sprocket to see if the sprocket can be used.
D65EX, PX, WX-16 30-102 19

SEN05120-02 Testing and adjusting track shoe tension
Testing and adjusting track shoe Adjusting

tension 1 a If the track shoe tension is abnormal, adjust it
k
Stop the machine on level ground, lower
1. Remove cover (1).
2. When the tension is too high
Loosen plug (2) to discharge the grease.
k Since the high-pressure grease may
tion.
spout out, do not loosen the plug more
Testing than 1 turn.
1. Drive the machine slowly on a level place, then 3 Plug: 59 – 88 Nm {6 – 9 kgm}
stop it.
a Do not apply the brake when stopping. 3. When tension is low
Add grease through grease fitting (3).
2. Place straight steel bar [1] between the idler a If the track shoe is not tensed well, drive
and front carrier roller and measure clearance the machine forward and in reverse
(a) between the bottom of the steel bar and slowly.
shoe grouser.
q Standard clearance (a): 20 – 30 mm
4. After finishing adjustment, return the removed

parts.
30-102 20 D65EX, PX, WX-16

Testing and adjusting work equipment and HSS oil pressure SEN05120-02
Testing and adjusting work 2. Testing main valve LS pressure

equipment and HSS oil pressure 1
Remove pressure pickup plug (1) on the
machine center side of the main valve and
a Testing and adjusting instruments for work measure the oil pressure.
equipment and HSS oil pressure a Use the following pressure gauge.
Symbol Part No. Part name Work equipment oil pressure:
60 MPa {600 kg/cm2}
1 HSS oil pressure: 60 MPa {600 kg/cm2}
M
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

work equipment lock lever in the LOCK
position.
a When measuring and adjusting the work
equipment and HSS oil pressure, remove the
control valve cover.
Testing
a Test the work equipment and HSS oil pressure
under the following condition.
ing range
a The unload pressure, work equipment oil pres-
sure, and HSS oil pressure can be checked
with the monitoring function of the service
mode of the machine monitor.
a Measure the LS pressure directly through the
pressure pickup port of the device.
1. Measuring with machine monitor

Turn the starting switch ON and set the
machine monitor to Monitoring function of the
service mode. 3. Testing unload pressure
q Monitoring code: Run the engine at high idle and measure the
70700 Hydraulic Pump Pressure 1 unload pressure with the blade control lever
a For the operating method, see “Special and ripper control lever in neutral.
functions of machine monitor (EMMS)”. a The unload pressure may be measured
with the work equipment control lever in
the lock position.
a Check unload pressure with machine
monitor.
D65EX, PX, WX-16 30-102 21

SEN05120-02 Testing and adjusting work equipment and HSS oil pressure
4. Testing work equipment oil pressure 5. Testing HSS oil pressure

1) Install nipple M2 to the LS pressure pickup 1) Install nipple M2 to the LS pressure pickup
port and connect it to oil pressure gauge port and connect it to oil pressure gauge
[1] of hydraulic tester M1. [1] of hydraulic tester M1.
2) Start the engine and set the work equip- a Measuring points of the HSS oil pres-
ment lock lever in the FREE position. sure are the same as those of the
3) Run the engine at high idle, operate the work equipment oil pressure.
blade control lever and ripper control lever 2) Start the engine, set the parking brake
to relieve each cylinder at a stroke end, lever in the FREE position, and keep
and measure the work equipment oil pres- pressing the brake pedal.
sure and work equipment LS oil pressure. 3) Run the engine at high idle, set the PCCS
a Check work equipment oil pressure lever in the right or left steering position to
with machine monitor. oil the steering circuit, and measure the
HSS oil pressure and HSS LS oil pres-
sure.
k Since the steering circuit is
relieved, keep pressing the brake
pedal securely and keep your right
foot on the decelerator pedal for
safety until the work is finished.
a Check HSS oil pressure with machine
monitor.

measuring instrument and return the
removed parts.

measuring instruments and return the
removed parts.
30-102 22 D65EX, PX, WX-16

Testing and adjusting work equipment and HSS oil pressure SEN05120-02
Adjusting 4) After finishing measurement, check the

1. Adjusting unload pressure HSS oil pressure according to the above
a The unload pressure cannot be adjusted. measuring method.
2. Adjusting work equipment oil pressure

a Work equipment oil pressure cannot be
adjusted.
3. Adjusting HSS oil pressure

a If the HSS oil pressure is abnormal, adjust
it with HSS LS relief valve (2) according to
the following procedure.
1) While fixing adjustment screw (6), loosen

locknut (7).
2) Adjust the pressure by rotating adjustment
screw (6).
a If the adjustment screw is
q rotated to the right, the pressure
is heightened.
q rotated to the left, the pressure is
lowered.
a Quantity of adjustment per turn of
adjustment screw:
Approx. 15.1 MPa
{Approx. 154 kg/cm2}
3) While fixing adjustment screw (6), tighten
locknut (7).
3 Locknut:
68.6 – 78.5 Nm {7 – 8 kgm}
D65EX, PX, WX-16 30-102 23

SEN05120-02 Testing control circuit basic pressure
Testing control circuit basic 3. Install oil pressure pickup adapter N2 and con-
pressure 1
nect the disconnected hose again.
a Instruments for testing and adjusting control 4. Install nipple [1] of hydraulic tester N1 and con-
circuit basic pressure nect oil pressure gauge [2].
Symbol Part No. Part name a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.
1
N 790-261-1204 Digital type hydraulic tester
2 799-401-3100 Adapter (size 02)
a The control circuit main pressure is the pres-

sure lowered by the self pressure reducing
valve. It is used commonly for blade PPC, HSS
pump control, fan pump control, steering EPC
and ripper PPC (if equipped).
Measuring
tion. 5. Run the engine at high idle and set the blade
a Measure the control circuit basic pressure lever and ripper lever in neutral and measure
under the following condition. the oil pressure.
ing range
1. Remove the control valve cover at the right

side of the operator cab.
2. Disconnect hose (1).

parts.
Adjusting
a The self pressure reducing valve cannot be
adjusted.
30-102 24 D65EX, PX, WX-16

Testing PPC valve output pressure SEN05120-02
Testing PPC valve output 3. Install oil pressure pickup adapter O2 and con-
pressure 1
nect the disconnected hose again.
a Testing instruments for PPC valve output pres- 4. Install nipple [1] of hydraulic tester O1 and con-
sure nect oil pressure gauge [2].
1
O 790-261-1204 Digital type hydraulic tester
2 799-401-3100 Adapter (size 02)

tion.
a Before measuring the PPC valve output pres-

sure, check that the control circuit basic pres-
sure is normal.
a Measure the PPC valve output pressure under 5. Run the engine and set the work equipment
the following condition. lock lever in the free position.
ing range 6. Run the engine at high idle and operate the
control lever of the circuit to be measured and
1. Remove the control valve cover at the right measure the oil pressure.
side of the operator cab. a Measure the oil pressure with the lever at
a stroke end.
2. Disconnect PPC valve output pressure hose a When measuring the blade circuit, operate
(1). the lever until the blade floats.
a For the circuits to be measured, see the
drawing on the next page.

parts.
D65EX, PX, WX-16 30-102 25

SEN05120-02 Testing PPC valve output pressure
1. Main valve A. Blade LEFT TILT

2. Self pressure reducing valve B: Blade LOWER
3. PPC lock valve C. Ripper RAISE
4. Blade PPC valve D. Ripper LOWER
5. Ripper PPC valve (If equipped) E. Blade RAISE
F. Blade RIGHT TILT
30-102 26 D65EX, PX, WX-16

Adjusting work equipment PPC valve play SEN05120-02
Adjusting work equipment PPC valve play 1
2-axis PPC valve

(Part R in hatched area must not be disassembled)
k Stop the machine on level ground, lower 1. Measuring play in directions of ports P3
the work equipment to the ground, stop the and P4
engine, and set the parking brake lever and Measure play (x) in the neutral position of the
work equipment lock lever in the lock posi- lever at 240 mm from the turn center of the
tions. lever.
a If the blade lever end play is large, adjust the (x): Max. 24 mm
PPC valve according to the following proce- a If the play is out of the above range, joint
dure. (1) may be worn. In this case, replace joint
a The ripper valve cannot be adjusted. (1).
D65EX, PX, WX-16 30-102 27

SEN05120-02 Adjusting work equipment PPC valve play
Replacement procedure for joint (1) 3. Applying grease

1) Remove boot (2), nut (3), disc (4) and nut 1) Apply grease to the sliding part of joint (1)
(5). and contact parts of disc (4) and piston
2) Replace joint (1). (6).
a Install joint (1) to valve body (7) 2 Grease (G2-LI)
according to the following procedure. 2) Quantity of grease to be applied

1] Thoroughly degrease and dry the 1] Sliding part of joint (1): 7 – 10 ml/
threaded portion and body of the periphery
joint. 2] Contact parts of disc (4) and piston
2] Apply a drop (about 0.02 g) of (6) (4 places): 0.3 – 0.8 ml/place
LOCTITE (No. 262) each to 2
places at dimension (a) from the 4. Install boot (2).
threaded portion of the body end.
q Dimension (a): 5 – 7 mm
3 Joint (1): 39 – 49 Nm {4 – 5 kgm}

3) Install nut (5) and disc (4).
a Take care of the installed direction of
disc (4).
(Take care of the shape of part Q.)
4) Install nut (3).
2. Adjusting lever end play

1) Remove boot (2) and nut (3).
2) Tighten disc (4) and tighten nut (3) tempo-
rarily.
a Take care of the installed direction of
disc (4).
(Take care of the shape of part Q.)
3) Measure the lever end play.
q Measuring play in directions of
ports P3 and P4
Measure play (x) in the neutral posi-
tion of the lever at 240 mm from the
turn center of the lever.
(x): 0.6 – 3.6 mm
q Measuring play in direction of port
P1 (Full stroke)
(y): 0.03 – 0.3 mm
4) Tighten nut (3).
a Fix disc (4) and tighten nut (3).
3 Nut (3):
93.1 – 112.7 Nm {9.5 – 11.5 kgm}
30-102 28 D65EX, PX, WX-16

Adjusting work equipment PPC valve play SEN05120-02
3-axis PPC valve (For power angle tiltdozer)

(Part R in hatched area must not be disassembled)
1. Measuring play in directions of ports P1

and P2
Measure play (x) in the neutral position of the
lever at 240 mm from the turn center of the
lever.
(x): Max. 24 mm
a If the play is out of the above range, joint
(1) may be worn. In this case, replace joint
(1).
Replacement procedure for joint (1)

1) Remove boot (2), nut (3) and disc assem-
bly (4).
2) Replace joint (1).
a Install joint (1) to valve body (6) according 3 Joint (1): 39 – 49 Nm {4 – 5 kgm}
to the following procedure.
1] Thoroughly degrease and dry the 3) Install nut (3) and disc assembly (4).
threaded portion and body of the joint.
2] Apply a drop (about 0.02 g) of LOC-
TITE (No. 262) each to 2 places at
dimension (a) from the threaded por-
tion of the body end.
D65EX, PX, WX-16 30-102 29

SEN05120-02 Adjusting work equipment PPC valve play
2. Adjusting lever end play

1) Remove boot (2) and nut (3).
2) Tighten disc assembly (4) and tighten nut
(3) temporarily.
3) Measure the lever end play.
q Measuring play in directions of
ports P1 and P2
Measure play (x) in the neutral posi-
tion of the lever at 240 mm from the
turn center of the lever.
(x): Max. 2.4 mm
4) Tighten nut (3).
3 Nut (3):
98 – 127 Nm {10 – 13 kgm}
3. Applying grease
1) Apply grease to the sliding part of joint (1)
and contact parts of disc (4) and piston
(5).
2 Grease (G2-LI)
2) Quantity of grease to be applied
1] Sliding part of joint (1): 7 – 10 ml/
periphery
2] Contact parts of disc (4) and piston
(5) (4 places): 0.3 – 0.8 ml/place
4. Install boot (2).
30-102 30 D65EX, PX, WX-16

Testing internal leakage of work equipment cylinder SEN05120-02
Testing internal leakage of work q Hose (2): Ripper lift cylinder

equipment cylinder 1
Plug: 07376-70522 (Size #05)
O-ring: 02896-11015 (Size #05)
a Testing instruments for leakage of work equip-
ment cylinder
Commercially
P Measuring cylinder
available

position.
a Measure the internal leakage of work equip-
ment cylinder under the following condition.
q Hydraulic oil temperature: 45 – 55°C
a Since the blade lift cylinder and blade angle
cylinder (for power angle tilt dozer) is equipped
with a piston valve, its internal leakage cannot
be measured.
1. Extend the cylinder to be measured to the

stroke end and set the machine in the measur-
ing position.
1) Blade tilt cylinder
Lower the blade tip to the ground.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper
to the end.
3. Run the engine at high idle and apply the relief
pressure to the cylinder bottom side.
2. Disconnect hoses (1), (2) on the head side of
q Blade tilt cylinder:
the tested cylinder and stop the control valve
Operate to tilt blade to left.
side with a plug.
q Ripper lift cylinder:
a When working on the blade tilt cylinder
Operate to lower ripper.
hoses, remove the hose cover (3) of the
frame.
k Take care not to disconnect the hoses
4. After 30 second, measure leakage in 1 minute
with measuring cylinder P.
on the bottom side.
q Hose (1): Blade tilt cylinder
5. After finishing measurement, return the
Plug: 07376-70315 (Size #03)
removed parts.
O-ring: 02896-11009 (Size #03)
a Bleed air from the cylinder circuit. For
details, see “Bleeding air from work equip-
ment cylinder”.
D65EX, PX, WX-16 30-102 31

SEN05120-02 Bleeding air from work equipment cylinder
Bleeding air from work equipment Releasing residual pressure from

cylinder 1 work equipment cylinder 1
a If the work equipment cylinder is removed and a When disconnecting the piping between the
installed or its piping is disconnected and con- control valve and work equipment cylinder,
nected, bleed air from its circuit according to release the residual pressure from the circuit
the following procedure. according to the following procedure.
a Before performing the following operation, k Stop the machine on level ground, lower
check that the hydraulic oil level is normal. the work equipment to the ground, stop the
1. Run the engine at low idle for about 5 minutes. work equipment lock lever in the LOCK
position.
2. While running the engine at low idle, extend
and retract the cylinder to be bled 4 – 5 times. 1. Loosen oil filler cap (1) of the hydraulic tank
a Move the piston rod to about 100 mm gradually to release the residual pressure from
before the stroke end and never relieve the tank.
the oil.
3. While running the engine at high idle, carry out

the operation in step 2.
4. While running the engine at low idle, move the

cylinder to the stroke end to relieve the oil.
2. Turn the starting switch ON and set the work

equipment lock lever in the FREE position.
3. Operate the blade control lever and ripper

control lever to each direction.
a If the control lever is operated 2 – 3 times,
the residual pressure in the accumulator is
released.
4. Run the engine at low idle for about 10 sec-

onds to increase the pressure in the accumula-
tor, then stop it.
5. Repeat steps 2 – 4 above 2 – 3 times.
30-102 32 D65EX, PX, WX-16

Checking parts which caused hydraulic drift of blade or ripper SEN05120-02
Checking parts which caused 3) Ripper lift cylinder

hydraulic drift of blade or ripper 1
Tense the ripper to push up the rear of the
machine.
a When a hydraulic drift of blade or ripper
occurred, check if the parts causing the drift is
located in cylinder packing side or in control
valve side according to the following proce-
dure.
1. Stop the engine with the cylinder at the follow-

ing positions.
1) Blade lift cylinder
Tense the blade to push up the front of the
machine.
a Do not extend the blade lift cylinder to
the stroke end since it is equipped
with the piston valve.
2. Turn the starting switch ON and set the work

equipment lock lever in the FREE position.
3. Move the control lever of cylinder to be

checked to the direction of extending cylinder
and validate the movement of cylinder.
q If the drift speed becomes faster, a cylin-
der packing is defective.
q If the speed does not change, an control
valve is defective.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumulator.
2) Blade tilt cylinder [Reference] In case of the hydraulic drift is caused

Retract the tilt cylinder to the stroke end by defective cylinder packing, the rea-
and tense blade further to push up the son why the drift speed becomes
right side of the machine. faster by above mentioned operation
is as follows:
1) When work equipment is set in the above
mentioned position, where the holding
pressure is applied to the bottom side, the
oil leaks from bottom side to head side.
Since the volume of head side is smaller
than that of bottom side by the volume of
the rod, the inner pressure of head side
rises by the oil leak from bottom side.
2) If the inner pressure of head side rises,
cylinder is balanced at certain pressure
(depending on the amount of leakage)
which is in proportion to the inner pres-
sure. Therefore, the drifting speed
becomes slower.
3) At this time, if the circuit in the head side is
opened (bottom side is closed by check
valve) to drain circuit by above mentioned
lever operation, the oil in the head side
flows into the drain circuit causing the lost
of the pressure balance. Then the drift
speed becomes faster.
D65EX, PX, WX-16 30-102 33

SEN05120-02 Adjusting work equipment lock lever
Adjusting work equipment lock lever 1
k Stop the machine on level ground, lower a Monitoring code: 70300 Blade Sw Input
the work equipment to the ground, stop the a For the operating method, see “Special
engine, and set the parking brake lever and functions of machine monitor (EMMS)”.
position.
a Tighten the locknut of the rod securely and
bend the cotter pin securely.
a When adjusting the work equipment lock lever,
remove the control valve cover.
1. Set work equipment lock lever (1) in the LOCK

position.
2. Set and install limit switch (2) to sliding surface

(a) of lever (3).
a Just set the roller of the limit switch to the
sliding surface. Do not move it.
5. Check that the limit switch signal is input nor-
3. Set work equipment lock lever (1) in the FREE
mally when work equipment lock lever (1) is
position and check that limit switch (2) oper-
set in the FREE position and LOCK position.
ates normally.
q FREE position:
q Stroke of limit switch: 2.5 – 3 mm
Work equipment lock NC OFF, Work
equipment lock NO ON
4. Turn the starting switch ON and set the
q LOCK position:
machine monitor to Monitoring function of the
Work equipment lock NC ON, Work equip-
service mode.
ment lock NO OFF
30-102 34 D65EX, PX, WX-16

Adjusting work equipment lock lever (FRP canopy specification) SEN05120-02
Adjusting work equipment lock lever (FRP canopy specification) 1
k Place the machine on a level ground, lower 5. Turn the starting switch to the ON position and
the work equipment to the ground, stop the set the machine monitor to "Monitoring" func-
engine, and set the parking brake lever and tion of the service mode.
work equipment lock lever in the LOCK a Monitoring code:
position. 70300 Blade knob switch input
a For the operation procedure of the
a Tighten the locknut of the rod securely and
machine monitor, see "Special functions of
bend the cotter pin securely. machine monitor (EMMS)".
a When adjusting the work equipment lock lever,
remove the control valve cover.
q Adjustment procedure for lock lever

1. Set lever (1) in FREE position (b).
2. At this time, adjust angle "a" to 66 degrees with
bolt (2).
3. In addition, adjust dimension B to 118.4 mm
with rod (5).
4. Set lever (1) in LOCK position (c) and adjust
dimension C to 114.5 mm with bolt (3).
q Adjustment procedure for limit switch

1. Set lever (1) in FREE position (b).
2. Touch limit switch (4) to sliding surface (A) and
6. Check that the limit switch signal is input nor-
fix it with bolt (6). mally when work equipment lock lever (1) is
a Just set the roller of the limit switch to the set in the FREE position and LOCK position.
sliding surface. Do not move it. q FREE position:
3. Set lever (1) in FREE position (b). Work equipment lock NC OFF, Work
4. Check that limit switch (4) moves by 2.5 to 3 equipment lock NO ON
mm. q LOCK position:
D65EX, PX, WX-16 30-102 35

SEN05120-02 Adjusting work equipment lock lever (FRP canopy specification)
Work equipment lock NC ON, Work equip-

ment lock NO OFF
30-102 36 D65EX, PX, WX-16

Testing fan speed SEN05120-02
Testing fan speed 1 2. Start the engine and set the machine monitor
to Adjusting function of the service mode.
a Testing instrument for fan speed a Adjustment code: 1005 (Fan 100% mode)
Symbol Part No. Part name a For the operation method, see “Special
Q 799-205-2200 Tachometer
a If this adjustment code is displayed, the
k Stop the machine on level ground, lower fan speed is kept at 100% speed in accor-
the work equipment to the ground, stop the dance wit the engine speed, regardless of
engine, and set the parking brake lever and the state of the machine.
work equipment lock lever in the lock posi- a When using this adjustment code, keep
tion. the hydraulic oil temperature above 50°C.
a Measure the fan motor speed under the follow- If the hydraulic oil temperature lowers
ing condition. below 40°C, the fan speed fluctuates.
q Hydraulic oil temperature: Min. 50°C a “FAN SPEED” of adjustment code is differ-
a Avoid measuring in direct sunlight. ent from the actual fan speed.
1. Set tachometer Q with stand [2], matching it to

reflective tape [1] stuck to fan (1).
3. While running the engine at low idle and high

idle, measure the fan speed.

parts.
D65EX, PX, WX-16 30-102 37

SEN05120-02 Testing fan circuit oil pressure
Testing fan circuit oil pressure 1
a Testing instruments for fan circuit oil pressure

1
R 2 799-401-3400 Adapter (size 05)
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring

5. Close the radiator mask.
k Before starting the engine, be sure to
tion.
a Measure the fan circuit oil pressure under the
close the radiator mask. Do not start
following condition.
the engine while the radiator mask is
q Hydraulic oil temperature: Min. 50°C
open.
1. Open the radiator mask and remove the fan
6. Start the engine and set the machine monitor
net.
to Adjusting function of the service mode.
a Adjustment code: 1005 (Fan 100% mode)
2. Disconnect supply hose (1) of the fan motor.
a For the operation method, see “Special
a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accor-
dance wit the engine speed, regardless of
the state of the machine.
a “FAN SPEED” of adjustment code is differ-
ent from the actual fan speed.
a When using this adjustment code, keep
the hydraulic oil temperature above 50°C.
If the hydraulic oil temperature lowers
below 40°C, the fan speed fluctuates.
3. Install adapter R2 and connect the discon-

nected hose again.
4. Install nipple R3 and connect it to oil pressure

gauge [2].
a When using an analog oil pressure gauge,
use one of 40 MPa {400 kg/cm2}.
30-102 38 D65EX, PX, WX-16

Bleeding air from fan pump SEN05120-02
7. While running the engine at high idle, measure Bleeding air from fan pump 1
the fan circuit oil pressure.
a If the fan pump was removed and installed or
its piping was disconnected and connected,
bleed air from the pump case according to the
a Before performing the following procedure,
check that the hydraulic oil is at the specified
level.
a Remove operator seat (1) and move it toward
the dashboard.
1. Remove the cover under the operator seat.
2. Loosen air bleeder (3) of fan pump (2) and

leave it for 15 minutes.

parts.
3. After 15 minutes, run the engine at low idle.
4. When oil flows out of air bleeder (3), tighten air

bleeder (3).
3 Bleeder: 8.8 ± 1.0 Nm {0.9 ± 0.1 kgm}
D65EX, PX, WX-16 30-102 39

SEN05120-02 Bleeding air from HSS pump
Bleeding air from HSS pump 1
a If the HSS pump was removed and installed or

its piping was disconnected and connected,
bleed air from the pump case according to the
a Before performing the following procedure,
check that the hydraulic oil is at the specified
level.
a Remove operator seat (1) and move it toward
the dashboard.
1. Remove the cover under the operator seat.
2. Loosen air bleeder (3) of HSS pump (2) and

leave it for 15 minutes.
3. After 15 minutes, run the engine at low idle.
4. Steer to the right and left alternately 2 – 3 times

each.
5. When oil flows out of air bleeder (3), tighten air

bleeder (3).
3 Bleeder: 8.8 ± 1.0 Nm {0.9 ± 0.1 kgm}
30-102 40 D65EX, PX, WX-16

Adjusting straight tiltdozer SEN05120-02
Adjusting straight tiltdozer 1
a If the blade was removed and installed or dis-

assembled and assembled, adjust it according
1. Adjusting blade tilting distance

1) After installing the blade, adjust installa-
tion dimension (A) of brace (1) by handle
(2).
q Installation dimension (A) of brace
PX EX
A
1,150 1,150
(mm)
2. Adjusting shims for blade assembly
1) After assembling the blade, adjust the
shims of tilt section (3), center section (4),
lift section (5), and trunnion section (6).
Adjustment of shims Unit: mm
Trunnion section (6)

Adjustment
Center section (4)

sections
Lift section (5)

Tilt section (3)
Check item
Clearance a b c d
Standard clearance
0.2 – 0.7 0.2 – 0.7 0.2 – 0.7 0.2 – 1.2
(Note)
Standard thickness
5 5 4 10
of shim
2) Measure right and left tilting distances Note: Play of spherical part in axial direction
(B1) and (B2).
2) Supply grease to each adjustment section
PX EX and check that each part rotates smoothly.
Right tilting 2 Adjustment sections (3), (4), (5):
distance Approx. 430 Approx. 440 Grease (G2-T)
B1 (mm)
Left tilting
distance Approx. 430 Approx. 440
B2 (mm)
3) If the tilting distances are different remark-

ably, adjust installation dimension (A) of
brace (1) according to the following proce-
dure.
q (B1) > (B2):
Increase installation dimension
(A) finely.
q (B1) > (B2):
Decrease installation dimension
(A) finely.
D65EX, PX, WX-16 30-102 41

SEN05120-02 Adjusting straight tiltdozer
3. Adjusting center brace

a Adjust the center brace tension according
1) Adjust clearance (b) of ball joint (7) with
shim (8).
q Clearance (b): 0.2 – 0.5 mm
2) Loosen bolt (9).
3) Operate the blade control lever to float the
blade.
k After operating the blade control
lever, lock it with the safety lever
securely.
4) Insert a bar in the hole of center brace
(10) and turn it in the tensing direction.
a Tension adjustment torque of center
brace (10)
3 Center brace:
24.5 – 49 Nm {2.5 – 5 kgm}
5) Installation dimension of center brace (10)

Standard dimension (C)
PX EX
C
991.5 990.5
(mm)
a Adjust center brace so that clear-

ances (e) between the track and
frame on both sides will be the same.
30-102 42 D65EX, PX, WX-16

Adjusting play of blade center ball SEN05120-02
Adjusting play of blade center ball1 7. Angle and tilt the blade and check that no
abnormal noise is heard and the blade moves
a After the blade is disassembled and assem- smoothly.
bled or transported, adjust the play of the cen- a If the blade does not move smoothly or
ter ball according to the following procedure. abnormal noise is heard, return to step 2
and select shims (5) again.
1. Install cap (1) and tighten mounting bolts (2)
and (3) without inserting any shim. 8. Tighten mounting bolts (2) and (3).
3 Cap mounting bolt:
2. Measure clearance (a) between cap (1) and 785 – 980 Nm {80 – 100 kgm}
blade (4).
3. Calculate the thickness of shims (5) to be

inserted from measured clearance (a), and
then select shims to be used.
q Thickness of shims to be inserted =
(Measured clearance (a)) + (0.5 mm)
q Thickness of provide shims: 0.5 mm, 1.0
mm
q Standard shim thickness (Reference):
8 mm (2 pieces of 0.5 mm shim and 7
pieces of 1.0 mm shim)
4. Loosen mounting bolts (2) and remove mount-

ing bolts (3).
5. Insert selected shims (5).
6. Tighten the mounting bolts (2) and (3) tempo-

rarily.
D65EX, PX, WX-16 30-102 43

SEN05120-02 Adjusting operator’s cab
Adjusting operator’s cab 1
a If the operator's cab is removed and installed

or disassembled and transported and assem-
bled in the field, test and adjust it according to
1. Measuring internal pressure of cab

a Criterion
Criterion:
Measured value X 68.6 Pa {7 mmH2O}
a Measurement condition
q Engine speed: High idle
q Fan speed: Fan 100% mode
q EXTERNAL/INTERNAL air
7) Start the engine and set the machine mon-
changeover switch:
itor to Adjusting function of the service
EXTERNAL position
mode.
q Air conditioner fan switch: High (FULL)
a Adjustment code:
1) Prepare a transparent vinyl hose.
1005 (Fan 100% mode)
q Outside diameter: 6 mm,
a For the operation method, see “Spe-
Length: 3,000 mm
2) Secure the inside end of the hose to the
(EMMS)”.
top of the back seat with a tape.
3) Remove bolt (2) (for grounding the wiring
harness) at the rear of left console box (1),
insert the opposite end of the hose in the
bolt hole, and pull it out of the battery
cover on the left side of the cab.
8) Run the engine at high idle and measure

water level difference (c) in hose [1].
q (a): Inside of cab (Pressurized)
q (b): Out of cab (Ambient pressure)
q (c): Measured value (Internal pres-
sure of cab)
4) Seal the clearance between the hole of
a If the measured value (internal pres-
bolt (2) and hose [1] with tape (3).
sure of the cab) is lower than the
5) Pour water in the hose up to about half
standard value, check the seals of the
and bend the hose in a U-shape.
holes for wiring harnesses and
6) Secure hose [1] to the outside of the cab
optional parts in the cab.
and set the water level in the vinyl hose
out of the cab to that in the cab.
30-102 44 D65EX, PX, WX-16

Adjusting operator’s cab SEN05120-02
2. Testing and adjusting door lock (damper Adjusting

rubber) 1) Loosen the mounting bolts of damper rub-
a Close the door and check the relationship ber (6).
between the operator ’s cab and door a You can remove and install the shims
(damper rubber portions). If there is any without removing the mounting bolts.
abnormality, adjust it. 2) Increase or decrease shims (7) under
damper rubber (6) to adjust the height of
Testing damper rubber (6) properly.
1) Stick adhesive tape [2] to the contact face
of damper rubber (6) of door (5).
a Check both sides, 2 pieces on each
side.
2) Open and close the door (5) 2 – 3 times.
3) Check the contact portions of adhesive
tape [2] and operator’s cab.
q Normal:
When the door is closed, the damper
rubber comes in contact lightly (No
adjustment is required).
q Abnormal:
When the door is closed, the damper
rubber does not come in contact or
comes in contact so strongly that the
3. Testing and adjusting door lock (latch and
adhesive tape is removed (Adjust-
striker)
ment is required).
a Close the door and check the relationship
between the operator ’s cab and door
(latch and striker). If there is any abnor-
mality, adjust it.
Testing
1) Move door (5) in the closing direction and
check the engaging condition of latch (8)
and striker (9).
a Check quantity of misalignment (f)
between center of latch (d) and center
of striker (e).
q Normal: Quantity of misalignment (f)
is 0.5 mm or less.
D65EX, PX, WX-16 30-102 45

SEN05120-02 Adjusting operator’s cab
Adjusting 4. Testing and adjusting open lock (latch and

1) Tighten the mounting bolts of striker (9) striker)
temporarily. Then, open and close door (5) a Check the relationship between the opera-
2 – 3 times to align latch (8) with striker tor’s cab and door (latch and striker) while
(9). the door is locked open. If there is any
2) Check the engaging of latch (8) and striker fault, adjust the open lock.
(9).
3) Tighten the mounting bolts of striker (9) Testing
securely. 1) Check the relationship between the open
4) Open and close door (5) and check that it lock latch and striker from the direction of
is locked and unlocked smoothly. (B).
a If the door is not locked or unlocked a Move the door in the opening direc-
smoothly (the operating effort of the tion to check the engagement of the
knob is large), repeat adjustment latch and striker.
from the first.
a Operating effort of door knob:
58.8 ± 19.6 N {6 ± 2 kg}
5) Apply grease to latch (8).
a If the latch dries up, the operating
e ff o r t o f t h e k n o b i s i n c r e a s e d .
Accordingly, apply sufficient grease to
the latch.
2 Latch: Grease (G2-LI)
2) Check that striker (10) is not leaning

against or from center of latch (11).
3) Check that striker (10) is aligned with cen-
ter of latch (11).
q Normal: Quantity of misalignment is
0.5 mm or less.
Adjusting
1) Loosen the mounting bolts of striker (10).
2) While setting striker (10) upright, tighten
the mounting bolts.
30-102 46 D65EX, PX, WX-16

Adjusting operator’s cab SEN05120-02
5. Testing and adjusting open lock (stopper

rubber)
a Check the relationship between the opera-
tor's cab and door (stopper rubber) while
the door is locked open. If there is any
fault, adjust the open lock.
1) Lock the door open and move it in the for-
ward and reverse directions to check that
it does not have play.
a Check both sides, 2 places on each
side.
2) Check that the operating effort of the
unlock lever is not large.
3) Loosen the locknut of stopper rubber (12)
(upper one).
4) Loosen the locknut of stopper rubber (13)
(lower one).
5) Adjust the height of stopper rubbers (12)

and (13) according to the trouble.
a If there is play, project (heighten) the
stopper rubber until the play is elimi-
nated.
a If the door is not locked easily or the
unlock lever is heavy, return (lower)
the stopper rubber in the range that
the door does not have play.
6) While fixing stopper rubbers (12) and (13),
tighten the locknuts.
D65EX, PX, WX-16 30-102 47

SEN05120-02

©2011 KOMATSU
All Rights Reserved
30-102 48
SEN05121-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Special functions of machine monitor (EMMS) ............................................................................................... 2
D65EX, PX, WX-16 30-103 1

SEN05121-02 Special functions of machine monitor (EMMS)
Special functions of machine monitor (EMMS) 1
Air conditioner specification
30-103 2 D65EX, PX, WX-16

Special functions of machine monitor (EMMS) SEN05121-02
Heater specification Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a The figure shows an example of display of
symbols and gauges in the ordinary display
mode (The contents of display depend on the
condition of the machine and oper ating
method).
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambi-
ent temperature and the condition of the bat-
tery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a fail-
ure, however.
Upper section of machine monitor (Switch sec-
tion)
[F1]: F1 function switch
a The function of each function switch is indi-
cated by graphic mark in the multi-display (a)
above that function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.
Lower section of machine monitor (Switch sec-
tion)
[1]: Numeral 1 input switch/Operation mode selec-
tor switch
[2]: Numeral 2 input switch/Gearshift mode selec-
tor switch
[3]: Numeral 3 input switch/Customize switch
[4]: Numeral 4 input switch/Buzzer cancel switch
[5]: Numeral 5 input switch
[6]: Numeral 6 input switch/Customize memory
switch
[7]: Numeral 7 input switch/Air conditioner or heat-
er switch
er switch
er switch
er switch
Switch having no numerals: Air conditioner or
heater switch
a Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display (a).
a The difference between the air conditioner
specification and heater specification is only
the functions of the switches in this section.
D65EX, PX, WX-16 30-103 3

t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
Operator mode (Outline) Service mode
5p 16 p
A Display of KOMATSU logo 5p 01 Monitoring 17 p
Mechanical system "Abnormality
A Display of screen to input password 6p 22 p
Record"
02 Abnormal- Electrical system "Abnormality
A Display of check before starting 6p 23 p
ity Record Record"
Air conditioner "Abnormality Record"/
A Display of warning after check before starting 6p 25 p
Heater "Abnormality Record"
A Display of ending of maintenance interval 6p 03 Maintenance Record 26 p
A Display of check of preset 7p 04 Maintenance Mode Change 27 p
A Display of ordinary screen 7p 05 Phone Number Entry 29 p
A Display of end screen 7p Key-on Mode 30 p
B Selection of operation mode 7p Selecting of unit 31 p
B Selection of gearshift mode 8p o 06 Default Setting of maintenance password 32 p
Special operations
B Customizing operation 8p Setting of camera 33 p

B Operation of customize memory 8p Setting of ECO display 34 p
B Operation to cancel alarm buzzer 8p 07 Adjustment 35 p
B Operation of air conditioner/heater 9p 08 PM CLINIC 49 p
Operation to display camera mode
B 9p 09 Cylinder Cut-Out 50 p
(if camera is installed)
B Operation to display clock and service meter 10 p 10 No Injection 51 p
B Check of maintenance information 10 p 11 Fuel Consumption 53 p
Setting and display of user mode
B 11 p Terminal Status 54 p
(including KOMTRAX messages for user) 12 KOMTRAX
C Display of caution monitor 12 p Settings GPS & Communication Status 55 p
C Display of action code and failure code 12 p Modem S/N 56 p
O (Special operations) 13 Service Message 57 p
Function of checking display of LCD
D 14 p
(Liquid Crystal Display)
D Function of checking service meter 14 p
D Function of changing maintenance password 14 p
a Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
30-103 4 D65EX, PX, WX-16

t Operator mode (Outline) a Display pattern of operator mode

a Only outline of the operator mode is described The contents of display from the time when
in this section. For details of contents/operation starting switch is turned ON to the time when
of each function/display, see the "Structure, screen changes to ordinary screen depends on
function and maintenance standard, or Opera- the setting and condition of the machine.
tion and Maintenance Manual". a: When engine start lock is set effective
a The followings are the displays or functions of b: When engine start lock is set ineffective
the operator mode explained in this section c: When there is abnormal item in check-
(including some items which need special before-starting items
operations). d: When there is maintenance item which is
not maintained after specified interval
Display pattern
Display of KOMATSU logo
a b c d
When the starting switch is turned ON, the
Display of KOMATSU logo 1 1 1 1
KOMATSU logo is displayed for 2 seconds.
Display of screen to input password 2 – – – After the KOMATSU logo is displayed for 2 sec-
Display of check before starting 3 2 2 2 onds, the screen changes to "Display of screen to
Display of warning after check before input password" or "Display of check before start-
– – 3 – ing".
starting
Display of ending of maintenance inter-
– – – 3
val
Display of check of preset 4 4 4 4
Display of ordinary screen 5 4 5 5
Display of end screen
Selection of operation mode
Selection of gearshift mode
Customizing operation
Operation of customize memory
Operation to cancel alarm buzzer
Operation of air conditioner/heater
Operation to display camera mode a The following screen may be displayed instead
(if camera is installed) of the above "Display of screen to input pass-
word screen".
Operation to display clock and service meter
a If this screen is displayed, call the person
Check of maintenance information responsible to operation of KOMTRAX in your
Setting and display of user mode Komatsu distributor and ask for remedy.
(including KOMTRAX messages for user)
Display of caution monitor
Display of action code and failure code
O (Special operations)
Function of checking display of LCD (Liquid Crystal Dis-
play)
Function of checking service meter
D65EX, PX, WX-16 30-103 5

Display of screen to input password Display of warning after check before starting
After the KOMATSU logo is displayed, the screen If any abnormality is detected by the check before
to input the engine start lock password is displayed. starting, the warning monitor is displayed on the
a This screen is displayed only when the engine screen.
start lock function is set effective. a The following figure shows that the water sep-
a If the password is input normally, the screen arator monitor (a) is warning of water collected
changes to "Display of check before starting". in water separator.
a The machine monitor has some password
functions other than the engine start lock.
Those functions are independent from one
another.
Display of ending of maintenance interval

When the check before starting is carried out, if a
maintenance item is near or after the end of the set
interval, the maintenance monitor is displayed for
Display of check before starting 30 seconds to urge the operator to maintenance.
When the screen changes to the check-before- a This screen is displayed only when the mainte-
starting screen, the check before starting is carried nance function is effective. The color of the
out for 2 seconds. maintenance monitor (yellow or red) indicates
a If any abnormality is detected by the check the length of the time after the maintenance
before starting, the screen changes to "Display interval.
of warning after check before starting" or "Dis- a Set or change the maintenance function in the
play of ending of maintenance interval". service mode.
a If no abnormality is detected by the check
before starting, the screen changes to "Display
of check of preset".
a The monitors (3 pieces) displayed on the
screen are the items under the check before
starting.
30-103 6 D65EX, PX, WX-16

Display of check of preset Display of end screen

If the check before starting is finished normally, the When the starting switch is turned OFF, the end
screen to check the preset (gear speed at start) is screen is displayed for 5 seconds.
displayed for 2 seconds. a Another message may be displayed on the
a After display of check of preset is finished, the end screen, depending on the message dis-
screen changes to "Display of ordinary screen". play function of KOMTRAX.
Display of ordinary screen Selection of operation mode

If the machine monitor starts normally, the ordinary While the ordinary screen is displayed, press the
screen is displayed. operation mode selector switch, and the operation
a Service meter (a) or a clock is displayed at the mode monitor (a) changes.
center upper section of the screen (The ser- a Each time the switch is pressed, the operation
vice meter or clock is selected with [F4]). mode changes between [P (Power)] and [E
a Power train oil temperature gauge (b) is dis- (Economy)].
played on the multi-gauge section (It is turned
ON and OFF with the user mode function or
[F2]).
a ECO gauge (c) is displayed at the right end of
the screen (It is turned ON and OFF in the ser-
vice mode).
D65EX, PX, WX-16 30-103 7

Selection of gearshift mode Operation of customize memory

While the ordinary screen is displayed, press the While the ordinary screen is displayed, press the
gearshift mode selector switch, and the gearshift customize memory switch, and you can select the
mode monitor (a) in the gear speed display section recorded setting of customization.
changes.
a Each time the switch is pressed, the gearshift
mode changes between [Automatic gearshift]
and [Manual gearshift].
a If dozing (automatic gearshift) is selected,
AUTO symbol (b) is displayed in the gear
speed display section.
Operation to cancel alarm buzzer

While the alarm buzzer is sounding, if the buzzer
cancel switch is pressed, the alarm buzzer stops.
a Even if the buzzer cancel switch is pressed,
the screen does not change.
Customizing operation
While the ordinary screen is displayed, press the
customize switch, and you can change the setting
of the machine.
a If the customize memory switch is operated
while the above screen is displayed, up to 5
settings can be saved.
30-103 8 D65EX, PX, WX-16

Operation of air conditioner/heater Operation to display camera mode (if camera is

While the ordinary screen is displayed, press the air installed)
conditioner switch or heater switch, and the Air- When a camera is installed, if [F3] is pressed, the
conditioner Adjustment screen or Heater Adjust- multi-display changes to the camera image.
ment screen is displayed. a Set the connection of the camera in the service
a While the Air-conditioner Adjustment screen or mode.
Heater Adjustment screen is displayed, if you
do not touch any switch for 5 seconds, the
screen changes to the ordinary screen.
a Air conditioner specification
a Up to 3 cameras can be connected. If the

camera mode is selected, however, only the
image of camera 1 is always displayed.
a Heater specification
a If a caution is generated in the camera mode,

the caution monitor is displayed at the left
upper of the screen.
a When an error that there is a action code
occurs in the camera mode, if the machine
stops for 10 seconds, the screen changes to
the ordinary screen and displays the error
information.
a When 2 or more cameras are connected, the
image of one of them or the images of 2 of
them can be displayed.
a If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is dis-
played on the right side. The image of camera
3 is displayed only singly.
a If the images of 2 cameras are displayed
simultaneously, images are displayed at inter-
vals of 1 second on the right and left screen.
D65EX, PX, WX-16 30-103 9

Operation to display clock and service meter Check of maintenance information

While the ordinary screen is displayed, press [F4], While the maintenance monitor or ordinary screen
and section (a) changes to the service meter and is displayed, press [F5], and the maintenance table
clock alternately. screen is displayed.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the sum-
mer time with the user mode function.
a Display of service meter
a To reset the time left after finishing mainte-

nance, more operations are necessary.
a Display of clock
30-103 10 D65EX, PX, WX-16

Setting and display of user mode [KOMTRAX message]

(including KOMTRAX messages for user) q There are 2 types of KOMTRAX message; one
While the ordinary screen is displayed, press [F6], is for the user and the other is for the service.
and the user menu screen is displayed. q For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the ordinary
screen. To see the contents of the message,
operate "Message display" in the above user
menu.
q For service:
A message transmitted from the KOMTRAX
base station for the service. Even if it is
received, nothing is displayed on the ordinary
screen. To see the contents of the message,
operate "KOMTRAX message display" in the
service menu.
a There are following items in the user menu.
Utility Screen Select
Multi Gage Select
Screen Adjustment
Clock Adjustment
Language
Message display
Hydraulic fan reversing
D65EX, PX, WX-16 30-103 11

Display of caution monitor Display of action code and failure code

If an abnormality which displays a caution monitor If an abnormality which displays an action code and
occurs on the ordinary screen or camera mode a failure code occurs on the ordinary screen or
screen, the caution monitor is displayed large for a camera mode screen, all the information of the
moment and then displayed at (a) in the screen. abnormality is displayed.
a On the camera mode screen, the caution mon- (a) : Action code (3 digits)
itor blinks at the left upper of the screen when (b) : Failure code (5 or 6 digits)
the caution is generated. (c) : Telephone mark
(d) : Telephone No.
a This screen is displayed only when an abnor-
mality (failure code) for which an action code is
set occurs.
a The telephone mark and telephone No. are
displayed only when the telephone No. is reg-
istered in the service mode.
a If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the fault history in the ser-
vice mode, check the details in the service
mode.
30-103 12 D65EX, PX, WX-16

a Remedies given by displayed action codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
Action
Method of indicating trouble Examples of trouble Remedy given to operator to take
code
• Although all or a part of automatic
function stops, machine can be
• Action code and failure code are • Backup alarm does not sound.
E01 operated.
displayed. • Fan speed is kept at maximum.
• Ask your Komatsu distributor for
repair.
• If operator stops and restarts
engine, machine can be operated
• Action code and failure code are • Gear is not shifted up or down. without limiting any function.
E02 displayed. • Exhaust gas color is bad when Operator must take care, how-
• Alarm buzzer sounds. temperature is low. ever.
• Ask your Komatsu distributor for
repair.
• Action code and failure code are • Usable gear speeds are limited.
displayed. • Engine speed does not rise to • Move machine to safe place.
E03 • Telephone No. is displayed (if maximum. • Ask your Komatsu distributor for
set). • Gearshift shock is increased. repair.
• Alarm buzzer sounds. • Steering performance lowers.
• Action code and failure code are
displayed. • Engine cannot be controlled. • Stop machine immediately.
E04 • Telephone No. is displayed (if • Machine cannot travel. • Ask your Komatsu distributor for
set). • Machine stops. repair.
• Alarm buzzer sounds.
D65EX, PX, WX-16 30-103 13

Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + a Since there is some time lag in start of the
[F2] LCD, hold down the switches until the LCD dis-
a When finishing the operation of the switches, plays normally.
release [F2] first. a After the machine monitor is used continu-
a If there is a display error in the LCD, only that ously, blue points (points which do not go off)
part is indicated in black. may be seen on this screen. This phenome-
a The LCD panel sometimes has black points non does not indicate a failure or a defect.
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.

When changing the maintenance password used
for the maintenance setting function, follow these
procedures.
a To use this function, the machine monitor must
be set to "Use maintenance password setting"
in the service mode.
a See "Initialize (Set maintenance password)".
1. While the ordinary screen is displayed, perform
the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
30-103 14 D65EX, PX, WX-16

4. After the "New Password" screen is displayed

2. After the "Password" screen is displayed, input
again, input a new password again with the
the current password with the numeral input
numeral input switches and confirm it with the
switches and confirm it with the function
function switch.
switch.
q [F5]: Delete input numeral/Return to ordi-
nary screen
nary screen
q [F6]: Confirm input numeral
a If a password different from the password
a Default password: [000000]
input before is input, the message to input
a If the input password is correct, the screen
again is displayed.
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
5. If the screen to notify completion of setting is

displayed and then the ordinary screen is dis-
played, the password is changed successfully.
3. After the "New Password" screen is displayed,

input a new password with the numeral input
switches and confirm it with the function
switch.
a Set a new password of 4 – 6 digits (If it
has only 3 or less digits or has 7 or more
digits, it is not accepted).
nary screen
D65EX, PX, WX-16 30-103 15

t Service mode a The items which can be selected in the

To change the operator mode to the service mode, service menu are as follows.
perform the following operation.
01 Monitoring
This operation is always required when you use the
service mode. Mechanical system "Abnormality
Record"
1. Check of display of screen and operation of 02 Abnormality Electrical system "Abnormality
switches Record Record"
While the ordinary screen is displayed, perform Air conditioner "Abnormality Record"/
the following operation with the numeral input Heater "Abnormality Record"
switches. 03 Maintenance Record
q Operation of switches (While pressing [4],
04 Maintenance Mode Change
perform the operation in order):
[4] + [1] o [2] o [3] 05 Phone Number Entry
a This operation of the switches is accepted Key-on Mode
only while the ordinary screen is dis- Selecting of unit
played.
06 Default Setting of maintenance password
Setting of camera
Setting of ECO display
07 Adjustment
08 PM CLINIC
09 Cylinder Cut-Out
10 No Injection
11 Fuel Consumption
Terminal Status
12 KOMTRAX
GPS & Communication Status
Settings
Modem S/N
13 Service Message
2. Selection of service menu
When the "Service Menu" screen is displayed, a Items with 2-digit codes are the menus dis-
the service mode is selected. Select a service played on the Service menu screen. The items
menu you use with the function switches or on their right are the menus on the next hierar-
numeral input switches. chy.
q [F3]: Move to lower menu
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the menu
of that code and confirm it with [F6].
30-103 16 D65EX, PX, WX-16

Monitoring 2. Selecting monitoring items

The machine monitor can monitor the condition of After the "Monitoring" screen is displayed,
the machine in real time by receiving signals from select items to be monitored with the function
various switches, sensors, and actuators installed switches or numeral input switches.
to many parts of the machine and the information q [F1]: Move to next page (screen)
from the controllers which are controlling switches, q [F2]: Move to previous page (screen)
etc. q [F3]: Move to lower item
q [F4]: Move to upper item
1. Selecting menu q [F5]: Delete input numeral/Return to ser-
Select "01 Monitoring" on the "Service Menu" vice menu screen
screen. q [F6]: Confirm selection
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with
[F6].
a Selection with numeral input switches:
Enter a 5-digit code, and the item of that
code is selected directly. Confirm that
item with [F6].
a If the color of the selected box changes
from yellow to red, selection of the item of
that box is confirmed.
a Up to 6 monitoring items can be selected
at a time. You may not able to set up to 6
items, however, depending on the display
form of those items.
D65EX, PX, WX-16 30-103 17

3. Deciding monitoring items 5. Holding monitoring information

After selecting monitoring items, execute moni- The monitoring information can be held and
toring with the function switch or numeral input holding is reset with the function switches.
switch. q [F3]: Reset holding
a Execution with function switch: Double- q [F4]: Hold information (displayed data)
click or hold down [F6] (about 2 seconds). q [F5]: Return to monitoring selection menu
a Execution with numeral input switch: Input screen
[99999] and press [F6].
a When monitoring only 2 items, for exam-
ple, select them and confirm with [F6]. If
[F6] is pressed once more at this time,
monitoring is executed.
a If monitoring items are selected up to the
limit number, monitoring is executed auto-
matically.
6. Changing machine setting mode

To change the setting of the "Operation Mode"
or "Gearshift Mode" during monitoring, operate
the corresponding switch under the current
condition, and the mode setting screen is dis-
played.
While this screen is displayed, if the corre-
sponding switch is operated further, the corre-
4. Executing monitoring sponding mode is changed.
After the "Monitoring" screen is displayed, per- a After finishing changing the setting, press
form the necessary operation of the machine [F6] to return to the monitoring information
and check the monitoring information. screen.
a Monitoring information is indicated by a If the setting is changed during monitoring,
value, ON/OFF, or special display. the new setting is held even after the
a The unit of display can be set to SI unit, screen returns to the ordinary screen after
metric unit, or inch unit with the Default monitoring is finished.
function in the service mode.
30-103 18 D65EX, PX, WX-16

Monitoring items list
Code Monitoring item Unit (Initial setting: ISO) Component

Remarks
No. (Display on screen) ISO meter inch in charge
50300 S/T Lever 1 Potentio mV mV mV P/T

50301 S/T Lever 2 Potentio mV mV mV P/T
50400 Brake Pedal Potentio mV mV mV P/T
50600 HSS Solenoid LH (F/B) mA mA mA P/T
50601 HSS Solenoid RH (F/B) mA mA mA P/T
32900 Pitch Angle ° ° ° P/T
60100 Pitch Angle Sensor mV mV mV P/T
18800 Water in Fuel WIF sensor ON • OFF ENG
60600 BR Hold Relay mV mV mV P/T
03001 Fuel Dial Throttle % % % P/T
03000 Fuel Dial Sensor mV mV mV P/T
50200 T/M Lever 1 Potentio mV mV mV P/T
50201 T/M Lever 2 Potentio mV mV mV P/T
31622 T/M Clutch F ECMV (F/B) mA mA mA P/T
31616 T/M Clutch R ECMV (F/B) mA mA mA P/T
31612 T/M Clutch 1st ECMV (F/B) mA mA mA P/T
31613 T/M Clutch 2nd ECMV (F/B) mA mA mA P/T
31614 T/M Clutch 3rd ECMV (F/B) mA mA mA P/T
30100 T/C Oil Temperature C C F P/T
30101 T/C oil temp sensor mV mV mV P/T
31400 T/M Out Speed r/min rpm rpm P/T
32600 T/C AVR Pressure MPa kg/cm² psi P/T
32605 T/C AVR Pressure Sensor mV mV mV P/T
31642 L/U ECMV (F/B) mA mA mA P/T
40001 Vehicle Speed km/h km/h MPh P/T
60000 Traction W W W P/T
70200 T/M Out Speed Sensor mV mV mV P/T
31624 Fan Pump Solenoid (F/B) mA mA mA P/T
10000 Fan Speed r/min rpm rpm P/T
SUNC (Gear shift up sw) ON • OFF P/T
SUNO (Gear shift up sw) ON • OFF P/T
SDNC
ON • OFF P/T
(Gear shift down sw)
40905 T/M Sw Input 1 SDNO

ON • OFF P/T
(Gear shift down sw)
PNC
ON • OFF P/T
(Parking brake lever sw)
PNO
ON • OFF P/T
(Parking brake lever sw)
D65EX, PX, WX-16 30-103 19


Remarks
F (F clutch fill sw) ON • OFF P/T

R (R clutch fill sw) ON • OFF P/T
T/M Fill Sw
40906 1st (1st clutch fill sw) ON • OFF P/T
Input 1
2nd (2nd clutch fill sw) ON • OFF P/T
3rd (3rd clutch fill sw) ON • OFF P/T
T/M Fill Sw
31520 L/U (Lock-up clutch fill sw) ON • OFF P/T
Input 2
Brly (Back Alarm relay) ON • OFF P/T
Prly (Parking lock relay) ON • OFF P/T
40909 T/M Output 1
Fres
ON • OFF P/T
(Fan reverse solenoid)
70700 Hydraulic Pump Pressure 1 MPa kg/cm² psi P/T
70701 Hydraulic Pressure Sensor 1 mV mV mV P/T
Current to PC-EPC
01300 TVC Solenoid (F/B) mA mA mA P/T
valve is displayed
KUNC (Knob raise sw) ON • OFF P/T
KUNO (Knob raise sw) ON • OFF P/T
KLNC (Knob down sw) ON • OFF P/T
70300 Blade Sw Input KLNO (Knob down sw) ON • OFF P/T

WLNC
ON • OFF P/T
(Work equipment lock sw)
WLNO
ON • OFF P/T
(Work equipment lock sw)
WE lock sol. ON • OFF P/T
90803 Blade Output 1 Pitch selector sol. ON • OFF P/T
Amber light relay ON • OFF P/T
20227 Monitor Ass’y P/N — MON
20402 Monitor Serial No — MON
20228 Monitor Prog P/N — MON
20242 P/T Con Ass’y P/N — P/T
20404 P/T Con Serial No — P/T
20243 P/T Con Prog P/N — P/T
04200 Fuel Level Sensor Volt V V V MON
04300 Battery Charge Volt V V V MON
04401 Hyd Oil Temperature C C F MON
04402 Hyd Temp Sens Volt V V V MON
18900 ECM Internal Temp C C F ENG
00201 Machine ID — ENG
20216 ECM Build Version — ENG
20217 ECM Calibration Data Ver — ENG
30-103 20 D65EX, PX, WX-16


Remarks
20400 ECM Serial No — ENG

01002 Engine Speed r/min rpm rpm ENG
36700 Engine Torque Ratio % % % ENG
31701 Decel Pedal Position % % % ENG
31703 Decel pedal pos sens volt V V V ENG
17500 Engine Power Mode — ENG
36400 Rail Pressure MPa kg/cm² psi ENG
36401 Rail Pressure Sens Volt V V V ENG
36200 Rail Press Command MPa kg/cm² psi ENG
36300 Injection Timing Command CA CA CA ENG
04107 Coolant Temperature C C F ENG
04105 Coolant Temp Sens Volt V V V ENG
Indication by abso-
37400 Ambient Pressure kPa kg/cm² psi ENG
lute value
37401 Ambient Press Sens Volt V V V ENG
Indication by abso-
36500 Charge Pressure-Abs kPa kg/cm² psi ENG lute value (including
ambient pressure)
36501 Charge Press Sens Volt V V V ENG
03203 Battery Power Supply (ENG) V V V ENG
37300 Fuel Rate l/h l/h gal/h ENG
31706 Final Throttle Position % % % ENG
18500 Charge Temperature C C F ENG
18501 Charge Temp Sens Volt V V V ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
18700 Engine Output Torque Nm kgm lbft ENG
C-sig ON • OFF P/T
40912 P/T Sw Input R-sig ON • OFF P/T
ACC ON • OFF P/T
a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit in "Default" of the service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Components in charge
MON : The machine monitor is in charge of detection of monitoring information.
ENG : The engine controller is in charge of detection of monitoring information.
P/T : The power train controller is in charge of detection of monitoring information.
D65EX, PX, WX-16 30-103 21

"Abnormality Record" (Mechanical system 3. Information displayed on "Abnormality Record"

"Abnormality Record") screen
The machine monitor classifies and records the On the "Mechanical Systems" screen, the fol-
abnormality which occurred in the past or which are lowing information is displayed.
occurring at present into the mechanical system (a): Occurrence order of abnormality from lat-
abnormality, electrical system abnormality, and air est one/Total number of records
conditioner abnormality or heater abnormality. (b): Failure code
To check the mechanical system "Abnormality (c): Contents of trouble
Record", perform the following procedures. (d): Number of occurrence time
a See section "Failure code table and fuse loca- (e): Service meter reading at first occurrence
tions" for the list of failure codes. (f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if dis-
1. Selecting menu played)
Select "02 Abnormality Record" on the "Ser- q [F2]: Move to previous page (screen) (if
vice Menu" screen. displayed)
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded,
"No Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
2. Selecting sub menu

After the "Abnormality Record" screen is dis-
played, select "01 Mechanical Systems" with
the function switches or numeral input switches.
q [F3]: Move to lower record
q [F4]: Move to upper record
q [F5]: Return to service menu screen
numeral input switches to select the
record of that code and confirm it with 4. Deleting "Abnormality Record"
[F6]. The contents of the mechanical system
a The following figure shows the display of "Abnormality Record" cannot be deleted.
the air conditioner specification. If the
heater specification is selected, "03
Heater Abnormality Record" is displayed.
30-103 22 D65EX, PX, WX-16

"Ab normality Reco rd" (Electrical system 3. Information displayed on "Abnormality Record"
"Abnormality Record") screen
The machine monitor classifies and records the On the "Electrical Systems" screen, the follow-
abnormality which occurred in the past or which are ing information is displayed.
occurring at present into the mechanical system (a):Occurrence order of abnormality from lat-
abnormality, electrical system abnormality, and air est one/Total number of records
conditioner abnormality or heater abnormality. (b):Failure code
To check the electrical system "Abnormality (c): Contents of trouble
Record", perform the following procedures. (d):Number of occurrence time
a See section "Failure code table and fuse loca- (e):Service meter reading at first occurrence
tions" for the list of failure codes. (f): Service meter reading at last occurrence
q [F1]: Move to next page (screen) (if dis-
1. Selecting menu played)
Select "02 Abnormality Record" on the "Ser- q [F2]: Move to previous page (screen) (if
vice Menu" screen. displayed)
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded,
"No Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.

After the "Abnormality Record" screen is dis-
played, select "02 Electrical Systems" with the
function switches or numeral input switches.
numeral input switches to select the
record of that code and confirm it with
[F6].
a The following figure shows the display of 4. Deleting "Abnormality Record"
the air conditioner specification. If the 1) While the "Electrical Systems" screen is
heater specification is selected, "03 displayed, perform the following operation
Heater Abnormality Record" is displayed. with the numeral input switches.
q Operation of switches (While pressing
[4], perform the operation in order):
[4] + [1] o [2] o [3]
a Operate the switches similarly to the
procedure for changing the ordinary
display to the service mode.
D65EX, PX, WX-16 30-103 23

3) After the "Electrical Sys. Error Reset"

screen is displayed, operate the function
switches.
q [F5]: Return to "Electrical Sys. Error
Reset" screen (Delete mode)
q [F6]: Execute deletion
a The following figure shows the screen
displayed when the items are deleted
one by one (which is a little different
from the screen displayed when all
the items are deleted together).
2) Check that the screen is set in the delete

mode, and then delete the items one by
one or together with the function switches.
a If the screen is set in the delete mode,
[CLEAR] graphic mark is indicated at
[F2].
q [F2]: Delete all items
q [F3]: Move to lower item
q [F5]: Return to "Abnormality Record"
screen
q [F6]: Delete selected item 4) If the screen to notify completion of dele-
a To delete items one by one: Select tion is displayed and then the "Electrical
the item to be deleted with [F3] or [F4] Sys. Error Reset" (delete mode) screen is
and press [F6]. displayed, the deletion of the "Abnormality
a To delete all items together: Press Record" is completed.
[F2], and all the items are deleted, a After a while, the screen returns to
regardless of selection of the items. the "Electrical Sys. Error Reset"
a If [E] is displayed on the left of a fail- screen.
ure code, the deleting operation is
accepted but the information is not
deleted.
30-103 24 D65EX, PX, WX-16

"Abnormality Record" (Air conditioner "Abnor- 3. Information displayed on "Abnormality Record"

mality Record"/Heater "Abnormality Record") screen
The machine monitor classifies and records the On the air conditioner "Abnormality Record" or
abnormality which occurred in the past or which are heater "Abnormality Record" screen, the fol-
occurring at present into the mechanical system lowing information is displayed.
abnormality, electrical system abnormality, and air (a): System/Component name
conditioner abnormality or heater abnormality. (b): Number of occurrence time
To check the air conditioner "Abnormality Record" (c): Condition (Normal or abnormal)
or heater "Abnormality Record", perform the follow- q [F2]: Delete "Abnormality Record"
ing procedures. q [F5]: Return to "Abnormality Record" screen
a All the following figures show the air condi- a If [E] is displayed on the left of a condition,
tioner specification. the abnormality is still occurring or reset-
ting of it has not been confirmed.
1. Selecting menu a If "CAN Status" is displayed in Communi-
Select "02 Abnormality Record" on the Service cation condition, communication cannot
menu screen. be carried out normally. Accordingly, the
conditions of other items are turned OFF.

After the "Abnormality Record" screen is dis- 4. Deleting "Abnormality Record"
played, select "03 Air-conditioning System" or While the "Abnormality Record" screen is dis-
"03 Heater Abnormality Record" with the func- played, press [F2], and the number of occur-
tion switches or numeral input switches. rence time of fault is deleted. If it is confirmed
q [F3]: Move to lower record at this time that the abnormality has been
q [F4]: Move to upper record reset, the display changes to Normal.
q [F6]: Confirm selection a Heater specification
a You may enter a 2-digit code with the In the heater specification, the display of "Air
numeral input switches to select the conditioner" is replaced with "Heater" and the
record of that code and confirm it with items which are not related to the heater are
[F6]. not displayed.
D65EX, PX, WX-16 30-103 25

Maintenance Record a The following items can be selected in the

The machine monitor records the maintenance maintenance record.
information of the filters, oils, etc., which the opera-
tor can display and check by the following opera- 01 Engine Oil Change
tions. When maintenance is carried out, if the data 02 Eng Oil Filter Change
are reset in the operator mode, the number of the
03 Fuel Main Filter Change
times of maintenance is recorded in this section.
41 Fuel Pre Filter Change
1. Selecting menu 04 Hyd Oil Filter Change
Select "03 Maintenance Record" on the "Ser- 06 Corrosion Resistor Change
vice Menu" screen.
07 Check and addition of damper case oil
08 Replacement interval of final drive case oil
10 Replacement of hydraulic oil
19 Replacement of power train oil
20 Replacement of power train oil filter
3. Items displayed on “Maintenance Record”

screen. The following items are displayed.
(a): Maintenance items
(b): Number of times of change up to now
(c): Service meter reading (SMR) at previous
change
2. Selecting maintenance record item

After the "Maintenance Record" screen is dis-
played, select an item to be checked with the
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
numeral input switches to select the item
of that code.
30-103 26 D65EX, PX, WX-16

Maintenance Mode Change a The following items can be selected on

The operating condition for maintenance function in the "Maintenance Mode On/Off" screen.
the operation mode can be set and changed with
this menu. 00 Maintenance Mode On/Off
q Set function effective or ineffective 01 Engine Oil Change Int
q Change set change interval (by items)
02 Eng Oil Filter Change Int
q Initialize all set change intervals
03 Fuel Main Filter Change Int
1. Selecting menu 41 Fuel Pre Filter Change Int
Select "04 Maintenance Mode Change" on the 04 Hyd Oil Filter Change Int
Service menu screen.
06 Replacement interval of corrosion resistor
07 Check and replacement interval of damper case oil
08 Replacement interval of final drive case oil
10 Replacement interval of hydraulic oil
19 Replacement interval of power train oil
20 Replacement interval of power train oil filter
99 Use Default Value
3. Contents of setting of ON/OFF of maintenance

mode
After selecting "00 Maintenance Mode On/Off",
if the screen is displayed, set ON or OFF with
the function switches.
q ON: Functions of all maintenance items
After the "Maintenance Mode On/Off" screen is
are set effective in operator mode
displayed, select an item to be monitored with
q OFF: Functions of all maintenance items
t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t
are set ineffective in operator mode
switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F5]: Cancel selection and return to Main-
tenance mode screen
q [F6]: Confirm selection and return to
Maintenance mode screen
a Even if ON/OFF of each item has been
set, if the above setting is changed, it is
numeral input switches to select the item
applied.
of that code and confirm it with [F6].
D65EX, PX, WX-16 30-103 27

4. Contents of setting of each maintenance item 5. Function of “All Default Value”

After selecting each maintenance item, if the After selecting “99 Use Default Value”, if the
screen is displayed, set the item with the func- screen is displayed, set with the function
tion switches. switches.
q Default: Maintenance interval set in machine a If this operation is executed, the set val-
monitor (Recommended by manufacturer ues of all the maintenance items are set to
and not changeable). default values.
q Set: Maintenance interval which can be q [F5]: Return to “Maintenance Mode
set freely. Maintenance functions in oper- Change” screen
ator mode operate on basis of this set time q [F6]: Execute default setting
(which is increased or decreased by 25 a A while after [F6] is pressed, the default
hours). setting completion screen is displayed.
q ON: Maintenance function of this item is Then, if the "Maintenance Mode Change"
set effective in operator mode. screen is displayed, default setting is com-
q OFF: Maintenance function of this item is pleted.
set ineffective in operator mode. a The default setting of the corrosion resis-
q [F3]: Select Reduce set value (Upper) or tor is “OFF”.
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to “Maintenance Mode
Change” screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower
lines is confirmed with [F6] and the screen
chang es to the “ Maintena nce M ode
Change” screen with [F5], the setting is
effective.
30-103 28 D65EX, PX, WX-16

Phone Number Entry a If [F6] is pressed without inputting a digit,

The phone No. displayed when the action code/fail- there is not information of phone No.
ure code is displayed in the operator mode can be Accordingly, no phone No. is displayed in
input and changed according to the following pro- the operator mode.
cedure.
If a phone No. is not input with this function, no
phone No. is displayed in the operator mode.
1. Selecting menu
Select "05 Phone Number Entry" on the "Ser-
vice Menu" screen.
2. Registering and changing telephone No.

After the "Phone Number Entry" screen is dis-
played, register or change the phone No.
q [F2]: Delete all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Delete input digit/Return to service
menu
q [F6]: Confirm input
a Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (and its background changes to
orange) and overwrite it with the correct
digit.
D65EX, PX, WX-16 30-103 29

Default setting (Key-on Mode) 3. Selecting mode

Check or change various settings related to the After the "Key-on Mode" screen is displayed,
machine monitor and machine by default setting. select the mode to be set with the function
The function of Key-on Mode is used to set the ini- switches.
tial mode displayed on the machine monitor when q Mode at Previous Key-off: Final mode in
the starting switch is turned ON. previous operation is displayed when
starting switch is turned ON
1. Selecting menu q Default Value (ALL OFF): Default setting
Select "06 Default" on the "Service Menu" of all mode items (Operation mode: P,
screen. other item: OFF) is displayed when start-
ing switch is turned ON
q [F5]: Cancel selection and return to
default screen
q [F6]: Confirm selection and return to
default screen
a When the machine is delivered, “Mode at
Previous Key-off”.

After the "Default" screen is displayed, select
"01 Key-on Mode" with the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.
a This function sets the following 2 mode
items (which are the items set with the
customize switch in the operator mode).
q Operation mode: P/E
q Reverse slow mode: ON/OFF
30-103 30 D65EX, PX, WX-16

Default setting (Selecting of unit) 3. Selecting unit

Check or change various settings related to the After the "Unit" screen is displayed, select the
machine monitor and machine by default setting. unit to be set with the function switches.
The unit selecting function is used to select the unit q [F3]: Move to lower unit
of the data displayed for monitoring, etc. q [F4]: Move to upper unit
q [F5]: Cancel selection and return to default
1. Selecting menu screen
Select "06 Default" on the "Service Menu" q [F6]: Confirm selection and return to default
screen. screen
a When the machine is delivered, the SI unit
system is set.

"02 Unit" with the function switches or numeral
input switches.
D65EX, PX, WX-16 30-103 31

Default setting (Setting of maintenance pass- 3. Selecting Enable/Disable

word) After the "Maintenance Password" screen is
Check or change various settings related to the displayed, select the setting with the function
machine monitor and machine by default setting. switches.
The function of setting maintenance password is q Disable: Password screen is not displayed
used to set the display of the password screen q Enable: Password screen is displayed
when the functions related to the maintenance are q [F3]: Move to lower item
used in the operator mode. q [F4]: Move to upper item
q [F5]: Cancel selection and return to Initial-
1. Selecting menu ization screen
Select "06 Default" on the "Service Menu" q [F6]: Confirm selection and return to default
screen. screen
2. Selecting sub menu 4. Displaying maintenance password screen

After the "Default" screen is displayed, select When the following operation is performed, the
"03 Maintenance Password" with the function password screen is displayed in the operator
switches or numeral input switches. mode.
a Select this item similarly to an item on the q The ordinary screen is changed to the
Service menu screen. maintenance mode (with [F5]) and then
the "Maintenance table" screen is
changed to the "Maintenance interval
reset" screen.
5. Changing maintenance password

The password can be changed by operating
the switches specially in the operator mode.
a See "Function of changing maintenance
password" in the operator mode.
a Default password: [000000]
a If the password setting is changed from
"Enable" to "Disable", the password is
reset to the default.
a When "Enable" is set again, be sure to set
a new password.
a The maintenance password is different
from the engine start lock password.
30-103 32 D65EX, PX, WX-16

Default setting (Setting of camera) 3. Selecting camera setting

Check or change various settings related to the After the "Camera" screen is displayed, select
machine monitor and machine by default setting. the setting with the function switches.
The camera setting function is used to set default q OFF: Camera is not connected
setting and removal of a camera. q Original image: Image of connected cam-
era is displayed in original position (as in
1. Selecting menu mirror, used as back monitor)
Select "06 Default" on the "Service Menu" q Reverse image: Image of connected cam-
screen. era is displayed in reverse position (as
seen directly, used as front or side moni-
tor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before confirmation
and return to “Default” screen
q [F6]: Confirm selection in each line
a After "Camera" screen is displayed, cam-
era 1 can be always set.
When 2 or more cameras are connected,
if camera 1 is set, the screen changes to
setting of camera 2 automatically.
a After confirming the setting of each line
with [F6], return to the “Default” screen
2. Selecting sub menu with [F5], and the setting is effective.
After the "Default" screen is displayed, select a If a camera is connected but not set nor-
"04 Camera" with the function switches or mally with this function, the graphic mark
numeral input switches. of camera is not displayed at [F3] in the
a Select this item similarly to an item on the operator mode. Accordingly, the image of
"Service Menu" screen. the camera cannot be used.
a If 2 or more cameras are connected, be
sure to set the use of them from camera 1
in order.
a The function of displaying 2 images simul-
taneously is effective when use of camera
1 and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizon-
tally in the operator mode.
D65EX, PX, WX-16 30-103 33

Default setting (Setting of ECO display) 3. Selecting display setting

Check or change various settings related to the After the "ECO Display" screen is displayed,
machine monitor and machine by initialization. select the setting with the function switches.
The ECO display setting function is used to set the q ON: Display ECO
display of the ECO gauge. q OFF: Do not display ECO
q [F3]: Move to left item
1. Selecting menu q [F4]: Move to right item
Select "06 Default" on the "Service Menu" q [F5]: Cancel selection and return to default
screen. screen
q [F6]: Confirm selection and return to default
screen
a If ECO display is turned ON, ECO is dis-
played when the screen changes to the
ordinary screen.

"05 ECO Display" with the function switches or
a Select this item similarly to an item on the a Display of ECO gauge (a)
30-103 34 D65EX, PX, WX-16

Adjustment a If the input adjustment ID is incorrect, the

The operator can adjust various items related to the message of "No ready Adjustment" is dis-
machine with the machine monitor. played and the ID input screen does not
When using an adjustment item, select it according change (Another ID can be input again
to the following procedure. with the numeral input switches while this
screen is displayed).
1. Selecting menu
Select "07 Adjustment" on the "Service Menu"
screen.
3. Displaying adjustment screen

After the "Adjustment" screen for the adjust-
ment ID is displayed, you can start adjustment.
a In the figure, adjustment ID [0002] is
2. Selecting adjustment item selected and displayed as an example.
After the "Adjustment" screen is displayed, a "000", "00", and "0" on the left of the
input the 4-digit adjustment ID of the adjust- adjustment ID must be filled but they are
ment item to be used with the numeral input not displayed on the adjustment screen.
switches. a The functions given to function switches
q [F5]: Cancel adjustment and return to [F3] – [F6] depend on the adjustment item.
“Service menu” screen a For the method of operating each adjust-
q [F6]: Confirm input adjustment ID and go ment item, see the explanation of its
to “Adjustment” screen adjustment ID.
a For the adjustment ID's and their adjust-
ment items, see the “Adjustment items
table”.
D65EX, PX, WX-16 30-103 35

Adjustment items table

Adjustment
Adjustment item Remarks
ID
0002 Power train controller initialization
0004 Work equipment specification setting
0005 Brake pedal potentiometer initial correction
0007 Engine decelerator cutting
0009 Pitch angle sensor initial correction
0010 Fan 70% mode
0530 Stall mode Recommended mode of torque converter stall
0910 Load record check mode
1005 Fan 100% mode
1012 Steering lever neutral position adjustment
1013 Steering lever leftmost position adjustment
1014 Steering lever rightmost position adjustment
2021 Power train controller voltage check mode
2222 HSS min. current setting mode
6001 R1 reverse slow set speed Fine adjustment of reverse slow mode
Transmission clutch IP and fill time automatic initial
7842
correction
7843 Transmission clutch IP manual initial correction
7845 Transmission clutch IP learning display
7847 Transmission clutch fill time manual initial correction
9997 High idle cut mode
9998 Max. gear speed setting mode
30-103 36 D65EX, PX, WX-16

Adjustment ID: 0002 (Power train controller initial- Adjustment ID: 0004 (Work equipment specifica-
ization) tion setting)
q This adjustment code is used to initialize the q This adjustment code is used to make the work
specification code recognized by the power equipment controller recognize the type of the
train controller and the set values of the mem- work equipment.
ory in the controller. a After the power train controller is replaced, be
a After the power train controller is replaced, be sure to carry out this adjustment once.
sure to carry out this adjustment once.
q Functions of function switches
q Functions of function switches [F3]: Increase specification value [CODE]
[F3]: Unused [F4]: Decrease specification value [CODE]
[F4]: Unused [F5]: Return to adjustment item selecting
[F5]: Return to adjustment item selecting screen (ID inputting screen)
screen (ID inputting screen) [F6]: Save setting
[F6]: Save setting
q Operating method:
q Operating method: 1) Press [F3] or [F4] to select the specifica-
1) Press [F6] and check that the alarm tion value [CODE] of the work equipment
buzzer sounds. concerned.
2) Check that the displayed specification
CODE Type of work equipment
code [CODE] has changed from [5x5] to
[555]. Standard dozer (including PAT
0
a If specification code [555] is not displayed, dozer)
the controller unit may be defective. 2 Power pitch dozer
a Even if this adjustment code is turned off,
the setting is effective. 2) Press [F6] and check that the alarm
buzzer sounds.
k If the specification of the work equip-
ment is different from the setting in the
controller, the work equipment may
move unexpectedly or an error may be
made. Accordingly, be sure to match
the controller to the work equipment.
the setting is effective.
D65EX, PX, WX-16 30-103 37

Adjustment ID: 0005 (Brake pedal potentiometer Adjustment ID: 0007

initial correction) (Engine decelerator cutting)
q This adjustment code is used to make the q This adjustment code is used to stop the auto-
power train controller recognize the zero point deceleration function of the engine and check
of the brake pedal potentiometer. the high idle speed of the engine unit.
a After the power train controller or brake pedal a Since this machine does not use the auto-
potentiometer is replaced or the brake pedal deceleration function in neutral, the high idle
linkage is disconnected and connected, be speed can be checked without using this
sure to carry out this adjustment once. adjustment code.
a Use this adjustment code for testing, adjusting,
q Functions of function switches or troubleshooting when necessary.
[F3]: Unused
[F4]: Unused q Functions of function switches
[F5]: Return to adjustment item selecting [F3]: Unused
screen (ID inputting screen) [F4]: Unused
[F6]: Save corrected value [F5]: Return to adjustment item selecting
screen (ID inputting screen)
q Operating method: [F6]: Unused
1) Check that the brake pedal is in the neu-
tral position (it is not pressed at all) and q Operating method:
keep it in that position. When this adjustment code is displayed, its
2) Press [F6] and check that the alarm function is effective and the auto-deceleration
buzzer sounds. function is stopped.
a Even if the adjustment is carried out, the a After this adjustment code is turned OFF,
displayed value does not change. its function is ineffective.
the correction is effective.
a This adjustment code is used to make the
controller recognize the zero point of the
potentiometer. It is not used to adjust the
braking force.
30-103 38 D65EX, PX, WX-16

Adjustment ID: 0009 (Pitch angle sensor initial cor- Adjustment ID: 0010
rection) (Fan 70% mode)
q This adjustment code is used to make the q This adjustment code is used to set the cooling
power train controller recognize the zero point fan speed to about 70% forcibly.
of the pitch angle sensor and to correct the a Use this adjustment code for testing, adjusting,
installation error. or troubleshooting when necessary.
a After the power train controller is replaced or
the pitch angle sensor is removed and installed q Functions of function switches
or replaced, be sure to carry out this adjust- [F3]: Increase adjustment value [FAN 70%
ment once. SPEED MODE]
[F4]: Decrease adjustment value [FAN 70%
q Functions of function switches SPEED MODE]
[F4]: Unused screen (ID inputting screen)
[F6]: Save corrected value q Operating method:
When this adjustment code is displayed, its
q Operating method: function is effective and the cooling fan speed
1) Check that the machine is level. is controlled to about 70% of the maximum
2) Press [F6] and check that the alarm speed.
buzzer sounds. a Since [FAN SPEED] of this adjustment
a If adjustment is carried out, displayed item code is different from the actual fan speed,
[BODY PITCH ANGLE] changes to [0.0°] see Testing and adjusting, "Testing fan
(The other displayed items do not speed", for the fan speed testing method.
change). a After this adjustment code is turned OFF,
a Even if this adjustment code is turned off, its function is ineffective.
D65EX, PX, WX-16 30-103 39

Adjustment ID: 0530 a When using this adjustment code, keep

(Stall mode) the hydraulic oil temperature above 50°C.
(If the hydraulic oil temperature lowers
below 40°C, the fan speed fluctuates.)
a After this adjustment code is turned OFF,
its function is ineffective.
q This adjustment code is used to set the fan

speed in the 100% mode automatically and
make it possible to set the preset (gear speed
at start) to [F3-R3] to stall the torque converter.
a The preset (gear speed at start) can be
set to [F3-R3] only while this adjustment
code is selected.
a Use this adjustment code for testing,
adjusting, or troubleshooting when neces-
sary.

[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
[F6]: Unused
q Mode setting information within screen

[P-AUTO SFT MODE]:
Automatic gearshift in P mode
[E-AUTO SFT MODE]:
Automatic gearshift in E mode
[P-MANUAL SFT MODE]:
Manual gearshift in P mode
[E-MANUAL SFT MODE]:
Manual gearshift in E mode
q Operating method:
When this adjustment code is displayed, its
function is effective and the preset (gear speed
at start) is set to [F3-R3].
k This adjustment code does not stall the
t o r q u e c o n v e r t e r a u t o m a t i c a l l y.
Accordingly, operate the levers and
pedals securely when stalling the
torque converter (For the procedure for
stalling the torque converter, see "Mea-
suring engine speed").
30-103 40 D65EX, PX, WX-16

Adjustment ID: 0910 (Load record check mode) Adjustment ID: 1005 (Fan 100% mode)
q This adjustment code is used to check the load q This adjustment code is used to set the cooling
on the machine, odometer, and reverse odom- fan speed to about 100% forcibly. It is also
eter. used to set the adjustment value of the maxi-
a Use this adjustment code for testing, adjusting, mum speed.
or troubleshooting when necessary. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
[F3]: Unused q Functions of function switches
[F4]: Unused [F3]: Increase adjustment value [FAN 100%
[F5]: Return to adjustment item selecting SPEED MODE]
screen (ID inputting screen) [F4]: Decrease adjustment value [FAN 100%
[F6]: Unused SPEED MODE]
q Mode setting information within screen screen (ID inputting screen)
[1000 rpm SMR]: Time displayed by service [F6]: Save adjustment value
meter in which engine speed
was above 1,000 rpm q Operating method:
[ODO METER FORWARD]: a When this adjustment code is displayed,
Total forward travel distance its function is effective and the cooling fan
[ODO METER REVERSE]: speed is controlled to about 100% of the
Total reverse travel distance maximum speed.
1) Increase or decrease the adjustment
q Operating method: value by pressing [F3] or [F4].
When this adjustment code is displayed, its 2) When confirming the adjustment value,
function is effective and the load on the press [F6] and check that the alarm
machine, odometer, and reverse odometer are buzzer sounds.
displayed simultaneously. a Since [FAN SPEED] of this adjustment
a The data cannot be reset. code is different from the actual fan speed,
a After this adjustment code is turned OFF, see Testing and adjusting, "Testing fan
its function is ineffective. speed", for the fan speed testing method.
a When using this adjustment code, keep
the hydraulic oil temperature above 50°C.
(If the hydraulic oil temperature lowers
below 40°C, the fan speed fluctuates.)
its function is ineffective but the set adjust-
ment value is effective.
D65EX, PX, WX-16 30-103 41

Adjustment ID: 1012 (Steering lever neutral posi- Adjustment ID: 1013 (Steering lever leftmost posi-
tion adjustment) tion adjustment)
q This adjustment code is used to make the q This adjustment code is used to make the
power train controller recognize the neutral power train controller recognize the leftmost
position of the steering potentiometer of the position of the steering potentiometer of the
PCCS lever. PCCS lever.
a After the power train controller or PCCS lever a After the power train controller or PCCS lever
is replaced, be sure to carry out this adjust- is replaced, be sure to carry out this adjust-
ment once. ment once.
q Functions of function switches q Functions of function switches

[F3]: Unused [F3]: Unused
[F5]: Return to adjustment item selecting [F5]: Return to adjustment item selecting
screen (ID inputting screen) screen (ID inputting screen)
[F6]: Save adjustment value [F6]: Save adjustment value
q Operating method: q Operating method:

1) Check that the PCCS lever is in the neu- 1) Operate the PCCS lever to the left stroke
tral position of the steering direction and end of the steering direction and keep it in
keep it in that position. that position.
2) Press [F6] and check that the alarm 2) Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the adjustment is effective. the adjustment is effective.
a This adjustment code is used to make the a This adjustment code is used to make the
controller recognize the neutral position of controller recognize the leftmost position
the potentiometer. It is not used to adjust of the potentiometer. It is not used to
the steering force. adjust the steering force.
30-103 42 D65EX, PX, WX-16

Adjustment ID: 1014 (Steering lever rightmost posi- Adjustment ID: 2021 (Power train controller voltage
tion adjustment) check mode)
q This adjustment code is used to make the q This adjustment code is used to check the con-
power train controller recognize the rightmost stant power supply voltage and switch power
position of the steering potentiometer of the supply voltage applied to the power train con-
PCCS lever. troller.
a After the power train controller or PCCS lever a Use this adjustment code for testing, adjusting,
is replaced, be sure to carry out this adjust- or troubleshooting when necessary.
ment once.
q Functions of function switches [F3]: Unused
[F5]: Return to adjustment item selecting screen (ID inputting screen)
[F6]: Save adjustment value
q Information displayed on screen
q Operating method: [PT CONTROLLER UNSWITCH POWER]:
1) Operate the PCCS lever to the right stroke Constant power supply voltage
end of the steering direction and keep it in [PT CONTROLLER ACC POWER]:
that position. Switch power supply voltage
2) Press [F6] and check that the alarm
buzzer sounds. q Operating method:
a Even if this adjustment code is turned off, When this adjustment code is displayed, its
the adjustment is effective. function is effective and the constant power
a This adjustment code is used to make the supply voltage and switch power supply volt-
controller recognize the rightmost position age are displayed simultaneously.
of the potentiometer. It is not used to a After this adjustment code is turned OFF,
adjust the steering force. its function is ineffective.
D65EX, PX, WX-16 30-103 43

Adjustment ID: 2222 (HSS min. current setting a The following figure shows an example of
mode) reducing the set current for the left steer-
ing to increase the turning radius.
q This adjustment code is used to adjust the

turning radius to start steering the machine a Even if this adjustment code is turned off, the
when the steering feel is different by the steer- adjustment is effective.
ing direction.
a Use this adjustment code for work when nec-
essary.

[F3]: Unused
[F4]: Unused
q Operating method
1) Set the parking brake lever in the free
position.
2) Tilt the PCCS lever to a right or left posi-
tion at which the current to be set is indi-
cated and hold it at that position.
q If the lever is tilted to the left, the cur-
rent becomes negative.
q If the lever is tilted to the right, the
current becomes positive.
buzzer sounds.
4) Set the PCCS lever in neutral and depress
[F6], and the values are set to the initial
setting at the delivery time.
a The current (mA) varies in the range from
-395 (left end) to 395 (right end).
a As the set current is increased in the posi-
tive or negative direction, the turning
radius to start steering is reduced more
(the machine is steered more quickly).
a It is not necessary to steer the machine
during adjustment. After finishing adjust-
ment, however, steer the machine and
check that there is not a problem in the
actual steering feel.
30-103 44 D65EX, PX, WX-16

Adjustment ID: 6001 (R1 reverse slow set speed) Adjustment ID: 6002 (R2 reverse slow set speed)
q This adjustment code is used to adjust the q This adjustment code is used to adjust the
engine speed applied to travel at gear speed engine speed applied to travel at gear speed
R1 with the reverse slow mode ON. R2 with the reverse slow mode ON.
a Use this adjustment code for work when nec- a Use this adjustment code for work when nec-
essary. essary.
q Functions of function switches q Functions of function switches

[F3]: Increase adjustment value [F3]: Increase adjustment value
[F4]: Decrease adjustment value [F4]: Decrease adjustment value
q Information displayed on screen q Information displayed on screen

The speed reduced from the high idle speed The speed reduced from the high idle speed
(2,100 rpm) is displayed and the adjustment (2,100 rpm) is displayed and the adjustment
value is increased or decreased by 50 rpm value is increased or decreased by 50 rpm
a The adjustment value at the time of the a The adjustment value at the time of the
factory shipment is 300 rpm. factory shipment is 300 rpm.
(Setting at factory shipment: 2,100 – 300 = (Setting at factory shipment: 2,100 – 300 =
1,800 rpm) 1,800 rpm)
q Operating method q Operating method

1) Increase or decrease the adjustment 1) Increase or decrease the adjustment
value by pressing [F3] or [F4]. value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm 2) Press [F6] and check that the alarm
buzzer sounds. buzzer sounds.
a If the engine speed has been adjusted, it a If the engine speed has been adjusted, it
is displayed. It can be adjusted again is displayed. It can be adjusted again
within the adjustment range, however. within the adjustment range, however.
a It is not necessary to drive the machine a It is not necessary to drive the machine
during adjustment. After finishing adjust- during adjustment. After finishing adjust-
ment, however, drive the machine at R1 ment, however, drive the machine at R2
with the reverse slow mode ON and check with the reverse slow mode ON and check
that there is not a problem in the actual that there is not a problem in the actual
travel speed. travel speed.
a Even if this adjustment code is turned off, a Even if this adjustment code is turned off,
the adjustment is effective. the adjustment is effective.
D65EX, PX, WX-16 30-103 45

Adjustment ID: 6003 (R3 reverse slow set speed) Adjustment ID: 7842 (Transmission clutch IP and
fill time automatic initial correction)
q This adjustment code is used to adjust the

engine speed applied to travel at gear speed q This adjustment code is used to make the
R3 with the reverse slow mode ON. power train controller recognize the mechani-
a Use this adjustment code for work when nec- cal condition of the transmission.
essary. a After the power train controller or transmission
is replaced, be sure to carry out this adjust-
q Functions of function switches ment once.
[F3]: Increase adjustment value
[F4]: Decrease adjustment value q Functions of function switches
[F6]: Save adjustment value [F5]: Return to adjustment item selecting
q Information displayed on screen [F6]: Save adjustment value
The speed reduced from the high idle speed
(2,100 rpm) is displayed and the adjustment q Conditions for correction work
value is increased or decreased by 50 rpm 1) [ENGINE SPEED]: 1,800 – 2,100 rpm
a The adjustment value at the time of the 2) [T/C TEMPERATURE]: 65 – 85°C
factory shipment is 300 rpm. 3) Parking brake lever: LOCK position
(Setting at factory shipment: 2,100 – 300 = 4) PCCS lever: NEUTRAL position
1,800 rpm) a When using this adjustment code, keep
the abo ve c ond iti ons ( In pa rti c ula r,
q Operating method increase the power train oil temperature
1) Increase or decrease the adjustment sufficiently before starting adjustment).
value by pressing [F3] or [F4].
2) Press [F6] and check that the alarm q Operating method:
buzzer sounds. 1) Start the engine and keep its speed in the
a If the engine speed has been adjusted, it specified range of condition with the fuel
is displayed. It can be adjusted again control dial.
within the adjustment range, however. 2) Press [F6] and start the correction work
a It is not necessary to drive the machine and check that [I/P AUTO CHECK F
during adjustment. After finishing adjust- CLUTCH] is displayed newly on the
ment, however, drive the machine at R3 screen.
with the reverse slow mode ON and check 3) If [End of teaching. Press F6] is displayed
that there is not a problem in the actual on the screen, press [F6]. If the alarm
travel speed. buzzer sounds at this time, correction
a Even if this adjustment code is turned off, work is completed.
the adjustment is effective. a The machine does not move during the
correction work.
30-103 46 D65EX, PX, WX-16

Adjustment ID: 7843 (Transmission clutch IP man- Adjustment ID: 7845 (Transmission clutch IP learn-
ual initial correction) ing display)
q This adjustment code is used to carry out cor- q This adjustment code is used to check the
rection manually when the correction is not information of correction made by the opera-
carried out normally by the operation of IP tion of IP automatic correction (Adjustment ID:
automatic correction (Adjustment ID: 7842). 7842) or IP manual correction (Adjustment ID:
a Use this adjustment code after the IP correc- 7843).
tion work, if necessary. a Use this adjustment code for testing, adjusting,
or troubleshooting when necessary.
[F3]: Increase adjustment value q Functions of function switches
[F4]: Decrease adjustment value [F3]: Change display
[F5]: Return to adjustment item selecting [F4]: Change display
screen (ID inputting screen) [F5]: Return to adjustment item selecting
[F6]: Save adjustment value screen (ID inputting screen)
a If [F2] is pressed while [F1] is pressed, all [F6]: Unused
the correction values are set to 0.
q Operating method
q Functions of shift-up and shift-down switches When this adjustment code is displayed, its
You can select a clutch to be corrected manu- function is effective and the correction informa-
ally with the shift-up and shift-down switches. tion is displayed.
q Conditions for correction work its function is ineffective.
Same as the conditions for IP automatic cor-
rection (Adjustment ID: 7842).
q Operating method:
1) Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2) Select a clutch to be corrected manually
with the shift-up or shift-down switches.
buzzer sounds.
a The machine does not move during the
correction work.
D65EX, PX, WX-16 30-103 47

Adjustment ID: 7847 (Transmission clutch fill time Adjustment ID: 9997
manual initial correction) (High idle cut mode)
q This adjustment code is used to carry out cor- q This adjustment code is used to limit the high
rection manually when the correction is not idle speed.
carried out normally by the operation of fill time a Use this adjustment code for work when nec-
automatic correction (Adjustment ID: 7842). essary.
a Use this adjustment code after the fill time cor-
rection work, if necessary. q Functions of function switches
[F3]: Increase adjustment value [HI IDLE RPM
q Functions of function switches SET MODE]
[F3]: Increase adjustment value [F4]: Decrease adjustment value [HI IDLE
[F4]: Decrease adjustment value RPM SET MODE]
a If [F2] is pressed while [F1] is pressed, all
the correction values are set to 0. q Operating method
q Functions of shift-up and shift-down switches value by pressing [F3] or [F4].
You can select a clutch to be corrected manu- 2) Press [F6] and check that the alarm
ally with the shift-up and shift-down switches. buzzer sounds.
a The value displayed when the clutch is a When resetting the limitation of the high
selected is correction information set automati- idle speed, set the adjustment value which
cally or manually before. is the initial setting at factory shipment to
q Conditions for correction work the original high idle speed (2,100 rpm).
Same as the conditions for fill time automatic a Even if this adjustment code is turned off,
correction (Adjustment ID: 7842). the adjustment is effective.
q Operating method:
1) Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2) Select a clutch to be corrected manually
with the shift-up or shift-down switches.
buzzer sounds.
a The machine does not move during the
correction work.
30-103 48 D65EX, PX, WX-16

Adjustment ID: 9998 (Max. gear speed setting mode) Pm Clinic

The machine monitor can check the condition of the
machine without connecting testing tools to assist
the Pm Clinic and other periodic inspections.
1. Selecting menu
Select "08 PM CLINIC" on the Service menu
screen.
q This adjustment code is used to limit the maxi-

mum transmission gear speed.
q The limited gear speed is applied in both auto-
matic gearshift mode and manual gearshift
mode.
a Use this adjustment code for work when nec-
essary.
q Functions of function switches 2. Information displayed on Pm Clinic screen

[F3]: Increase adjustment value [MAX SHIFT] The Pm Clinic function displays the following
[F4]: Decrease adjustment value [MAX SHIFT] information on 2 pages.
[F5]: Return to adjustment item selecting q 1st screen
q Operating method
buzzer sounds.
a When resetting the maximum gear speed
limit, set the adjustment value to the maxi-
mum gear speed (3RD) that is the initial
set value at delivery.
a The setting with this adjustment code
becomes effective after the starting switch
is turned to the OFF position and turned to
the ON position again.
D65EX, PX, WX-16 30-103 49

q 2nd screen Cylinder Cut-Out operation

The operator can perform Cylinder Cut-Out opera-
tion with the machine monitor.
Cylinder cut-out operation means to run the engine
with 1 or more fuel injectors disabled electrically to
reduce the number of effective cylinders. This
operation is used to find out a cylinder which does
not output power normally (combustion in it is
abnormal).
1. Selecting menu
Select "09 Cylinder Cut-Out" on the "Service
Menu" screen.
q [F1]: Change screen

q [F2]: Change screen
q [F3]: Reset holding
q [F4]: Hold (displayed data)
3. Holding displayed information

The displayed information can be held and
released with [F3] and [F4].
2. Selecting cylinder to be disabled

After the "Cylinder Cut-Out" screen is dis-
played, select a cylinder to be disabled with the
function switches.
q [F1]: Move selection mark (R) to left
q [F2]: Move selection mark (R) to right
q [F3]: Reset holding
q [F4]: Hold
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is disabled.
a If the machine monitor disables a cylinder
but the engine controller cannot disable
that cylinder, the background of the cylin-
der No. becomes yellow.
a One or more cylinders can be disabled.
30-103 50 D65EX, PX, WX-16

3. Resetting disabled cylinder Display of No Injection

When changing a cylinder to be disabled or If the engine is operated after long storage of the
when cylinder cut-out operation is finished, machine, it may be worn or damaged because of
select a disabled cylinder to be reset with the insufficient lubrication with oil. To prevent this, the
function switches. function to lubricate the engine before starting it by
a This operation may be performed while cranking it without injecting fuel is installed.
the engine is running. Set the No Injection while the engine is stopped.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes light 1. Selecting menu
blue, the cylinder is reset. Select "10 No Injection" on the "Service Menu"
a If the machine monitor resets a cut-out screen.
cylinder but the engine controller cannot
reset that cut-out cylinder, the background
(a) of the cylinder No. becomes red.
a The cylinder cut-out operation is not auto-
matically reset after the screen returns to
the operator mode. Accordingly, be sure
to perform the resetting operation after the
cylinder cut-out operation is finished.
4. Function of holding displayed information

If [F4] is pressed during the reduced cylinder
mode operation, the displayed information is
newly held (b) (The real-time information is
kept displayed on the left side). 2. Preparation for no injection cranking
a While the information is held, if [F3] is When the “No injection” screen is displayed,
pressed, the holding function is reset. the machine monitor checks automatically if no
a The holding function is effective, regard- injection cranking can be performed.
less of setting of the cylinder cut-out oper- If no injection cranking can be performed, the
ation. screen changes to the next screen automati-
cally.
a If no injection cranking cannot be per-
formed because the engine is running or
the communication is abnormal, the
screen does not change from the following
screen. In this case, depress [F5] to return
to the "Service Menu" screen and solve
the problem.
[Reference]
q If a normally operating cylinder is disabled, the
following phenomena occur.
1) Lowering of engine speed
2) Increase of final injection rate command
(quantity)
q If the engine is running near the high idle, how-
ever, the engine speed may not lower for the
reason of engine control.
q In this case, lower the engine speed with the
fuel control dial and judge by increase of the
injection rate command.
D65EX, PX, WX-16 30-103 51

3. Display of confirmation screen 5. Finishing no injection cranking

The confirmation screen for no injection crank- After completing the no injection cranking
ing is displayed. Select with the function operation, press [F6], and finish of no injection
switch. cranking is displayed and the screen returns to
q [F5]: Do not perform (Return to Service the "2. Preparation of No Injection cranking"
menu screen) screen automatically.
q [F6]: Perform
6. Prohibiting no injection cranking

4. Starting no injection cranking If the operator tries to perform the no injection
If no injection cranking (Fuel injection in no cyl- cranking while the engine is running, the mes-
inders) becomes effective, that is displayed on sage that the engine is running is displayed and
the screen. Under this condition, crank the the no injection cranking is not set effective.
engine with the starting motor. a Depress [F5] to return to the "Service
a While the screen is changing to the follow- Menu" screen, stop the engine, and select
ing screen, the screen of "Being prepared" no injection cranking again.
is displayed.
a Limit the cranking time to 20 seconds to
protect the starting motor.
30-103 52 D65EX, PX, WX-16

Display of Fuel Consumption 3. Display and function during measurement

This function calculates the hourly fuel consump- Clock mark (a) flashes during measurement.
tion from the actual fuel consumption in a measur- a While the fuel consumption is being mea-
ing period and indicates it. sured, the operator can work with the
operator mode and other functions. Mea-
1. Selecting menu surement is not finished until this screen is
Select "11 Fuel Consumption" on the "Service displayed again and [F1] is pressed (Even
Menu" screen. if the starting switch is turned OFF, this
function is kept effective, although fuel
consumption is measured only while the
engine is running).
2. Starting measurement
After the screen of "Fuel Consumption" is dis-
played, start measurement with the function
switches. 4. Finishing measurement
q [F1]: Start Press [F1], and measurement is finished and
q [F2]: Clear the data are displayed on the finishing date
q [F5]: Return to “Service Menu” screen and time side.
a When the screen of "Fuel Consumption" is
displayed, if a data is indicated, it is the 5. Displaying fuel consumption
data of the previous measurement. This If the measurement is finished, the hourly fuel
data is not an obstacle to new measure- consumption calculated from the fuel con-
ment and can be deleted by pressing [F2]. sumption calculated by the engine controller
a If [F1] is pressed, the data is displayed on and the elapsed time are displayed.
the starting date and time side and mea-
surement starts.
a The display unit of the fuel changes
according to the unit set with the initializa-
tion (unit setting) function.
SI and meter: l/h,
inch: gal/h
D65EX, PX, WX-16 30-103 53

Display of KOMTRAX Settings (Terminal Status) 3. Contents of Terminal Status

The setting condition and operating condition of On the "Terminal Status" screen, the following
KOMTRAX can be checked with "KOMTRAX Set- items are displayed.
tings". q Terminal Type: model name of KOMTRAX
Terminal Status is used to check the setting condi- communication modem
tion of the KOMTRAX terminal. q KOMTRAX communication: Executing
condition of KOMTRAX communication
1. Selecting menu q GMT time: Greenwich Meant Time (+ 9
Select "12 KOMTRAX Settings" on the "Ser- hours in Japan)
vice Menu" screen. q [F5]: Return to “KOMTRAX Settings”
screen

After the "KOMTRAX Settings" screen is dis-
played, select "01 Terminal Status" with the
30-103 54 D65EX, PX, WX-16

Display of KOMTRAX Settings (GPS & Commu- 3. Contents of display of condition of positioning
nication Status) and communication
The setting condition and operating condition of On the screen of "GPS & Communication Sta-
KOMTRAX can be checked with KOMTRAX Set- tus", the following items are displayed.
tings. q Positioning: Positioning condition of GPS
Condition of positioning and communication is used q Communication: Communication environ-
to check the condition of positioning and communi- ment of communication modem and con-
cation of the KOMTRAX terminal. necting condition of c ommunication
modem
1. Selecting menu q Number of message not yet sent: Number
Select "12 KOMTRAX Settings" on the "Ser- of mails in machine monitor not yet sent
vice Menu" screen. q [F5]: Return to “KOMTRAX Settings”
screen

After the display of "KOMTRAX Settings"
screen is displayed, select "02 GPS & Commu-
nication Status" with the function switches or
D65EX, PX, WX-16 30-103 55

Display of KOMTRAX Settings (Modem S/N) 3. Contents of display of modem S/N

The setting condition and operating condition of The serial No. of KOMTRAX communication
KOMTRAX can be checked with “KOMTRAX Set- modem is displayed.
tings”. q [F5]: Return to “KOMTRAX Settings”
Modem S/N is used to check the serial No. of the screen
KOMTRAX communication modem.
1. Selecting menu
Select "12 KOMTRAX Settings" on the "Ser-
vice Menu" screen.

After the display of "KOMTRAX Settings"
screen is displayed, select "03 Modem S/N"
with the function switches or numeral input
switches.
30-103 56 D65EX, PX, WX-16

Display of Service Message 3. Display of message (with return mail function)

Special messages for the serviceman sent from the If a box to enter a value with the numeral keys
KOMTRAX base station (a distributor, etc.) can be is displayed under the message, enter a
checked with this function. proper number with the numeral input switches
If there is setting in a message, a return mail can be and function switches and confirm it, and the
sent by using numeral input switches. information is returned to the KOMTRAX base
station.
1. Operation to display menu q [F5]: Return to service menu screen
Select "13 Service Message" on the "Service q [F6]: Confirm and return input value
Menu" screen. a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the ser-
viceman, the message monitor is not dis-
played when it is received as in the
operator mode.
2. Display of message (Read-only)

If there is a message, its contents are dis-
played. If there is not a message, "No mes-
sage" is displayed.
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the ser-
viceman, the message monitor is not dis-
played when it is received as in the
operator mode.
D65EX, PX, WX-16 30-103 57

SEN05121-02

©2010 KOMATSU
All Rights Reserved
30-103 58
SEN05122-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Handling of voltage circuit of engine controller ............................................................................................... 2
Adjustment method when controller has been replaced ................................................................................. 3
Preparation work for troubleshooting of electrical system .............................................................................. 5
Inspection procedure of diode......................................................................................................................... 9
Pm-Clinic service .......................................................................................................................................... 10
D65EX, PX, WX-16 30-104 1

SEN05122-01 Handling of voltage circuit of engine controller
Handling of voltage circuit of

engine controller 1
1. When disconnecting or connecting a connector

between engine controller and engine, be sure
to turn off the starting switch.
k Before connecting the harness connec-
tor, be sure to completely remove sand,
dust, water, etc., from inside of control-
ler side connector.
2. Do not start the engine with T-adapter inserted

in or connected to a connector between engine
controller and engine for troubleshooting.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
30-104 2 D65EX, PX, WX-16

Adjustment method when controller has been replaced SEN05122-01
Adjustment method when 2. Adjusting power train controller

controller has been replaced 1
Select “power train controller initialization
(0002)” and adjust the power train controller.
a After the machine is assembled or power train
controller is replaced, adjust the system
k If the system is not adjusted, the machine
may not operate normally and may move
suddenly. Accordingly, be sure to adjust it.
a Precautions for replacing a controller:
If a controller is replaced, the following adjust-
ment values are reset to the initial set values at
factory shipment.
Accordingly, take a record of the set values
before replacement, if necessary.
q Load record check mode: (0910)
q Fan 100% mode (1005)
q HSS min. current setting mode (2222)
q R1 reverse slow set speed (6001) 3. Turning power on again
q R2 reverse slow set speed (6002) Turn the starting switch OFF then ON, and set
q R3 reverse slow set speed (6003) the machine monitor in the “07 Adjustment” of
q High idle cut mode (9997) the service mode again.
q Max. gear speed setting mode (9998)
a Precautions for replacing a controller: 4. Adjusting work equipment specification
When replacing a controller, stop the machine Select “work equipment specification setting
in a safe place and turn the starting switch off. (0004)” and adjust the machine specification.
1. Setting system in service mode.

Turn the starting switch ON and set the
machine monitor in the “07 Adjustment” of the
service mode.
5. Adjusting brake pedal potentiometer

Select “brake pedal potentiometer initial cor-
rection (0005)” and adjust the brake potentiom-
eter.
D65EX, PX, WX-16 30-104 3

SEN05122-01 Adjustment method when controller has been replaced
6. Adjusting pitch angle sensor 9. Adjustment of steering lever right maxi-

Select “pitch angle sensor initial correction mum position
(0009)” and adjust the pitch angle sensor. Select “steering lever rightmost position adjust-
ment (1014)” and perform adjustment.
7. Adjustment of steering lever neutral posi-

tion 10. Adjustment of transmission clutch IP and
Select “steering lever neutral position adjust- fill time
ment (1012)” and perform adjustment. Select “transmission clutch IP and fill time
automatic initial correction (7842)” and perform
adjustment.
8. Adjustment of steering lever left maximum

position
Select “steering lever leftmost position adjust- 11. Turning on power again
ment (1013)” and perform adjustment. Turn the starting switch to the OFF position
and to the ON position again.
12. Confirmation of failure code

1) Set the machine monitor to “Abnormality
Record” in the service mode.
2) Check for a failure code occurring cur-
rently. If no failure code is occurring cur-
rently, delete all the recorded failure
codes.
a If any failure code is occurring cur-
rently, remove the cause of the trou-
ble by troubleshooting, and then
perform steps 11 and 12 again.
a Precautions after replacing controller
Re-set the adjustment values
recorded before replacing the control-
ler, if necessary.
30-104 4 D65EX, PX, WX-16

Preparation work for troubleshooting of electrical system SEN05122-01
Preparation work for a If a camera is installed, CM05 is also

troubleshooting of electrical wired.
system 1
a When carrying out troubleshooting of an elec-

tric circuit related to the machine monitor,
engine controller, or power train controller,
expose the related connectors according to the
1. Machine monitor
1) Remove cover (1).
2) Remove the mounting bolts (2) and
remove cover (3).
2. Engine controller
1) Open the left engine side cover (1) and
remove lower cover (2).
3) Remove the mounting bolts (4) of machine

monitor (5) bracket and pull out machine
monitor (5) and switch together toward the
operator's seat.
2) Insert or connect troubleshooting T-adapt-
ers in or to connectors (4) (ECM), (5)
(CE02) and (6) (CE03) of engine controller
(3).
a Since connectors ECM and CE02 are
fixed with screws, loosen those
screws before disconnecting.
a When returning connectors ECM and
CE02, tighten the screws to the spec-
ified torque.
3 Screw:
2.83 ± 0.28 Nm {0.28 ± 0.03 kgm}

ers in or to connectors CM01, CM02, and
CM03 of machine monitor (5).
a AT11 is for the GPS antenna.
D65EX, PX, WX-16 30-104 5

SEN05122-01 Preparation work for troubleshooting of electrical system
k In order to prevent malfunction and mis- a If the removal and installation of the
taken system error warning, be sure to connector is difficult, remove the con-
completely remove foreign object (b) such nector from the console box and per-
as sand, dust, water, etc., from inside of form the work.
controller side connector (a) with air blow a Since the connectors are fixed with
etc., before connecting to harness connec- screws, loosen those screws before
tor. disconnecting.
a When returning the connectors,
tighten the screws to the specified
torque.
3 Screw: 2.83 ± 0.28 Nm
{0.28 ± 0.03 kgm}
4. KOMTRAX terminal
1) Remove covers (1), (2) and (3) of the right
console box.

1) Slide the operator’s seat (1) rearward and
remove the inside lower cover (2) of the
left console.

ers in or to connectors (4) (STC1), (5)
(STC2), and (6) (STC3) of power train
controller (3).
30-104 6 D65EX, PX, WX-16

Preparation work for troubleshooting of electrical system SEN05122-01
2) Insert or connect the troubleshooting T- 6. Boost pressure sensor and intake manifold
adapters in or to connectors (5) (CK01) temperature sensor (BOOST PRES & IMT)
and (6) (CK02) of KOMTRAX terminal (4). a Disconnecting and connecting connectors
a Connector (7) (AT21) is for the com- Since the connectors of boost pressure
munication antenna. and temperature sensor have special lock
mechanism, disconnect in the order of (a)
– (b) and connect in the order of (c) – (d)
as shown in the below figure.
Disconnect: (a) release lock – (b) discon-
nect connector
Connect: (c) connect connector – (d)
mesh lock
5. Air pressure sensor (AIR PRESSURE SEN-

SOR)
Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnecting and connecting connectors a Removal and installation of sensor
Since the connectors of air pressure sen- When removing and installing boost pres-
sor, engine Ne speed sensor, engine Bkup sure and intake manifold temperature sen-
speed sensor and engine oil pressure sor, use T type torque wrench [bearing
switch have special lock mechanism, dis- number : T15].
connect in the order of (a) – (c) and con-
nect in the order of (d) – (f) as shown in 7. Fuel supply pump IMV solenoid (FUEL
the below figure. REGULATOR)
Disconnect: (a) slide lever – (b) release a Disconnecting and connecting connectors
lock – (c) disconnect con- Since the connector of fuel supply pump
nector IMV solenoid has special lock mechanism,
Connect: (d) connect connector – (e) disconnect in the order of (a) – (b) and
mesh lock – (f) slide lever connect in the order of (c) – (d) as shown
in the below figure.
Disconnect: (a) release lock – (b) discon-
nect connector
Connect: (c) connect connector – (d)
mesh lock
a Removal and installation of sensor

When removing and installing engine oil
pressure switch, use deep sockets with 27
mm width across flats and φ22mm center
hole diameter.
D65EX, PX, WX-16 30-104 7

SEN05122-01 Preparation work for troubleshooting of electrical system
8. Common rail pressure sensor (FUEL RAIL 9. Engine coolant temperature sensor (COOL-
PRESS) ANT TEMP)
a Disconnecting and connecting connectors a Disconnecting and connecting connectors
Since the connector of common rail pres- Since the connector of engine coolant
sure sensor has special lock mechanism, temperature sensor has special lock
disconnect in the order of (a) – (b) and mechanism, disconnect in the order of (a)
connect in the order of (c) – (d) as shown – (b) and connect in the order of (c) – (d)
in the below figure. as shown in the below figure.
Disconnect: (a) release lock – (b) discon- Disconnect: (a) release lock – (b) discon-
nect connector nect connector
Connect: (c) connect connector – (d) Connect: (c) connect connector – (d)
mesh lock mesh lock
a Removal and installation of sensor

When removing and installing engine
coolant temperature sensor, use deep
sockets with 19 mm width across flats and
φ18 mm center hole diameter.
30-104 8 D65EX, PX, WX-16

Inspection procedure of diode SEN05122-01
Inspection procedure of diode 1 2. When using analog tester

1) Switch to resistance range.
a The direction of continuity of diode is marked 2) Check the deflection of needle while con-
on the surface of the diode. necting as follows.
i) Set red (+) test lead to diode anode
(P) side and black (–) test lead to
cathode (N) side.
ii) Set red (+) test lead to diode cathode
(N) side and black (–) test lead to
anode (P) side.
3) Based on the deflection of needle, judge
the quality of diode.
q Needle does not deflect with connec-
tion i) but deflects with connection ii):
Normal. (however deflection range
(resistance value) varies depending
on the type of tester and measuring
range.
1. When using digital tester q Needle deflects with both connection
1) Switch to diode range and check dis- i) and ii): Defective (internal short cir-
played value. cuit)
a Voltage of internal battery is dis- q Needle does not deflect with either
played by normal tester. connection i) or ii): Defective (internal
2) Set red (+) test lead to diode anode (P) disconnection)
side and black (–) test lead to cathode (N)
side. Check displayed value.
3) Judge quality of diode from displayed
value.
q Displayed value does not change:
No continuity (defect)
q Displayed value changes:
Continue (normal) (note)
Note: In the case of silicon diode, the
value between 460 – 600 mV is dis-
played.
q Displayed value becomes 0 or near 0
: Short-circuiting of diode internal part
(defect)
D65EX, PX, WX-16 30-104 9

SEN05122-01 Pm-Clinic service
Pm-Clinic service 1
Model Serial No. Service meter

T D65EX-16 TD65WX-16
h
T D65PX-16
User name Date of clinic Serviceman

/ /
Specifications
Blade Attachment Shoe width
T Sigma blade T Multi-shank ripper T 510 mm T 760 mm
T Angle blade T Towing winch T 560 mm T 940 mm
T Straight tilt blade T Drawbar T 610 mm T 940 mm
T Power angle power tilt blade T Long drawbar T 660 mm
T Counterweight
Operating conditions
Quarry, mine Construction Type of soil Type of work
(specific gravity)
T Coal T Construction, T Rock T Dozing, digging %
T Gold civil engineering T Gravel T Side cutting %
T Limestone T Roads T Sand T Grading %
T T Tunnels T Clay T Travel %
T
Existence of abnormalities
Oil, water level check
T Engine coolant level When necessary
T Engine oil level T Power train T Damper case
T Hydraulic oil level T Final drive T( )
Ambient temperature Height above sea level

Max.
°C
Min.
Operator's opinion
Visual check results
Failure code history

[ ] h [ ] h
Content: Content:
[ ] h [ ] h
Content: Content:
30-104 10 D65EX, PX, WX-16

Pm-Clinic service SEN05122-01
a Engine coolant temperature: Max. range a Power train oil temperature: Max. range
D65EX, PX, WX-16 30-104 11

Pm-clinic measuring points (1/2)
Reference pages for measurement procedure designated
*1. Engine speed: Testing and adjusting, No. 1 pages 5 – 6

*2. Blow-by pressure: Testing and adjusting, No. 1 page 18
*3. Engine oil pressure: Testing and adjusting, No. 1 page 19
*4. Boost pressure: Testing and adjusting, No. 1 pages 7 – 8
*5. Exhaust temperature: Testing and adjusting, No. 1 pages 9 – 10
30-104 12 D65EX, PX, WX-16

Pm-clinic measuring points for D65EX, PX, WX-15E0 (2/2)
Reference pages for measurement procedure designated

*6. Torque converter related: Testing and adjusting, No. 2 page 4
*7. Transmission related: Testing and adjusting, No. 2 pages 5 – 7
*8. Steering brake related: Testing and adjusting, No. 2 page 3
*9. Work equipment and HSS related: Testing and adjusting, No. 2 page 20 – 22
D65EX, PX, WX-16 30-104 13

T D65EX-16 #
Serial
Pm-clinic check sheet T D65PX-16 #
number
T D65WX-16 #
Work order Date Service meter Serviceman
/ / h
Standard
Service limit Measurement
Check item Measurement conditions Unit value for new Pass Fail
machine value results
Low idle 800 – 850 800 – 850

Deceleration pedal
High idle 975 – 1,025 975 – 1,025
Engine speed depressed rpm
High idle 2,020 – 2,120 2,020 – 2,120
Torque converter stall (P mode) 1,670 – 1,870 1,650
Blow-by kPa Max. 1.96 2.94
Torque converter stall
Engine
pressure {mmAq} {Max. 200} {300}

Engine at low Min. 0.15 0.08
Engine oil idle MPa {Min. 1.5} {0.8}
SAE15W-40, SAE30
pressure Engine at high {kg/cm2} 0.34 – 0.59 0.21
idle {3.5 – 6.0} {2.1}
Boost kPa 151 – 171 120
Torque converter stall
pressure {mmHg} {1,130 – 1,330} {900}
Exhaust
Torque converter stall °C Max. 600 Max. 650
temperature
Standard
Service limit Measurement
value results
machine
Torque converter
Inlet oil Transmission: Max. 0.98 Max. 0.98

pressure Neutral {Max. 10} {Max. 10}
MPa
Oil Engine at high idle
{kg/cm2}
Outlet oil temperature: 0.39 – 0.88 0.39 – 0.88
pressure 70 – 90°C {4 – 9} {4 – 9}
Standard Service limit Measurement

value results
machine
Cooling fan Transmission
3.10 – 3.50 Min. 3.01

Engine at low idle
{31.7 – 35.7} {Min. 30.7}
Main relief Transmission: MPa
pressure Neutral {kg/cm2} 3.25 – 3.65 Min. 3.17
Engine at high idle
{33.3 – 37.3} {Min. 32.3}
• Fan 100% speed mode Min.

550 – 650 500
• Engine: Low idle speed
Fan speed rpm
• Fan 100% speed mode Max.
1,700 – 1,800 1,600
• Engine: High idle speed
30-104 14 D65EX, PX, WX-16

T D65EX-16 #
Serial
Pm-clinic check sheet T D65PX-16 #
number
T D65WX-16 #
/ / h
Standard
Check item Measurement Unit value for new Service limit Measurement Pass Fail
conditions machine value results
35.2 – 38.1 Min. 32.8
Steering
HSS LS oil pressure when relieved

Engine at high{359 – 389} {Min. 335}
idle MPa 37.1 – 40.1 Min. 34.8
HSS oil pressure when relieved
{kg/cm2} {379 – 409} {Min. 355}
Engine at high 2.55 – 2.94 Min. 2.55
Brake actuating pressure
Brake
idle {26 – 30} {Min. 26.0}

Brake Apply brake and run engine at high idle with
Machine must not move
performance transmission gear in F2.
Standard
Work equipment
27.4 – 30.9 Min. 26.4
load sensing Engine at high idle {280 – 315} {Min. 270}
pressure
Min. 28.4 Min. 27.4
Hydraulic system
Ripper lift relief

Engine at low {Min. 290} {Min. 280}
idle Min. 28.4 Min. 27.4
HSS and Blade tilt relief MPa {Min. 290} {Min. 280}
work equipment {kg/cm }
2
pump Ripper lift relief 29.4 – 32.9 Min. 28.4

{300 – 335} {Min. 290}
Engine at high 29.4 – 32.9 Min. 28.4
Blade tilt relief
idle {300 – 335} {Min. 290}
PPC valve 3.19 – 4.17 3.19 – 4.17
Blade tilt relief
output pressure {32.5 – 42.5} {32.5 – 42.5}
Standard
EX/WX:
Straight tilt dozer Max. 3.1
2.2 – 2.8
Work equipment speed
Sigma dozer
Blade RAISE PX: 2.1 – 2.7 Max. 3.0
Power angle
power tilt dozer 2.2 – 2.8 Max. 3.1
Straight tilt dozer High idle second
1.3 – 1.9 Max. 2.1
Sigma dozer
Tilt (left o right)
Power angle
1.4 – 2.0 Max. 2.2
power tilt dozer
Angle (left o right) 3.5 – 4.5 Max. 5.0
Ripper RAISE 1.0 – 2.0 Max. 2.5
Standard
Hydraulic
Hydraulic oil temperature °C 45 – 55 —

drift
Blade lift cylinder Engine stopped mm/ Max. 35 Max. 35

Blade tilt cylinder 5 min. Max. 70 Max. 70
Standard
Visual inspection of final drive drain plug Engine stopped — There must be no
excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
D65EX, PX, WX-16 30-104 15

Pm-clinic
Serial T D65EX-16 #
undercarriage check sheet
number T D65WX-16 #

/ / h
q Measure the bushing temperature immediately after operations

Left side of machine
Right side of machine
a Measurement results
Pass Fail Left A: Clearance Right A: Clearance
Left side of machine track between links track between links
Right side of machine Pin Pin

1.4 1.4
No. No.
q Opening of track link
30-104 16 D65EX, PX, WX-16

Pm-clinic
Serial
undercarriage check sheet T D65PX-16 #
number

/ / h


1.4 1.4
No. No.
D65EX, PX, WX-16 30-104 17

Undercarriage troubleshooting report (Normal) (Program form No.: SELA195001)
30-104 18 D65EX, PX, WX-16

Undercarriage troubleshooting report (Impact) (Program form No.: SELA195001)
D65EX, PX, WX-16 30-104 19

Pm-clinic
Serial T D65EX-16 #
undercarriage check sheet (PLUS specification)
number T D65WX-16 #

/ / h


1.4 1.4
No. No.
30-104 20 D65EX, PX, WX-16

Pm-clinic
Serial
undercarriage check sheet (PLUS specification) T D65PX-16 #
number

/ / h


1.4 1.4
No. No.
D65EX, PX, WX-16 30-104 21

Undercarriage troubleshooting report (Normal, impact) (PLUS specification)

(Program form No.: SELA195001)
30-104 22 D65EX, PX, WX-16

D65EX, PX, WX-16 30-104 23

SEN05122-01

©2011 KOMATSU
All Rights Reserved
30-104 24
SEN05029-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
40 Troubleshooting 40
100 Failure code table and fuse locations

Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 7
D65EX, PX, WX-16 40-100 1

SEN05029-01 Failure codes table
Failure codes table 1
Action Failure Component Category of Reference

Trouble (Displayed on screen)
code code in charge history manual No.
E03 1500L0 Transmission clutch: Abnormal P/T Electrical system
E03 15SAL1 Forward clutch: Fill high P/T Electrical system
E03 15SALH Forward clutch: Fill low P/T Electrical system
E03 15SBL1 Reverse clutch: Fill high P/T Electrical system
E03 15SBLH Reverse clutch: Fill low P/T Electrical system
E03 15SEL1 Speed 1st clutch: Fill high P/T Electrical system
E03 15SELH Speed 1st clutch: Fill low P/T Electrical system
E03 15SFL1 Speed 2nd clutch: Fill high P/T Electrical system
Troubleshooting
E03 15SFLH Speed 2nd clutch: Fill low P/T Electrical system by failure code,
E03 15SGL1 Speed 3rd clutch: Fill high P/T Electrical system Part 1
SEN05031-00
E03 15SGLH Speed 3rd clutch: Fill low P/T Electrical system
E02 15SJL1 L/U: Fill high P/T Electrical system
E02 15SJLH L/U: Fill low P/T Electrical system
— AB00MA Battery Charge Abnormal MON Mechanical system
— B@BAZG Eng Oil Press Low ENG Mechanical system
— B@BCNS Eng Water Overheat ENG Mechanical system
— B@CENS T/C Oil Overheat P/T Mechanical system
— B@HANS Hyd Oil Overheat P/T Mechanical system
E04 CA111 EMC Critical Internal Failure ENG Electrical system
E04 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E03 CA122 Chg Air Press Sensor High Error ENG Electrical system
E03 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E03 CA131 Throttle Sensor High Error ENG Electrical system
E03 CA132 Throttle Sensor Low Error ENG Electrical system
E02 CA144 Coolant Temp Sens High Error ENG Electrical system
E02 CA145 Coolant Temp Sens Low Error ENG Electrical system
E01 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E01 CA154 Chg Air Temp Sensor Low Error ENG Electrical system Troubleshooting
E03 CA155 Chg Air Temp High Speed Derate ENG Electrical system by failure code,
Part 2
E03 CA187 Sens Supply 2 Volt Low Error ENG Electrical system SEN05032-01
E03 CA221 Ambient Press Sens High Error ENG Electrical system
E03 CA222 Ambient Press Sens Low Error ENG Electrical system
E03 CA227 Sens Supply 2 Volt High Error ENG Electrical system
— CA234 Eng Overspeed ENG Mechanical system
E03 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E03 CA271 IMV/PCV1 Short Error ENG Electrical system
E03 CA272 IMV/PCV1 Open Error ENG Electrical system
E03 CA281 Pump Press Balance Error ENG Electrical system
E03 CA322 Inj #1 (L#1) Open/Short Error ENG Electrical system
40-100 2 D65EX, PX, WX-16

Failure codes table SEN05029-01

E03 CA324 Inj #3 (L#3) Open/Short Error ENG Electrical system Troubleshooting
by failure code,
E03 CA325 Inj #6 (L#6) Open/Short Error ENG Electrical system Part 2
E03 CA331 Inj #2 (L#2) Open/Short Error ENG Electrical system SEN05032-01

E04 CA342 Calibration Code Incompatibility ENG Electrical system
E03 CA351 Injectors Drive Circuit Error ENG Electrical system
E03 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E03 CA386 Sens Supply 1 Volt High Error ENG Electrical system
E01 CA428 Water in Fuel Sensor High Error ENG Electrical system
E01 CA429 Water in Fuel Sensor Low Error ENG Electrical system
E02 CA435 Eng Oil Press Sw Error ENG Electrical system
E04 CA441 Battery Voltage Low Error ENG Electrical system
E04 CA442 Battery Voltage High Error ENG Electrical system
E03 CA449 Rail Press Very High Error ENG Electrical system
E03 CA451 Rail Press Sensor High Error ENG Electrical system
E03 CA452 Rail Press Sensor Low Error ENG Electrical system
E03 CA488 Chg Air Temp High Torque Derate ENG Electrical system
Troubleshooting
E02 CA553 Rail Press High Error ENG Electrical system by failure code,
E02 CA559 Rail Press Low Error ENG Electrical system Part 3
SEN05033-01
E03 CA689 Eng Ne Speed Sensor Error ENG Electrical system
E03 CA731 Eng Bkup Speed Sens Phase Error ENG Electrical system
E04 CA757 All Continuous Data Lost Error ENG Electrical system
E03 CA778 Eng Bkup Speed Sensor Error ENG Electrical system
E03 CA1633 KOMNET Datalink Timeout Error ENG Electrical system
E03 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E03 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E03 CA2249 Rail Press Very Low Error ENG Electrical system
E01 CA2265 Fuel Feed Pump Open Error ENG Electrical system
E01 CA2266 Fuel Feed Pump Short Error ENG Electrical system
E03 CA2311 IMV Solenoid Error ENG Electrical system
E01 CA2555 Grid Htr Relay Volt Low Error ENG Electrical system
E01 CA2556 Grid Htr Relay Volt High Error ENG Electrical system
— D110KB Battery Relay: Drive Short Circuit P/T Electrical system
E02 D130KA Neutral relay: Disconnection P/T Electrical system
E02 D130KB Neutral relay: Short circuit P/T Electrical system
Troubleshooting
E01 D161KA Back-up alarm relay: Disconnection P/T Electrical system by failure code,
E01 D161KB Back-up alarm relay: Short circuit P/T Electrical system Part 4
SEN05034-01
E01 D862KA GPS Antenna Open Circuit MON Electrical system
E03 DAFRKR CAN Disconnection P/T Electrical system
E03 DAFRMC CAN Discon (Monitor Detected) MON Electrical system
D65EX, PX, WX-16 40-100 3


E03 DB2RKR CAN Disconnection ENG Electrical system
E01 DBE0KT PT controller: Abnormality in controller P/T Electrical system
E04 DBE1KK Battery direct Source voltage reduction P/T Electrical system
E04 DBE2KK Solenoid Source voltage reduction P/T Electrical system
E03 DBE5KK PT cont.: Sensor voltage 5 V (1) reduction P/T Electrical system
E03 DBE6KK PT cont.: Sensor voltage 24 V reduction P/T Electrical system
Troubleshooting
E02 DBE7KK PT cont.: Sensor voltage 5 V (2) reduction P/T Electrical system by failure code,
E04 DBE9KQ PT controller: Type select signal P/T Electrical system Part 4
SEN05034-01
E02 DD12KA Shift up Sw: Disconnection P/T Electrical system
E02 DD12KB Shift up Sw: Short circuit P/T Electrical system
E02 DD13KA Shift down Sw: Disconnection P/T Electrical system
E02 DD13KB Shift down Sw: Short circuit P/T Electrical system
E03 DD14KA Parking lever Sw: Disconnection P/T Electrical system
E03 DD14KB Parking lever Sw: Short circuit P/T Electrical system
E02 DDN7KA WEQ Knob Sw (down): Disconnection P/T Electrical system
E02 DDN7KB WEQ Knob Sw (down): Short circuit P/T Electrical system
E02 DDN8KA WEQ Knob Sw (up): Disconnection P/T Electrical system
E02 DDN8KB WEQ Knob Sw (up): Short circuit P/T Electrical system
E03 DDNLKA Weq lock Sw: Disconnection P/T Electrical system
E03 DDNLKB Weq lock Sw: Short circuit P/T Electrical system
E01 DGS1KX Hyd oil temp sensor: Abnormal P/T Electrical system
E01 DGT1KA T/C oil temp sensor: Disconnection P/T Electrical system
E01 DGT1KX T/C oil temp sensor Short circuit P/T Electrical system
E01 DH21KA WEQ pressure sensor: Disconnection P/T Electrical system
E01 DH21KB WEQ pressure sensor: Short circuit P/T Electrical system
E02 DHT5KA T/C pressure sensor: Disconnection P/T Electrical system
E02 DHT5KB T/C pressure sensor: Short circuit P/T Electrical system Troubleshooting
E03 DK10KA Fuel control Dial: Disconnection P/T Electrical system by failure code,
Part 5
E03 DK10KB Fuel control Dial: Short circuit P/T Electrical system SEN05035-00
E03 DK30KA ST lever 1: Disconnection P/T Electrical system

E03 DK30KB ST lever 1: Short circuit P/T Electrical system
E04 DK30KX ST lever 1: Out of normal range P/T Electrical system
E04 DK30KZ ST lever: Disconnection or short circuit P/T Electrical system
E03 DK30L8 ST lever: Signal mismatch P/T Electrical system
E03 DK31KA ST lever 2: Disconnection P/T Electrical system
E03 DK31KB ST lever 2: Short circuit P/T Electrical system
E02 DK40KA Brake potentiometer: Disconnection P/T Electrical system
E02 DK40KB Brake potentiometer: Short circuit P/T Electrical system
E04 DK55KX FR lever: Out of normal range P/T Electrical system
E04 DK55KZ FR lever: Disconnection or short circuit P/T Electrical system
E03 DK55L8 FR lever: Signal mismatch P/T Electrical system
40-100 4 D65EX, PX, WX-16

Failure codes table SEN05029-01

E03 DK56KA FR lever 1: Disconnection P/T Electrical system
Troubleshooting
E03 DK56KB FR lever 1: Short circuit P/T Electrical system by failure code,
E03 DK57KA FR lever 2: Disconnection P/T Electrical system Part 5
SEN05035-00
E03 DK57KB FR lever 2: Short circuit P/T Electrical system
E03 DKH1KA Pitch angle sensor: Disconnection P/T Electrical system
E03 DKH1KB Pitch angle sensor: Short circuit P/T Electrical system
E02 DLT3KA T/M out-speed sensor: Disconnection P/T Electrical system
E02 DLT3KB T/M out-speed sensor: Abnormal P/T Electrical system
E02 DW5AKA Pitch selector Sol.: Disconnection P/T Electrical system
E02 DW5AKB Pitch selector Sol.: Short circuit P/T Electrical system
E02 DW5AKY Pitch selector Sol.: Hot Short P/T Electrical system
E02 DW7BKA Fan rev EPC: Disconnection P/T Electrical system
E01 DW7BKB Fan rev EPC: Short circuit P/T Electrical system
E03 DWN1KA Hss EPC1: Disconnection P/T Electrical system
E03 DWN1KB Hss EPC1: Short circuit P/T Electrical system
E04 DWN1KY Hss EPC1: Short circuit P/T Electrical system
E03 DWN2KA Hss EPC2: Disconnection P/T Electrical system
E03 DWN2KB Hss EPC2: Short circuit P/T Electrical system
E04 DWN2KY Hss EPC2: Short circuit P/T Electrical system
E01 DWN5KA Fan pump solenoid: Disconnection P/T Electrical system
E01 DWN5KB Fan pump solenoid: Short circuit P/T Electrical system
Troubleshooting
E02 DWN5KY Fan control solenoid.: Short circuit P/T Electrical system by failure code,
E01 DXA0KA TVC Sol.: Disconnection (*) P/T Electrical system Part 6
SEN05036-01
E01 DXA0KB TVC Sol.: Short circuit (*) P/T Electrical system
E01 DXA0KY TVC Sol.: Short circuit (*) P/T Electrical system
E02 DXH1KA Lock-up ECMV: Disconnection P/T Electrical system
E02 DXH1KB Lock-up ECMV: Short circuit P/T Electrical system
E03 DXH1KY Lock-up ECMV: Short circuit P/T Electrical system
E03 DXH4KA 1st clutch ECMV: Disconnection P/T Electrical system
E03 DXH4KB 1st clutch ECMV: Short circuit P/T Electrical system
E03 DXH4KY 1st clutch ECMV: Short circuit P/T Electrical system
E03 DXH5KA 2nd clutch ECMV: Disconnection P/T Electrical system
E03 DXH5KB 2nd clutch ECMV: Short circuit P/T Electrical system
E03 DXH5KY 2nd clutch ECMV: Short circuit P/T Electrical system
E03 DXH6KA 3rd clutch ECMV: Disconnection P/T Electrical system
E03 DXH6KB 3rd clutch ECMV: Short circuit P/T Electrical system
E03 DXH6KY 3rd clutch ECMV: Short circuit P/T Electrical system
E03 DXH7KA R clutch ECMV: Disconnection P/T Electrical system
E03 DXH7KB R clutch ECMV: Short circuit P/T Electrical system
E04 DXH7KY R clutch ECMV: Short circuit P/T Electrical system
(*): TVC solenoid means PC-EPC valve.
D65EX, PX, WX-16 40-100 5


E03 DXH8KA F clutch ECMV: Disconnection P/T Electrical system
E03 DXH8KB F clutch ECMV: Short circuit P/T Electrical system Troubleshooting
by failure code,
E04 DXH8KY F clutch ECMV: Short circuit P/T Electrical system Part 6
E03 DXJ4KA WEQ lock Sol.: Disconnection P/T Electrical system SEN05036-01
E03 DXJ4KB WEQ lock Sol.: Short circuit P/T Electrical system
a Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
a Action code
Attached: If a failure code is detected, the action code, failure code, and telephone No. (if registered)
are displayed on the ordinary screen to notify the operator of the fault.
Not attached: Even if a failure code is detected, the machine monitor does not notify the operator of the
fault.
a Component in charge
MON: The machine monitor is in charge of detection of fault.
ENG: The engine controller is in charge of detection of fault.
P/T: The power train controller is in charge of detection of fault.
a Category of history
Mechanical system: Fault information is recorded in the mechanical system fault history.
Electrical system: Fault information is recorded in the electrical system fault history.
40-100 6 D65EX, PX, WX-16

Fuse locations SEN05029-01
Fuse locations 1
Connection table of fusible link and fuse box

a This connection table shows the devices to which each power supply of fusible link and the fuse box
supplies power (An accessory power supply is a device which supplies power while the starting switch is
in the ON position and an unswitched power supply is a device which supplies power while the starting
switch is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fusible link and
and fuses to see if the power is supplied normally.
Fuse box (A)
Fusible link Power Fuse

Fuse No. Destination of power
(Connector No.) supply capacity (A)
1 20 Starting switch (B terminal)
FL2 [50 A] Unswitched 2 15 Monitor, power train controller
(FL2-4) power supply 3 30 Engine controller
4 15 Cab main circuit
5 15 Power train controller
7 5 Horn
8 5 Backup alarm
FL1 [120 A] Accessory 9 20 Electrical intake air heater, air suspension seat
(FL1-4) power supply 10 20 Spare
11 20 Head lamp
12 20 Rear lamp
13 20 Air conditioner
ACC power
— 6 5 Engine controller (ACC signal)
supply
Fuse box (B)

Unswitched
— 1 10 Radio memory
power supply
2 20 Additional lamp, rotation lamp
3 20 12 V converter
FL1 [50 A] Accessory Radio, room lamp, cigarettelighter, intermittent
4 20
(FL1-3) power supply wipper
5 10 Front wiper, rear wiper
6 10 LH and RH door wiper
Location of fusible link (FL1, FL2)
D65EX, PX, WX-16 40-100 7

SEN05029-01 Fuse locations
Location of fuse and fuse No.
40-100 8 D65EX, PX, WX-16

Fuse locations SEN05029-01
D65EX, PX, WX-16 40-100 9

SEN05029-01

©2010 KOMATSU
All Rights Reserved
40-100 10
SEN05030-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
200 General information on troubleshooting

Points to remember when troubleshooting ..................................................................................................... 2
How to proceed troubleshooting ..................................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 6
Symptom supposed to be failure and troubleshooting No. ........................................................................... 10
Information contained in troubleshooting table ............................................................................................. 12
Troubleshooting method for disconnecting wiring harness of pressure sensor system................................ 14
Connector list and stereogram...................................................................................................................... 16
Connection table for connector pin numbers ................................................................................................ 30
T- branch box and T- branch adapter table ................................................................................................... 66
D65EX, PX, WX-16 40-200 1

SEN05030-01 Points to remember when troubleshooting
Points to remember when troubleshooting 1
k Stop the machine on a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.
If components are disassembled in confusion immediately after any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Check for any sign of abnormality on the machine.
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating a machine to reproduce the symptom of failure for troubleshooting, do not carry out
any investigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
40-200 2 D65EX, PX, WX-16

How to proceed troubleshooting SEN05030-01
How to proceed troubleshooting 1
D65EX, PX, WX-16 40-200 3

SEN05030-01 Checks before troubleshooting
Checks before troubleshooting 1
Judgement
No. Check item Action
value
1 Check for abnormal noise and smell — Repair
2 Garabage check around engine — Removal
3 Water leak check around engine — Repair
4 Oil leak check around engine — Repair

a. Engine, Lubricating oil, Coolant
5 Check fuel line leakl — Repair
6 Check radiator for clogging — Removal
7 Check fuel level and type — Add fuel
8 Check for impurities in fuel — Clean and drain
9 Check fuel filter — Replace
Between
10 Check engine oil level (engine oilpan level) and type Add oil
H and L
Between
11 Check coolant level (sub-tank level) Add coolant
H and L
12 Check dustindicator for clogging No red color Clean or replace
1 Check for abnormal noise and smell — Repair
2 Check for oil leakage — Repair

b. Hydraulic and mechanical equipment
Between
3 Check hydraulic oil level Add oil
H and L
4 Check oil level in damper case — Add oil
5 Check hydraulic oil strainer — Clean and drain
Between
6 Check power train oil level Add oil
H and L
7 Check hydraulic oil filter — Replace
8 Carry out bleeding — Bleed air
40-200 4 D65EX, PX, WX-16

Checks before troubleshooting SEN05030-01
Judgement
No. Check item Action
value
1 Check for looseness and corrosion of battery terminals — Retighten or replace
2 Check for looseness and corrosion of alternator terminals — Retighten or replace
3 Check for looseness and corrosion of starting motor terminals — Retighten or replace
4 Check battery voltage (engine stopped) 20 – 30 V Charge or replace
Between
5 Check battery electrolyte level Add or replace
H and L
Check for discoloration, burnout of wiring, and peeling of harness
6 — Repair or replace
coating
c. Electrical equipment
7 Check for missing wiring clamps and a slack of wire. — Repair
Check for water leaking on wiring (pay particularly careful

8 — Dry
attention to water leaking on connectors or terminals)
9 Check for loose connector and damage to connector lock Repair or replace
10 Check connector pins for corrosion, bent ot deformation Repair or replace
11 Check for dirt or debris in the connector Clean or replace
12 Check the continuity and insulation of the harness Repair or replace
13 Check for blown or corroded fuse — Replace
After running
for several
14 Check alternator voltage (engine running at half speed or above) Replace
minutes:
27.5 – 29.5 V
Check operating sound of battery relay
15 — Replace
(when turning starting switch ON or OFF)
1 Check for undercarriage — Repair

d. EXterior
2 Check for handrail and step — Repair
3 Check for mirror — Repair

e. Interior
1 Check for gauge and monitor — Replace
2 Check for seat belt — Repair
D65EX, PX, WX-16 40-200 5

SEN05030-01 Classification and procedures for troubleshooting
Classification and procedures for troubleshooting 1
Classification of troubleshooting
Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon which appears a source of a trouble occurs on the machine, select a proper troubleshoot-
ing No. according to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting when action code and failure code are displayed on machine
monitor:
If an action code and a failure code are displayed on the machine monitor, perform the troubleshooting
for the corresponding "Display of code".
a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in
order. Note down all the codes.
2. Procedure for troubleshooting when an action code and a failure code are not displayed on
machine monitor
Check a mechanical system failure code and an electrical system failure code with the abnormality
record function of the machine monitor. (See [*1].)
1) If a failure code is displayed, perform troubleshooting for the corresponding "Display of code"
according to the failure code.
a If an electrical system failure code is dispayed after having noted down all the codes, delete all
the codes and reproduce them, and then see if the trouble is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner system by the abnormality record function, per-
form "Inspection with self-diagnosis function" in "Air conditioner". (See [*3].)
2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show a trouble again and select the same
phenomenon from the list on the next page, and then perform troubleshooting corresponding to that
phenomenon in the "E-mode", "H-mode", or "S-mode".
3. Action to take after trouble is eliminated

Referring to the next page, clear all the failure codes in the electrical system abnormality record.
40-200 6 D65EX, PX, WX-16

Classification and procedures for troubleshooting SEN05030-01
[*1], [*2] 5. Press the [F3] switch (R) on the panel switch
1. While pressing numerical key [4] on the panel to see if the next failure code is displayed and
switch at the normal screen, press [1], [2] and note down all the failure codes.
[3] in order. a A mechanical system failure code cannot
be cleared.
6. Press [F5] switch (Return) on the panel switch
to return to the “Abnormality record” screen.
7. Enter the “Electrical system abnormality
record” similarly to steps 2 and 3.
8. Press the [F3] switch [R] on the panel switch
to see if the next failure code is displayed and
note down all of the failure codes.
a “E” on the left of a failure code indicates
that the failure code is “active” (the failure
remains or restoration to normal has not
been checked). A failure code having no
“E” on its left is a “non-active” one. Since it
disappears at the following clear step, be
2. On the service menu screen, press [F3] switch sure to note it down.
(R) on the panel switch once to select “02 9. While pressing numerical key [4] on the panel
Abnormality Record”. switch, press [1], [2] and [3] in this order to
3. Press [F6] switch (3) on the panel switch to enter the “Clear mode”. (Same as 1)
confirm and go to “Abnormality Record” 10. Press [F2] switch(CLEAR) on the panel switch.
screen. 11. Press [F6] switch (3) on the panel switch to
clear all the failure codes temporarily.
to return to the “Electrical system abnormality
record” screen. See if any failure code is still
displayed and note down displayed ones.
to return to the “Abnormality record” screen.
4. Press [F6] switch (3) on the panel switch to

confirm and go to “Mechanical system” screen.
D65EX, PX, WX-16 40-200 7

SEN05030-01 Classification and procedures for troubleshooting
[*3]
a For how to enter the “Abnormality record”
screen, see steps 1 – 3 in [*1] and [*2].
1. On the “Abnormality Record” screen, press
[F3] switch (R) on the panel switch twice to
select “03 Air-conditioning System”.
2. Press [F6] switch (3) on the panel switch to
confirm and enter the “Air conditioner abnor-
mality record” screen.
3. Note down of information in all the columns.

a “E” on the left of a failure code (same as
electrical abnormality record) indicates
that the failure code is “active” (the failure
remains or its elimination has not been
confirmed).
4. Press [F2] switch (CLEAR) on the panel switch
section to clear all the codes temporarily. See if
“Abnormality” is still displayed and take a note.
(Same as 10 of [*1] and [*2])
section to return to the “Abnormality record”
screen.
40-200 8 D65EX, PX, WX-16

Classification and procedures for troubleshooting SEN05030-01
D65EX, PX, WX-16 40-200 9

SEN05030-01 Symptom supposed to be failure and troubleshooting No.
Symptom supposed to be failure and troubleshooting No. 1
Troubleshooting
No. Symptom supposed to be failure Code
E-mode H-mode S-mode
display
Symptom related to action code and failure code
Check fail-
1 Display action code on monitor panel.
ure code.
2 Display failure code in failure code display mode. q
Engine related
3 Engine is hard to start. (Engine starting always takes time.) S-1
4 Engine does not crank. E-1 S-2a)
Engine cranks but no exhaust smoke
5 S-2b)
Engine does not start. comes out.
Exhaust smoke comes out but engine
6 S-2c)
does not start.
7 Engine does not pick-up smoothly. (Poor follow-up performance) S-3
8 Engine stops during operation. S-4
9 Engine does not rotate smoothly (hunting). S-5
10 Engine lacks in output or power. S-6
11 Exhaust smoke is black (incomplete combustion). S-7
12 Oil consumption is excessive or exhaust smoke is blue. S-8
13 Oil gets contaminated quickly. S-9
14 Fuel consumption is excessive. S-10
Oil mixes in coolant or coolant spurts back or coolant level goes
15 S-11
down.
16 Engine oil pressure drops. S-12
17 Oil level rises (water or fuel mixes). S-13
18 Coolant temperature rises too high. (overheat) S-14
19 Abnormal noise occurs. S-15
20 Vibration is excessive. S-16
21 Preheater does not operate. E-2
Power train related
22 There is no travel power. (no drawbar pull) H-1 S-6
23 Machine does not travel (at 2nd or 3rd speed) H-2
24 Machine does not start at any gear speed. H-3
25 Machine travels only in one direction, forward or reverse. H-4
Time lag is excessive at shifting gear speed or shifting forward-
26 H-5
reverse.
Machine cannot be steered. (Machine does not turn leftward or
27 H-6
rightward.)
28 Steering speed or power is insufficient. H-7
29 Brake does not work. H-8
30 Power train oil overheats. H-9
Abnormal sound comes out around HSS and hydraulic pump or
31 H-10
HSS motor.
40-200 10 D65EX, PX, WX-16

Symptom supposed to be failure and troubleshooting No. SEN05030-01
Troubleshooting
No. Symptom supposed to be failure Code
E-mode H-mode S-mode
display
Work equipment related
32 Speed of all work equipments is slow. H-11
33 All work equipments do not move. H-12
34 Blade lift moves slowly or lacks power. H-13
35 Blade tilt moves slowly or lacks power. H-14
36 Ripper lift moves slowly or lacks power. H-15
37 Hydraulic drift of blade lift is excessive. H-16
38 Hydraulic drift of blade tilt is excessive. H-17
39 Hydraulic drift of ripper lift is excessive. H-18
Machine monitor related (operator mode: normal screen)
40 When starting switch turned ON, machine monitor displays nothing. E-3
When starting switch turned ON (before starting engine), basic
41 E-4
check item lights up.
42 Precaution item lights up while engine is running. E-5
43 Emergency stop item lights up while engine is running. E-6
44 Engine coolant temperature gauge does not indicate normally. E-7
45 Fuel gauge does not indicate properly. E-8
Power train oil temperature gauge (multi-gauge) does not indicate
46 E-9
normally.
Hydraulic temperature gauge (multi-gauge) does not indicate nor-
47 E-10
mally.
Contents of display by machine monitor are different from applicable
48 E-11
machine.
49 Machine monitor does not display some items. E-12
50 Function switch does not work. E-13
51 Operation mode does not change. E-14
52 Gearshift mode does not change. E-15
53 Customize function does not operate normally. E-16
54 Customize memory function does not operate normally. E-17
55 Alarm buzzer cannot be stopped. E-18
56 When starting switch is turned OFF, service meter is not displayed. E-19
Machine monitor related (service mode: special function screen)
57 Machine monitor cannot be set in service mode. E-20
Other items
58 The horn does not sound or does not stop. E-21
59 The back-up alarm does not sound or does not stop. E-22
60 The head lamp and rear lamp do not light up. E-23
61 Windshield wiper does not operate. E-24
62 Window washer does not operate. E-25
63 KOMTRAX system does not operate correctly. E-26
D65EX, PX, WX-16 40-200 11

SEN05030-01 Information contained in troubleshooting table
Information contained in troubleshooting table 1
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before performing troubleshooting, understand that information fully.
Action code Failure code
Monitor Trouble Problem that appears on machine
Monitor display
display
Failure
Description of the trouble detected by the machine monitor or controller
description
Action of Action taken by machine monitor or controller to protect system or devices when machine mon-
controller itor or controller detects trouble
Indication of
Problem that appears on machine as result of action taken by machine monitor or controller
problem on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Cause Procedure, measuring location, standard (value) and remarks
<Information described>
• Procedure
1 • Measuring location
a “Between A – B” means A and B “Measure voltage or resistance and so on
between A and B.”
• Standard value in normal condition to evaluate assumed cause if it is good
condition or not.
• Remarks required to evaluate the cause is correct
<Phenomenon of defective wiring harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness is disconnected.
2 • Grounding fault
A harness not connected to ground (earth) circuit contacts the ground (earth)
circuit or machine.
• Hot short circuit
Possible causes of trouble A harness not connected to the power (24 V) circuit contacts the power (24 V)
is assumed to be detected circuit.
• Short circuit
An independent wire in the harness abnormally contact another wire.
3 <Notes on troubleshooting>
(1) How to indicate connector number and handle T-branch
For troubleshooting, insert or connect T-branch adapter as follows unless
especially specified.
• When “male” or “female” is not indicated with a connector number, disconnect the
connector, and insert T-branch adapter in both male and female.
• When “male” or “female” is indicated with a connector number, disconnect the
connector, and connect T-branch adapter only to either male or female end.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect plus (+) and minus (–) leads as follows unless
4 especially specified.
• Connect the plus (+) lead to a pin or harness indicated in the front.
• Connect the minus (–) lead to a pin or harness indicated in the rear.
40-200 12 D65EX, PX, WX-16

Information contained in troubleshooting table SEN05030-01
Related circuit diagram
This drawing is a part of the circuit diagram related to

troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• "Connector No. and pin No." from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
• NO: Normally open
• NC: Normally closed
a See “Electrical circuit diagram” in chapter 90
for branch label in wiring harness.
D65EX, PX, WX-16 40-200 13

SEN05030-01 Troubleshooting method for disconnecting wiring harness of pressure sensor system
Troubleshooting method for disconnecting wiring harness of pressure

sensor system 1
a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the deferences among the registances measured and its own polarities. So troubleshoting must
be performed carefully.
Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA451: Rail pressure sensor high error
Procedure
1. Measure and record resistance of pressure sensor unit
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore,
when measuring resistances, apply the same tester probe polarities to the pressure sensor in
steps 1 and 2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each
other and record the finite value obtained as a measured value.
a Since measured values may be diferent from each other, take several measurements.
Cause of the diferences appears to be that the sensor may be charged by the tester. Take sev-
eral measurement in both steps 1 and 2.
Take the fact into consideration this diferences when determining whether the wiring harness is
disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine con-
troller connected.
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sen-
sor connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
3. Judging disconnection
If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is disconnected".
a "Apparent difference" means a difference of 10 or more times.
40-200 14 D65EX, PX, WX-16

Troubleshooting method for disconnecting wiring harness of pressure sensor system SEN05030-01
List of pressure sensor measuring locations and reference values

Internal resistance of measured
Sensor Sensor pin measuring location Remarks
sensor (reference value)
R2: Between (2) and (4) Approx. 5.5 kz

Charge pressure Sensor is common to engine
sensor models 107 and 114
R1: Between (1) and (4) Approx. 7 kz
Sensor is common to engine

R2: Between (3) and (1) Approx. 23 kz
Common rail pressure models 107 and 114
sensor If polarities are reversed,
R1: Between (2) (+) and (1) (-) Approx. 17 Mz
resistance is infinite
*: When measuring R2', disconnect the following connectors.(See circuit diagram related to each code)
q When measuring R2' of charge pressure sensor (CA123)
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separa-
tor)
q When measuring R2' of common rail pressure sensor (CA451)
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor + Wiring harness
Sensor unit (Measuring Measured Measured
Sensor (Measuring location on wiring
location on sensor pin side) value value
harness side of engine controller)
R2: Between (2) and (4) R2': Between (37) and (47) (*)
Charge pressure
sensor
R1: Between (1) and (4) R1': Between (44) and (47)
R2: Between (3) and (1) SR2': Between (37) and (47) (*)
Common rail
pressure sensor
R1: Between (2) (+) and (1) (-) R1': Between (25) (+) and (47) (-)
D65EX, PX, WX-16 40-200 15

SEN05030-01 Connector list and stereogram
Connector list and stereogram 1
D65EX-16, D65PX-16, D65WX-16
Number
Connector No. Model Component name Address
of pins
250 Terminal 1 Starting switch (Terminal B) O-3
255 Terminal 1 Starting switch (Terminal R1) O-2
256 Terminal 1 Starting switch (Terminal R2) N-2
260 Terminal 1 Starting switch (Terminal BR) N-2
270 Terminal 1 Starting switch (Terminal ACC) N-3
280 Terminal 1 Starting switch (Terminal C) N-3
1 SOL DT 2 Transmission 1st clutch ECMV (Solenoid) AL-6
1 SW DT 2 Transmission 1st clutch ECMV (Fill switch) AL-6
2 SOL DT 2 Transmission 2nd clutch ECMV (Solenoid) AN-4
2 SW DT 2 Transmission 2nd clutch ECMV (Fill switch) AN-4
3 SOL DT 2 Transmission 3rd clutch ECMV (Solenoid) AK-6
3 SW DT 2 Transmission 3rd clutch ECMV (Fill switch) AK-6
3DMC DT-A 12 Intermediate connector (3D-MC select switch) S-9
A DT 2 Air suspension seat (If equipped) S-8
A/C DT 2 Intermediate connector (Air conditioner compressor) AC-6
AC01 YAZAKI 8 Intermediate connector (Air conditioner controller) X-8
AC02 SUMITOMO 4 Intermediate connector (Air conditioner controller) W-8
AC03 — 5 Blower relay (Air conditioner) X-3
AC04 — 4 Compressor relay (Air conditioner) X-3
AC05 S090 2 A/C refrigerant pressure switch (Air conditioner) H-1
ACB1 — 7 Blow off motor 1 (Air conditioner) —
ACB2 — 7 Blow off motor 2 (Air conditioner) —
ACBM — 2 Blower motor (Air conditioner) —
ACCN 040 36 Air conditioner controller —
ACD SWP 8 Diode (Air conditioner) W-2
ACFS — 2 Frost sensor (Air conditioner) —
ACG DT 2 Diode (Air compressor) AC-8
ACIS — 7 Inside-outside servo motor (Air conditioner) —
ACPS — 2 Inside temperature sensor (Air conditioner) —
ACPT — 4 Power transistor (Air conditioner) —
ACSM — 7 A/C servo motor (Air conditioner) —
AL/B Terminal 1 Alternator terminal B AC-5
AL/E Terminal 1 Alternator terminal E AC-5
AL/R Terminal 1 Alternator terminal R AC-4
AMB. AIR PRESSURE
FRAMATOME 3 Air pressure sensor AH-6
[C29]
ASUS DT 2 Intermediate connector (Air suspension seat) T-9
40-200 16 D65EX, PX, WX-16

Connector list and stereogram SEN05030-01
Number
of pins
AT11 — 1 Monitor panel O-4
AT12 — 1 GPS antenna T-1
AT21 — 1 KOMTRAX modem T-9
AT22 — 1 ORBCOMM antenna J-9
AUXO DTHD#12 1 Device drive (If equipped) E-8
BCV DT 6 Intermediate connector (Backup lamp, washer motor) L-5
BKA SUMITOMO 5 Backup alarm relay S-1
BKAL DT 2 Backup alarm L-5
BNSW DT 6 Intermediate connector (Blade pitch switch) S-8
BOOST PRESS & IMT
SUMITOMO 4 Boost pressure & Intake manifold temperature sensor AH-5
[C4]
BRB Terminal 1 Battery relay (Terminal B) E-7
BRC Terminal 1 Battery relay (Terminal M) E-7
BRE Terminal 1 Battery relay (Terminal E) E-6
BRK DT 3 Brake pedal potentiometer S-1
BRSW Terminal 1 Battery relay (Terminal BR) E-6
BVRV DT 2 Transmission bevel speed sensor AN-5
C28 DT 2 Intermediate connector (Water-In-Fuel sensor) AE-1
CA1 DT 3 CAN terminal resistance AF-2
CA3 DT 3 CAN terminal resistance W-2
CA4 DT 3 CAN terminal resistance (If equipped) —
CAM SENSOR
FRAMATOME 3 CAM sensor (G) AC-2
[C13]
CB01 DT 4 Intermediate connector (Rear lamp) K-8
CB02 M 2 Rear speaker (R.H.) K-8
CB04 M 2 Rear speaker (L.H.) J-9
CB07 PA 9 Radio J-9
CB08 M 3 Accessory (12 V output) B-8
CB10 SWP 6 Additional lamp switch B-8
CB11 SWP 6 Wiper intermittent switch B-8
CB12 SWP 6 Rear wiper switch A-7
CB13 SWP 6 R.H. wiper switch A-7
CB14 SWP 6 Front wiper switch A-7
CB15 SWP 6 L.H. wiper switch A-7
CB16 KES-1 2 Room lamp H-9
CB17 DT 4 Intermediate connector (Wiper motor for right door) G-8
CB18 DT 4 Intermediate connector (Front lamp) G-8
CB23 DT 6 Front wiper motor G-8
CB24 DT 4 Intermediate connector (Wiper motor for left door) K-1
CB25 YAZAKI 4 Lamp relay L-8
D65EX, PX, WX-16 40-200 17

Number
of pins
CB26 YAZAKI 11 F, R wiper intermittent unit L-8
CB27 YAZAKI 11 LH, RH wiper intermittent unit L-7
CB34 SWP 6 Rotary lamp switch B-8
CB35 DT 2 Intermediate connector (Rotary lamp) G-8
CB37 DT 6 Rear wiper motor K-9
CBACC — 2 Accessory socket X-7
CBBCN DT 2 Rotary lamp H-9
CBCIG — 2 Cigarette lighter X-7
CBCV1 DT 6 DC converter L-8
CBFB1 Terminal 1 Fuse box C-8
CBFL DT 2 Front lamp (L.H.) H-9
CBFR DT 2 Front lamp (R.H.) H-8
CBRL DT 2 Rear lamp (L.H.) K-8
CBRR DT 2 Rear lamp (R.H.) J-9
CE02 DRC26 50 Engine controller CM850 AG-3
CE03 DTP 4 Engine controller CM850 AF-2
Ck01 070 14 KOMTRAX modem S-9
CK02 070 10 KOMTRAX modem T-9
CLP SUMITOMO 5 Rotary lamp relay U-1
CM01 070 18 Monitor panel O-9
CM02 070 12 Monitor panel P-7
CM03 070 18 Monitor panel M-8
COOLANT TEMP
PACKARD 2 Coolant temperature sensor AD-9
[C5]
CRANK SENSOR
FRAMATOME 3 Crank sensor (Ne) AH-4
[C15]
DCL DT 3 Decelerator pedal potentiometer S-2
DIA2 DT 3 Fuel control dial V-9
DIAL DT 3 Intermediate connector (Fuel control dial) S-5
DPNL DT 2 Diode (Emergency switch) AM-9
DSH DRC 40 Intermediate connector M-5
ECM
DRC26 60 Engine controller CM850 AF-2
[CE01]
Intermediate connector
EG1 DTP 2 AH-6
(Engine harness from left fender harness)
EG2 DT-A 12 AH-6
(Left fender harness from engine harness)
EP1 SHINAGAWA 5 Engine power relay 1 V-1
EP2 SHINAGAWA 5 Engine power relay 2 U-1
40-200 18 D65EX, PX, WX-16

Number
of pins
F SOL DT 2 Transmission F clutch ECMV (Solenoid) AN-3
F SW DT 2 Transmission F clutch ECMV (Fill switch) AN-3
F50 DTP 4 E-7
(Cab power and engine controller power)
F120 DTHD#4 1 Intermediate connector (Main power 24 V) E-7
FAC DT 2 Fan pump control valve AI-4
FAR DT 2 Fan reverse solenoid valve C-2
FAR_OPT DT 2 Fan reverse solenoid valve (If equipped) —
FD1 DRC 40 Intermediate connector D-8, X-2
FL1 — — Fusible link E-9
FL2 — — Fusible link E-9
FLP1 SUMITOMO 5 Front lamp relay U-1
FLP2 SUMITOMO 5 Front lamp relay (If equipped) —
FLSW SWP 6 Front lamp switch M-8
FLV DT 2 Fuel level sensor L-1
FS11 — — Fuse box S-2
FS12 — — Fuse box S-2
FTK DT 4 L-7
(Fuel level sensor and backup alarm)
FUEL LIFT PUMP
DT 2 Lift pump valve AD-2
[C18]
FUEL RAIL PRESS.
BOSCH 3 Common rail pressure sensor AH-3
[C8]
GND Terminal 1 GND (ROPS) K-1
GND03 Terminal 1 GND (Fame R.H.) E-5
GND1 Terminal 1 GND (Engine body) AF-2
GND2 Terminal 1 GND (Engine body) AD-8
GND3 Terminal 1 GND (Engine body) AC-3
GND4 Terminal 1 GND (Engine body) AC-7
GND11 Terminal 1 GND (Engine connector) (floor) X-4
GND12 Terminal 1 GND (Air conditioner) (floor) X-4
GNDC1 Terminal 1 GND (Cab) I-9
GNDC2 Terminal 1 GND (Cab) I-9
GNDC3 Terminal 1 GND (Cab) K-8
GNDC4 Terminal 1 GND (Cab) J-9
GNDC5 Terminal 1 GND (Cab) X-5
HDT DT 2 Hydraulic oil temperature sensor A-2
HHP AMP 3 Hydraulic oil pump pressure sensor AJ-5
HNSW — 2 Horn switch S-7
HRN — 1 Horn C-3
D65EX, PX, WX-16 40-200 19

Number
of pins
HRN_OPT — 1 Horn (If equipped) —
HSL DT 2 HSS left EPC valve C-3
HSR DT 2 HSS right EPC valve A-2
HT/A Terminal 1 Heater relay (Terminal A) AF-9
HT/B Terminal 1 Heater relay (Terminal B) AG-8
HT/C Terminal 1 Heater relay (Terminal C) AE-9
HTD DT 2 Diode AE-9
INJECTOR CYL 1&2
DTP 4 Intermediate connector (Injector #1and #2) AC-7
[C9]
INJECTOR CYL 3&4
DTP 4 Intermediate connector (Injector #3 and #4) AC-8
[C10]
INJECTOR CYL 5&6
DTP 4 Intermediate connector (Injector #5 and #6) AH-7
[C11]
INLET METERING
VALVE DT 2 Inlet metering valve AC-4
[C17]
KEY DT 6 Starting switch P-8
L SOL DT 2 Torque converter lockup clutch ECMV (Solenoid) AJ-5
L SW DT 2 Torque converter lockup clutch ECMV (Fill switch) AJ-5
LDNE DT 2 Lift down EPC valve (If equipped) —
LDNS DT 2 Lift down EPC switch (If equipped) —
LHDL DT 2 Front lamp (L.H.) C-4
LHDL1 DT 2 Front lamp (L.H.) (If equipped) —
LHDL2 DT 2 Front lamp (L.H.) (If equipped) —
LHDR DT 2 Front lamp (R.H.) C-4
LHDR1 DT 2 Front lamp (R.H.) (If equipped) —
LHDR2 DT 2 Front lamp (R.H.) (If equipped) —
LMD SWP 8 Diode N-9
LREL DT 2 Rear lamp L-6
LRSE DT 2 Lift raise EPC valve (If equipped) —
LRSS DT 2 Lift raise EPC switch (If equipped) —
NSF SUMITOMO 5 Neutral safety relay T-1
OIL PRESSURE
SWITCH FRAMATOME 2 Engine oil pressure switch AG-2
[C2]
OPPW DT 2 Device power (If equipped) T-1
PAC DT 6 S-1
(Brake and decelerator pedal potentiometer)
PHR SUMITOMO 5 Preheater relay U-1
PKSW DT 3 Parking brake lock switch X-4
PL1 DRC 70 Intermediate connector (Power train controller) X-3
PL1F DRC 70 Intermediate connector (Emergency switch) AM-9
40-200 20 D65EX, PX, WX-16

Number
of pins
PL1M DRC 70 Intermediate connector (Emergency switch) AN-9
PNL HD-24 31 Intermediate connector (Emergency switch) AL-9
POA — 3 3D-MC select switch (If equipped) —
POB — 3 Blade pitch select switch (If equipped) S-6
POB — 3 3D-MC select switch (If equipped) —
PRT DT-A 8 D-5
(Front lamp, horn and fan reverse solenoid valve)
PT1 DT 3 Pitch angle sensor D-5
PTF X 4 Intermediate connector (Flash power train controller) W-2
PTP DT 2 Blade pitch select solenoid (If equipped) C-5
R SOL DT 2 Transmission R clutch ECMV (Solenoid) AK-5
R SW DT 2 Transmission R clutch ECMV (Fill switch) AJ-5
Intermediate connector (HSS EPC solenoid and C-3,
RFD DT-A 12
hydraulic oil temperature sensor) AI-5
RLP SUMITOMO 5 Rear lamp relay V-1
RLSW SWP 6 Rear lamp switch M-7
RSD SWP 8 Diode W-2
SFTD — 3 Shift-down switch U-9
SFTU — 3 Shift-up switch V-9
SLS YAZAKI 2 Daylight sensor M-9
SRV DT-A 12 Intermediate connector (Service connector) S-5
ST DT 2 Intermediate connector (Starting motor) AH-8
ST/B Terminal 1 Starting motor (Terminal B) AG-8
STC1 DRC26 24 Power train controller V-1
STC2 DRC26 40 Power train controller V-2
STC3 DRC26 40 Power train controller W-2
STRG X 2 Resistor (Emergency switch) AN-8
TCT DT 2 Torque converter oil temperature sensor AM-2
TIP AMP 3 Torque converter oil pressure sensor AL-1
TLHE DT 2 Blade left tilt EPC valve (If equipped) —
TLHS DT 2 Blade left tilt switch (If equipped) —
TLV1 DT-B 8 Lever assembly W-8
TLV2 DT 6 Intermediate connector (Shift switch) S-6
TMRG M 2 Resistor (Emergency switch) AM-7
TOOL PORT
DT 3 CAN AE-1
[C12]
TRHE DT 2 Blade right tilt EPC valve (If equipped) —
TRHS DT 2 Blade right tilt switch (If equipped) —
TVC DT 2 Pump TVC solenoid valve AI-4
WELK DT 3 Work equipment lock lever switch S-8
D65EX, PX, WX-16 40-200 21

Number
of pins
W.I.F.
DT 2 Water-In-Fuel sensor AG-8
[WIF]
WLK DT 2 Work equipment lock lever solenoid C-2
WSFR — 2 Window washer motor (Front) K-1
WSLH — 2 Window washer motor (Left) L-2
WSRH — 2 Window washer motor (Right) L-1
WSRR — 2 Window washer motor (Rear) L-1
a The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles, 12 poles) are as follows.
DT-A = Gray, DT-B = Black, DT-C = Green, DT-D = Brown
40-200 22 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 23

Connector arrangement diagram (1/6)
40-200 24 D65EX, PX, WX-16

(2/6)
D65EX, PX, WX-16 40-200 25

(3/6)
40-200 26 D65EX, PX, WX-16

(4/6)
D65EX, PX, WX-16 40-200 27

(5/6)
40-200 28 D65EX, PX, WX-16

(6/6)
D65EX, PX, WX-16 40-200 29

SEN05030-01 Connection table for connector pin numbers
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
40-200 30 D65EX, PX, WX-16

Connection table for connector pin numbers SEN05030-01
D65EX, PX, WX-16 40-200 31

40-200 32 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 33

40-200 34 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 35

40-200 36 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 37

40-200 38 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 39

40-200 40 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 41

40-200 42 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 43

40-200 44 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 45

40-200 46 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 47

40-200 48 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 49

40-200 50 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 51

40-200 52 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 53

40-200 54 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 55

40-200 56 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 57

40-200 58 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 59

40-200 60 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 61

40-200 62 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 63

40-200 64 D65EX, PX, WX-16

D65EX, PX, WX-16 40-200 65

SEN05030-01 T- branch box and T- branch adapter table
T- branch box and T- branch adapter table (Rev. 2009.03)1
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
40-200 66 D65EX, PX, WX-16

T- branch box and T- branch adapter table SEN05030-01
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
D65EX, PX, WX-16 40-200 67

SEN05030-01 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
40-200 68 D65EX, PX, WX-16

T- branch box and T- branch adapter table SEN05030-01
D65EX, PX, WX-16 40-200 69

SEN05030-01

©2009 KOMATSU
All Rights Reserved
40-200 70
SEN05031-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
301 Troubleshooting by failure code

(Display of code), Part 1
Failure code [1500L0] Transmission clutch: Abnormal ................................................................................... 3
Failure code [15SAL1] Forward clutch: Fill high ............................................................................................. 4
Failure code [15SALH] Forward clutch: Fill low .............................................................................................. 6
Failure code [15SBL1] Reverse clutch: Fill high ............................................................................................. 8
Failure code [15SBLH] Reverse clutch: Fill low ............................................................................................ 10
Failure code [15SEL1] Speed 1st clutch: Fill high......................................................................................... 12
Failure code [15SELH] Speed 1st clutch: Fill low ......................................................................................... 14
Failure code [15SFL1] Speed 2nd clutch: Fill high........................................................................................ 16
Failure code [15SFLH] Speed 2nd clutch: Fill low ........................................................................................ 18
Failure code [15SGL1] Speed 3rd clutch: Fill high........................................................................................ 20
Failure code [15SGLH] Speed 3rd clutch: Fill low......................................................................................... 22
Failure code [15SJL1] L/U: Fill high .............................................................................................................. 24
Failure code [15SJLH] L/U: Fill low............................................................................................................... 26
Failure code [AB00MA] Battery Charge Abnormal ....................................................................................... 28
Failure code [B@BAZG] Eng Oil Press Low................................................................................................. 30
Failure code [B@BCNS] Eng Water Overheat.............................................................................................. 30
Failure code [B@CENS] T/C Oil Overheat ................................................................................................... 31
Failure code [B@HANS] Hyd Oil Overheat................................................................................................... 31
D65EX, PX, WX-16 40-301 1

301 Troubleshooting by failure code (Display of code), Part 1
SEN05031-00
40-301 2 D65EX, PX, WX-16

Failure code [1500L0] Transmission clutch: Abnormal SEN05031-00
Failure code [1500L0] Transmission clutch: Abnormal 1
Action code Failure code Transmission clutch: Abnormal

Trouble
E03 1500L0 (Power train controller system)
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Gear speed is limited.)
(1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Machine can not travel.)
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Failure
(3) Either of [DXH6KA] or [DXH6KB] and (1) above
description
(4) [15SALH] and [15SBLH]
(5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY]
(6) [15SELH], [15SFLH], and [15SGLH]
(7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY]
(8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY]
(9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY]
Action of
• Limits operation of engine and transmission.
controller
• The auto shift down function does not work.
Indication of
• Once machine is stopped, engine speed is limited to medium (half).
problem on
• Once machine is stopped, traveling is limited to specific gear speeds.
machine
• Machine cannot travel.
Related
• Duplication of failure code: Engine start and travel
information

Confirm the failure codes displayed at the same time, then perform troubleshooting for the codes.
[15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH]
[DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA], [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB], [DXH6KY], [DXH7KA],
[DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
D65EX, PX, WX-16 40-301 3

SEN05031-00 Failure code [15SAL1] Forward clutch: Fill high
Failure code [15SAL1] Forward clutch: Fill high 1
Action code Failure code Forward clutch: Fill high

Trouble
E03 15SAL1 (Power train controller system)
Failure • Nevertheless controller does not output to transmission F clutch ECMV solenoid circuit, fill switch
description signal is turned ON.
• Sets transmission in neutral when operator sets it in reverse position (Prevention of double engage-
Action of
ment).
controller
Indication of
problem on
• Once machine is stopped, travel is limited to F1.
machine
• State of F clutch ECMV fill switch signal can be checked with monitoring function.
(Code: 40906 T/M Fill Sw Input 1)
Related • Method of reproducing failure code: Start engine and set transmission in neutral.
information • Remove seat (approx. 50 kg) and seat bottom cover.
• First, check the power train oil filter for clogging etc.
• Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.

1. Turn starting switch to OFF position.
Defective F clutch ECMV fill 2. Disconnect connector F SW and connect T-adapter to male side.
1
switch (Internal short circuit) Between F SW (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
2. Disconnect connector F SW.
Ground fault of wiring 3. Start engine.
2 harness or defective
power train controller If failure code [15SAL1] is still displayed, there is ground fault of wiring harness or
power train controller is defective.
(If failure code [15SAL1] is not displayed, F clutch fill switch is defective)
a If cause 2 is not the cause for the trouble, this check is not required.
Ground fault of wiring
2. Disconnect connectors STC2 and F SW and connect T-adapter to female side of
3 harness (Contact with either of them.
ground circuit)
Between STC2 (female) (35) or F SW (female) (1) and
ground
If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”,
• Reference; the followings are standard values in normal condition.
2. Insert T-adapter into connector STC2.
Defective power train 3. Start engine.
4
controller a Keep PCCS lever in N position.
Between STC2 (35) and ground Voltage 7 – 11 V
1. – 3. are same as above.
4. While depressing brake pedal, operate PCCS lever (travel gear speed) and
perform troubleshooting.
Between STC2 (35) and ground F1/F2/F3 Voltage Max. 1 V
40-301 4 D65EX, PX, WX-16

Failure code [15SAL1] Forward clutch: Fill high SEN05031-00
D65EX, PX, WX-16 40-301 5

SEN05031-00 Failure code [15SALH] Forward clutch: Fill low
Failure code [15SALH] Forward clutch: Fill low 1
Action code Failure code Forward clutch: Fill low

Trouble
E03 15SALH (Power train controller system)
Failure • Nevertheless controller outputs to transmission F clutch ECMV solenoid circuit, fill switch signal is
description turned OFF.
• Sets transmission in neutral when operator sets it in forward position (Prevention of defective
Action of
engagement).
controller
Indication of
problem on
• Once machine is stopped, travel is limited to R1.
machine
• State of F clutch ECMV fill switch signal can be checked with monitoring function.
Related • Method of reproducing failure code: Start engine and set transmission in forward position.

2. Disconnect connector F SW and connect T-adapter to male side.
3. Start engine.
a Keep PCCS lever in N position.
Defective F clutch ECMV fill Between F SW (male) (1) and ground Resistance Min. 1 Mz
1
switch (It does not turn ON)
Between F SW (male) (1) and ground F1/F2/F3 Resistance Max. 1 z
Disconnection in wiring 2. Disconnect connectors STC2 and F SW and connect T-adapters to female side of
2 harness (Disconnection or
them.
defective contact)
Between STC2 (female) (35) and F SW (female) (1) Resistance Max. 1 z
3. Start engine.
Defective power train
3 Between STC2 (35) and ground Voltage 7 – 11 V
controller
Between STC2 (35) and ground F1/F2/F3 Voltage Max. 1 V
40-301 6 D65EX, PX, WX-16

Failure code [15SALH] Forward clutch: Fill low SEN05031-00
D65EX, PX, WX-16 40-301 7

SEN05031-00 Failure code [15SBL1] Reverse clutch: Fill high
Failure code [15SBL1] Reverse clutch: Fill high 1
Action code Failure code Reverse clutch: Fill high

Trouble
E03 15SBL1 (Power train controller system)
Failure • Nevertheless controller does not output to transmission R clutch ECMV solenoid circuit, fill switch
• Sets transmission in neutral when operator sets it in forward position (Prevention of double engage-
Action of
ment).
controller
Indication of
problem on
• Once machine is stopped, travel is limited to R1.
machine
• State of R clutch ECMV fill switch signal can be checked with monitoring function.

Defective R clutch ECMV fill 2. Disconnect connector R SW and connect T-adapter to male side.
1
switch (Internal short circuit) Between R SW (female) (1) and ground
(Fill switch OFF)
2. Disconnect connector R SW.
power train controller If failure code [15SBL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SBL1] is not displayed, R clutch fill switch is defective)
2. Disconnect connectors STC2 and R SW and connect T-adapter to female side of
ground circuit)
Between STC2 (female) (25) or R SW (female) (1) and
ground
4
Between STC2 (25) and ground R1/R2/R3 Voltage Max. 1 V
40-301 8 D65EX, PX, WX-16

Failure code [15SBL1] Reverse clutch: Fill high SEN05031-00
D65EX, PX, WX-16 40-301 9

SEN05031-00 Failure code [15SBLH] Reverse clutch: Fill low
Failure code [15SBLH] Reverse clutch: Fill low 1
Action code Failure code Reverse clutch: Fill low

Trouble
E03 15SBLH (Power train controller system)
Failure • Nevertheless controller outputs to transmission R clutch ECMV solenoid circuit, fill switch signal is
• Sets transmission in neutral when operator sets it in reverse position (Prevention of defective
Action of
engagement).
controller
Indication of
problem on
• Once machine is stopped, travel is limited to F1.
machine
• State of R clutch ECMV fill switch signal can be checked with monitoring function.
Related • Method of reproducing failure code: Start engine and set transmission in reverse position.

2. Disconnect connector R SW and connect T-adapter to male side.
3. Start engine.
Defective R clutch ECMV fill Between R SW (male) (1) and ground Resistance Min. 1 Mz
1
switch (It does not turn ON)
Between R SW (male) (1) and ground R1/R2/R3 Resistance Max. 1 z
Disconnection in wiring 2. Disconnect connectors STC2 and R SW and connect T-adapters to female side of
them.
defective contact)
Between STC2 (female) (25) and R SW (female) (1) Resistance Max. 1 z
3. Start engine.
controller
Between STC2 (25) and ground R1/R2/R3 Voltage Max. 1 V
40-301 10 D65EX, PX, WX-16

Failure code [15SBLH] Reverse clutch: Fill low SEN05031-00
D65EX, PX, WX-16 40-301 11

SEN05031-00 Failure code [15SEL1] Speed 1st clutch: Fill high
Failure code [15SEL1] Speed 1st clutch: Fill high 1
Action code Failure code Speed 1st clutch: Fill high

Trouble
E03 15SEL1 (Power train controller system)
Failure • Nevertheless controller does not output to transmission 1st clutch ECMV solenoid circuit, fill switch
Action of
controller
Indication of
problem on
• Once machine is stopped, travel is limited to F1 and R1.
machine
• State of 1st clutch ECMV fill switch signal can be checked with monitoring function.

Defective 1st clutch ECMV
2. Disconnect connector 1 SW and connect T-adapter to male side.
1 fill switch (Internal short
Between 1 SW (female) (1) and ground
circuit) Resistance Min. 1 Mz
(Fill switch OFF)
2. Disconnect connector 1 SW.
3. Start engine.
power train controller If failure code [15SEL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SEL1] is not displayed, 1st clutch fill switch is defective)
2. Disconnect connectors STC3 and 1 SW and connect T-adapter to female side of
3 harness (Contact with
either of them.
ground circuit)
Between STC3 (female) (19) or 1 SW (female) (1) and
ground
4
Between STC3 (19) and ground F1/R1 Voltage Max. 1 V
40-301 12 D65EX, PX, WX-16

Failure code [15SEL1] Speed 1st clutch: Fill high SEN05031-00
D65EX, PX, WX-16 40-301 13

SEN05031-00 Failure code [15SELH] Speed 1st clutch: Fill low
Failure code [15SELH] Speed 1st clutch: Fill low 1
Action code Failure code Speed 1st clutch: Fill low

Trouble
E03 15SELH (Power train controller system)
Failure • Nevertheless controller outputs to transmission 1st clutch ECMV solenoid circuit, fill switch signal is
Action of
controller
Indication of
problem on
machine
• State of 1st clutch ECMV fill switch signal can be checked with monitoring function.
Related • Method of reproducing failure code: Start engine and set transmission in F1 or R1 position.

3. Start engine.
Defective 1st clutch ECMV a Keep PCCS lever in N position.
1 fill switch (It does not turn Between 1 SW (male) (1) and ground Resistance Min. 1 Mz
ON) 1. – 3. are same as above.
Between 1 SW (male) (1) and ground F1/R1 Resistance Max. 1 z
Disconnection in wiring
2. Disconnect connectors STC3 and 1 SW and connect T-adapters to female side of
2 harness (Disconnection or them.
defective contact)
Between STC3 (female) (19) and 1 SW (female) (1) Resistance Max. 1 z
3. Start engine.
Defective power train Between STC3 (19) and ground Voltage 7 – 11 V
3
controller
40-301 14 D65EX, PX, WX-16

Failure code [15SELH] Speed 1st clutch: Fill low SEN05031-00
D65EX, PX, WX-16 40-301 15

SEN05031-00 Failure code [15SFL1] Speed 2nd clutch: Fill high
Failure code [15SFL1] Speed 2nd clutch: Fill high 1
Action code Failure code Speed 2nd clutch: Fill high

Trouble
E03 15SFL1 (Power train controller system)
Failure • Nevertheless controller does not output to transmission 2nd clutch ECMV solenoid circuit, fill switch
Action of
controller
Indication of
problem on
machine
• State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.

Defective 2nd clutch ECMV
(Fill switch OFF)
3. Start engine.
power train controller If failure code [15SFL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective)
either of them.
ground circuit)
ground
4
40-301 16 D65EX, PX, WX-16

Failure code [15SFL1] Speed 2nd clutch: Fill high SEN05031-00
D65EX, PX, WX-16 40-301 17

SEN05031-00 Failure code [15SFLH] Speed 2nd clutch: Fill low
Failure code [15SFLH] Speed 2nd clutch: Fill low 1
Action code Failure code Speed 2nd clutch: Fill low

Trouble
E03 15SFLH (Power train controller system)
Failure • Nevertheless controller outputs to transmission 2nd clutch ECMV solenoid circuit, fill switch signal is
Action of
controller
Indication of
problem on
machine
• State of 2nd clutch ECMV fill switch signal can be checked with monitoring function.

3. Start engine.
Defective 2nd clutch ECMV a Keep PCCS lever in N position.
defective contact)
3. Start engine.
3
controller
40-301 18 D65EX, PX, WX-16

Failure code [15SFLH] Speed 2nd clutch: Fill low SEN05031-00
D65EX, PX, WX-16 40-301 19

SEN05031-00 Failure code [15SGL1] Speed 3rd clutch: Fill high
Failure code [15SGL1] Speed 3rd clutch: Fill high 1
Action code Failure code Speed 3rd clutch: Fill high

Trouble
E03 15SGL1 (Power train controller system)
Failure • Nevertheless controller does not output to transmission 3rd clutch ECMV solenoid circuit, fill switch
Action of
controller
Indication of
problem on
machine
• State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.

Defective 3rd clutch ECMV
(Fill switch OFF)
3. Start engine.
power train controller If failure code [15SGL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SGL1] is not displayed, 3rd clutch fill switch is defective)
either of them.
ground circuit)
ground
4
40-301 20 D65EX, PX, WX-16

Failure code [15SGL1] Speed 3rd clutch: Fill high SEN05031-00
D65EX, PX, WX-16 40-301 21

SEN05031-00 Failure code [15SGLH] Speed 3rd clutch: Fill low
Failure code [15SGLH] Speed 3rd clutch: Fill low 1
Action code Failure code Speed 3rd clutch: Fill low

Trouble
E03 15SGLH (Power train controller system)
Failure • Nevertheless controller outputs to transmission 3rd clutch ECMV solenoid circuit, fill switch signal is
Action of
controller
Indication of
problem on
machine
• State of 3rd clutch ECMV fill switch signal can be checked with monitoring function.

3. Start engine.
Defective 3rd clutch ECMV a Keep PCCS lever in N position.
defective contact)
3. Start engine.
3
controller
40-301 22 D65EX, PX, WX-16

Failure code [15SGLH] Speed 3rd clutch: Fill low SEN05031-00
D65EX, PX, WX-16 40-301 23

SEN05031-00 Failure code [15SJL1] L/U: Fill high
Failure code [15SJL1] L/U: Fill high 1
Action code Failure code L/U: Fill high

Trouble
E02 15SJL1 (Power train controller system)
Failure • Nevertheless controller does not output to torque converter lockup clutch ECMV solenoid circuit, fill
description switch signal is turned ON.
Action of
• Prohibits lockup.
controller
Indication of
problem on • Engine may stall during travel.
machine
• State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
• Method of reproducing failure code: Start engine and set transmission in R (reverse) position (in
Related automatic gearshift mode).
• Next, check that clutch pressure is normal in lockup operation with reference to the troubleshooting
(H mode), “H-1”.

Defective lockup clutch 2. Disconnect connector L SW and connect T-adapter to male side.
1 ECMV fill switch (Internal
short circuit) Between L SW (female) (1) and ground
(Fill switch OFF)
2. Disconnect connector L SW.
2 harness or defective a Keep PCCS lever in N position.
power train controller If failure code [15SJL1] is still displayed, there is ground fault of wiring harness or
(If failure code [15SJL1] is not displayed, lockup clutch fill switch is defective)
2. Disconnect connectors STC2 and L SW and connect T-adapter to female side of
either of them.
ground circuit)
Between STC2 (female) (36) or L SW (female) (1) and
ground
3. Start engine.
Defective power train a Keep PCCS lever in N position.
controller
4. Put machine on the stands and keep all the track shoe in the air.
5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in
operation.
a See “Testing torque converter lockup clutch” in “Testing and adjusting”.
Between STC2 (36) and ground R1 Voltage Max. 1 V
40-301 24 D65EX, PX, WX-16

Failure code [15SJL1] L/U: Fill high SEN05031-00
D65EX, PX, WX-16 40-301 25

SEN05031-00 Failure code [15SJLH] L/U: Fill low
Failure code [15SJLH] L/U: Fill low 1
Action code Failure code L/U: Fill low

Trouble
E02 15SJLH (Power train controller system)
Failure • Nevertheless controller outputs to torque converter lockup clutch ECMV solenoid circuit, fill switch
description signal is turned OFF.
Action of
• Prohibits lockup.
controller
Indication of
problem on • It is impossible to lockup.
machine
• State of lockup clutch ECMV fill switch signal can be checked with monitoring function.
• Method of reproducing failure code: Start engine and set transmission in R (reverse) position (in
Related automatic gearshift mode).
• Next, check that clutch pressure is normal in lockup operation with reference to the troubleshooting
(H mode), “H-1”.

2. Disconnect connector L SW, and connect T-adapter to male side.
3. Start engine.
Defective lockup clutch
1 ECMV fill switch (It does not 5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in
turn ON)
operation.
Between L SW (female) (1) and ground (Fill switch ON) Resistance Max. 1 z
2. Disconnect connectors STC2 and L SW and connect T-adapters to female side of
them.
defective contact)
Between STC2 (female) (36) and L SW (female) (1) Resistance Max. 1 z
If no abnormality is found by the above checks, power train controller is defective.
3. Start engine.
controller
5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in
operation.
Between STC2 (36) and ground R1 Voltage Max. 1 V
40-301 26 D65EX, PX, WX-16

Failure code [15SJLH] L/U: Fill low SEN05031-00
D65EX, PX, WX-16 40-301 27

SEN05031-00 Failure code [AB00MA] Battery Charge Abnormal
Failure code [AB00MA] Battery Charge Abnormal 1
Action code Failure code Battery Charge Abnormal

Trouble
— AB00MA (Machine monitor system)
Failure • While engine was running, voltage from alternator lowered, and machine monitor detected that bat-
description tery charge voltage was low.
Action of
• Displays charge level monitor red on machine monitor.
controller
Indication of
problem on • If machine is used as it is, battery may not be charged.
machine
• Battery voltage can be checked with monitoring function.
Related
(Code: 04300 Charge voltage)
information
• Method of reproducing failure code: Start engine.

Defective charge by
2. Inert T-adapter into connector CM01.
1 alternator (When system is
3. Start engine and troubleshoot above medium of engine speed.
normal)
Between CM01 (11) and (3) Voltage 26 – 30.5 V
Defective charge level If cause 1 is not detected, charge level monitor system may be defective.
2
monitor system Perform “E-5 Caution item lights up while engine is running” in E mode.
40-301 28 D65EX, PX, WX-16

Failure code [AB00MA] Battery Charge Abnormal SEN05031-00
D65EX, PX, WX-16 40-301 29

SEN05031-00 Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BAZG] Eng Oil Press Low 1
Action code Failure code Eng Oil Press Low

Trouble
— B@BAZG (Engine controller system)
Failure • While engine was running, voltage from engine oil pressure switch became GND level, and engine
description controller detected that engine oil pressure was abnormally low.
Action of
• Displays engine oil pressure monitor red on machine monitor.
controller
Indication of
problem on • If machine is used as it is, engine may be seized.
machine
• Engine controller inputs engine oil pressure switch signal and then transmits the data to machine
Related monitor through CAN communication system.
information • See failure code [CA435] for troubleshooting about engine oil pressure switch in engine stop.

Low engine oil pressure
1 Check engine oil pressure. If it is low, remove cause.
(When system is normal)
Defective engine oil If cause 1 is not detected, engine oil pressure sensor may be defective.
2
pressure sensor system Perform troubleshooting for failure code [CA435].
Failure code [B@BCNS] Eng Water Overheat 1
Action code Failure code Eng Water Overheat

Trouble
— B@BCNS (Engine controller system)
Failure • While engine was running, voltage from engine coolant temperature sensor lowered, and engine
description controller detected that engine coolant was overheated.
Action of
• Displays engine coolant temperature monitor red on machine monitor.
controller
Indication of
problem on • If machine is used as it is, engine may be seized.
machine
• Engine controller inputs voltage of engine coolant temperature sensor signal and then transmits the
data to machine monitor through CAN communication system.
Related
• Engine coolant temperature can be checked with monitoring function.
information
(Code: 04107 Coolant Temperature)

Overheated engine coolant
1 Check engine coolant for overheating. If it is overheated, remove cause.
Defective engine coolant If cause 1 is not detected, engine coolant temperature sensor may be defective.
2
temperature sensor system Perform troubleshooting for failure codes [CA144] and [CA145].
40-301 30 D65EX, PX, WX-16

Failure code [B@CENS] T/C Oil Overheat SEN05031-00
Failure code [B@CENS] T/C Oil Overheat 1
Action code Failure code T/C Oil Overheat

Trouble
— B@CENS (Power train controller system)
Failure • While engine was running, voltage from torque converter oil temperature sensor lowered, and
description power train controller detected that power train oil was overheated.
Action of
• Displays power train oil temperature monitor red on machine monitor.
controller
Indication of
problem on • If machine is used as it is, power train components may be damaged.
machine
• Torque converter oil temperature is considered as power train oil temperature.
• Power train controller inputs voltage of torque converter oil temperature sensor signal and then
Related transmits the data to machine monitor through CAN communication system.
information • Torque converter oil temperature can be checked with monitoring function.
(Code: 30100 T/C Oil Temperature)

Overheated torque converter
Check torque converter (power train) oil for overheating. If it is overheated, remove
1 (power train) oil
cause.
Defective torque converter
If cause 1 is not detected, torque converter oil temperature sensor system may be
2 oil temperature sensor
defective. Perform troubleshooting for failure code [DGT1KA] or [DGT1KX].
system
Failure code [B@HANS] Hyd Oil Overheat 1
Action code Failure code Hyd Oil Overheat

Trouble
— B@HANS (Machine monitor system)
Failure • While engine was running, voltage from hydraulic oil temperature sensor lowered, and power train
description controller detected that hydraulic oil was overheated.
Action of
• Displays hydraulic oil temperature monitor red on machine monitor.
controller
Indication of
problem on • If machine is used as it is, work equipment and HSS circuit components may be damaged.
machine
• Signal voltage of hydraulic oil temperature sensor is input to machine monitor and then the data is
transmitted to power train controller through CAN communication system.
Related
• Hydraulic oil temperature can be checked with monitoring function.
information
(Code: 04401 Hyd Oil Temperature)

Overheated hydraulic oil
1 Check hydraulic oil for overheating. If it is overheated, remove cause.
If cause 1 is not detected, hydraulic oil temperature gauge system may be defective.
Defective hydraulic oil
2 Perform troubleshooting for failure code [DGS1KX] or “E-10 Hydraulic oil
temperature gauge system
temperature gauge (Multi-gauge) does not indicated normally” in E mode.
D65EX, PX, WX-16 40-301 31

SEN05031-00

©2009 KOMATSU
All Rights Reserved
40-301 32
SEN05032-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Failure code [CA111] ECM Critical Internal Failure......................................................................................... 3
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................................ 3
Failure code [CA122] Chg Air Press Sensor High Error ................................................................................. 4
Failure code [CA123] Chg Air Press Sensor Low Error .................................................................................. 6
Failure code [CA131] Throttle Sensor High Error ........................................................................................... 8
Failure code [CA132] Throttle Sensor Low Error .......................................................................................... 10
Failure code [CA144] Coolant Temp Sens High Error .................................................................................. 12
Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 14
Failure code [CA153] Chg Air Temp Sensor High Error................................................................................ 16
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 18
Failure code [CA155] Chg Air Temp High Speed Derate .............................................................................. 20
Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................... 22
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 24
Failure code [CA222] Ambient Press Sens Low Error .................................................................................. 26
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................... 28
Failure code [CA234] Eng Overspeed .......................................................................................................... 28
Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 29
Failure code [CA271] IMV/PCV1 Short Error................................................................................................ 30
Failure code [CA272] IMV/PCV1 Open Error................................................................................................ 32
Failure code [CA281] Abnormal supply pump pressure balance.................................................................. 34
D65EX, PX, WX-16 40-302 1

SEN05032-01

40-302 2 D65EX, PX, WX-16

Failure code [CA111] ECM Critical Internal Failure SEN05032-01
Failure code [CA111] ECM Critical Internal Failure 1
Action code Failure code ECM critical internal failure

Trouble
E04 CA111 (Engine controller system)
Failure
• Memory or power supply circuit in engine controller is defective.
description
Action of
• None in particular.
controller
Indication of
• Engine stops.
problem on
• Engine does not start.
machine
Related
information

Check another failure code displayed simultaneously. If another failure code is also
1 Related defective system
displayed, perform troubleshooting for it first.
2 Perform troubleshooting for failure code [CA441].
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1
Action code Failure code Engine Ne and Bkup speed sensor error
Trouble
Failure
• Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal.
description
Action of
controller
Indication of
• Engine stops.
problem on
machine
Related
• Method of reproducing failure code: Start engine
information

Connector of Ne speed sensor or Bkup speed sensor may be connected defectively
Defective connection of sen-
1 (or wrong connection - Ne speed sensor harness is connected to Bkup speed sensor,
sor connector
and Bkup speed sensor harness to Ne speed sensor). Check them directly.
Defective Ne speed sensor
2 Perform troubleshooting for causes 1 –10 in failure code CA689.
system
Defective Bkup speed sen-
3 Perform troubleshooting for failure code CA778.
sor system
If no abnormality is found by the above checks, the engine controller is defective.
4 Defective engine controller
(Since the trouble is in system, troubleshooting cannot be performed.)
D65EX, PX, WX-16 40-302 3

SEN05032-01 Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA122] Chg Air Press Sensor High Error 1
Action code Failure code Charge air pressure sensor high error
Trouble
Failure
• High voltage was detected in pressure signal circuit of charge (boost) pressure/temperature sensor.
description
Action of
• Fixes charge pressure value and continues operation.
controller
Indication of
problem on • Engine output lowers.
machine
• Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with
monitoring function. (Code: 36501 Boost pressure sensor voltage)
Related
• Method of reproducing failure code: Turn starting switch to ON position.
information
• Even under normal condition if sensor connector is disconnected, failure code of “low error”, that is
[CA123] is displayed.

See the items related to wiring harness and connectors in "c: Electric and electrical
Defective wiring harness
1 equipment" in "Checks before troubleshooting" in "General information on
connector
troubleshooting" section, and check them directly.
Defective sensor power sup-
2 If failure code [CA227] is also indicated, perform troubleshooting for it first.
ply 2 system
2. Disconnect connector BOOST PRESS & IMT.
Defective boost pressure/ 3. Turn starting switch to ON position.
3
temperature sensor If failure code changes from [CA122] to [CA123], the sensor is defective.
a Failure code [CA153] is displayed together with [CA123].
This is because that the sensor connector is disconnected. So, it can be ignored.
Short circuit in wiring har- 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to
4 female side of ECM.
ness
Between ECM (female) (37) and (44) Resistance Min. 100 kz
2. Disconnect connector BOOST PRESS & IMT, and insert T-adapter into connector
Hot short in wiring harness ECM.
5 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
(Contact with 24 V circuit)
disconnected).
Between ECM (44) and (47) Voltage Max. 1 V
40-302 4 D65EX, PX, WX-16

Failure code [CA122] Chg Air Press Sensor High Error SEN05032-01
D65EX, PX, WX-16 40-302 5

SEN05032-01 Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA123] Chg Air Press Sensor Low Error 1
Action code Failure code Charge air pressure sensor low error
Trouble
Failure
• Low voltage was detected in pressure signal circuit of boost pressure/temperature sensor.
description
Action of
• Fixes charge pressure value and continues operation.
controller
Indication of
machine
• Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with
monitoring function. (Code: 36501 Boost pressure sensor voltage)
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Disconnection in wiring harness and voltage at sensor connector cannot be checked, because that
T-adapter for sensor connector is socket type.
• This failure code is displayed if the sensor connector or harness is disconnected.

connector
Defective power supply sys- If failure code [CA187] (ground fault of sensor power supply line) or [CA227] is
2
tem of sensor indicated, perform troubleshooting for it first.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS &
Short circuit in wiring har- IMT and ECM.
3 3. Connect T-adapter to female side of connector ECM.
ness
Ground fault of wiring har- 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to
4 ness female side of ECM.
(Contact with ground circuit)
Between ECM (female) (44) and ground Resistance Min. 100 kz
Disconnection in wiring har-
ness If no abnormality is found by the above checks, disconnection in wiring harness is
5
(Disconnection or defective considered. (*)
contact in connector)
a If causes 1 – 5 are not the cause of the trouble and the check result of cause 6 is
abnormal, sensor is defective.
Defective boost pressure/ 1. Turn starting switch to OFF position.
temperature sensor 2. Insert T-adapter between male and female sides of connector ECM.
6
(Improper input voltage to 3. Turn starting switch to ON position.
engine controller)
Sensor
Between ECM (44) and (47) Voltage Min. 0.2 V
output
(Since trouble is in system, troubleshooting cannot be performed.)
*: See "Troubleshooting for disconnection in wiring harness of pressure sensor system" in "General
information on troubleshooting" section.
40-302 6 D65EX, PX, WX-16

Failure code [CA123] Chg Air Press Sensor Low Error SEN05032-01
D65EX, PX, WX-16 40-302 7

SEN05032-01 Failure code [CA131] Throttle Sensor High Error
Failure code [CA131] Throttle Sensor High Error 1
Action code Failure code Throttle sensor high error

Trouble
Failure
• High voltage was detected in signal circuit of decelerator pedal (throttle sensor).
description
Action of • Controller considers decelerator pedal (throttle) sensor voltage as a fixed value and continues oper-
controller ation.
Indication of
problem on • Engine speed cannot be controlled with decelerator pedal (throttle sensor).
machine
• Signal voltage of decelerator pedal (throttle sensor) can be checked with monitoring function.
Related (Code: 31703 Decelerator pedal sensor voltage)
information • Method of reproducing failure code: Turn starting switch to ON position and depress decelerator
pedal.

connector
Defective throttle sensor
power supply system
2. Disconnect connector DCL and connect T-adapter to male side.
Defective decelerator pedal
3 Between DCL (male) (B) and (C) Resistance Approx. 2 kz
(throttle sensor)
Between DCL (male) (A) and (C) Resistance 0.2 – 1.8 kz
Between DCL (male) (B) and (A) Resistance 0.2 – 1.8 kz
Disconnection or short circuit 2. Disconnect connector CE02 and connect T-adapter to female side.
4
in wiring harness Between CE02 (female) (22) and (23) Resistance Approx. 2 kz
Between CE02 (female) (9) and (23) Resistance 0.2 – 1.8 kz
Short circuit in wiring 2. Disconnect connector CE02 and DCL and connect T-adapter to female side of
5 either one of them.
harness
Between CE02 (female) (9) and (22), or between DCL
(female) (A) and (B)
Hot short in wiring harness 2. Disconnect connector DCL and connect T-adapter to female side.
6
(Contact with 24 V circuit) 3. Turn starting switch to ON position.
Between DCL (female) (A) and ground Voltage Max. 1 V
a If no abnormality is found by the above checks, the engine controller is defective.
• Reference; The following is standard value in normal condition.
2. Insert T-adapter between male and female sides of CE02.
3. Turn starting switch to ON position.
7 Defective engine controller 4. Troubleshoot with decelerator pedal operation.
Between CE02 (22) and (23) Voltage 4.75 – 5.25 V
With decelerator pedal
Between CE02 (9) and (23) Voltage Approx. 3.5 V
stamping
Away from decelerator
Between CE02 (9) and (23) Voltage Approx. 2 V
pedal
40-302 8 D65EX, PX, WX-16

Failure code [CA131] Throttle Sensor High Error SEN05032-01
D65EX, PX, WX-16 40-302 9

SEN05032-01 Failure code [CA132] Throttle Sensor Low Error
Failure code [CA132] Throttle Sensor Low Error 1
Action code Failure code Throttle sensor low error

Trouble
Failure
• Low voltage was detected in signal circuit of decelerator pedal (throttle sensor).
description
Action of • Controller considers decelerator pedal (throttle) sensor voltage as a fixed value and continues oper-
controller ation.
Indication of
problem on • Engine speed cannot be controlled with decelerator pedal (throttle sensor).
machine
• Signal voltage of decelerator pedal (throttle sensor) can be checked with monitoring function.
Related (Code: 31703 Decelerator pedal sensor voltage)
information • Method of reproducing failure code: Turn starting switch to ON position and depress decelerator
pedal.

connector
Defective throttle sensor
power supply system
2. Disconnect connector DCL and connect T-adapter to male side.
Defective decelerator pedal
3 Between DCL (male) (B) and (C) Resistance Approx. 2 kz
(throttle sensor)
Between DCL (male) (A) and (C) Resistance 0.2 – 1.8 kz
Between DCL (male) (B) and (A) Resistance 0.2 – 1.8 kz
4
in wiring harness Between CE02 (female) (22) and (23) Resistance Approx. 2 kz
Between CE02 (female) (9) and (23) Resistance 0.2 – 1.8 kz
Disconnection in wiring har- 2. Disconnect connectors CE02 and DCL and connect T-adapter to each female
ness side.
5
(Disconnection or defective
Between CE02 (female) (22) and DCL (female) (B) Resistance Max. 1 z
Between CE02 (female) (9) and DCL (female) (A) Resistance Max. 1 z
Between CE02 (female) (23) and DCL (female) (C) Resistance Max. 1 z
Short circuit in wiring 2. Disconnect connectors CE02 and DCL and connect T-adapter to female side of
6
harness either one of them.
Between CE02 (female) (9) and (23), or between DCL
(female) (A) and (C)
Ground fault of wiring 2. Disconnect connectors CE02 and DCL and connect T-adapter to female side of
7 harness either one of them.
(Contact with ground circuit) Between CE02 (female) (9) or DCL (female) (A) and
ground
40-302 10 D65EX, PX, WX-16

Failure code [CA132] Throttle Sensor Low Error SEN05032-01

a If no abnormality is found by the above checks, the engine controller is defective.
• Reference; The following is standard value in normal condition.
2. Insert T-adapter between male and female sides of CE02.
8 Defective engine controller 4. Troubleshoot with decelerator pedal operation.
Between CE02 (22) and (23) Voltage 4.75 – 5.25 V
With decelerator pedal
Between CE02 (9) and (23) Voltage Approx. 3.5 V
stamping
Away from decelerator
Between CE02 (9) and (23) Voltage Approx. 2 V
pedal
D65EX, PX, WX-16 40-302 11

SEN05032-01 Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA144] Coolant Temp Sens High Error 1
Action code Failure code Coolant temperature sensor high error

Trouble
Failure
• High voltage was detected in signal circuit of coolant temperature sensor.
description
Action of
• Fixes coolant temperature value and continues operation.
controller
Indication of • Engine is hard to start at low temperature.
problem on • Exhaust gas becomes white.
machine • Overheat prevention function does not work.
• Signal voltage of coolant temperature sensor can be checked with monitoring function.
(Code: 04105 Coolant temperature sensor voltage)
information • This failure code is displayed if temperature sensor connector or harness is disconnected.
• Because that T-adapter for sensor connector is socket type, it cannot be connected to wiring har-
ness.

connector
2. Disconnect connector COOLANT TEMP and connect socket to male side.
a When coolant temperature is above 0°C, if coolant temperature sensor resistance
is 700 z – 37 kz, coolant temperature sensor is regarded as normal.
Defective coolant tempera- 0°C Resistance 30 – 37 kz
2
ture sensor 9.3 –
COOLANT TEMP (male) between (A) 25°C Resistance
10.7 kz
and (B)
50°C Resistance 3.2 – 3.8 kz
a Coolant temperature characteristic
95°C Resistance 700 – 800 z
2. Disconnect connector ECM and connect T-adapter to female side.
Disconnection or short circuit Between ECM (female) (15) and (38) (Coolant tempera-
3 ture is above 0°C)
in wiring harness 700 z –
a Resistance value is the same as the one on “coolant Resistance
37 kz
temperature – resistance characteristics table” for
coolant temperature sensor in cause 2.
40-302 12 D65EX, PX, WX-16

Failure code [CA144] Coolant Temp Sens High Error SEN05032-01
D65EX, PX, WX-16 40-302 13

SEN05032-01 Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA145] Coolant Temp Sens Low Error 1
Action code Failure code Coolant temperature sensor low error

Trouble
Failure
• Low voltage was detected in signal circuit of coolant temperature sensor.
description
Action of
• Fixes coolant temperature value and continues operation.
controller
Indication of • Engine is hard to start at low temperature.
problem on • Exhaust gas becomes white.
machine • Overheat prevention function does not work.
• Signal voltage of coolant temperature sensor can be checked with monitoring function.
(Code: 04105 Coolant temperature sensor voltage)
Related
information
• This code is not displayed but High Error failure code is displayed, if sensor connector or harness is
disconnected.

connector
2. Disconnect connector COOLANT TEMP and connect socket to male side.
a When coolant temperature is above 0°C, if coolant temperature sensor resistance
is 700 z – 37 kz, coolant temperature sensor is regarded as normal.
Defective coolant tempera- 0°C Resistance 30 – 37 kz
2
ture sensor 9.3 –
COOLANT TEMP (male) between (A) 25°C Resistance
10.7 kz
and (B)
a Coolant temperature characteristic
Short circuit in wiring har- Between ECM (female) (15) and (38) (Coolant tempera-
3 ture is above 0°C)
ness 700 z –
a Resistance value is the same as the one on “coolant Resistance
37 kz
coolant temperature sensor in cause 2.
Ground fault of wiring har-
2. Disconnect connectors ECM and COOLANT TEMP, and connect T-adapter to
4 ness female side of ECM.
40-302 14 D65EX, PX, WX-16

Failure code [CA145] Coolant Temp Sens Low Error SEN05032-01
D65EX, PX, WX-16 40-302 15

SEN05032-01 Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA153] Chg Air Temp Sensor High Error 1
Action code Failure code Charge air temperature sensor high error
Trouble
Failure • High voltage was detected in temperature signal circuit of charge (boost) pressure/temperature sen-
description sor.
Action of
• Fixes charge air temperature value and continues operation.
controller
Indication of
• Exhaust gas becomes white.
problem on
• Engine protection function based on boost temperature does not work.
machine
• Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked
with monitoring function.
Related
(Code: 18501 Boost temperature sensor voltage)
information
• This failure code is displayed if temperature sensor connector or harness is disconnected.

connector
2. Disconnect connector BOOST PRESS & IMT and connect socket to male side.
a If charge temperature sensor resistance is 80 z – 48 kz, regard charge tempera-
ture sensor as normal.
–40°C Resistance 41 – 48 kz
Defective charge –20°C Resistance 14 – 16 kz
2
temperature sensor 0°C Resistance 5.4 – 6.1 kz
BOOST PRESS & IMT (male) between
(3) and (4) 30°C Resistance 1.6 – 1.8 kz
a Charge temperature characteristic 60°C Resistance 560 – 600 z
Disconnection or short circuit Between ECM (female) (23) and (47)
3
in wiring harness a Resistance value is the same as the one on “charge
Resistance 80 z – 48 kz
charge temperature sensor in cause 2.
40-302 16 D65EX, PX, WX-16

Failure code [CA153] Chg Air Temp Sensor High Error SEN05032-01
D65EX, PX, WX-16 40-302 17

SEN05032-01 Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA154] Chg Air Temp Sensor Low Error 1
Action code Failure code Charge air temperature sensor low error
Trouble
Failure • Low voltage was detected in temperature signal circuit of charge (boost) pressure/temperature sen-
description sor.
Action of
• Fixes charge temperature value and continues operation.
controller
Indication of
• Exhaust gas becomes white.
problem on
• Engine protection function based on boost temperature does not work.
machine
• Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked
with monitoring function.
Related
(Code: 18501 Boost temperature sensor voltage)
information
• This failure code is displayed if temperature sensor connector or harness is disconnected.

connector
2. Disconnect connector BOOST PRESS & IMT and connect socket to male side.
a If charge temperature sensor resistance is 80 z – 48 kz, regard charge tempera-
ture sensor as normal.
–40°C Resistance 41 – 48 kz
Defective charge –20°C Resistance 14 – 16 kz
2
temperature sensor 0°C Resistance 5.4 – 6.1 kz
BOOST PRESS & IMT (male) between
(3) and (4) 30°C Resistance 1.6 – 1.8 kz
a Charge temperature characteristic 60°C Resistance 560 – 600 z
Short circuit in wiring Between ECM (female) (23) and (47)
3
harness a Resistance value is the same as the one on “charge
Resistance 80 z – 48 kz
charge temperature sensor in cause 2.
Ground fault of wiring 2. Disconnect connectors ECM and BOOST PRESS & IMT and connect T-adapter to
4 harness female side of ECM.
(Contact with ground circuit) Between ECM (female) (23) or BOOST PRESS & IMT
Resistance Min. 100 kz
(female) (3) and ground
40-302 18 D65EX, PX, WX-16

Failure code [CA154] Chg Air Temp Sensor Low Error SEN05032-01
D65EX, PX, WX-16 40-302 19

SEN05032-01 Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA155] Chg Air Temp High Speed Derate 1
Action code Failure code Charge air temperature high speed derate
Trouble
Failure • Temperature signal from charge (boost) pressure/temperature sensor exceeded temperature upper
description control limit.
Action of
• Limits output and continues operation.
controller
Indication of
• Engine output lowers.
problem on
• Engine stops.
machine
• Boost temperature can be checked with monitoring function.
Related
(Code: 18500 Boost temperature)
information

Cooling performance of aftercooler may be low. Check following points directly.
Lowering of cooling • Looseness and breakage of fan belt
1
performance of aftercooler • Insufficiency of cooling air
• Clogging of aftercooler fins
Abnormal rise of
Outlet temperature of turbocharger may be abnormally high. Check related parts
2 turbocharger outlet
directly.
temperature
If no abnormality is found by the above checks, charge air temperature sensor
Defective charge air
3 system is defective.
temperature sensor system
Perform troubleshooting for failure codes [CA153] and [CA154]
40-302 20 D65EX, PX, WX-16

Failure code [CA155] Chg Air Temp High Speed Derate SEN05032-01
D65EX, PX, WX-16 40-302 21

SEN05032-01 Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error 1
Action code Failure code Sensor power supply 2 voltage low error
Trouble
Failure
• Low voltage was detected in sensor power supply 2 circuit.
description
• Fixes charge (boost) pressure value and continues operation.
Action of
• Fixes charge (boost) air temperature value and continues operation.
controller
Indication of
problem on
• Engine does not start easily.
machine
Related
information

connector
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to 1.
If this failure code is not displayed when a sensor is disconnected, that sensor or
engine wiring harness is defective.
Defective sensor or wiring a Other failure code(s) is(are) displayed together. This is because that the sensor
2 connector is disconnected. So, code(s) can be ignored except the failure code
harness
[CA187].
Sensor or harness Connector
Boost pressure/temperature sensor BOOST PRESS & IMT
Common rail pressure sensor FUEL RAIL PRESS
Bkup sensor CAM SENSOR
Engine wiring harness ECM
2. Disconnect connector ECM and connect T-adapter to male side.
3 Defective engine controller 3. Turn starting switch to ON position without connecting engine wiring harness.
4.75 –
Between ECM (male) (37) and (47) Voltage
5.25 V
40-302 22 D65EX, PX, WX-16

Failure code [CA187] Sens Supply 2 Volt Low Error SEN05032-01
D65EX, PX, WX-16 40-302 23

SEN05032-01 Failure code [CA221] Ambient Press Sens High Error
Failure code [CA221] Ambient Press Sens High Error 1
Action code Failure code Ambient pressure sensor high error

Trouble
Failure
• High voltage was detected in signal circuit of ambient pressure sensor.
description
Action of
• Fixes ambient pressure value and continues operation.
controller
Indication of
problem on
machine
• Signal voltage of ambient pressure sensor can be checked with monitoring function.
Related
(Code: 37401 Ambient pressure sensor voltage)
information

connector
Defective sensor power
supply 1 system
Defective ambient pressure 2. Disconnect connector AMB. AIR PRESSURE.
3 3. Turn starting switch to ON position.
sensor
If failure code changes from [CA221] to [CA222], sensor is defective.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter
Short circuit in wiring to female side of either one of them.
4
harness
Between ECM (female) (33) and (3) or between AMB.
AIR PRESSURE (female) (1) and (3)
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or insert T-
Hot short in wiring harness adapter in connector ECM.
5 4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE
disconnected).
Between ECM (3) and (38), or between AMB. AIR
Voltage Max. 1 V
PRESSURE (female) (3) and (2)
40-302 24 D65EX, PX, WX-16

Failure code [CA221] Ambient Press Sens High Error SEN05032-01
D65EX, PX, WX-16 40-302 25

SEN05032-01 Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA222] Ambient Press Sens Low Error 1
Action code Failure code Ambient pressure sensor low error

Trouble
Failure
• Low voltage was detected in signal circuit of ambient pressure sensor.
description
Action of
controller
Indication of
problem on
machine
• Signal voltage of ambient pressure sensor can be checked with monitoring function.
Related
(Code: 37401 Ambient pressure sensor voltage)
information

connector
If failure code [CA352] (Ground fault in sensor power supply line) or [CA386] is
Defective power supply
2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to female
2 system of ambient pressure
side.
sensor
Between AMB. AIR PRESSURE (female) Power 4.75 –
Voltage
(1) and (2) supply input 5.25 V
2. Disconnect connectors ECM and AMB. AIR PRESSURE and connect T-adapters
to each female side.
a If power supply in checks on cause 2 is normal, this
check is not required.
Disconnection in wiring Resistance Max. 10 z
Between ECM (female) (33) and AMB. AIR PRES-
harness
3 SURE (female) (1)
a If power supply in checks on cause 2 is normal, this
Resistance Max. 10 z
Between ECM (female) (38) and AMB. AIR PRES-
SURE (female) (2)
Between ECM (female) (3) and AMB. AIR PRESSURE
(female) (3) (Sensor output)
Ground fault of wiring 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter
4 harness to female side of either one of them.
(Contact with ground circuit) Between ECM (female) (3) and ground, or between
AMB. AIR PRESSURE (female) (3) and ground
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter
Short circuit in wiring
5 to female side of either one of them.
harness
Between ECM (female) (3) and (38), or between AMB.
AIR PRESSURE (female) (2) and (3)
a If causes 1 – 5 are not the cause for the trouble and check result of cause 6 is
Defective ambient pressure 1. Turn starting switch to OFF position.
6 sensor (Improper input 2. Insert T-adapter between male and female sides of connector ECM.
voltage to engine controller) 3. Turn starting switch to ON position.
Sensor
Between ECM (3) and (38) Voltage 0.5 – 4.5 V
output
40-302 26 D65EX, PX, WX-16

Failure code [CA222] Ambient Press Sens Low Error SEN05032-01

D65EX, PX, WX-16 40-302 27

SEN05032-01 Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA227] Sens Supply 2 Volt High Error 1
Action code Failure code Sensor power supply 2 voltage high error
Trouble
Failure
• High voltage was detected in sensor power supply No.2 circuit.
description
• Fixes boost pressure value and continues operation.
Action of
• Fixes charge air temperature value and continues operation.
controller
Indication of
problem on
machine
Related
information

Perform troubleshooting for failure code [CA187].
Failure code [CA234] Eng Overspeed 1
Action code Failure code Engine overspeed

Trouble
— CA234 (Engine controller system)
Failure
• Engine speed exceeded upper limit.
description
Action of
• Stops injection until engine speed lowers to normal level.
controller
Indication of
problem on • Engine speed fluctuates.
machine
• Engine speed can be checked with monitoring function.
Related
(Code: 01002 Engine speed)
information
• Method of reproducing failure code: Run engine at high idle.

1 Use of improper fuel Improper fuel may be used. Check it directly.
2 Improper use Machine may be used improperly. Instruct operator proper way of use.
40-302 28 D65EX, PX, WX-16

Failure code [CA238] Ne Speed Sens Supply Volt Error SEN05032-01
Failure code [CA238] Ne Speed Sens Supply Volt Error 1
Action code Failure code Ne speed sensor power supply voltage error
Trouble
Failure
• Low voltage was detected in power supply circuit for engine Ne speed sensor.
description
Action of
• Continues control with signal from engine Bkup speed sensor.
controller
Indication of
problem on
• Engine hunts.
machine
Related
information

connector
position each time.
If this failure code is not displayed when a sensor is disconnected, sensor or engine
Defective sensor or wiring wiring harness is defective.
2 a Other failure code(s) is(are) displayed at the same time. This is because the sen-
harness
sor connector is disconnected. Therefore, code(s) can be ignored except the fail-
ure code [CA238].
Ne speed sensor CRANK SENSOR
4.75 –
5.25 V
D65EX, PX, WX-16 40-302 29

SEN05032-01 Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA271] IMV/PCV1 Short Error 1
Action code Failure code IMV/PCV1 short circuit error

Trouble
Failure
• Short circuit was detected in drive circuit for supply pump actuator.
description
Action of
controller
Indication of • Engine speed does not rise from low idle.
machine • Common rail fuel pressure rises above command value.
Related
information

connector
Defective supply pump 2. Disconnect connector INLET METERING VALVE.
2
actuator 3. Turn starting switch to ON position.
If failure code changes from [CA271] to [CA272], supply pump actuator is defective.
Short circuit in, or ground 2. Disconnect connector ECM and connect T-adapter to female side.
3
fault of wiring harness Between ECM (female) (2) and (32) Resistance 1–5z
Short circuit in wiring 2. Disconnect connectors ECM and INLET METERING VALVE, and connect T-
4
harness adapter to female side of ECM.
Between ECM (female) (2) and (32), or between INLET
METERING VALVE (female) (1) and (2)
2. Disconnect connectors ECM and INLET METERING VALVE, and connect T-
5 harness adapter to female side of ECM.
Between ECM (female) (2) and ground, or between
INLET METERING VALVE (female) (1) and ground
40-302 30 D65EX, PX, WX-16

Failure code [CA271] IMV/PCV1 Short Error SEN05032-01
D65EX, PX, WX-16 40-302 31

SEN05032-01 Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA272] IMV/PCV1 Open Error 1
Action code Failure code IMV/PCV1 open error

Trouble
Failure
• Disconnection was detected in drive circuit for supply pump actuator.
description
Action of
controller
Indication of
• Engine runs but its operation is unstable.
problem on
• Common rail fuel pressure rises above command value.
machine
Related
information

connector
Defective supply pump
2 2. Disconnect connector INLET METERING VALVE.
actuator
Between INLET METERING VALVE (male) (1) and (2) Resistance Max. 5 z
Disconnection or short circuit 2. Disconnect connector ECM and connect T-adapter to female side.
3
in wiring harness
Between ECM (female) (2) and (32) Resistance Max. 5 z
a If no abnormality is found in checks on cause 3, this check is not required.
Disconnection in wiring 2. Disconnect connectors ECM and INLET METERING VALVE and connect T-
harness adapters to each female side.
4 (Disconnection in wiring or
Between ECM (female) (2) and INLET METERING
defective contact in Resistance Max. 10 z
VALVE (1)
connector)
Between ECM (female) (32) and INLET METERING
VALVE (2)
2. Disconnect connector INLET METERING VALVE.
3. Insert T-adapter into connector ECM or connect female side of INLET METERING
VALVE.
Hot short in wiring harness
5 4. Turn starting switch to ON position and perform troubleshooting after one minute
or longer (with connector INLET METERING VALVE disconnected).
a Average voltage is displayed because of PWM.
Between ECM (2) and (32), or between INLET
Voltage Max. 3 V
METERING VALVE (female) (1) and (2)
40-302 32 D65EX, PX, WX-16

Failure code [CA272] IMV/PCV1 Open Error SEN05032-01
D65EX, PX, WX-16 40-302 33

SEN05032-01 Failure code [CA281] Abnormal supply pump pressure balance
Failure code [CA281] Abnormal supply pump pressure balance 1
Action code Failure code Abnormal supply pump pressure balance

Trouble
Failure • Due to the abnormality in supply pump mechanical system, response of fuel pressure feed is not
description appropriate, that is abnormal.
Action of
• No particular action
controller
Indication of
• Engine does not start. Or it starts, but it does not stabilize.
problem on
• The pressure of high-pressure fuel is different in front side and rear side of supply pump.
machine
Related
• Method of reproducing failure code: Start the engine.
information

Refer to “Bleeding air from fuel circuit” in Testing and adjusting, and bleed air from
1 Residual air in the fuel circuit
the fuel circuit.
connector
Engine controller is possibly defective if no problem is found in causes 1 – 2.
40-302 34 D65EX, PX, WX-16

Failure code [CA281] Abnormal supply pump pressure balance SEN05032-01
D65EX, PX, WX-16 40-302 35

SEN05032-01 Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA322] Inj #1(L#1) Open/Short Error 1
Action code Failure code Injector #1(L#1) open/short circuit error

Trouble
Failure
• Open or short circuit was detected in drive circuit of No. 1 injector.
description
Action of
controller
Indication of
• Combustion becomes irregular or engine hunts.
problem on
machine
• Method of reproducing failure code: Run engine.
Related
• While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but it
information
cannot be measured with tester since tester cannot measure pulse voltages.

connector
2. Disconnect connector INJECTOR CYL 1&2, and connect T-adapter to male side.
2 Defective No. 1 injector
Between INJECTOR CYL 1&2 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (3) and ground Resistance Min. 100 kz
Disconnection in, or ground 2. Disconnect connector ECM and connect T-adapter to female side.
3
fault of wiring harness Between ECM (female) (45) and (53) Resistance Max. 2 z
a If cause 3 is not the cause of the trouble, this check is not required.
Disconnection in wiring 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapters to
harness each female side.
Between ECM (female) (45) and INJECTOR CYL 1&2
(female) (3)
connector)
Resistance Max. 2 z
(female) (4)
a If cause 3 is not the cause of the trouble, this check is not required.
2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to
5 harness
female side of either one of them.
Between ECM (female) (45) or INJECTOR CYL 1&2
(female) (3), and ground
female side of ECM.
Short circuit in wiring a Check with tester in continuity mode.
6
harness Between ECM (female) (45) and each pin other than pin No continuity
(45) (No sound is heard)
Between ECM (female) (53) and each pin other than pin No continuity
Defective other cylinder If the failure codes of other injectors are displayed, perform troubleshooting of them,
7
injectors or wiring harness too.
If causes 1 – 7 are not the cause for the trouble, the engine controller is defective.
40-302 36 D65EX, PX, WX-16

Failure code [CA322] Inj #1(L#1) Open/Short Error SEN05032-01
D65EX, PX, WX-16 40-302 37

Action code Failure code Injector #5(L#5) open/short circuit error

Trouble
Failure
description
Action of
controller
Indication of
problem on
machine
Related
a While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but it
information

connector
3
(female) (3)
connector)
Resistance Max. 2 z
(female) (4)
5 harness
female side of ECM.
6
Defective other cylinder If the failure codes of other injectors are displayed, perform troubleshooting for them,
7
40-302 38 D65EX, PX, WX-16

D65EX, PX, WX-16 40-302 39

Action code Failure code Injector #3(L#3) open /short circuit error
Trouble
Failure
description
Action of
controller
Indication of
problem on
machine
Related
information

connector
3
(female) (3)
connector)
Resistance Max. 2 z
(female) (4)
5 harness
female side of ECM.
6
7
40-302 40 D65EX, PX, WX-16

D65EX, PX, WX-16 40-302 41

Action code Failure code Injector #6 (L#6) open / short circuit error
Trouble
Failure
description
Action of
controller
Indication of
problem on
machine
Related
information

connector
3
(female) (1)
connector)
Resistance Max. 2 z
(female) (2)
5 harness
female side of ECM.
6
Defective other cylinder If the failure codes of other injectors are displayed, perform troubleshooting of them,
7
40-302 42 D65EX, PX, WX-16

D65EX, PX, WX-16 40-302 43

Action code Failure code Injector #2(L#2) open /short circuit error
Trouble
Failure
description
Action of
controller
Indication of
problem on
machine
Related
information

connector
3
(female) (2)
connector)
Resistance Max. 2 z
(female) (1)
5 harness
female side of ECM.
6
7
40-302 44 D65EX, PX, WX-16

D65EX, PX, WX-16 40-302 45

Action code Failure code Injector #4 (L#4) open / short circuit error
Trouble
Failure
description
Action of
controller
Indication of
problem on
machine
Related
information

connector
3
(female) (2)
connector)
Resistance Max. 2 z
(female) (1)
5 harness
female side of ECM.
6
7
40-302 46 D65EX, PX, WX-16

D65EX, PX, WX-16 40-302 47

SEN05032-01

©2009 KOMATSU
All Rights Reserved
40-302 48
SEN05033-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Failure code [CA342] Calibration Code Incompatibility................................................................................... 3
Failure code [CA351] Injectors Drive Circuit Error .......................................................................................... 3
Failure code [CA352] Sens Supply 1 Volt Low Error ...................................................................................... 4
Failure code [CA386] Sens Supply 1 Volt High Error...................................................................................... 6
Failure code [CA428] Water in Fuel Sensor High Error .................................................................................. 8
Failure code [CA429] Water in Fuel Sensor Low Error ................................................................................. 10
Failure code [CA435] Eng Oil Press Sw Error .............................................................................................. 12
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 14
Failure code [CA442] Battery Voltage High Error ......................................................................................... 16
Failure code [CA449] Rail Press Very High Error ......................................................................................... 18
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 20
Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 22
Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................. 24
Failure code [CA553] Rail Press High Error ................................................................................................. 25
Failure code [CA559] Rail Press Low Error .................................................................................................. 26
Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 32
Failure code [CA757] All Continuous Data Lost Error................................................................................... 33
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 34
Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 37
Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................ 38
D65EX, PX, WX-16 40-303 1

SEN05033-01
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 40

Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 42
Failure code [CA2265] Fuel Feed Pump Open Error .................................................................................... 44
Failure code [CA2266] Fuel Feed Pump Short Error .................................................................................... 46
Failure code [CA2311] IMV Solenoid Error ................................................................................................... 47
Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 48
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................................... 50
40-303 2 D65EX, PX, WX-16

Failure code [CA342] Calibration Code Incompatibility SEN05033-01
Failure code [CA342] Calibration Code Incompatibility 1
Action code Failure code Calibration code incompatibility

Trouble
Failure
• Calibration code incompatibility occurred in engine controller.
description
Action of
controller
Indication of
problem on • Continues normal operation.
machine
Related
information

Abnormal power supply
voltage
Failure code [CA351] Injectors Drive Circuit Error 1
Action code Failure code Injector drive circuit error

Trouble
Failure
• Power supply circuit to drive injectors is defective.
description
Action of
• Limits engine output and continues operation.
controller
• Exhaust gas becomes black.
Indication of
• Combustion becomes irregular.
problem on
machine
• Engine cannot be started.
Related • Method of reproducing failure code: Start engine.
information a If it outputs failure code, power supply to engine controller is normal.

Check another failure code displayed simultaneously. If another failure code is
Abnormal power supply
voltage
D65EX, PX, WX-16 40-303 3

SEN05033-01 Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA352] Sens Supply 1 Volt Low Error 1
Action code Failure code Sensor power supply 1 voltage low error
Trouble
Failure
• Low voltage was detected in sensor power supply No.1 circuit.
description
Action of
controller
Indication of
problem on
machine
Related
information

connector
position to check whether the failure code is displayed or not.
If this failure code is not displayed when a sensor is disconnected, that sensor or
Defective sensor or wiring engine wiring harness is defective.
2 a Other failure code(s) is(are) displayed at the same time. This is because the sen-
harness
sor connector is disconnected. Therefore, code(s) may be ignored except for the
failure code [CA352].
Ambient pressure sensor AMB. AIR PRESSURE
4.75 –
5.25 V
40-303 4 D65EX, PX, WX-16

Failure code [CA352] Sens Supply 1 Volt Low Error SEN05033-01
D65EX, PX, WX-16 40-303 5

SEN05033-01 Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA386] Sens Supply 1 Volt High Error 1
Action code Failure code Sensor power supply 1 voltage high error
Trouble
Failure
• High voltage was detected in sensor power supply No.1 circuit.
description
Action of
• Sets ambient pressure at a fixed value and continues operation.
controller
Indication of
problem on
machine
Related
information

40-303 6 D65EX, PX, WX-16

Failure code [CA386] Sens Supply 1 Volt High Error SEN05033-01
D65EX, PX, WX-16 40-303 7

SEN05033-01 Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA428] Water in Fuel Sensor High Error 1
Action code Failure code Water-in-fuel sensor high error

Trouble
Failure
• High voltage was detected in signal circuit of water-in-fuel sensor.
description
Action of
controller
Indication of
problem on • Water separator monitor is not displayed properly.
machine
• Condition of water-in-fuel sensor signal can be checked with monitoring function.
Related
(Code: 18800 Condition of WIF sensor)
information

connector
Defective water-in-fuel 2. Disconnect connector WIF and connect T-adapter to female side.
2 a If water is in water separator, drain it.
sensor
Between WIF (female) (1) and (2) Resistance Max. 100 kz
3
in wiring harness Between ECM (female) (14) and (47)
Resistance Max. 100 kz
(resistance in water-in-fuel sensor)
Disconnection in wiring 2. Disconnect connectors ECM and WIF, and connect T-adapters to each female
harness side.
Between connector ECM (female) (14) and WIF
(female) (1)
connector)
Between connector ECM (female) (47) and WIF
(female) (2)
2. Disconnect connectors ECM and WIF, and connect T-adapters to each female
Short circuit in wiring side.
5 a Check with tester in continuity mode.
harness
Between ECM (female) (14) and each pin other than No continuity
(14) pin (No sound is heard)
40-303 8 D65EX, PX, WX-16

Failure code [CA428] Water in Fuel Sensor High Error SEN05033-01
D65EX, PX, WX-16 40-303 9

SEN05033-01 Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA429] Water in Fuel Sensor Low Error 1
Action code Failure code Water-in-fuel sensor low error

Trouble
Failure
• Low voltage was detected in signal circuit of water-in-fuel sensor.
description
Action of
controller
Indication of
problem on • Water separator monitor is not displayed properly.
machine
• Condition of water-in-fuel sensor signal can be checked with monitoring function.
Related
(Code: 18800 Condition of WIF sensor)
information

connector
2. Disconnect connector WIF and connect T-adapter to female side.
Defective water-in-fuel a If water is in water separator, drain it.
2
sensor
Between WIF (female) (1) and (2) Resistance Max.100 kz
Between WIF (female) (1) and ground Resistance Min. 100 kz
Short circuit in, or ground
3 Between ECM (female) (14) and (47) (Water-in-fuel
fault of wiring harness Resistance Max.100 kz
sensor resistance)
2. Disconnect connectors ECM and WIF, and connect T-adapter to female side of
Short circuit in wiring either one of them.
4
harness a Check with tester in continuity mode.
Between ECM (female) (14) and each pin other than No continuity
Ground fault of wiring 2. Disconnect connectors ECM and WIF and connect T-adapter to female side of
5 harness
either one of them.
Between ECM (female) (14) or WIF (female) (1) and
ground
40-303 10 D65EX, PX, WX-16

Failure code [CA429] Water in Fuel Sensor Low Error SEN05033-01
D65EX, PX, WX-16 40-303 11

SEN05033-01 Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA435] Eng Oil Press Sw Error 1
Action code Failure code Engine oil pressure switch error

Trouble
Failure
• Abnormality is detected in signal circuit of engine oil pressure switch.
description
Action of
controller
Indication of
• Engine protection function based on engine oil pressure does not work.
problem on
• Engine oil pressure monitor is not displayed properly.
machine
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
• Engine oil pressure switch closes (ON) with starting switch at OFF position and opens (OFF) with
Related engine running.
information • In this failure code, engine controller checks whether oil pressure switch is closed (ON), that is
“GND level” only with engine stopped.
• With engine running, failure code [B@BAZG] applies to engine oil pressure switch abnormality.

connector
2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapter to male
Defective engine oil side.
2
pressure switch
Between OIL PRESSURE SWITCH (male) (1) and
ground
3
in wiring harness
Between ECM (female) (17) and ground Resistance Max. 10 z
40-303 12 D65EX, PX, WX-16

Failure code [CA435] Eng Oil Press Sw Error SEN05033-01
D65EX, PX, WX-16 40-303 13

SEN05033-01 Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error 1
Action code Failure code Battery voltage low error

Trouble
Failure
• Low voltage was detected in voltage source circuit of controller.
description
Action of
controller
Indication of
• Engine stops.
problem on
machine
Related
information

Looseness or corrosion of Looseness or corrosion of battery terminal may be cause of failure. Check them
1
battery terminal directly.
Loosened terminal or partial 1. Turn starting switch to OFF position.
2
disconnection at terminal Check terminals of alternator, battery relay, ground (GND1) etc. for looseness.
connector
4 Improper battery voltage 2. Measure voltage with starting switch at OFF and when starting engine.
Between battery terminal (+) and (–). Voltage 20 – 30 V
2. Insert T-adapter between male and female side of connector EG2.
5 Defective alternator
3. Start engine (Engine speed: Middle or faster)
Between EG2 (7) and ground Voltage 26 – 30.5 V
• Reference: The followings are standard value in normal condition.
1. Turn starting switch to OFF position and disconnect ground cable.
6 Defective engine controller 2. Insert T-adapter between male and female sides of CE03.
3. Connect ground cable.
4. Measure voltage with starting switch at OFF and when starting engine.
Between CE03 (3) and (1) Voltage 20 – 30 V
Between CE03 (4) and (2) Voltage 20 – 30 V
40-303 14 D65EX, PX, WX-16

Failure code [CA441] Battery Voltage Low Error SEN05033-01
D65EX, PX, WX-16 40-303 15

SEN05033-01 Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error 1
Action code Failure code Battery voltage high error

Trouble
Failure
• High voltage (36 V or higher) was detected in voltage source circuit of controller.
description
Action of
controller
Indication of
problem on • Engine may stop.
machine
Related
information

40-303 16 D65EX, PX, WX-16

Failure code [CA442] Battery Voltage High Error SEN05033-01
D65EX, PX, WX-16 40-303 17

SEN05033-01 Failure code [CA449] Rail Press Very High Error
Failure code [CA449] Rail Press Very High Error 1
Action code Failure code Common rail pressure very high error
Trouble
Failure
• There is high pressure error (2) in common rail circuit.
description
Action of
controller
Indication of
• Engine sound becomes large when no or light load is applied.
problem on
machine
• Common rail pressure can be checked with monitoring function.
Related
(Code: 36400 Common rail pressure)
information

1 Defect in related system If another failure code is displayed, perform troubleshooting for it, too.
There may be air in low pressure circuit. Check it directly according to the following
procedure.
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
2 Air in low pressure circuit 3. Check pressure pickup plug for leakage of fuel and air.
• If this failure occurs during air bleeding after the fuel filter was replaced, air may
remain in the fuel circuit. Keep running the engine at low idle for about three min-
utes. As air is bled from the fuel circuit, the engine speed will be stabilized, erasing
the failure indication.
a For check of pressure in fuel low pressure circuit, see Testing and adjusting,
“Checking fuel pressure”.
• Measured in fuel filter outlet side.
Pressure in fuel During high idle Max. 0.48 MPa
low-pressure circuit (if engine can be started) {Max. 4.9 kg/cm2}
• Measured in fuel filter inlet and outlet sides.
• Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure – Fuel filter
outlet pressure
Pressure drop in fuel Max. 0.14 MPa
Defect in fuel low pressure During high idle
3 low-pressure circuit {Max. 1.4 kg/cm2}
circuit parts
a For check of fuel suction pressure, see Testing and adjusting, “Checking fuel pres-
sure”.
• Measured in gear pump fuel inlet side of supply pump.
Fuel suction circuit
Max. 33.9 kPa
pressure During high idle
{Max. 254 mmHg}
(gear pump side)
a For check of fuel return circuit pressure, see Testing and adjusting, “Checking fuel
pressure”.
Max. 27.1 kPa
{Max. 203 mmHg}
(fuel connector side)
a Directly check for fuel leakage from fuel tube of fuel cooler, O-ring, seal washer
4 Defective fuel cooler
damage, and check valve clogging or damage.
1. Turn starting switch to OFF position
Defective common rail 2. Display monitoring code: 36400 with monitoring function of machine monitor.
5
pressure sensor Common rail pressure: 0 ± 0.39 MPa
While engine is stopped
36400 {0 ± 4 kg/cm2}
Defective O-ring of supply
6 a Directly check that O-ring of supply pump actuator is not damaged.
pump actuator
40-303 18 D65EX, PX, WX-16

Failure code [CA449] Rail Press Very High Error SEN05033-01

1. Turn starting switch to OFF position
2. Display monitoring code: 36400 with monitoring function of machine monitor.
Common rail pressure: 0 ± 0.39 MPa
While engine is stopped
36400 {0 ± 4 kg/cm2}
Defective supply pump 1. Turn starting switch to OFF position
7
actuator 2. Display monitoring code: 36400 with monitoring function of machine monitor.
3. Start engine.
• Measured after one minute or more lapsed at idle.
Common rail pressure: 1.96 MPa
During low idle
36400 {20 kg/cm2}
connector
Defective engine controller 2. Disconnect connector CE03, and connect T-adapter to female side.
9
ground wiring harness a Check looseness and corrosion of GND1 terminal.
Between CE03 (female) (1) and ground Resistance Max. 10 z
10 Defective supply pump If causes 1 – 9 are not detected, supply pump may be defective.
D65EX, PX, WX-16 40-303 19

SEN05033-01 Failure code [CA451] Rail Press Sensor High Error
Failure code [CA451] Rail Press Sensor High Error 1
Action code Failure code Common rail pressure sensor high error
Trouble
Failure
• High voltage was detected in signal circuit of common rail pressure sensor.
description
Action of
controller
Indication of
problem on
• Engine speed or output lowers.
machine
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor voltage)
information • This code is displayed if common rail pressure sensor connector or harness is disconnected.
• Disconnection in wiring harness and voltage at sensor connector cannot be checked, because that
T-adapter for sensor connector is socket type.

connector
Defective common rail
2 pressure sensor power If failure code [CA227] or [CA187] is displayed, perform troubleshooting for it first.
supply line
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS &
3 IMT and ECM.
harness
3. Connect T-adapter to female side of ECM.
2. Disconnect connector FUEL RAIL PRESS and insert T-adapter in connector ECM.
Hot short in wiring harness 3. Turn starting switch to ON position (with connector FUEL RAIL PRESS
4 disconnected).
a ECM (25) pin is connected to 5 V source through resistor in engine controller.
Between ECM (25) and (47) Voltage Approx. 5 V
harness If no abnormality is found by the above checks, disconnection in wiring harness is
5
(Disconnection or defective considered. (*)
a If causes 1 – 5 are not the cause of the trouble and check result of cause 6 is
Defective common rail 1. Turn starting switch to OFF position.
pressure sensor 2. Insert T-adapter in connector ECM.
6
(Improper input voltage to
engine controller)
Sensor
Between ECM (25) and (47) Voltage 0.2 – 4.6 V
output
*: See "Troubleshooting for disconnection in wiring harness of pressure sensor system" in "General
information on troubleshooting" section.
40-303 20 D65EX, PX, WX-16

Failure code [CA451] Rail Press Sensor High Error SEN05033-01
D65EX, PX, WX-16 40-303 21

SEN05033-01 Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA452] Rail Press Sensor Low Error 1
Action code Failure code Common rail pressure sensor low error
Trouble
Failure
• Low voltage was detected in signal circuit of common rail pressure sensor.
description
Action of
controller
Indication of
problem on
• Engine speed or output lowers.
machine
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor voltage)
Related
information
• This code is not displayed but “High Error” failure code, that is [CA451] is displayed if sensor con-
nector is disconnected even under normal condition.

connector
If failure code [CA187] (Ground fault of sensor power supply line) or [CA227] is
2 pressure sensor power
supply line
a Check that failure code [CA187] (Ground fault of sensor power supply line) is not
displayed.
Defective common rail 1. Turn starting switch to OFF position.
3
pressure sensor 2. Disconnect connector FUEL RAIL PRESS.
If failure code changes from [CA452] to [CA451], sensor is defective.
2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to
4 harness
female side of ECM.
Short circuit in wiring 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to
5
harness female side of ECM.
40-303 22 D65EX, PX, WX-16

Failure code [CA452] Rail Press Sensor Low Error SEN05033-01
D65EX, PX, WX-16 40-303 23

SEN05033-01 Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA488] Chg Air Temp High Torque Derate 1
Action code Failure code Charge air temperature high torque derate
Trouble
Failure • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature
description limit.
Action of
controller
Indication of
machine
• Boost temperature can be checked with monitoring function.
Related
information

Cooling performance of aftercooler may be low. Check following points directly.
Lowering of cooling • Looseness and breakage of fan belt
1
performance of aftercooler • Insufficiency of cooling air
• Clogging of aftercooler fins
Abnormal rise of
Outlet temperature of turbocharger may be abnormally high. Check related parts
2 turbocharger outlet
directly.
temperature
Defective charge
3 Perform troubleshooting for failure codes [CA153] and [CA154].
temperature sensor
40-303 24 D65EX, PX, WX-16

Failure code [CA553] Rail Press High Error SEN05033-01
Failure code [CA553] Rail Press High Error 1
Action code Failure code Common rail pressure high error

Trouble
Failure
• High voltage (1) was detected in common rail circuit.
description
Action of
controller
Indication of
• Engine sound becomes large when no or light load is applied.
problem on
machine
Related
information

indicated, perform troubleshooting for it first.
Ground terminal may be connected defectively. Check following terminals directly.
• Ground terminal of chassis ((–) terminal of battery)
Defective connection of
2 • Ground terminal of engine
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor
Breakage of O-ring of supply
3 O-ring of supply pump may be broken. Check it directly.
pump
4 Perform troubleshooting for failure codes [CA451] and [CA452].
pressure sensor
D65EX, PX, WX-16 40-303 25

SEN05033-01 Failure code [CA559] Rail Press Low Error
Failure code [CA559] Rail Press Low Error 1
Action code Failure code Common rail pressure low error

Trouble
Failure
• There is low pressure error (1) in common rail circuit.
description
Action of
controller
Indication of • Engine does not start at all or does not start easily.
problem on • Exhaust gas becomes black.
machine • Engine output lowers.
Related
information

1 Non-fuel Check fuel remain.
2 Defective fuel tank breather Fuel tank breather may be clogged. Check it directly.
Fuel may be leaking to outside. Check it directly (Check visually while running engine
3 Fuel leakage to outside
at low idle).
• Measured in fuel filter inlet side.
• Cranking speed: Min. 150 rpm
Pressure in fuel Min. 0.14 MPa
During cranking
low-pressure circuit {Min. 1.4 kg/cm2}
• Measured in fuel filter outlet side.
Pressure in fuel Min. 0.48 MPa
During high idle
low-pressure circuit {Min. 4.9 kg/cm2}
• Measured in fuel filter inlet and outlet sides.
Defect in low pressure circuit
4 • Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure – Fuel filter
parts (Note 1)
outlet pressure
Pressure drop in fuel Max. 0.14 MPa
During high idle
low-pressure circuit {Max. 1.4 kg/cm2}
sure”.
• Measured in gear pump fuel inlet side of supply pump.
Fuel suction circuit Max. 33.9 kPa
During high idle
pressure (gear pump side) {Max. 254 mmHg}
sure”.
• Measured in fuel connector side.
Max. 27.1 kPa
{Max. 203 mmHg}
(fuel connector side)
a For check of return rate from injector, see Testing and adjusting, “Checking fuel
return rate and leakage”.
Defective injector During cranking
5 (including high pressure (if engine cannot be Max. 100 cc/30 sec.
piping in head) Return rate from injector started)
During low idle
Max. 300 cc/45 sec.
(if engine can be started)
40-303 26 D65EX, PX, WX-16

Failure code [CA559] Rail Press Low Error SEN05033-01

a For check of return rate from supply pump, see Testing and adjusting, “Checking
fuel return rate and leakage”.
During cranking
6 Defective supply pump (if engine cannot be Max. 200 cc/30 sec.
Return rate from supply
started)
pump
During low idle
Max. 300 cc/30 sec.
(if engine can be started)
a For check of leakage through pressure limiter, see Testing and adjusting, “Check-
ing fuel return rate and leakage”.
7 Defective pressure limiter
Leakage through pressure
At low idle Below 30 drops/60 sec.
limiter
Defective supply pump a Remove the supply pump head, and directly check that the plunger is not dam-
8
plunger aged.
There may be air in low pressure circuit. Check it directly according to the following
procedure.
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
9 Air in low pressure circuit 3. Check pressure pickup plug for leakage of fuel and air.
• If this failure occurs during air bleeding after the fuel filter was replaced, air may
remain in the fuel circuit. Keep running the engine at low idle for about three min-
utes. As air is bled from the fuel circuit, the engine speed will be stabilized, erasing
the failure indication.
Note 1: When low-pressure circuit equipment is detective, check the following:

1) Clogged fuel tank breather
2) Clogged check valve (3) installed cooling plate (2) on engine controller (1).
3) Leaked or clogged low-pressure fuel pipe
4) Clogging in fuel pre-filter
5) Clogging in fuel main filter
a Replace fuel main filter if cause of failure is not detected with checking clogging.
D65EX, PX, WX-16 40-303 27

SEN05033-01 Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA689] Eng Ne Speed Sensor Error 1
Action code Failure code Engine Ne speed sensor error

Trouble
Failure
• Signals from engine Ne speed sensor are abnormal.
description
Action of
• Continues engine control with signal from engine Bkup speed sensor.
controller
Indication of • Engine hunts.
problem on • Engine does not start easily.
• Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
Related
sensor cannot be determined to be normal by measuring its resistance with tester.
information
• Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with tester.
• Speed sensor senses tooth missing part of rotating speed-sensed ring installed on crankshaft.

connector
Defective Ne speed sensor
power supply line
Breakage or improper
Engine Ne speed sensor may be broken or may have improper installation
3 installation (looseness) of
(looseness). Check it directly.
engine Ne speed sensor
2. Disconnect connector CRANK SENSOR and connect T-adapter to female side.
Defective Ne speed sensor 3. Turn starting switch to ON position.
4
power supply input
Between CRANK SENSOR (female) (1) Power 4.75 –
Voltage
and (2) supply input 5.25 V
2. Disconnect connectors ECM and CRANK SENSOR.
a If no abnormality is found in checks on cause 4, this
Disconnection in wiring Resistance Max. 10 z
Between ECM (female) (16) and CRANK SENSOR
harness
(female) (1)
defective contact in a If no abnormality is found in checks on cause 4, this
connector) Resistance Max. 10 z
(female) (2)
(female) (3)
2. Disconnect connectors ECM and CRANK SENSOR.
Short circuit in wiring Between ECM (female) (16) and (27) or between
6 Resistance Min. 100 kz
harness CRANK SENSOR (female) (1) and (3)
Between ECM (female) (27) and (48) or between
CRANK SENSOR (female) (2) and (3)
Ground fault of wiring 2. Disconnect connectors ECM and CRANK SENSOR.
7 harness
Between ECM (female) (27) or CRANK SENSOR
(Contact with ground circuit) Resistance Min. 100 kz
Hot short in wiring harness 2. Disconnect connector CRANK SENSOR.
8
Between CRANK SENSOR (female) (3) and ground Voltage Max. 1 V
40-303 28 D65EX, PX, WX-16

Failure code [CA689] Eng Ne Speed Sensor Error SEN05033-01

1. Remove Ne speed sensor (CRANK SENSOR).
2. Check speed sensing wheel (R) from sensor mounting hole directly.
9 installation (looseness) of
a Speed sensing wheel (R) has tooth missing part (A) to sense rotation.
speed-sensed ring
a When speed sensing wheel (R) is loose, see “Reference”.
If no abnormality is found by the above checks, the Ne speed sensor is defective.
10 Defective Ne speed sensor
D65EX, PX, WX-16 40-303 29

SEN05033-01 Failure code [CA689] Eng Ne Speed Sensor Error
Reference 6. Check that mounting bolts (4) of Ne speed

Check of crankshaft speed sensing wheel for (crank) sensing wheel (3) are not loose.
loose installation (Engine Model 114) a If the bolts are loose, replace them with
Remove the damper, flywheel, flywheel housing new ones.
and outer main cap and check the crankshaft a Tighten all the bolts evenly.
speed sensing wheel for loose installation. 3 Mounting bolt (4):
a When replacing the crankshaft speed sensing 8 ± 2 Nm {0.8 ± 0.2 kgm}

wheel, the crankshaft must be removed. (5): Crankshaft
a Keep the rear seal, gasket and gasket sealants
LG-6 and LG-7 on hand.
Removal
1. Remove the engine. For details, see Disas-
sembly and assembly, "Removal and installa-
tion of engine assembly".
2. Remove the following parts. For details, see

Disassembly and assembly, "Removal and
installation of engine rear seal".
1) Damper
2) Flywheel
3) Flywheel housing
4) Rear seal housing
3. Remove the oil pan.
4. Remove mounting bolts (2) of main cap (1).
5. Insert mounting bolts (2) into the bolt holes of

main cap (1) and remove main cap (1) while
shaking it.
a Check that embossed letters "BACK" on
side (A) of main cap (1) face the rear of
the cylinder block.
(3): Speed sensing wheel
40-303 30 D65EX, PX, WX-16

Failure code [CA689] Eng Ne Speed Sensor Error SEN05033-01
Installation
a For drawings, see the “Removal”.
1. Install main cap (1) with the embossed letters
“BACK” facing toward the rear of the cylinder
block.
2 Crankshaft journal surface:

Engine oil (EO15W-40)
a Tap the main cap lightly with a plastic or
rubber hammer to install.
2. Install main cap (1) with mounting bolts (2).
2 Mounting bolt: Engine oil (EO15W-40)
3 Main cap mounting bolt:

1]: 167 ± 8 Nm {17.0 ± 0.8 kgm}
2]: Loosen 360°
3]: 30.4 ± 3.0 Nm {3.1 ± 0.3 kgm}
4]: 50 ± 4.9 Nm {5.1 ± 0.5 kgm}
5]: 120° ± 5°
3. Install the oil pan.

Tighten the mounting bolts in the order of [1] to
[32].
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
4. Install the engine rear seal and engine assem-

bly. For details, see Disassembly and assem-
bly, "Removal and installation of engine rear
seal" and "Removal and installation of engine
assembly".
D65EX, PX, WX-16 40-303 31

SEN05033-01 Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1
Action code Failure code Engine Bkup speed sensor phase error
Trouble
Failure
• Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor.
description
Action of
• Continues engine control with signal from engine Ne speed sensor.
controller
Indication of • Engine does not start at all or does not start easily.
problem on • Idle speed is unstable.
machine • Exhaust gas becomes black.
Related
information

Breakage of engine Ne
1 Engine Ne speed sensor (CRANK SENSOR) may be broken. Check it directly.
speed (CRANK) sensor
Breakage of engine Bkup
2 Engine Bkup speed sensor (CAM SENSOR) may be broken. Check it directly.
speed (CAM) sensor
Rotation sensor ring on crankshaft side may be installed defectively or broken.
Check it according to the following procedure.
Defective installation or
1. Set No. 1 cylinder at compression top dead center (Match stamped mark).
3 breakage of rotation sensing
2. Remove Ne speed sensor (CRANK SENSOR).
wheel on crankshaft
3. If tooth missing part (A) of rotation speed sensing wheel (R) can be seen through
mounting hole of Ne speed sensor, the wheel is installed normally.
Rotation sensing wheel on camshaft is camshaft gear (CAMG) itself, and it may be
installed defectively or broken. Check it according to the following procedure.
Defective installation or
1. Set No. 1 cylinder at compression top dead center (Match stamped mark).
4 breakage of camshaft gear
2. Remove Bkup speed sensor (CAM SENSOR).
on camshaft
3. If two ribs (B) of camshaft gear (CAMG) can be seen through sensor mounting
hole, the gear is installed normally.
Defective timing of
5 Timing of crankshaft and camshaft may be defective. Check it directly.
crankshaft and camshaft
Ground terminal may be connected defectively. Check following terminals directly.
• Ground terminal of machine ((–) terminal of battery)
Defective connection of
6 • Ground terminal of engine
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor
40-303 32 D65EX, PX, WX-16

Failure code [CA757] All Continuous Data Lost Error SEN05033-01
Failure code [CA757] All Continuous Data Lost Error 1
Action code Failure code All continuous data lost error

Trouble
Failure
• All data in engine controller are lost.
description
Action of
controller
Indication of
• Engine may stop and may not be restarted.
problem on
• Monitoring function of machine monitor (engine controller system) may not work normally.
machine
Related
information

D65EX, PX, WX-16 40-303 33

SEN05033-01 Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA778] Eng Bkup Speed Sensor Error 1
Action code Failure code Engine Bkup speed (CAM) sensor error
Trouble
Failure
• Abnormality was detected in signal from engine Bkup speed (CAM) sensor.
description
Action of
• Continues engine control with signal from engine Ne speed sensor.
controller
Indication of
problem on
machine
• Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
Related
sensor cannot be determined to be normal by measuring its resistance with tester.
information
• Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with tester.
• Speed sensor senses rotation with two ribs on camshaft gear.

connector
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it
2
supply line 2 first.
installation (looseness) of Engine Bkup speed (CAM) sensor may be broken or may have improper installation
3
engine Bkup speed (CAM) (looseness). Check it directly.
sensor
Defective power supply input 2. Disconnect connector CAM SENSOR and connect T-adapter to female side.
4 of engine Bkup speed 3. Turn starting switch to ON position.
sensor Between CAM SENSOR (female) (1) and Power 4.75 –
Voltage
(2) supply input 5.25 V
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapters to each
female side.
Between ECM (female) (37) and CAM SENSOR
harness Resistance Max. 10 z
5 (female) (1)
contact in connector) Resistance Max. 10 z
(female) (2)
(female) (3)
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
6 Between ECM (female) (26) and (37) or between CAM
harness Resistance Min. 100 kz
SENSOR (female) (1) and (3)
Between ECM (female) (26) and (47) or between CAM
SENSOR (female) (2) and (3)
Ground fault of wiring 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
7 harness female side of either one of them.
(Contact with ground circuit) Between ECM (female) (26) or CAM SENSOR (female)
(3) and ground
Hot short in wiring harness 2. Disconnect connector CAM SENSOR and connect T-adapter to female side.
8
Between CAM SENSOR (female) (3) and ground Voltage Max. 1 V
40-303 34 D65EX, PX, WX-16

Failure code [CA778] Eng Bkup Speed Sensor Error SEN05033-01

Remove engine Bkup speed (CAM) sensor and check from sensor mounting hole
9 Loosened camshaft gear directly.
a If camshaft gear (CAMG) is loosened, see “Reference.”
If no abnormality is found by the above checks, the engine Bkup speed (CAM)
Defective engine Bkup
10 sensor is defective. (Since trouble is in system, troubleshooting cannot be
speed (CAM) sensor
performed.)
q (B): Speed sensor senses rotation with two

ribs on camshaft gear.
D65EX, PX, WX-16 40-303 35

SEN05033-01 Failure code [CA778] Eng Bkup Speed Sensor Error
Reference 4. Check mounting bolt (10) of gear (9) on cam-

Checking camshaft gear for loose installation shaft (11) for looseness.
(114 engine) 3 Mounting bolt (10):
Remove the pulley, damper, front seal, front cover 24 ± 4 Nm {2.4 ± 0.4 kgm}
and housing, and check the camshaft gear for
looseness.
a Prepare the front seal, gasket, liquid gasket
LG-7 and front seal installation tool (795-799-
8120) on hand.
Removal
1. Remove followings, see Disassembly and
assembly, “Removal and installation of engine
front seal”.
1) Remove the fan and fan belt.
2) Remove pulley (1).
3) Remove damper assembly (2).
(DP): Dowel pin
Installation
a For figures, see “Removal”.
1. Install gasket (8) to housing (7) and install front
cover (6) to housing (7).
2 Housing: Liquid gasket LG-7
2. See Disassembly and assembly, “Removal

and installation of engine front seal” and,
1) Install front seal (5) and dust seal (4) to
carrier (3).
2) Install carrier assembly to front cover (6).
3) Install dowel pin (DP) and damper (2).
4) Install pulley (1).
4) Remove carrier assembly (3). 5) Install the fan belt and fan.
5) Remove dust seal (4) and front seal (5) 6) Install the cooling assembly.
from carrier assembly (3).
2. Remove front cover (6).
3. Remove housing (7).

(8): gasket
40-303 36 D65EX, PX, WX-16

Failure code [CA1633] KOMNET Datalink Timeout Error SEN05033-01
Failure code [CA1633] KOMNET Datalink Timeout Error 1
Action code Failure code KOMNET Datalink timeout error

Trouble
Failure • Engine controller detected communication error in CAN (KOMNET) communication circuit between
description engine controller and power train controller or machine monitor.
Action of • Continues operation in default mode.
controller • If cause of failure disappears, system resets itself.
Indication of
• Information may not be transmitted normally by CAN (KOMNET) communication and machine may
problem on
not operate normally. (Trouble phenomenon depends on failed section.)
machine
Related
information

Perform troubleshooting for failure code [DB2RKR].
D65EX, PX, WX-16 40-303 37

SEN05033-01 Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2185] Throt Sens Sup Volt High Error 1
Action code Failure code Throttle sensor supply voltage high error
Trouble
Failure
• High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit.
description
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just
Action of before detection of trouble and continues operation.
controller • If starting switch is turned from OFF to ON position while voltage is abnormally high, controller con-
tinues operation with voltage at 100% value.
Indication of
problem on • Engine speed cannot be controlled with decelerator pedal.
machine
Related
information

connector
2. Disconnect connectors CE02, CE03 and DCL and connect T-adapters to female
Short circuit in wiring sides of CE02 and CE03.
2
harness Between CE02 (female) (22) and each pin other than
CE02 (female) (22) pin
Between CE02 (female) (22) and CE03 (female) (3) Resistance Min. 100 kz
2. Disconnect connector DCL and connect T-adapter to female side.
4.75 –
Between DCL (female) (B) and ground Voltage
5.25 V
2. Disconnect connector CE02 and connect T-adapter to male side.
4.75 –
Between CE02 (male) (22) and (23) Voltage
5.25 V
40-303 38 D65EX, PX, WX-16

Failure code [CA2185] Throt Sens Sup Volt High Error SEN05033-01
D65EX, PX, WX-16 40-303 39

SEN05033-01 Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2186] Throt Sens Sup Volt Low Error 1
Action code Failure code Throttle sensor supply voltage low error
Trouble
Failure
• Low voltage was detected in throttle sensor power supply circuit.
description
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just
Action of before detection of trouble and continues operation.
controller • If starting switch is turned from OFF to ON position while abnormal voltage is detected, controller
continues operation with voltage at 100% value.
Indication of
problem on • Engine speed cannot be controlled with decelerator pedal.
machine
Related
information

connector
2. Disconnect connector DCL and turn starting switch to ON position.
2 Defective throttle sensor If this failure code is not displayed when a sensor is disconnected, throttle sensor is
defective.
a Other failure code is displayed together. This is because that the sensor connector
is disconnected. So, code can be ignored except the failure code [CA2186].
Ground fault of wiring 2. Disconnect connectors CE02 and DCL and connect T-adapter to female side of
3 harness either one of them.
(Contact with ground circuit) Between CE02 (female) (22) or DCL (female) (B) and
ground
2. Disconnect connectors CE02 and DCL and connect T-adapter to female side of
Short circuit in wiring CE02.
4
harness 3. Turn starting switch to ON position.
Between CE02 (female) (22) and each pin other than
CE02 (female) (22) pin
4.75 –
Between CE02 (male) (22) and (23) Voltage
5.25 V
40-303 40 D65EX, PX, WX-16

Failure code [CA2186] Throt Sens Sup Volt Low Error SEN05033-01
D65EX, PX, WX-16 40-303 41

SEN05033-01 Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2249] Rail Press Very Low Error 1
Action code Failure code Common rail pressure very low error
Trouble
Failure
• Low pressure was detected in common rail circuit.
description
Action of
controller
Indication of • Engine does not start easily.
problem on • Exhaust gas becomes black.
Related
information

40-303 42 D65EX, PX, WX-16

Failure code [CA2249] Rail Press Very Low Error SEN05033-01
D65EX, PX, WX-16 40-303 43

SEN05033-01 Failure code [CA2265] Fuel Feed Pump Open Error
Failure code [CA2265] Fuel Feed Pump Open Error 1
Action code Failure code Fuel feed pump open error

Trouble
Failure
• Opening was detected in drive circuit of electric fuel feed pump actuator.
description
Action of
controller
Indication of
machine
Related
information

connector
Defective electric fuel feed 1. Turn starting switch to OFF position.
pump 2. Disconnect connector FUEL LIFT PUMP.
2
(Internal disconnection or
short circuit) Between FUEL LIFT PUMP (male) (1) and (2) Resistance Max. 20 z
3
in wiring harness
Between ECM (female) (1) and (11) Resistance Max. 20 z
Disconnection in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors ECM and FUEL LIFT PUMP and connect T-adapters to
4 (Disconnection in wiring or each female side.
defective contact in
Between ECM (female) (1) and FUEL LIFT PUMP (1) Resistance Max. 10 z
connector)
Between ECM (female) (11) and FUEL LIFT PUMP (2) Resistance Max. 10 z
2. Disconnect connectors ECM and FUEL LIFT PUMP, and connect T-adapter to
Short circuit in wiring female side of ECM.
5
Between ECM (female) (1) and each pin other than (1) No continuity
pin (No sound is heard)
2. Disconnect connector FUEL LIFT PUMP.
3. Insert T-adapter between male and female sides of connector ECM or connect T-
adapter to female side of FUEL LIFT PUMP.
Hot short in wiring harness 4. Turn starting switch to ON position and perform troubleshooting after one minute
6
or longer (with connector FUEL LIFT PUMP disconnected).
a Average voltage is displayed because of PWM.
Between ECM (female) (1) and (11), or between FUEL
Voltage Max. 6 V
LIFT PUMP (female) (1) and (2)
40-303 44 D65EX, PX, WX-16

Failure code [CA2265] Fuel Feed Pump Open Error SEN05033-01
D65EX, PX, WX-16 40-303 45

SEN05033-01 Failure code [CA2266] Fuel Feed Pump Short Error
Failure code [CA2266] Fuel Feed Pump Short Error 1
Action code Failure code Fuel feed pump short error

Trouble
Failure
• Short circuit was detected in electric fuel feed pump actuator.
description
Action of
controller
Indication of
machine
Related
information

connector
Defective electric fuel feed 2. Disconnect connector FUEL LIFT PUMP.
2 pump 3. Turn starting switch to ON position.
(Internal short circuit) If failure code changes from [CA2266] to [CA2265], electric fuel feed pump is
defective.
Short circuit in, or ground 2. Disconnect connector ECM and connect T-adapter to female side.
3
fault of wiring harness Between ECM (female) (1) and (11) Resistance 1 – 20 z
Short circuit in wiring 2. Disconnect connectors ECM and FUEL LIFT PUMP, and connect T-adapter to
4
harness female side of ECM.
Between ECM (female) (1) and (11), or between FUEL
LIFT PUMP (female) (1) and (2)
Ground fault of wiring 2. Disconnect connectors ECM and FUEL LIFT PUMP, and connect T-adapter to
5 harness
female side of ECM.
Between ECM (female) (1) and ground, or between
FUEL LIFT PUMP (female) (1) and ground
40-303 46 D65EX, PX, WX-16

Failure code [CA2311] IMV Solenoid Error SEN05033-01
Failure code [CA2311] IMV Solenoid Error 1
Action code Failure code IMV solenoid error

Trouble
Failure
• Resistance of supply pump actuator circuit is abnormally high or low.
description
Action of
controller
Indication of
machine
Related
information

Perform troubleshooting for failure codes [CA271] and [CA272].
D65EX, PX, WX-16 40-303 47

SEN05033-01 Failure code [CA2555] Grid Htr Relay Volt High Error
Failure code [CA2555] Grid Htr Relay Volt High Error 1
Action code Failure code Auto pre-heater relay voltage high error
Trouble
Failure
• Disconnection was detected in drive circuit (primary coil side) of auto pre-heater relay.
description
Action of
controller
Indication of
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
problem on
temperature).
machine
Related • The troubleshooting for this failure code covers defect between engine controller and primary coil
information side of auto pre-heater relay PHR. See E-mode E-2 for troubleshooting for intake air heater relay
and secondary coil side of auto pre-heater replay PHR.

connector
2. Disconnect relay PHR and connect T-adapter to male side.
Between PHR (male) (1) and (2) Resistance 300 – 600 z
Defective auto pre-heater
2 1. Turn starting switch to OFF position.
relay PHR
2. Replace relay PHR with other relay.
If this failure code disappears, auto pre-heater relay PHR is defective.
3
in wiring harness Between CE02 (female) (40) and ground
Resistance 300 – 600 z
a Relay PHR coil resistance
Disconnection in wiring 2. Disconnect connector CE02 and relay PHR and connect T-adapters to female
4 side.
harness
Between CE02 (female) (40) and PHR (female) (1) Resistance Max. 10 z
Between PHR (female) (2) and ground Resistance Max. 10 z
2. Disconnect connector CE02 and relay PHR and connect T-adapter to female side
Short circuit in wiring of CE02.
harness
Between CE02 (female) (40) and each pin other than No continuity
(40) pin. (No sound is heard)
40-303 48 D65EX, PX, WX-16

Failure code [CA2555] Grid Htr Relay Volt High Error SEN05033-01
D65EX, PX, WX-16 40-303 49

SEN05033-01 Failure code [CA2556] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt Low Error 1
Action code Failure code Auto pre-heater relay voltage low error
Trouble
Failure
• Short circuit was detected in drive circuit (primary coil side) of auto pre-heater relay.
description
Action of
controller
Indication of
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
problem on
temperature).
machine
• Method of reproducing failure code: Turn starting switch ON.
Related • The troubleshooting for this failure code covers defect between engine controller and primary coil
information side of auto pre-heater relay PHR. See E-2 for troubleshooting for intake air heater relay and sec-
ondary coil side of auto pre-heater replay PHR.

connector
2. Disconnect relay PHR and connect T-adapter to male side.
Between PHR (male) (1) and (2) Resistance 300 – 600 z
Defective auto pre-heater
relay PHR
4. Replace relay PHR with other relay.
If this failure code disappears, auto pre-heater relay PHR is defective.
Ground fault of wiring of either one of them.
3
harness
Between CE02 (female) (40) or PHR (female) (1) and
Resistance Max. 100 kz
ground
Short circuit in wiring of CE02.
4
Between CE02 (female) (40) and each pin other than No continuity
40-303 50 D65EX, PX, WX-16

Failure code [CA2556] Grid Htr Relay Volt Low Error SEN05033-01
D65EX, PX, WX-16 40-303 51

SEN05033-01

©2009 KOMATSU
All Rights Reserved
40-303 52
SEN05034-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Failure code [D110KB] Battery relay drive: Short circuit ................................................................................. 4
Failure code [D130KA] Neutral relay: Disconnection...................................................................................... 6
Failure code [D130KB] Neutral relay: Short circuit ......................................................................................... 8
Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 10
Failure code [D161KB] Back-up alarm relay: Short circuit............................................................................ 12
Failure code [D862KA] GPS Antenna Open Circuit...................................................................................... 14
Failure code [DAFRKR] CAN Disconnection ................................................................................................ 15
Failure code [DAFRMC] CAN Discon (Monitor Detected) ............................................................................ 16
Failure code [DB2RKR] CAN Disconnection ................................................................................................ 19
Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 24
Failure code [DBE1KK] Battery direct Source voltage reduction .................................................................. 26
Failure code [DBE2KK] Solenoid Source voltage reduction ......................................................................... 28
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction ................................................................. 32
Failure code [DBE9KQ] PT controller: Type select signal............................................................................. 36
Failure code [DD12KA] Shift up Sw: Disconnection ..................................................................................... 38
Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 40
Failure code [DD13KA] Shift down Sw: Disconnection ................................................................................. 42
Failure code [DD13KB] Shift down Sw: Short circuit .................................................................................... 44
Failure code [DD14KA] Parking lever Sw: Disconnection............................................................................. 46
D65EX, PX, WX-16 40-304 1

SEN05034-01
Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 48
40-304 2 D65EX, PX, WX-16

SEN05034-01
D65EX, PX, WX-16 40-304 3

SEN05034-01 Failure code [D110KB] Battery relay drive: Short circuit
Failure code [D110KB] Battery relay drive: Short circuit 1
Action code Failure code Battery relay drive: Short circuit

Trouble
E00 D110KB (Power train controller system)
Failure
• Abnormal current flowed when outputting 24 V to battery relay primary (coil side) circuit.
description
Action of
• Stops 24 V output to battery relay primary (coil side) circuit.
controller
Indication of
problem on • Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
machine
• Output condition (voltage) to battery relay primary (coil side) circuit can be checked in monitoring
Related function.
information (Code 60600: Battery relay drive voltage)
• Method of reproducing failure code: Switch starting switch from ON to OFF.

Defective battery relay 1. Turn starting switch to OFF position.
1
(Internal short circuit) Between terminals BRSW and BRE Continuity
Ground fault of wiring 2. Disconnect ground cable (Not to make short circuit).
2 harness (Contact with 3. Disconnect terminal BRE and connector STC3.
ground circuit)
Between terminal BRSW and ground Resistance Min. 1 Mz
If cause is not found by the above checks, power train controller is defective.
• Reference: the followings are standard values in normal condition.
Defective power train 1. Turn starting switch to OFF position.
3 2. Insert T-adapter into connector STC3.
controller
Between STC3 (4) and (21) Voltage 20 – 30 V
40-304 4 D65EX, PX, WX-16

Failure code [D110KB] Battery relay drive: Short circuit SEN05034-01
D65EX, PX, WX-16 40-304 5

SEN05034-01 Failure code [D130KA] Neutral relay: Disconnection
Failure code [D130KA] Neutral relay: Disconnection 1
Action code Failure code Neutral safety relay: Disconnection

Trouble
E02 D130KA (Power train controller system)
Failure • No current flows when grounding to neutral safety relay primary (coil side) circuit or no voltage is
description applied when no grounding.
Action of
• Stops grounding to neutral safety relay primary (coil side) circuit.
controller
Indication of
problem on • Engine does not start.
machine
• Output condition to neutral safety relay primary (coil side) circuit can be checked in monitoring func-
tion.
(Code 40909: T/M Output1)
• Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (to free
Related
position).
information
• This failure code detects failure on primary side (coil side) of neutral safety relay, but not on second-
ary side (contact side).
• If STC2 (8) has ground fault, engine can start even if PCCS lever is set to any gear speed except for
“Neutral”.

Defective neutral safety 1. Turn starting switch to OFF position.
1 relay (Internal disconnection 2. Disconnect connector NSF and connect T-adapter to male side.
or short circuit) Between NSF (male) (1) and (2) Resistance 300 – 600 z
2. Disconnect connectors STC2 and KEY and connect T-adapters to female side of
Disconnection or short circuit them.
2
in wiring harness a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is
below 1 z, wiring harness has short circuit.
Between KEY (male) (1) and STC2 (female) (8) Resistance 300 – 600 z
Disconnection in wiring 2. Disconnect connectors STC2, NSF and KEY, and connect T-adapters to female
3 harness (Disconnection or side of them.
defective contact)
Between STC2 (female) (8) and NSF (female) (2) Resistance Max. 1 z
Between KEY (male) (1) and NSF (female) (1) Resistance Max. 1 z
Ground fault of wiring 2. Disconnect connectors STC2 and NSF and connect T-adapters to female side of
4 harness (Contact with them.
ground circuit) Between NSF (female) (2) or STC2 (female) (8) and
ground
Defective power train 2. Insert T-adapter into connector STC2.
controller
4. Operate parking brake lever and perform troubleshooting.
Between STC2 (8) and Free Voltage 20 – 30 V
ground Lock Voltage Max. 1 V
40-304 6 D65EX, PX, WX-16

Failure code [D130KA] Neutral relay: Disconnection SEN05034-01
D65EX, PX, WX-16 40-304 7

SEN05034-01 Failure code [D130KB] Neutral relay: Short circuit
Failure code [D130KB] Neutral relay: Short circuit 1
Action code Failure code Neutral safety relay: Short circuit

Trouble
Failure
• Abnormal current flowed in neutral safety relay primary (coil side) circuit when grounding.
description
Action of
• Stops grounding to neutral safety relay primary (coil side) circuit.
controller
Indication of
problem on • Engine does not start.
machine
• Output condition to neutral safety relay primary (coil side) circuit can be checked in monitoring func-
tion.
Related
• Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (to free
information
position).
• This failure code detects failure on primary side (coil side) of neutral safety relay, but not on second-

Defective neutral safety 1. Turn starting switch to OFF position.
1 relay (Internal disconnection 2. Disconnect connector NSF and connect T-adapter to male side.
or short circuit) Between NSF (male) (1) and (2) Resistance 300 – 600 z
2. Disconnect connectors STC2 and STC3 and connect T-adapters to female side of
them.
Disconnection or short circuit a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is
2
in wiring harness below 1 z, wiring harness has short circuit.
Between STC2 (female) (8) and STC3 (female) (14) or
Resistance 300 – 600 z
(24)
Hot short circuit in wiring 2. Disconnect connectors STC2 and NSF, and connect T-adapter to female side of
3 harness STC2.
Between STC2 (female) (8) and ground Voltage Max. 1 V
controller
4. Operate parking brake lever and perform troubleshooting.
Between STC2 (8) and Free Voltage 20 – 30 V
ground Lock Voltage Max. 1 V
40-304 8 D65EX, PX, WX-16

Failure code [D130KB] Neutral relay: Short circuit SEN05034-01
D65EX, PX, WX-16 40-304 9

SEN05034-01 Failure code [D161KA] Back-up alarm relay: Disconnection
Failure code [D161KA] Back-up alarm relay: Disconnection 1
Action code Failure code Back-up alarm relay: Disconnection

Trouble
E01 D161KA (Power train controller system)
Failure • Current does not flow to back-up alarm relay primary (coil side) circuit when grounding or voltage is
description applied when no grounding.
Action of
• Stops grounding to back-up alarm relay primary (coil side) circuit.
controller
Indication of
problem on • Back-up alarm does not sound.
machine
• Output condition to back-up alarm relay primary (coil side) circuit can be checked in monitoring
function.
Related
• Method of reproducing failure code: Turn starting switch ON and operate PCCS lever to neutral.
information
• This failure code detects failure on primary side (coil side) of back-up alarm relay, but not in second-
• If pin STC2 (18) has ground fault, back-up alarm keeps sounding.

If fuse FS12-8 is broken, circuit probably has ground fault. In this case, perform
1 Defective fuse FS12-8
troubleshooting for cause 5 first.
Defective back-up alarm 1. Turn starting switch to OFF position.
2 relay (Internal disconnection 2. Disconnect connector BKA and connect T-adapter to male side.
or short circuit) Between BKA (male) (1) and (2) Resistance 300 – 600 z
2. Disconnect fuse FS12-8.
Disconnection or short circuit 3. Disconnect connector STC2 and connect T-adapter to female side.
3
Between STC2 (female) (18) and FS12-8 Resistance 300 – 600 z
Disconnection in wiring 2. Disconnect connectors STC2 and BKA and connect T-adapters to female side of
defective contact)
Between STC2 (female) (18) and BKA (female) (2) Resistance Max. 1 z
Between FS12-8 and BKA (female) (1) Resistance Max. 1 z
Ground fault of wiring 3. Disconnect connectors BKA and STC2, and connect T-adapters to female side of
5 harness (Contact with them.
ground circuit)
Between BKA (female) (1) and ground Resistance Min. 1 Mz
Between BKA (female) (2) or STC2 (18) and ground Resistance Min. 1 Mz
controller
4. Operate PCCS lever and perform troubleshooting.
Between STC2 (18) and N Voltage 20 – 30 V
ground R (Reverse) Voltage Max. 1 V
40-304 10 D65EX, PX, WX-16

Failure code [D161KA] Back-up alarm relay: Disconnection SEN05034-01
D65EX, PX, WX-16 40-304 11

SEN05034-01 Failure code [D161KB] Back-up alarm relay: Short circuit
Failure code [D161KB] Back-up alarm relay: Short circuit 1
Action code Failure code Back-up alarm relay: Short circuit

Trouble
Failure
• Abnormal current flowed in back-up alarm relay circuit when grounding.
description
Action of
• Stops grounding to back-up alarm relay primary circuit.
controller
Indication of
problem on • Back-up alarm does not turn on.
machine
• Output condition to back-up alarm relay can be checked in monitoring function.
Related
• Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (to reverse).
information
• This failure code detects failure on primary side (coil side) of back-up alarm relay, but not in second-

Defective back-up alarm 1. Turn starting switch to OFF position.
1 relay (Internal disconnection 2. Disconnect connector BKA and connect T-adapter to male side.
or short circuit) Between BKA (male) (1) and (2) Resistance 300 – 600 z
Disconnection or short circuit 3. Disconnect connector STC2 and connect T-adapter to female side.
2
Between STC2 (female) (18) and FS12-8 Resistance 300 – 600 z
Hot short circuit in wiring 1. Turn starting switch to OFF position.
3 harness 2. Disconnect connector STC2 and connect T-adapter to female side.
(Contact with 24 V circuit) Between STC2 (female) (18) and ground Voltage Max. 1 V
controller
4. Operate PCCS lever and perform troubleshooting.
Between STC2 (18) and N Voltage 20 – 30 V
ground R (Reverse) Voltage Max. 1 V
40-304 12 D65EX, PX, WX-16

Failure code [D161KB] Back-up alarm relay: Short circuit SEN05034-01
D65EX, PX, WX-16 40-304 13

SEN05034-01 Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D862KA] GPS Antenna Open Circuit 1
Action code Failure code GPS antenna disconnection

Trouble
— D862KA (KOMTRAX system in machine monitor)
Failure
• Disconnection was detected in GPS antenna circuit.
description
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Indication of
problem on • GPS cannot locate position.
machine
Related
information

Defective GPS antenna or Possible causes are defective GPS antenna, disconnection or short circuit in
1
antenna cable antenna cable, and defective connection of antenna cable connector (GPS).
Configuration drawing
40-304 14 D65EX, PX, WX-16

Failure code [DAFRKR] CAN Disconnection SEN05034-01
Failure code [DAFRKR] CAN Disconnection 1
Action code Failure code CAN disconnection

Trouble
E03 DAFRKR (Power train controller system)
Failure
• Power train controller cannot recognize machine monitor with CAN communication circuit.
description
Action of
controller
Indication of • System may not operate normally.
problem on • Once machine stops, engine speed is limited to medium (half).
machine • Once machine stops, travel is limited to F1 and R1.
• Method of reproducing failure code: Turn the starting switch to ON position.
• Start of CAN communication is notified to each controller by ACC signal of starting switch.
• Since air conditioner also uses CAN communication, ensure that air conditioner can be operated
(turned ON/OFF and air flow can be adjusted) on air conditioner screen.
(Air conditioner can be operated even while failure code is displayed on the monitor screen.)
If air conditioner can be operated, there is no ground fault, short circuit or hot short in wiring harness
Related (CAN communication line)
information • Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN commu-
nication of machine monitor has error, code [DAFRKR] is not displayed on machine monitor and
can be confirmed only through KOMTRAX system.
• Since each controller and machine monitor receive power from battery directly, they have power
even while starting switch is OFF.
• Since CAN communication line signal in operation is pulse voltage, it cannot be measured with mul-
timeter.

Defective power supply to
1 Perform troubleshooting for E-mode, “E-3”.
machine monitor
Defective CAN
2 Perform troubleshooting for failure code [DAFRMC], cause 4 and after.
communication
D65EX, PX, WX-16 40-304 15

SEN05034-01 Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DAFRMC] CAN Discon (Monitor Detected) 1
Action code Failure code CAN disconnection (Machine monitor detected)

Trouble
E03 DAFRMC (Machine monitor system)
Failure • Machine monitor cannot recognize engine controller or power train controller with CAN communica-
description tion circuit.
Action of
controller
(turned ON/OFF and air flow can be adjusted) on air conditioner screen.
(Air conditioner can be operated even while failure code is displayed on the monitor screen.)
If air conditioner can be operated, there is no ground fault, short circuit or hot short in wiring harness
Related
(CAN communication line)
information • If failure code [DB2RKR] is also displayed, cause of this trouble is probably engine controller prob-
lem in causes 1 – 3.
timeter.

Broken engine controller
1 2. Remove fuses in fuse boxes F12-3 and F12-6.
fuse
a If fuse is broken, controller probably has short circuit in it.
a If fuse is not broken, this check is not required.
2
Defective engine controller a Measured value: approx. 9 – 20 kz.
(Internal short circuit) a If measured value is below 10 z, engine controller is defective (Internal short cir-
cuit).
Between CE03 (male) (3) and (1) Resistance Min. 10 z
2. Disconnect connector CE03 and connect T-adapter to female side.
3. If fuse is broken, replace it.
3
Defective power supply to a If result is abnormal, perform troubleshooting for [DB2RKR], Failure description 2)
engine controller Defective power supply circuit to engine controller.
Between CE03 (female) (3) and (1) or ground Voltage 20 – 30 V
Defective CAN terminal 2. Disconnect connectors CA1 and CM02 and connect T-adapters to male sides of
resistor them.
4
Between CA1 (male) (A) and (B) Resistance 120 ± 12 z
short circuit)
Between CM02 (male) (8) and (10) Resistance 120 ± 12 z
40-304 16 D65EX, PX, WX-16

Failure code [DAFRMC] CAN Discon (Monitor Detected) SEN05034-01

• CAN communication line
a There is 120 z CAN terminal resistor inside machine monitor, too. Since 120 z
resistor is connected in parallel, if resistance measured at connector of controller
other than machine monitor is 60 z which is combined resistance, wiring harness
is not disconnected.
2. Disconnect one of following connectors CE02, STC2, AC02, CA1 and CM02 and
connect T-adapter to female side of that connector.
a If connector has short circuit (Resistance between terminals is 1 z or less), dis-
Disconnection or short circuit connect all of CE02, STC2, AC02, CA1 and CM02 and check again to see if there
5
in wiring harness
is short circuit between wiring harnesses or in controller.
Between CE02 (female) (46) and (47) Resistance Approx. 60 z
Between STC2 (female) (32) and (22) Resistance Approx. 60 z
Between AC02 (female) (1) and (2) Resistance Approx. 60 z
Approx.
Between CA1 (female) (A) and (B) Resistance
120 z
Approx.
Between CM02 (female) (9) and (10) Resistance
120 z
a If check result of cause 5 is normal, this check is not required.
2. Disconnect connectors CE02, C01, N10, K02 and CM02 and connect T-adapters
to female side of them.
Between STC2 (female) (32) and CM02 (female) (9), (8) Resistance Max. 1 z
Disconnection in wiring Between STC2 (female) (22) and CM02 (female) (10) Resistance Max. 1 z
harness (Disconnection or
6
defective contact in Between STC2 (female) (32) and CE02 (female) (46) Resistance Max. 1 z
connector) Between STC2 (female) (22) and CE02 (female) (47) Resistance Max. 1 z
Between STC2 (female) (32) and AC02 (female) (1) Resistance Max. 1 z
Between CE02 (female) (46) and K02 (female) (A) Resistance Max. 1 z
Between CE02 (female) (47) and K02 (female) (B) Resistance Max. 1 z
• Signal ACC of starting switch
Disconnection in wiring 2. Insert T-adapters into connectors CE02, STC3 and CM01.
harness (Disconnection or 3. Connect ground cable and turn starting switch to ON position.
7
defective contact in Between CE02 (39) and ground Voltage 20 – 30 V
connector)
Between STC3 (14) or (24) and (31) Voltage 20 – 30 V
Between CM01 (14) and (3) Voltage 20 – 30 V
a If air conditioner can be operated, this check is not required.
a If check result of cause 5 is normal (there is no disconnection), measure at only 1
place.
Ground fault of wiring 2. Disconnect connectors CE02, STC2, CM02 and AC02, and connect T-adapter to
8 harness (Contact with female side of one of them.
ground circuit)
Between STC2 (female) (32), CM02 (female) (8), (9) or
CE02 (female) (46) and ground
Between STC2 (female) (22), CM02 (female) (10) or
CE02 (female) (47) and ground
a If air conditioner can be operated, this check is not required.
a If check result of cause 5 is normal (there is no disconnection), measure at only 1
place each.
2. Insert T-adapter into connector CE02, STC2 or CM02.
Short circuit or hot short 3. Connect ground cable.
9 (contact with 24 V circuit) in 4. Turn starting switch to ON position.
wiring harness a Since voltages of CAN H and CAN L are 2.5 ± 1 V even while communication is
continued, they are judged to be normal if they are 1 – 4 V.
Between STC2 (32), CM02 (8), (9) or CE02 (46) and
Voltage 1–4V
ground
Between STC2 (22), CM02 (10) or CE02 (47) and
Voltage 1–4V
ground
D65EX, PX, WX-16 40-304 17

SEN05034-01 Failure code [DAFRMC] CAN Discon (Monitor Detected)

If cause is not found by above checks and failure code [DB2RKR] is not displayed or
air conditioner cannot be operated, identify which controller is defective according to
A. Procedure for judging by operating air conditioner
• Step 1
2. Disconnect engine controller (connector CE02) and power train controller
(connector STC2).
3. Connect ground cable and turn starting switch to ON position.
4. Operate air conditioner.
a If air conditioner can be operated, go to step 2.
Air conditioner unit is
NO
defective
Can air conditioner be operated?
Any one of removed
YES
controllers is defective
Defective engine controller, • Step 2
10 power train controller or air
conditioner unit
2. Disconnect either engine controller (connector CE02) or power train controller
(connector STC2).
3. Connect ground cable, turn starting switch to ON position and perform
troubleshooting.
4. Return to 1. and perform troubleshooting on next controller.
Removed controller is
Can air conditioner be operated? YES
defective
B. Procedure for judging from failure code [DB2RKR]
(When there is no air conditioner unit)
2. Disconnect engine controller (connector CE03).
Defective power
NO
Is failure code [DB2RKR] displayed? train controller
YES Defective engine controller
a If no failure is detected by above checks, machine monitor is defective.
11 Defective machine monitor
(Since trouble is in monitor system, troubleshooting cannot be performed.)
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Failure code [DB2RKR] CAN Disconnection SEN05034-01
Failure code [DB2RKR] CAN Disconnection 1
Action code Failure code CAN disconnection (Engine controller is disconnected)

Trouble
E03 DB2RKR (Power train controller system)
Failure • Power train controller cannot recognize engine controller with CAN communication circuit.
description 1) Except for power supply circuit to engine controller
Action of
controller
• System may not operate normally.
Indication of
• When machine is traveling, engine speed is limited up to medium (half) at a certain rate.
problem on
• Once machine stops, engine speed is limited to medium (half).
machine
• Once machine stops, travel is limited to F1 and R1.
• Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DB2RKR] is displayed on the machine monitor, CAN communication between power train control-
ler and machine monitor is normal.
That is, there cannot be short circuit, ground fault or hot short in CAN communication line.
Related (turned ON/OFF and air flow can be adjusted) on air conditioner screen.
information (Air conditioner can be operated even while failure code [DB2RKR] is displayed on the monitor
screen.)
• If failure code [DAFRMC] is also displayed, cause of this trouble is probably engine controller prob-
lem in cause 2.
timeter.

1 Broken fuse 2. Remove fuses in fuse boxes F12-3 and F12-6.
a If fuse is broken, controller probably has short circuit in it.
2
Defective engine controller a Measured value: approx. 9 – 20 kz.
(Internal short circuit) a If measured value is below 10 z, engine controller is defective (Internal short cir-
cuit).
Between CE03 (male) (3) and (1) Resistance Min. 10 z
3
Defective power supply to a If result is abnormal, perform troubleshooting for [DB2RKR], Failure description 2)
engine controller Defective power supply circuit to engine controller.
Defective CAN terminal 2. Disconnect connectors CA1 and CM02 and connect T-adapters to male side of
resistor (Internal them.
4
disconnection or short
Between CA1 (male) (A) and (B) Resistance 120 ± 12 z
circuit)
Between CM02 (male) (8) and (10) Resistance 120 ± 12 z
D65EX, PX, WX-16 40-304 19

SEN05034-01 Failure code [DB2RKR] CAN Disconnection

• CAN communication line
a There is 120 z CAN terminal resistor inside machine monitor, too. Since 120 z
resistor is connected in parallel, if resistance measured at connector of controller
other than machine monitor is 60 z which is combined resistance, wiring harness
is not disconnected.
2. Disconnect one of following connectors CE02, STC2, AC02, CA1 and CM02 and
connect T-adapter to female side of that connector.
a If connector has short circuit (resistance between terminals is 1 z or less), discon-
Disconnection or short circuit nect all of CE02, STC2, AC02, CA1 and CM02 and check again to see if there is
5
in wiring harness
short circuit between wiring harnesses or in controller.
Between CE02 (female) (46) and (47) Resistance Approx. 60 z
Between STC2 (female) (32) and (22) Resistance Approx. 60 z
Between AC02 (female) (1) and (2) Resistance Approx. 60 z
Approx.
Between CA1 (female) (A) and (B) Resistance
120 z
Approx.
120 z
a If check result of cause 5 is normal, this check is not required.
2. Disconnect connectors CE02, C01, N10, K02 and CM02 and connect T-adapters
to female side of them.
Between STC2 (female) (32) and CM02 (female) (9), (8) Resistance Max. 1 z
Disconnection in wiring Between STC2 (female) (22) and CM02 (female) (10) Resistance Max. 1 z
harness (Disconnection or
6
defective contact in Between STC2 (female) (32) and CE02 (female) (46) Resistance Max. 1 z
connector) Between STC2 (female) (22) and CE02 (female) (47) Resistance Max. 1 z
Between CE02 (female) (46) and K02 (female) (A) Resistance Max. 1 z
Between CE02 (female) (47) and K02 (female) (B) Resistance Max. 1 z
• Signal ACC of starting switch
Disconnection in wiring 2. Insert T-adapters into connectors CE02, STC3 and CM01.
harness (Disconnection or 3. Connect ground cable and turn starting switch to ON position.
7
defective contact in Between CE02 (39) and ground Voltage 20 – 30 V
connector)
Between STC3 (14) or (24) and (31) Voltage 20 – 30 V
If cause is not found by the above checks and failure code [DAFRMC] is displayed,
8 Defective engine controller engine controller is defective. (Since trouble is in controller system, troubleshooting
cannot be performed.)
Defective power train If cause is not found by the above checks, power train controller is defective. (Since
9
controller trouble is in controller system, troubleshooting cannot be performed.)
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D65EX, PX, WX-16 40-304 21

SEN05034-01 Failure code [DB2RKR] CAN Disconnection
Failure
2) Defective power supply circuit to engine controller
description

Loose or corroded battery
1 Check battery terminals and ground (GND1) terminal directly for loose and corrosion.
terminals or ground terminal
connector
1. Turn starting switch to OFF position and troubleshoot.
3 Defective battery voltage 2. Starting engine and troubleshoot.
Between (+) and (–) terminals of battery (2 pieces) Voltage 20 – 30 V
Defective engine controller 2. Replace engine controller power supply relay (EP1, EP2) with another relay.
power supply relay
If this failure code goes off, the relay is defective.
2. Remove diode RSD and connect T-adapter to male side.
a Measure in diode range.
5 Defective diode RSD Between RSD (male) (6) (+) and (2) (–) Continuity
Between RSD (male) (2) (+) and (6) (–) No continuity
Between RSD (male) (8) (+) and (4) (–) Continuity
• Ground circuit
2. Disconnect connectors CE03, EP1 and EP2 and connect T-adapters to female
side of them.
Between EP1 (female) (2) and ground
Resistance Max. 1 z
a Rusted or loose ground terminal (GND03)
Between EP2 (female) (2) and ground
Resistance Max. 1 z
Between CE03 (female) (1), (2) and ground
Resistance Max. 1 z
• Primary circuit of relay
Disconnection in wiring 2. Disconnect connector RSD and connect T-adapter to female side.
harness (Disconnection or a Coil resistance of a relay is 260 – 320 z, so it is reduced to half since two relays
6
are connected in parallel.
connector)
Between RSD (female) (2) and ground Resistance 130 – 160 z
2. Insert T-adapters into connectors RSD, EP1 and EP2.
a Check to where 24 V is supplied to identify disconnected place.
Between RSD (6) and ground Voltage 20 – 30 V
Between EP1 (1) and (2) Voltage 20 – 30 V
Between CE03 (3), (4) and (1), (2) Voltage 20 – 30 V
2. Disconnect connectors RSD, CE03, EP1 and EP2 and connect T-adapters to
female side of them.
Between RSD (female) (2) and ground Resistance Min. 1 Mz
7 harness (Contact with Between CE03 (female) (3) and ground Resistance Min. 1 Mz
ground circuit) Between CE03 (female) (4) and ground Resistance Min. 1 Mz
Between RSD (6) and ground Resistance Min. 1 Mz
Between EP1 (1), (3) and ground Resistance Min. 1 Mz
Between EP2 (1), (3) and ground Resistance Min. 1 Mz
40-304 22 D65EX, PX, WX-16


If cause is not found by the above checks, engine controller is defective.
(Since trouble is in controller system, troubleshooting cannot be performed.)
D65EX, PX, WX-16 40-304 23

SEN05034-01 Failure code [DBE0KT] PT controller: Abnormality in controller
Failure code [DBE0KT] PT controller: Abnormality in controller 1
Action code Failure code PT controller: Failure in controller

Trouble
E01 DBE0KT (Power train controller system)
Failure
• Information in ROM (non-volatile memory) of power train controller is abnormal.
description
Action of
• Sets internal adjustment values to default values.
controller
Indication of
• Shift feeling of transmission may become bad.
problem on
• Adjusting function may not operate normally.
machine
Related
information

Turn adjustment function in service mode ON and perform operation of reproducing
Defective adjustment of
1 trouble. If “E” of failure code disappears at this time, system is normal.
power train controller
• Adjustment code: 0002 (Initialization of power train controller)
Defective power train Troubleshooting cannot be performed since defect is in power train controller.
2
controller (If there is not any visible trouble in machine, controller may be used as it is.)
40-304 24 D65EX, PX, WX-16

Failure code [DBE0KT] PT controller: Abnormality in controller SEN05034-01
D65EX, PX, WX-16 40-304 25

SEN05034-01 Failure code [DBE1KK] Battery direct Source voltage reduction
Failure code [DBE1KK] Battery direct Source voltage reduction 1
Action code Failure code Battery direct source voltage drop

Trouble
E04 DBE1KK (Power train controller system)
Failure
• Main power source voltage of power train controller is less than 17 V.
description
Action of
controller
• Machine monitor may not display normally.
Indication of
• Relay and solenoid may not drive and therefore, system may not operate normally.
problem on
machine
• Once machine is stopped, it becomes impossible to travel.
• Main power source voltage of power train controller can be checked in adjusting function.
Related
(Code 2021: Power train controller voltage check mode)
information
• Power train controller power supply voltage can be checked with adjustment function.

Defective fuse FL2-4 or If fuse FL2-4 or FS12-2 is broken, circuit probably has ground fault. In this case,
1
FS12-2 perform troubleshooting for cause 6 first.
Loose terminal or 1. Turn starting switch to OFF position.
2
disconnection at terminal Check terminals of battery, battery relay, etc. for looseness or disconnection.
1. Turn starting switch to OFF position. After starting engine, troubleshoot.
3 Defective battery voltage
Between battery (+) and (–) Voltage 20 – 30 V
2. Disconnect ground cable.
3. Disconnect connector STC3 and connect T-adapter to female side.
Disconnection in or ground 4. Connect ground cable.
4
fault of wiring harness a If voltage is 0 V, wiring harness has disconnection or ground fault.
Between STC3 (female) (1) and (21), (31) Voltage 20 – 30 V
Between STC3 (female) (11) and (32), (33) Voltage 20 – 30 V
Disconnection in wiring 3. If fuse is broken, replace it.
5 harness (Disconnection or 4. Disconnect connector STC3 and connect T-adapter to female side.
defective contact) Between STC3 (female) (21), (31), (32), (33) and
ground Resistance Max. 1 z
a Check terminal GND11 for looseness and rust.
Between STC3 (female) (1), (2) and battery (+) Resistance Max. 1 z
Ground fault of wiring 2. Disconnect ground cable.
6 harness (Contact with 3. If fuse is broken, replace it.
ground circuit) 4. Disconnect connector STC3 and connect T-adapter to female side.
Between STC3 (female) (1) and (21), (31) Resistance Min. 1 Mz
Between STC3 (female) (11) and (32), (33) Resistance Min. 1 Mz
Defective power train 2. Disconnect ground cable.
controller
Between STC3 (1) and (21), (31) Voltage 20 – 30 V
Between STC3 (11) and (32), (33) Voltage 20 – 30 V
40-304 26 D65EX, PX, WX-16

Failure code [DBE1KK] Battery direct Source voltage reduction SEN05034-01
D65EX, PX, WX-16 40-304 27

SEN05034-01 Failure code [DBE2KK] Solenoid Source voltage reduction
Failure code [DBE2KK] Solenoid Source voltage reduction 1
Action code Failure code Load power source voltage drop of power train controller
Trouble
Failure
• Power source voltage for load (relay, solenoid and etc,) on power train controller is less than 17 V.
description
Action of
controller
Indication of • Relay and solenoid may not drive and therefore, system may not operate normally.
problem on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, it becomes impossible to travel.
• Main power source voltage of power train controller can be checked in adjusting function.
Related (Code 2021: Power train controller voltage check mode)
information • Power train controller power supply voltage can be checked with adjustment function.
• If battery relay is not turned ON, see E-mode, E-1.

1
FS12-5 perform troubleshooting for cause 6 first.
2
disconnection at terminal Check terminals of battery, battery relay, etc. for looseness or disconnection.
1. Turn starting switch to OFF position. After starting engine, troubleshoot.
3 Defective battery voltage
Between battery (+) and (–) Voltage 20 – 30 V
Defective wiring harness or 5. Turn starting switch to ON position.
4
2. Disconnect ground cable (not to make short circuit).
Disconnection in wiring 3. Disconnect connector STC3 and connect T-adapter to female side.
5 harness (Disconnection or Between STC3 (female) (21), (31), (32), (33) and
defective contact) ground Resistance Max. 1 z
a Check terminal GND11 for looseness and rust.
Between STC3 (female) (2), (12), (22) and terminal
Resistance Max. 1 z
BRC
Ground fault of wiring 2. Disconnect ground cable (not to make short circuit).
6 harness (Contact with 3. If fuse is broken, replace it.
ground circuit) 4. Disconnect connector STC3.
Between terminal BRC and ground Resistance Min. 1 Mz
7 If cause is not found by the above checks, power train controller is defective.
controller
40-304 28 D65EX, PX, WX-16

Failure code [DBE2KK] Solenoid Source voltage reduction SEN05034-01
D65EX, PX, WX-16 40-304 29

SEN05034-01 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction
Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction 1
Action code Failure code PT controller: Sensor voltage 5V (1) drop

Trouble
Failure • Voltage of 5 V power supply (1) circuit for power train controller sensors is below 4.5 V or above 5.5 V.
description • Abnormal current flowed in 5 V power supply (1) circuit for power train controller sensors.
Action of • Stops to output 5 V power supply (1) circuit, if abnormal current flows.
controller • Limits operation of engine and transmission.
machine • Once machine is stopped, travel is limited to F1 and R1.
Related
information

position each time.
• If this code is not displayed when a sensor is disconnected, that sensor is defec-
Defective fuel control dial or tive.
1
PCCS lever (Internal defect) a Other failure codes are displayed at the same time. This is because the connector
is disconnected. Ignore failure codes other than [DBE5KK].
Device Connector
Fuel control dial DIA2
PCCS lever TLV1
Defective power train 2. Disconnect connector STC1 and connect T-adapter to male side.
controller
Between STC1 (male) (22) and (21) Voltage 4.5 – 5.5 V
Ground fault of wiring 2. Disconnect connectors STC1, DIA2 and TLV1, and connect T-adapter to female
3 harness (Contact with side of one of them.
ground circuit) Between STC1 (female) (22), TLV1 (female) (4), (5) or
DIA2 (female) (A) and ground
2. Disconnect connectors DIA2 and TLV1, and connect T-adapter to female side of
Hot short in wiring harness either of them.
Between TLV1 (female) (4) or (5) and (8), or between
Voltage 4.5 – 5.5 V
DIA2 (female) (A) and (C)
40-304 30 D65EX, PX, WX-16

Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction SEN05034-01
D65EX, PX, WX-16 40-304 31

SEN05034-01 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction 1
Action code Failure code PT controller: Sensor voltage 24V drop

Trouble
Failure • Voltage of 24 V power supply circuit for power train controller sensor is below 17 V or above 30 V.
description • Abnormal current flowed in 24 V power supply circuit for power train controller sensor.
Action of • Stops to output 24 V power supply circuit, if abnormal current flows.
machine • Once machine is stopped, travel is limited to F1 and R1.
Related
information

2. Disconnect connector PT1.
Defective inclination angle • If this code is not displayed when a inclination angle sensor is disconnected, that
1
sensor (Internal defect) sensor is defective.
a Other failure codes are displayed at the same time. This is because the connector
is disconnected. Ignore failure codes other than [DBE6KK].
Defective power train 2. Disconnect connector STC1 and connect T-adapter to male side.
controller
Between STC1 (male) (16) and (21) Voltage 20 – 30 V
Ground fault of wiring 2. Disconnect connectors STC1 and PT1, and connect T-adapter to female side of
ground circuit) Between STC1 (female) (16) or PT1 (female) (C) and
ground
Short circuit in wiring 2. Disconnect connector PT1 and connect T-adapter to female side.
harness
Between PT1 (female) (C) and (A) Voltage 20 – 30 V
40-304 32 D65EX, PX, WX-16

Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction SEN05034-01
D65EX, PX, WX-16 40-304 33

SEN05034-01 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction
Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction 1
Action code Failure code PT controller: Sensor voltage 5V (2) drop

Trouble
Failure • Voltage of 5 V power supply (2) circuit for power train controller sensors is below 4.5 V or above 5.5 V.
description • Abnormal current flowed in 5 V power supply (2) circuit for power train controller sensors.
Action of
• Stops to output 5 V power supply (2) circuit, if abnormal current flows.
controller
Indication of
problem on • None in particular.
machine
Related
information

position each time.
• If this code is not displayed when a sensor or a device is disconnected, that sen-
Defective brake pedal
potentiometer, torque sor or device is defective.
converter pressure sensor or a Other failure codes are displayed at the same time. This is because the connector
1
work equipment pump oil is disconnected. Ignore failure codes other than [DBE5KK].
pressure sensor (Internal Device or sensor Connector
defect)
Brake pedal potentiometer BRK
Torque converter pressure sensor TIP
Work equipment pump
HHP
oil pressure sensor
Ground fault of wiring 2. Disconnect connectors STC3, BRK, TIP and HHP, and connect T-adapter to
2 harness (Contact with female side of one of them.
ground circuit) Between STC3 (female) (34), BRK (female) (B), TIP
(female) (3) or HHP (female) (3) and ground
2. Disconnect connectors BRK, TIP and HHP, and connect T-adapter to female side
of one of them.
Hot short in wiring harness 3. Turn starting switch to ON position.
3
Between BRK (female) (B) and (C), between TIP
(female) (3) and (1), or between HHP (female) (3) and Voltage 4.5 – 5.5 V
(1)
controller
a Since connector STC3 has 24 V power supply, 5 V output cannot be checked with
connector STC3 disconnected.
Between STC3 (34) and ground Voltage 4.5 – 5.5 V
40-304 34 D65EX, PX, WX-16

Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction SEN05034-01
D65EX, PX, WX-16 40-304 35

SEN05034-01 Failure code [DBE9KQ] PT controller: Type select signal
Failure code [DBE9KQ] PT controller: Type select signal 1
Action code Failure code PT controller: Type select signal

Trouble
E04 DBE9KQ (Power train controller system)
Failure • Specification setting in power train controller does not match specification setting memory
description (Initialization of power train controller is not performed).
Action of • Turns all outputs of power train controller OFF.
Indication of • Machine does not move at all.
machine • Once machine stops, it cannot travel at all.
Related
information

Display adjustment function in service mode and perform operation of reproducing
Defective adjustment of
1 trouble. If “E” of failure code disappears at this time, system is normal.
• Adjustment code: 0002 (Initialization of power train controller)
40-304 36 D65EX, PX, WX-16

Failure code [DBE9KQ] PT controller: Type select signal SEN05034-01
D65EX, PX, WX-16 40-304 37

SEN05034-01 Failure code [DD12KA] Shift up Sw: Disconnection
Failure code [DD12KA] Shift up Sw: Disconnection 1
Action code Failure code Shift up switch: Disconnection

Trouble
E02 DD12KA (Power train controller system)
Failure
• Both lines of NO* and NC* for shift up switch circuit are OPEN (switch: OFF) at the same time.
description
Action of
• Recognizes that shift up switch is not pressed.
controller
Indication of
• Transmission gear cannot be shifted up.
problem on
• Auto shift down function does not operate.
machine
• “NO*” line is used for sensing operation and “NC*” line is used for detecting error.
Related • Condition of shift up switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
• Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch.

2. Disconnect connector SFTU and connect T-adapter to male side.
3. Turn shift up switch ON/OFF and troubleshoot.
a “Switch OFF”: Release, “Switch ON”: Press
Defective shift up switch
1
(Internal disconnection) Between SFTU (male) (3) Switch: OFF Resistance Max. 1 z
and (2) Switch: ON Resistance Min. 1 Mz
Between SFTU (male) (1) Switch: OFF Resistance Min. 1 Mz
and (2) Switch: ON Resistance Max. 1 z
2. Disconnect connector SFTU and connect T-adapter to female side.
a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it
Disconnection or hot short in shows hot short in wiring harness.
2
wiring harness a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in
power train controller.
Between SFTU (female) (1) and (2) Voltage 7 – 11 V
Between SFTU (female) (3) and (2) Voltage 7 – 11 V
Disconnection in wiring 2. Disconnect connectors STC1, STC3 and SFTU and connect T-adapters to female
harness side of them.
3
(Disconnection or defective Between STC3 (female) (9) and SFTU (female) (1) Resistance Max. 1 z
contact)
Between STC1 (female) (4) and SFTU (female) (2) Resistance Max. 1 z
Between STC1 (female) (12) and SFTU (female) (3) Resistance Max. 1 z
2. Insert T-adapters into connectors STC1 and STC3.
4
Defective power train a Voltage of about 9 V is applied to STC1 pin (12) and STC3 pin (9) through resistor
controller in power train controller.
Switch: OFF Voltage Max. 1 V
Between STC1 (12) and (4)
Switch: ON Voltage 7 – 11 V
Between STC3 (9) and Switch: OFF Voltage 7 – 11 V
STC1 (4) Switch: ON Voltage Max. 1 V
*NO: Normally Open

*NC: Normally Closed
40-304 38 D65EX, PX, WX-16

Failure code [DD12KA] Shift up Sw: Disconnection SEN05034-01
D65EX, PX, WX-16 40-304 39

SEN05034-01 Failure code [DD12KB] Shift up Sw: Short circuit
Failure code [DD12KB] Shift up Sw: Short circuit 1
Action code Failure code Shift up switch: Short circuit

Trouble
E02 DD12KB (Power train controller system)
Failure
• Both lines of NO* and NC* for shift up switch circuit are 0 V (switch: ON) at the same time.
description
Action of
• Recognizes that shift up switch is not pressed.
controller
Indication of
• Transmission gear cannot be shifted up.
problem on
machine
Related • Condition of shift up switch signal can be checked with monitoring function.
information (Code: 40905 T/M Sw Input 1)
• Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch.

2. Disconnect connector SFTU and connect T-adapter to male side.
Defective shift up switch
1
(Internal disconnection) Between SFTU (male) (3) Switch: OFF Resistance Max. 1 z
Between SFTU (male) (1) Switch: OFF Resistance Min. 1 Mz
2. Disconnect connectors STC1, STC3 and SFTU and connect T-adapter to female
Ground fault of wiring side of one of them.
2 harness Between SFTU (female) (1) or STC3 (female) (9) and
(Contact with ground circuit) ground
Between SFTU (female) (3) or STC1 (female) (12) and
ground
2. Disconnect connectors STC1, STC3 and SFTU and connect T-adapters to female
side of STC1 and STC3.
3
harness Between STC1 (female) (12) and each pin other than No continuity
No continuity
Between STC3 (female) (9) and each pin other than (9)
(No sound is heard)
4
Defective power train a Voltage of about 9 V is applied to STC1 pin (12) and STC3 pin (9) through resistor
controller in power train controller.
*NO: Normally Open

40-304 40 D65EX, PX, WX-16

Failure code [DD12KB] Shift up Sw: Short circuit SEN05034-01
D65EX, PX, WX-16 40-304 41

SEN05034-01 Failure code [DD13KA] Shift down Sw: Disconnection
Failure code [DD13KA] Shift down Sw: Disconnection 1
Action code Failure code Shift down switch: Disconnection

Trouble
Failure
• Both lines of NO* and NC* for shift down switch circuit are OPEN (switch: OFF) at the same time.
description
Action of
• Recognizes that shift down switch is not pressed.
controller
Indication of
• Transmission gear cannot be shifted down.
problem on
machine
• Condition of shift down switch signal can be checked with monitoring function.
Related
(Code: 40905 T/M Sw Input 1)
information
• Method of reproducing failure code: Turn starting switch to ON position and operate shift down
switch.

2. Disconnect connector SFTD and connect T-adapter to male side.
Defective shift down switch
1
(Internal disconnection) Between SFTD (male) (3) Switch: OFF Resistance Max. 1 z
Between SFTD (male) (1) Switch: OFF Resistance Min. 1 Mz
2. Disconnect connector SFTD and connect T-adapter to female side.
2
Between SFTD (female) (1) and (2) Voltage 7 – 11 V
Between SFTD (female) (3) and (2) Voltage 7 – 11 V
Disconnection in wiring 2. Disconnect connectors STC1 and SFTD and connect T-adapters to female side of
harness them.
3
(Disconnection or defective Between STC1 (female) (18) and SFTD (female) (1) Resistance Max. 1 z
contact)
Between STC1 (female) (4) and SFTD (female) (2) Resistance Max. 1 z
Between STC1 (female) (24) and SFTD (female) (3) Resistance Max. 1 z
4. Turn shift down switch ON/OFF and troubleshoot.
4
Defective power train a Voltage of about 9 V is applied to STC1 pin (18) and pin (24) through resistor in
controller power train controller.
Switch: OFF Voltage 7 – 11 V
Switch: ON Voltage Max. 1 V
*NO: Normally Open

40-304 42 D65EX, PX, WX-16

Failure code [DD13KA] Shift down Sw: Disconnection SEN05034-01
D65EX, PX, WX-16 40-304 43

SEN05034-01 Failure code [DD13KB] Shift down Sw: Short circuit
Failure code [DD13KB] Shift down Sw: Short circuit 1
Action code Failure code Shift down switch: Short circuit

Trouble
Failure
• Both lines of NO* and NC* for shift down switch circuit are 0 V (switch: ON) at the same time.
description
Action of
• Recognizes that shift down switch is not pressed.
controller
Indication of
• Transmission gear cannot be shifted down.
problem on
machine
• Condition of shift down switch signal can be checked with monitoring function.
Related
(Code: 40905 T/M Sw Input 1)
information
• Method of reproducing failure code: Turn starting switch to ON position and operate shift down
switch.

2. Disconnect connector SFTD and connect T-adapter to male side.
Defective shift down switch
1
(Internal disconnection) Between SFTD (male) (3) Switch: OFF Resistance Max. 1 z
Between SFTD (male) (1) Switch: OFF Resistance Min. 1 Mz
2. Disconnect connectors STC1 and SFTD and connect T-adapter to female side of
Ground fault of wiring one of them.
2 harness Between SFTD (female) (1) or STC1 (female) (18) and
Between SFTD (female) (3) or STC1 (female) (24) and
ground
2. Disconnect connectors STC1 and SFTD and connect T-adapter to female side of
STC1.
3
Between STC1 (female) (24) and each pin other than No continuity
4
Switch: OFF Voltage 7 – 11 V
Switch: ON Voltage Max. 1 V
*NO: Normally Open

40-304 44 D65EX, PX, WX-16

Failure code [DD13KB] Shift down Sw: Short circuit SEN05034-01
D65EX, PX, WX-16 40-304 45

SEN05034-01 Failure code [DD14KA] Parking lever Sw: Disconnection
Failure code [DD14KA] Parking lever Sw: Disconnection 1
Action code Failure code Parking lever switch: Disconnection

Trouble
Failure • Both lines of NO* and NC* for parking brake lever switch circuit are OPEN (switch: OFF) at the
description same time.
Action of • Recognizes that parking brake lever is in FREE position.
Indication of • Once machine stops, engine speed is limited to medium (half).
problem on • Once machine stops, travel is limited to F1 and R1.
machine • Engine cannot start.
• “NO*” line is used for sensing operation and “NC” line is used for detecting error.
• Condition of parking brake lever switch signal can be checked with monitoring function.
Related (Code: 40905 T/M Sw Input 1)
information • Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
lever.
• When parking brake lever is free, parking brake lever switch becomes “ON”.

2. Disconnect connector PKSW and connect T-adapter to male side.
3. Operate parking brake lever and troubleshoot.
Defective parking brake a “Switch OFF”: Release, “Switch ON”: Press
1 lever switch (Internal Between PKSW (male) (A) Lever: free Resistance Min. 1 Mz
disconnection) and (B) Lever: lock Resistance Max. 1 z
Between PKSW (male) (A) Lever: free Resistance Max. 1 z
and (C) Lever: lock Resistance Min. 1 Mz
2. Disconnect connector PKSW and connect T-adapter to female side.
2
Between PKSW (female) (A) and (B) Voltage 7 – 11 V
Between PKSW (female) (A) and (C) Voltage 7 – 11 V
Disconnection in wiring 2. Disconnect connectors STC1, STC2 and PKSW and connect T-adapters to female
3
(Disconnection or defective Between STC1 (female) (4) and PKSW (female) (A) Resistance Max. 1 z
contact)
Between STC2 (female) (5) and PKSW (female) (B) Resistance Max. 1 z
Between STC2 (female) (15) and PKSW (female) (C) Resistance Max. 1 z
4
Between STC2 (5) and Lever: free Voltage 7 – 11 V
STC1 (4) Lever: lock Voltage Max. 1 V
Between STC2 (15) and Lever: free Voltage Max. 1 V
STC1 (4) Lever: lock Voltage 7 – 11 V
*NO: Normally Open

40-304 46 D65EX, PX, WX-16

Failure code [DD14KA] Parking lever Sw: Disconnection SEN05034-01
D65EX, PX, WX-16 40-304 47

SEN05034-01 Failure code [DD14KB] Parking lever Sw: Short circuit
Failure code [DD14KB] Parking lever Sw: Short circuit 1
Action code Failure code Parking lever switch: Short circuit

Trouble
Failure • Both lines of NO* and NC* for parking brake lever switch circuit are 0 V (switch: ON) at the same
description time.
Action of • Recognizes that parking brake lever is in FREE position.
machine • Engine cannot start.
• “NO*” line is used for sensing operation and “NC” line is used for detecting error.
• Condition of parking brake lever switch signal can be checked with monitoring function.
Related (Code: 40905 T/M Sw Input 1)
information • Method of reproducing failure code: Turn starting switch to ON position and operate parking brake
lever.
• When parking brake lever is free, parking brake lever switch becomes “ON”.

2. Disconnect connector PKSW and connect T-adapter to male side.
Defective parking brake a “Switch OFF”: Release, “Switch ON”: Press
1 lever switch (Internal Between PKSW (male) (A) Lever: free Resistance Min. 1 Mz
disconnection) and (B) Lever: lock Resistance Max. 1 z
Between PKSW (male) (A) Lever: free Resistance Max. 1 z
2. Disconnect connectors STC2 and PKSW and connect T-adapter to female side of
2 harness Between PKSW (female) (B) or STC2 (female) (5) and
Between PKSW (female) (C) or STC2 (female) (15) and
ground
2. Disconnect connectors STC2 and PKSW and connect T-adapter to female side of
STC2.
3
harness No continuity
(No sound is heard)
4
*NO: Normally Open

40-304 48 D65EX, PX, WX-16

Failure code [DD14KB] Parking lever Sw: Short circuit SEN05034-01
D65EX, PX, WX-16 40-304 49

SEN05034-01

©2009 KOMATSU
All Rights Reserved
40-304 50
SEN05035-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ..................................................................... 4
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit......................................................................... 6
Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection.......................................................................... 8
Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit ........................................................................... 10
Failure code [DDNLKA] Weq lock Sw: Disconnection .................................................................................. 12
Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................... 14
Failure code [DGS1KX] Hyd oil temp sensor: Abnormal .............................................................................. 16
Failure code [DGT1KA] T/C oil temp sensor: Disconnection ........................................................................ 18
Failure code [DGT1KX] T/C oil temp sensor: Short circuit ............................................................................ 20
Failure code [DH21KA] Weq pressure sensor: Disconnection...................................................................... 22
Failure code [DH21KB] Weq pressure sensor: Short circuit ......................................................................... 24
Failure code [DHT5KA] T/C pressure sensor: Disconnection ....................................................................... 26
Failure code [DHT5KB] T/C pressure sensor: Short circuit .......................................................................... 28
Failure code [DK10KA] Fuel control Dial: Disconnection.............................................................................. 30
Failure code [DK10KB] Fuel control Dial: Short circuit ................................................................................. 32
Failure code [DK30KA] ST lever 1: Disconnection ....................................................................................... 34
Failure code [DK30KB] ST lever 1: Short circuit ........................................................................................... 36
Failure code [DK30KX] ST lever: Out of normal range ................................................................................. 38
Failure code [DK30KZ] ST lever: Disconnection or short circuit ................................................................... 38
Failure code [DK30L8] ST lever: Signal mismatch ....................................................................................... 39
Failure code [DK31KA] ST lever 2: Disconnection ....................................................................................... 40
D65EX, PX, WX-16 40-305 1

SEN05035-01
Failure code [DK31KB] ST lever 2: Short circuit ........................................................................................... 42

Failure code [DK40KA] Brake potentiometer: Disconnection........................................................................ 44
Failure code [DK40KB] Brake potentiometer: Short circuit ........................................................................... 46
Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 48
Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 48
Failure code [DK55L8] FR lever: Signal mismatch ....................................................................................... 49
Failure code [DK56KA] FR lever 1: Disconnection ....................................................................................... 50
Failure code [DK57KA] FR lever 2: Disconnection ....................................................................................... 54
40-305 2 D65EX, PX, WX-16

SEN05035-01
D65EX, PX, WX-16 40-305 3

SEN05035-01 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection 1
Action code Failure code Work equipment knob switch (down): Disconnection
Trouble
E02 DDN7KA (Power train controller system)
Failure • Both lines of NO* and NC* for blade knob lower switch circuit are OPEN (switch: OFF) at the same
description time.
Action of
• Recognizes that blade knob lower switch is not pressed.
controller
Indication of
problem on • Blade knob lower switch does not work.
machine
• Condition of blade knob lower switch signal can be checked with monitoring function.
Related
(Code: 70300 Blade Sw Input)
information
• Method of reproducing failure code: Turn starting switch to ON position and operate blade knob
lower switch.

2. Disconnect connector POB and connect T-adapter to male side.
3. Turn blade knob lower switch ON/OFF and troubleshoot.
Defective blade knob lower a “Switch OFF”: Release, “Switch ON”: Press
1 switch Between POB (male) (3) Switch: OFF Resistance Max. 1 z
(Internal disconnection) and (2) Switch: ON Resistance Min. 1 Mz
Between POB (male) (1) Switch: OFF Resistance Min. 1 Mz
2. Disconnect connector POB and connect T-adapter to female side.
2
Between POB (female) (1) and (2) Voltage 7 – 11 V
Between POB (female) (3) and (2) Voltage 7 – 11 V
Disconnection in wiring 2. Disconnect connectors STC1, STC2 and POB and connect T-adapters to female
3
(Disconnection or defective Between STC2 (female) (37) and POB (female) (1) Resistance Max. 1 z
contact)
Between STC1 (female) (10) and POB (female) (2) Resistance Max. 1 z
Between STC2 (female) (27) and POB (female) (3) Resistance Max. 1 z
4
Between STC2 (27) and Switch: OFF Voltage Max. 1 V
STC1 (10) Switch: ON Voltage 7 – 11 V
*NO: Normally Open

40-305 4 D65EX, PX, WX-16

Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection SEN05035-01

a There are two types.
D65EX, PX, WX-16 40-305 5

SEN05035-01 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit 1
Action code Failure code Work equipment knob switch (down): Short circuit
Trouble
E02 DDN7KB (Power train controller system)
Failure
• Both lines of NO* and NC* for blade knob lower switch circuit are 0 V (switch: ON) at the same time.
description
Action of
• Recognizes that blade knob lower switch is not pressed.
controller
Indication of
problem on • Blade knob lower switch does not work.
machine
• Condition of blade knob lower switch signal can be checked with monitoring function.
Related
information
lower switch.

2. Disconnect connector POB and connect T-adapter to male side.
Defective blade knob lower a “Switch OFF”: Release, “Switch ON”: Press
1 switch Between POB (male) (3) Switch: OFF Resistance Max. 1 z
Between POB (male) (1) Switch: OFF Resistance Min. 1 Mz
2. Disconnect connectors STC2 and POB and connect T-adapter to female side of
2 harness Between POB (female) (1) or STC2 (female) (37) and
Between POB (female) (3) or STC2 (female) (27) and
ground
2. Disconnect connectors STC2 and POB and connect T-adapters to female side of
STC2.
3
4
*NO: Normally Open

40-305 6 D65EX, PX, WX-16

Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit SEN05035-01

a There are two types.
D65EX, PX, WX-16 40-305 7

SEN05035-01 Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection
Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection 1
Action code Failure code Work equipment knob switch (up): Disconnection
Trouble
E02 DDN8KA (Power train controller system)
Failure • Both lines of NO* and NC* for blade knob upper switch circuit are OPEN (switch: OFF) at the same
description time.
Action of
• Recognizes that blade knob upper switch is not pressed.
controller
Indication of
problem on • Blade knob upper switch does not work.
machine
• Condition of blade knob upper switch signal can be checked with monitoring function.
Related
information
upper switch.

2. Disconnect connector POA and connect T-adapter to male side.
3. Turn blade knob upper switch ON/OFF and troubleshoot.
Defective blade knob upper a “Switch OFF”: Release, “Switch ON”: Press
1 switch Between POA (male) (3) Switch: OFF Resistance Max. 1 z
Between POA (male) (1) Switch: OFF Resistance Min. 1 Mz
2. Disconnect connector POA and connect T-adapter to female side.
2
Between POA (female) (1) and (2) Voltage 7 – 11 V
Between POA (female) (3) and (2) Voltage 7 – 11 V
Disconnection in wiring 2. Disconnect connectors STC1, STC3 and POA and connect T-adapters to female
3
(Disconnection or defective Between STC3 (female) (10) and POA (female) (1) Resistance Max. 1 z
contact)
Between STC1 (female) (10) and POA (female) (2) Resistance Max. 1 z
Between STC3 (female) (20) and POA (female) (3) Resistance Max. 1 z
4
*NO: Normally Open

40-305 8 D65EX, PX, WX-16

Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 9

SEN05035-01 Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit
Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit 1
Action code Failure code Work equipment knob switch (up): Short circuit
Trouble
E02 DDN8KB (Power train controller system)
Failure
• Both lines of NO* and NC* for blade knob upper switch circuit are 0 V (switch: ON) at the same time.
description
Action of
• Recognizes that blade knob upper switch is not pressed.
controller
Indication of
problem on • Blade knob upper switch does not work.
machine
• Condition of blade knob upper switch signal can be checked with monitoring function.
Related
information
upper switch.

2. Disconnect connector POA and connect T-adapter to male side.
Defective blade knob upper a “Switch OFF”: Release, “Switch ON”: Press
1 switch Between POA (male) (3) Switch: OFF Resistance Max. 1 z
Between POA (male) (1) Switch: OFF Resistance Min. 1 Mz
2. Disconnect connectors STC1, STC3 and POA and connect T-adapter to female
2 harness Between POA (female) (1) or STC3 (female) (10) and
Between POA (female) (3) or STC3 (female) (20) and
ground
2. Disconnect connectors STC3 and POA and connect T-adapter to female side of
STC3.
3
4
*NO: Normally Open

40-305 10 D65EX, PX, WX-16

Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 11

SEN05035-01 Failure code [DDNLKA] Weq lock Sw: Disconnection
Failure code [DDNLKA] Weq lock Sw: Disconnection 1
Action code Failure code Work equipment lock switch: Disconnection

Trouble
E03 DDNLKA (Power train controller system)
Failure • Both lines of NO* and NC* for work equipment lock lever switch circuit are OPEN (switch: OFF) at
description the same time.
Action of • Recognizes that work equipment lock lever is in Lock position.
machine • Work equipment operation is impossible.
• Condition of work equipment lock lever switch signal can be checked with monitoring function.
Related
information
upper switch.

2. Disconnect connector WELK and connect T-adapter to male side.
3. Operate work equipment lock lever switch and troubleshoot.
Defective work equipment
1 lock lever switch Between WELK (male) (A) Lever: free Resistance Min. 1 Mz
(Internal disconnection) and (B) Lever: lock Resistance Max. 1 z
Between WELK (male) (A) Lever: free Resistance Max. 1z
2. Disconnect connector WELK and connect T-adapter to female side.
2
Between WELK (female) (A) and (B) Voltage 7 – 11 V
Between WELK (female) (A) and (C) Voltage 7 – 11 V
Disconnection in wiring 2. Disconnect connectors STC1, STC2 and WELK and connect T-adapters to female
3
(Disconnection or defective Between STC1 (female) (10) and WELK (female) (A) Resistance Max. 1 z
contact)
Between STC2 (female) (6) and WELK (female) (B) Resistance Max. 1 z
Between STC2 (female) (16) and WELK (female) (C) Resistance Max. 1 z
4
*NO: Normally Open
40-305 12 D65EX, PX, WX-16

Failure code [DDNLKA] Weq lock Sw: Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 13

SEN05035-01 Failure code [DDNLKB] Weq lock Sw: Short circuit
Failure code [DDNLKB] Weq lock Sw: Short circuit 1
Action code Failure code Work equipment lock switch: Short circuit
Trouble
E03 DDNLKB (Power train controller system)
Failure • Both lines of NO* and NC* for work equipment lock lever switch circuit are 0 V (switch: ON) at the
description same time.
Action of • Recognizes that work equipment lock lever is in Lock position.
machine • Work equipment operation is impossible.
• Condition of work equipment lock lever switch signal can be checked with monitoring function.
Related
information
upper switch.

2. Disconnect connector WELK and connect T-adapter to male side.
Defective work equipment
1 lock lever switch Between WELK (male) (A) Lever: free Resistance Min. 1 Mz
(Internal disconnection) and (B) Lever: lock Resistance Max. 1 z
Between WELK (male) (A) Lever: free Resistance Max. 1z
2. Disconnect connectors STC1, STC2 and WELK and connect T-adapter to female
2 harness Between WELK (female) (B) or STC2 (female) (6) and
Between WELK (female) (C) or STC2 (female) (16) and
ground
2. Disconnect connectors STC2 and WELK and connect T-adapters to female side of
STC2.
3
harness No continuity
(No sound is heard)
4
*NO: Normally Open

40-305 14 D65EX, PX, WX-16

Failure code [DDNLKB] Weq lock Sw: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 15

SEN05035-01 Failure code [DGS1KX] Hyd oil temp sensor: Abnormal
Failure code [DGS1KX] Hyd oil temp sensor: Abnormal 1
Action code Failure code Hydraulic oil temperature sensor: Abnormal

Trouble
E01 DGS1KX (Machine monitor system)
Failure
• Hydraulic oil temperature sensor signal is out of normal range.
description
Action of
controller
Indication of
• Hydraulic oil temperature on machine monitor is not displayed normally.
problem on
• Fan speed is limited to half.
machine
• Hydraulic oil temperature can be checked in monitoring mode.
Related
(Code 04401: Hydraulic oil temperature)
information

2. Disconnect connector HDT and connect T-adapter to male side.
Approx.
10°C Resistance
Defective hydraulic oil 90 kz
temperature sensor Approx.
1 Between HDT (male) (1) and (2) 30°C Resistance
(Internal disconnection or 35 kz
short circuit) a Temperature characteristics of oil tem-
perature sensor Approx.
80°C Resistance
6.5 kz
Approx.
100°C Resistance
3.5 kz
2. Disconnect connector HDT and connect T-adapter to female side.
Disconnection, short circuit a If voltage is 0 V, wiring harness has disconnection, ground fault or short circuit,
2 or hot short in or ground fault and if voltage is 24 V, wiring harness has hot short.
of wiring harness a Voltage of 5 V is applied to temperature sensor signal lines through resistor in
Between HDT (female) (1) and (2) Voltage Approx. 5 V
2. Disconnect connector CM01 and connect T-adapter to female side.
Disconnection or short circuit a Resistance accords with temperature characteristics table in cause 1.
3 a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is
in wiring harness
Approx.
3.5 – 90 kz
a If neither of causes 2 and 3 is the cause for the trouble, this check is not required.
Disconnection in wiring 2. Disconnect connectors CM01 and HDT, and connect T-adapters to female side of
defective contact)
Between CM01 (female) (8) and HDT (female) (1) Resistance Max. 1 z
Between CM01 (female) (12) and HDT (female) (2) Resistance Max. 1 z
Ground fault of wiring 2. Disconnect connectors CM01 and HDT, and connect T-adapter to female side of
5 harness either of them.
Between CM01 (female) (8) and (3), or between HDT
2. Disconnect connectors CM01 and HDT, and connect T-adapter to female side of
Short circuit in wiring CM01.
harness
No continuity
Between CM01 (female) (8) and each pin other than (8)
(No sound is heard)
40-305 16 D65EX, PX, WX-16

Failure code [DGS1KX] Hyd oil temp sensor: Abnormal SEN05035-01

7 Defective machine monitor a If no failure is detected by the above checks, machine monitor is defective.
D65EX, PX, WX-16 40-305 17

SEN05035-01 Failure code [DGT1KA] T/C oil temp sensor: Disconnection
Failure code [DGT1KA] T/C oil temp sensor: Disconnection 1
Action code Failure code Torque converter oil temperature sensor: Disconnection
Trouble
E01 DGT1KA (Power train controller system)
Failure
• Torque converter oil temperature sensor signal is out of normal range.
description
Action of
controller
Indication of • Power train oil temperature gauge may not indicate normally.
problem on • Fan speed is limited to half speed.
machine • Shock at gear shift is hard.
• Torque converter oil temperature can be checked with monitoring function.
Related
information

2. Disconnect connector TCT and connect T-adapter to male side.
Approx.
10°C Resistance
Defective torque converter 90 kz
oil temperature sensor Approx.
1 Between TCT (male) (1) and (2) 30°C Resistance
(Internal disconnection or 35 kz
short circuit) a Temperature characteristics of oil tem-
perature sensor Approx.
80°C Resistance
6.5 kz
Approx.
100°C Resistance
3.5 kz
2. Disconnect connector TCT and connect T-adapter to female side.
of wiring harness a Voltage of 5 V is applied to temperature sensor signal lines through resistor in
Between TCT (female) (1) and (2) Voltage Approx. 5 V
Disconnection or short circuit a Resistance accords with temperature characteristics table in cause 1.
in wiring harness
Approx.
Between STC1 (female) (9) and (12) Resistance
3.5 – 90 kz
Disconnection in wiring 2. Disconnect connectors STC1 and TCT, and connect T-adapters to female side of
defective contact)
Between STC1 (female) (9) and TCT (female) (1) Resistance Max. 1 z
Between STC1 (female) (21) and TCT (female) (2) Resistance Max. 1 z
2. Disconnect connectors STC1 and TCT, and connect T-adapter to female side of
Short circuit in wiring STC1.
harness
No continuity
(No sound is heard)
6 If cause is not found by the above checks, power train controller is defective.
controller
40-305 18 D65EX, PX, WX-16

Failure code [DGT1KA] T/C oil temp sensor: Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 19

SEN05035-01 Failure code [DGT1KX] T/C oil temp sensor: Short circuit
Failure code [DGT1KX] T/C oil temp sensor: Short circuit 1
Action code Failure code Torque converter oil temperature sensor: Short circuit
Trouble
E01 DGT1KX (Power train controller system)
Failure
• Torque converter oil temperature sensor signal is out of normal range.
description
Action of
controller
Indication of • Power train oil temperature gauge may not indicate normally.
problem on • Fan speed is limited to half speed.
machine • Shock at gear shift is hard.
• Torque converter oil temperature can be checked with monitoring function.
Related • Method of reproducing failure code: Turn starting switch to ON position or start engine.
information • If the sensor connector is disconnected in the normal condition and turn starting switch to ON posi-
tion, failure code [DGT1KA] is displayed.
• For temperature characteristics table of oil temperature sensor, see [DGT1KA].

2. Disconnect connector TCT.
Defective torque converter 3. Turn starting switch to ON position.
oil temperature sensor
1 If failure code [DGT1KX] goes off and disconnection code [DGT1KA] is displayed,
short circuit) torque converter oil temperature sensor is defective.
(If failure code [DGT1KX] is still displayed, it shows that wiring harness or power train
controller is defective.)
Ground fault of wiring 2. Disconnect connectors STC1 and TCT, and connect T-adapter to female side of
2 harness either of them.
(Contact with ground circuit) Between STC1 (female) (9) or TCT (female) (1) and
ground
2. Disconnect connectors STC1 and TCT, and connect T-adapter to female side of
harness
No continuity
(No sound is heard)
4 Defective machine monitor a If no failure is detected by the above checks, machine monitor is defective.
40-305 20 D65EX, PX, WX-16

Failure code [DGT1KX] T/C oil temp sensor: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 21

SEN05035-01 Failure code [DH21KA] Weq pressure sensor: Disconnection
Failure code [DH21KA] Weq pressure sensor: Disconnection 1
Action code Failure code Work equipment pressure sensor: Disconnection

Trouble
E01 DH21KA (Power train controller system)
Failure
• Signal voltage of work equipment pump oil pressure sensor is below 0.2 V.
description
Action of
controller
Indication of
problem on • Oil pressure of work equipment pump cannot be monitored.
machine
• Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring func-
Related
tion. (Code: 70701 Hydraulic Pressure Sensor 1)
information

If failure code [DBE7KK] is also displayed, troubleshoot it first.
2. Disconnect connector HHP and connect T-adapter to female side.
Defective sensor 5 V power
supply system
a If power supply voltage is abnormal, go to cause 3 or after.
Power
Between HHP (female) (3) and (1) Voltage 4.5 – 5.5 V
supply
2. Insert T-adapter into connector HHP.
Defective work equipment a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
pump oil pressure sensor below), internal disconnection and ground fault cannot be identified. In this case,
2
(Internal disconnection) or go to cause 4. If check result of cause 4 is normal, work equipment pump oil pres-
ground fault
sure sensor is defective.
Sensor
output
2. Disconnect connectors STC1, STC3 and HHP, and connect T-adapters to female
side of them.
a If power supply voltage in cause 1 is normal, this
Disconnection in wiring check is not required. Resistance Max. 1 z
3 harness (Disconnection or Between STC3 (female) (34) and HHP (female) (3)
defective contact)
check is not required. Resistance Max. 1 z
Between STC1 (female) (21) and HHP (female) (1)
Between STC1 (female) (14) and HHP (female) (2) Resistance Max. 1 z
2. Disconnect connectors STC1 and HHP, and connect T-adapter to female side of
Ground fault of wiring either of them.
ground circuit) Between STC1 (female) (14) and (21), or between HHP
(female) (1) and (2)
Between STC1 (female) (14) and ground, or between
HHP (female) (2) and ground
controller
Between STC1 (14) and (21) Voltage 0.5 – 4.5 V
40-305 22 D65EX, PX, WX-16

Failure code [DH21KA] Weq pressure sensor: Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 23

SEN05035-01 Failure code [DH21KB] Weq pressure sensor: Short circuit
Failure code [DH21KB] Weq pressure sensor: Short circuit 1
Action code Failure code Work equipment pressure sensor: Short circuit
Trouble
E01 DH21KB (Power train controller system)
Failure
• Signal voltage of work equipment pump oil pressure sensor is above 4.8 V.
description
Action of
controller
Indication of
problem on • Oil pressure of work equipment pump cannot be monitored.
machine
• Signal voltage of work equipment pump oil pressure sensor can be checked with monitoring func-
tion. (Code: 70701 Hydraulic Pressure Sensor 1)
Related
information
• If the sensor connector is disconnected in the normal condition and turn starting switch to ON posi-
tion, failure code [DH21KA] is displayed.

2. Disconnect connector HHP and connect T-adapter to female side.
supply system
Power
supply
2. Disconnect connector HHP.
Defective work equipment 3. Turn starting switch to ON position.
pump oil pressure sensor
2 If failure code [DH21KB] is not displayed but [DH21KA] of disconnection is
(Internal disconnection) or
ground fault displayed, work equipment pump oil pressure sensor is defective.
(If failure code [DH21KB] is still displayed, it shows that wiring harness or power train
Hot short in wiring harness 2. Disconnect connector HHP and connect T-adapter to female side.
Between HHP (female) (2) and (1) or ground Voltage Max. 1 V
2. Disconnect connectors STC1 and HHP, and connect T-adapter to female side of
harness
controller
40-305 24 D65EX, PX, WX-16

Failure code [DH21KB] Weq pressure sensor: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 25

SEN05035-01 Failure code [DHT5KA] T/C pressure sensor: Disconnection
Failure code [DHT5KA] T/C pressure sensor: Disconnection 1
Action code Failure code Torque converter pressure sensor: Disconnection

Trouble
E02 DHT5KA (Power train controller system)
Failure
• Signal voltage of torque converter pressure sensor is below 0.2 V.
description
Action of
controller
Indication of
• Torque converter pressure cannot be monitored.
problem on
• Shock at gear shift is hard.
machine
• Signal voltage of torque converter pressure sensor can be checked with monitoring function.
Related
(Code: 32605 T/C Pressure Sensor)
information

2. Disconnect connector TIP and connect T-adapter to female side.
supply system
Power
Between TIP (female) (3) and (1) Voltage 4.5 – 5.5 V
supply
2. Insert T-adapter into connector TIP.
Defective torque converter a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
pressure sensor (Internal below), internal disconnection and ground fault cannot be identified. In this case,
2
disconnection) or ground go to cause 4. If check result of cause 4 is normal, torque converter pressure sen-
fault
sor is defective.
Sensor
output
2. Disconnect connectors STC1, STC3 and TIP, and connect T-adapters to female
side of them.
3 harness (Disconnection or Between STC3 (female) (34) and TIP (female) (3)
defective contact)
Between STC1 (female) (21) and TIP (female) (1)
Between STC1 (female) (20) and TIP (female) (2) Resistance Max. 1 z
2. Disconnect connectors STC1 and TIP, and connect T-adapter to female side of
ground circuit) Between STC1 (female) (20) and (21), or between TIP
TIP (female) (2) and ground
controller
40-305 26 D65EX, PX, WX-16

Failure code [DHT5KA] T/C pressure sensor: Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 27

SEN05035-01 Failure code [DHT5KB] T/C pressure sensor: Short circuit
Failure code [DHT5KB] T/C pressure sensor: Short circuit 1
Action code Failure code Torque converter pressure sensor: Short circuit
Trouble
E02 DHT5KB (Power train controller system)
Failure
• Signal voltage of torque converter pressure sensor is above 4.7 V.
description
Action of
controller
Indication of
• Torque converter pressure cannot be monitored.
problem on
• Shock at gear shift is hard.
machine
• Signal voltage of torque converter pressure sensor can be checked with monitoring function.
(Code: 32605 T/C Pressure Sensor)
Related
information
tion, failure code [DHT5KA] is displayed.

2. Disconnect connector TIP and connect T-adapter to female side.
supply system
Power
supply
2. Disconnect connector TIP.
Defective torque converter 3. Turn starting switch to ON position.
pressure sensor (Internal
2 If failure code [DHT5KB] is not displayed but [DHT5KA] of disconnection is
disconnection) or ground
fault displayed, torque converter pressure sensor is defective.
(If failure code [DHT5KB] is still displayed, it shows that wiring harness or power
train controller is defective.)
Hot short in wiring harness 2. Disconnect connector TIP and connect T-adapter to female side.
Between TIP (female) (2) and (1) or ground Voltage Max. 1 V
2. Disconnect connectors STC1 and TIP, and connect T-adapter to female side of
harness
controller
40-305 28 D65EX, PX, WX-16

Failure code [DHT5KB] T/C pressure sensor: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 29

SEN05035-01 Failure code [DK10KA] Fuel control Dial: Disconnection
Failure code [DK10KA] Fuel control Dial: Disconnection 1
Action code Failure code Fuel control Dial: Disconnection

Trouble
— DK10KA (Power train controller system)
Failure
• Signal voltage of fuel control dial is below 0.5 V.
description
Action of • Continues control with signal of decelerator pedal potentiometer.
Indication of
problem on
machine
• Signal voltage of fuel control dial signal can be checked with monitoring function.
Related
(Code: 03000 Fuel Dial Sensor)
information

2. Disconnect connector DIA2 and connect T-adapter to female side.
supply system
Power
Between DIA2 (female) (A) and (C) Voltage 4.5 – 5.5 V
supply
2. Disconnect connector DIA2 and connect T-adapter to male side.
Defective fuel control dial 4. Rotate fuel control dial and troubleshoot.
2 (Internal disconnection or Between DIA2 (male) (A) and (C) Resistance Approx. 5 kz
ground fault)
Between DIA2 (male) (A) and (B) Resistance 0.5 – 4.5 kz
Between DIA2 (male) (B) and (C) Resistance 0.5 – 4.5 kz
Between DIA2 (male) (B) and ground Resistance Min. 1 Mz
2. Disconnect connectors STC1 and TL1, and connect T-adapter to female side of
STC1.
a Resistance is same as table in cause 2.
Disconnection or short circuit
in wiring harness
Between STC1 (female) (22) and (21) Resistance Approx. 5 kz
Between STC1 (female) (1) and (21) Resistance 0.5 – 4.5 kz
2. Disconnect connectors STC1 and DIA2, and connect T-adapters to female side of
them.
a If power supply voltage in cause 1 or check result of
cause 3 is normal, this check is not required. Resistance Max. 1 z
Disconnection in wiring Between STC1 (female) (22) and DIA2 (female) (A)
defective contact)
Between STC1 (female) (21) and DIA2 (female) (C)
a If check result of cause 3 is normal, this check is not
required. Resistance Max. 1 z
Between STC1 (female) (1) and DIA2 (female) (B)
2. Disconnect connectors STC1 and DIA2, and connect T-adapter to female side of
ground circuit) Between STC1 (female) (1) and (21), or between DIA2
(female) (B) and (C)
DIA2 (female) (B) and ground
40-305 30 D65EX, PX, WX-16

Failure code [DK10KA] Fuel control Dial: Disconnection SEN05035-01

6
controller 3. Turn starting switch to ON position.
4. Rotate fuel control dial and troubleshoot.
D65EX, PX, WX-16 40-305 31

SEN05035-01 Failure code [DK10KB] Fuel control Dial: Short circuit
Failure code [DK10KB] Fuel control Dial: Short circuit 1
Action code Failure code Fuel control Dial: Short circuit

Trouble
— DK10KB (Power train controller system)
Failure
• Signal voltage of fuel control dial is above 4.5 V.
description
Action of • Continues control with signal of decelerator pedal potentiometer.
Indication of
problem on
machine
• Signal voltage of fuel control dial signal can be checked with monitoring function.
Related
(Code: 03000 Fuel Dial Sensor)
information

2. Disconnect connector DIA2 and connect T-adapter to female side.
supply system
Power
Between DIA2 (female) (A) and (C) Voltage 4.5 – 5.5 V
supply
2. Disconnect connector DIA2 and connect T-adapter to male side.
Defective fuel control dial 4. Rotate fuel control dial and troubleshoot.
2 (Internal disconnection or
short circuit) Between DIA2 (male) (A) and (C) Resistance Approx. 5 kz
Between DIA2 (male) (A) and (B) Resistance 0.5 – 4.5 kz
Between DIA2 (male) (B) and (C) Resistance 0.5 – 4.5 kz
Hot short circuit in wiring 2. Disconnect connector DIA2 and connect T-adapter to female side.
3 harness 3. Turn starting switch to ON position.
Between DIA2 (female) (B) and (C) or ground Voltage Min. 1 V
2. Disconnect connectors STC1 and DIA2, and connect T-adapter to female side of
harness
No continuity
(No sound is heard)
5
4. Rotate fuel control dial and troubleshoot.
40-305 32 D65EX, PX, WX-16

Failure code [DK10KB] Fuel control Dial: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 33

SEN05035-01 Failure code [DK30KA] ST lever 1: Disconnection
Failure code [DK30KA] ST lever 1: Disconnection 1
Action code Failure code Steering lever 1: Disconnection

Trouble
E03 DK30KA (Power train controller system)
Failure
• Signal voltage of PCCS lever steering potentiometer 1 (ST lever 1) is below 0.5 V.
description
Action of • Continues control with signal of PCCS lever steering potentiometer 2 (ST lever 2).
Indication of
problem on
machine
• Signal voltage of PCCS lever steering potentiometer 1 can be checked with monitoring function.
Related (Code: 50300 S/T Lever 1 Potentio)
information • Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in
steering direction).

2. Disconnect connector TLV1 and connect T-adapter to female side.
supply system
Power
Between TLV1 (female) (5) and (8) Voltage 4.5 – 5.5 V
supply
2. Insert T-adapter into connector TLV1.
Defective PCCS lever 4. Operate PCCS lever (steering) and troubleshoot.
steering potentiometer 1 a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
2 below), internal disconnection and ground fault cannot be identified. In this case,
ground fault go to cause 4. If check result of cause 4 is normal, PCCS lever steering potentiom-
eter 1 is defective.
Sensor
Between TLV1 (7) and (8) Voltage 0.5 – 4.5 V
output
2. Disconnect connectors STC1 and TLV1, and connect T-adapters to female side of
them.
3 harness (Disconnection or Between STC1 (female) (22) and TLV1 (female) (5)
defective contact)
Between STC1 (female) (21) and TLV1 (female) (8)
Between STC1 (female) (2) and TLV1 (female) (7) Resistance Max. 1 z
2. Disconnect connectors STC1 and TLV1, and connect T-adapter to female side of
ground circuit) Between STC1 (female) (2) and (21), or between TLV1
TLV1 (female) (7) and ground
5
4. Operate PCCS lever (steering) and troubleshoot.
40-305 34 D65EX, PX, WX-16

Failure code [DK30KA] ST lever 1: Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 35

SEN05035-01 Failure code [DK30KB] ST lever 1: Short circuit
Failure code [DK30KB] ST lever 1: Short circuit 1
Action code Failure code Steering lever 1: Short circuit

Trouble
E03 DK30KB (Power train controller system)
Failure
• Signal voltage of PCCS lever steering potentiometer 1 (ST lever 1) is above 4.5 V.
description
Indication of
problem on
machine

1 If failure code [DBE5KK] is also displayed, troubleshoot it first.
supply system
2. Disconnect connector TLV1.
steering potentiometer 1
2 If failure code [DK30KB] is not displayed, PCCS lever steering potentiometer is
ground fault defective. (If failure code [DK30KB] is still displayed, wiring harness or power train
a Since connector TLV1 is disconnected, many failure codes are displayed. Ignore
all displayed failure codes other than [DK30KB], however.
Hot short in wiring harness 2. Disconnect connector TLV1 and connect T-adapter to female side.
Between TLV1 (female) (7) and (8) or ground Voltage Max. 1 V
harness
No continuity
(No sound is heard)
5
40-305 36 D65EX, PX, WX-16

Failure code [DK30KB] ST lever 1: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 37

SEN05035-01 Failure code [DK30KX] ST lever: Out of normal range
Failure code [DK30KX] ST lever: Out of normal range 1
Action code Failure code Steering lever: Out of normal range

Trouble
E04 DK30KX (Power train controller system)
• In PCCS lever steering potentiometer 1 (ST lever 1) and 2 (ST lever 2), either of failure codes
Failure
[DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] occurred at the
description
same time.
Action of
controller
Indication of
problem on
machine
• Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring func-
tion.
information (Code: 50301 S/T Lever 2 Potentio)
• Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever (in

Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Failure code [DK30KZ] ST lever: Disconnection or short circuit 1
Action code Failure code Steering lever: Disconnection or short circuit

Trouble
E04 DK30KZ (Power train controller system)
• In PCCS lever steering potentiometer 1 (ST lever 1) and 2 (ST lever 2), when starting switch is
Failure
turned ON, only either side is abnormal and then either of failure codes [DK30KA] and [DK30KB]
description
and either of failure codes [DK31KA] and [DK31KB] occurred at the same time.
Action of
controller
Indication of
problem on
• Once machine stops, it cannot travel at all.
machine
• Signal voltage of PCCS lever steering potentiometer 1 and 2 can be checked with monitoring func-
tion.
information (Code: 50301 S/T Lever 2 Potentio)

40-305 38 D65EX, PX, WX-16

Failure code [DK30L8] ST lever: Signal mismatch SEN05035-01
Failure code [DK30L8] ST lever: Signal mismatch 1
Action code Failure code Steering lever: Signal mismatch

Trouble
E03 DK30L8 (Power train controller system)
Failure • In PCCS lever steering potentiometer 1 (ST lever 1) and 2 (ST lever 2), total of both signal voltages
description is below 4.41 V or above 5.59 V.
• Continues control with signal of normal one of PCCS lever steering potentiometer 1 (ST lever 1) or
Action of
2 (ST lever 2).
controller
Indication of
problem on
machine
• Signal voltage of PCCS lever steering potentiometer can be checked with monitoring function.
(Code: 50300 S/T Lever 1 Potentio)
Related
(Code: 50301 S/T Lever 2 Potentio)
information

D65EX, PX, WX-16 40-305 39

SEN05035-01 Failure code [DK31KA] ST lever 2: Disconnection
Failure code [DK31KA] ST lever 2: Disconnection 1
Action code Failure code Steering lever 2: Disconnection

Trouble
Failure
• Signal voltage of PCCS lever steering potentiometer 2 (ST lever 2) is below 0.5 V.
description
Indication of
problem on
machine

supply system
Power
supply
steering potentiometer 2 a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
ground fault go to cause 4. If check result of cause 4 is normal, PCCS lever steering potentiom-
eter 2 is defective.
Sensor
output
them.
defective contact)
5
40-305 40 D65EX, PX, WX-16

Failure code [DK31KA] ST lever 2: Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 41

SEN05035-01 Failure code [DK31KB] ST lever 2: Short circuit
Failure code [DK31KB] ST lever 2: Short circuit 1
Action code Failure code Steering lever 2: Short circuit

Trouble
Failure
• Signal voltage of PCCS lever steering potentiometer 2 (ST lever 2) is above 4.5 V.
description
Indication of
problem on
machine

supply system
steering potentiometer 2
2 If failure code [DK31KB] is not displayed, PCCS lever steering potentiometer is
ground fault defective. (If failure code [DK31KB] is still displayed, wiring harness or power train
harness
5
40-305 42 D65EX, PX, WX-16

Failure code [DK31KB] ST lever 2: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 43

SEN05035-01 Failure code [DK40KA] Brake potentiometer: Disconnection
Failure code [DK40KA] Brake potentiometer: Disconnection 1
Action code Failure code Brake potentiometer: Disconnection

Trouble
Failure
• Signal voltage of brake pedal potentiometer is below 0.5 V.
description
Action of
• Cannot recognize brake pedal position.
controller
Indication of
• Auto shift down function may not operate normally.
problem on
• Once machine stops, gear shift mode is limited to manual gear shift mode.
machine
• Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related
(Code: 50400 Brake Pedal Potentio)
information
• Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal.

2. Disconnect connector BRK and connect T-adapter to female side.
supply system
Power
Between BRK (female) (B) and (C) Voltage 4.5 – 5.5 V
supply
2. Disconnect connector BRK and connect T-adapter to male side.
Defective brake pedal 4. Depress brake pedal and troubleshoot.
potentiometer (Internal
2 Between BRK (male) (B) and (C) Resistance Approx. 2 kz
disconnection or ground
fault) Between BRK (male) (A) and (B) Resistance 0.2 – 1.8 kz
Between BRK (male) (A) and (C) Resistance 0.2 – 1.8 kz
Between BRK (male) (A) and ground Resistance Min. 1 Mz
2. Disconnect connectors STC1, PL1 and STC3, and connect T-adapters to female
side of them.
a Resistance is same as table in cause 2.
Disconnection or short circuit
in wiring harness
Between STC3 (female) (34) and STC1 (female) (21) Resistance Approx. 2 kz
Between STC1 (female) (3) and (21) Resistance 0.2 – 1.8 kz
2. Disconnect connectors STC1, STC3 and BRK, and connect T-adapters to female
side of them.
Disconnection in wiring Between STC3 (female) (34) and BRK (female) (B)
defective contact)
Between STC1 (female) (21) and BRK (female) (C)
a If check result of cause 3 is normal, this check is not
required. Resistance Max. 1 z
Between STC1 (female) (3) and BRK (female) (A)
2. Disconnect connectors STC1, STC3 and BRK, and connect T-adapter to female
Ground fault of wiring side of either of them.
ground circuit) Between STC1 (female) (3) and (21), or between BRK
(female) (A) and (C)
BRK (female) (A) and ground
40-305 44 D65EX, PX, WX-16

Failure code [DK40KA] Brake potentiometer: Disconnection SEN05035-01

6
4. Depress brake pedal and troubleshoot.
D65EX, PX, WX-16 40-305 45

SEN05035-01 Failure code [DK40KB] Brake potentiometer: Short circuit
Failure code [DK40KB] Brake potentiometer: Short circuit 1
Action code Failure code Brake potentiometer: Short circuit

Trouble
Failure
• Signal voltage of brake pedal potentiometer is above 4.5 V.
description
Action of
• Cannot recognize brake pedal position.
controller
Indication of
• Auto shift down function may not operate normally.
problem on
machine
• Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related
(Code: 50400 Brake Pedal Potentio)
information
• Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal.

2. Disconnect connector BRK and connect T-adapter to female side.
supply system
Power
Between BRK (female) (B) and (C) Voltage 4.5 – 5.5 V
supply
2. Disconnect connector BRK and connect T-adapter to male side.
Defective brake pedal 3. Turn starting switch to ON position.
potentiometer (Internal 4. Depress brake pedal and troubleshoot.
2
disconnection or short Between BRK (male) (B) and (C) Resistance Approx. 2 kz
circuit)
Between BRK (male) (A) and (B) Resistance 0.2 – 1.8 kz
Between BRK (male) (A) and (C) Resistance 0.2 – 1.8 kz
Hot short in wiring harness 2. Disconnect connector BRK and connect T-adapter to female side.
Between BRK (female) (A) and (C) or ground Voltage Max. 1 V
2. Disconnect connectors STC1 and BRK, and connect T-adapter to female side of
harness
No continuity
(No sound is heard)
5
4. Depress brake pedal and troubleshoot.
40-305 46 D65EX, PX, WX-16

Failure code [DK40KB] Brake potentiometer: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 47

SEN05035-01 Failure code [DK55KX] FR lever: Out of normal range
Failure code [DK55KX] FR lever: Out of normal range 1
Action code Failure code F/R lever 1: Out of normal range

Trouble
E04 DK55KX (Power train controller system)
• In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), either of failure codes
Failure
[DK56KA] and [DK56KB] and either of failure codes [DK57KA] and [DK57KB] occurred at the
description
same time.
Action of
controller
Indication of
problem on
machine
• Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentio)
Related
information
F-R direction).

Failure code [DK55KZ] FR lever: Disconnection or short circuit 1
Action code Failure code F/R lever: Disconnection or short circuit

Trouble
E04 DK55KZ (Power train controller system)
• In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), when starting switch is turned
Failure
ON, only either side is abnormal and then either of failure codes [DK56KA] and [DK56KB] and
description
either of failure codes [DK57KA] and [DK57KB] occurred at the same time.
Action of
controller
Indication of
problem on
machine
Related
information
F-R direction).

40-305 48 D65EX, PX, WX-16

Failure code [DK55L8] FR lever: Signal mismatch SEN05035-01
Failure code [DK55L8] FR lever: Signal mismatch 1
Action code Failure code F/R lever: Signal mismatch

Trouble
E03 DK55L8 (Power train controller system)
Failure • In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), total of both signal voltages is
description below 4.41 V or above 5.59 V.
Action of • Continues control with signal of normal one of PCCS lever F-R potentiometer 1 or 2.
Indication of
problem on
machine
Related
information
F-R direction).

D65EX, PX, WX-16 40-305 49

SEN05035-01 Failure code [DK56KA] FR lever 1: Disconnection
Failure code [DK56KA] FR lever 1: Disconnection 1
Action code Failure code F/R lever 1: Disconnection

Trouble
Failure
• Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is below 0.5 V.
description
Action of • Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4).
Indication of
problem on
machine
• Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring function.
Related (Code: 50200 T/M Lever 1 Potentio)
F-R direction).

supply system
Power
supply
Defective PCCS lever F-R 4. Operate PCCS lever (F-R) and troubleshoot.
potentiometer 1 (Internal a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
fault go to cause 4. If check result of cause 4 is normal, PCCS lever F-R potentiometer
1 is defective.
Sensor
output
them.
defective contact)
5
4. Operate PCCS lever (F-R) and troubleshoot.
40-305 50 D65EX, PX, WX-16

Failure code [DK56KA] FR lever 1: Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 51

SEN05035-01 Failure code [DK56KB] FR lever 1: Short circuit
Failure code [DK56KB] FR lever 1: Short circuit 1
Action code Failure code F/R lever 1: Short circuit

Trouble
Failure
• Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is above 4.5 V.
description
Indication of
problem on
machine
F-R direction).

supply system
potentiometer 1 (Internal
2 If failure code [DK56KB] is not displayed, PCCS lever F-R potentiometer is
fault defective. (If failure code [DK56KB] is still displayed, wiring harness or power train
harness
5
40-305 52 D65EX, PX, WX-16

Failure code [DK56KB] FR lever 1: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 53

SEN05035-01 Failure code [DK57KA] FR lever 2: Disconnection
Failure code [DK57KA] FR lever 2: Disconnection 1
Action code Failure code F/R lever 2: Disconnection

Trouble
Failure
• Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is below 0.5 V.
description
Indication of
problem on
machine
F-R direction).

supply system
Power
supply
potentiometer 2 (Internal a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
fault go to cause 4. If check result of cause 4 is normal, PCCS lever F-R potentiometer
2 is defective.
Sensor
output
them.
defective contact)
5
40-305 54 D65EX, PX, WX-16

Failure code [DK57KA] FR lever 2: Disconnection SEN05035-01
D65EX, PX, WX-16 40-305 55

SEN05035-01 Failure code [DK57KB] FR lever 2: Short circuit
Failure code [DK57KB] FR lever 2: Short circuit 1
Action code Failure code F/R lever 2: Short circuit

Trouble
Failure
• Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is above 4.5 V.
description
Indication of
problem on
machine
F-R direction).

supply system
potentiometer 2 (Internal
2 If failure code [DK57KB] is not displayed, PCCS lever F-R potentiometer is
fault defective. (If failure code [DK57KB] is still displayed, wiring harness or power train
harness
No continuity
(No sound is heard)
5
40-305 56 D65EX, PX, WX-16

Failure code [DK57KB] FR lever 2: Short circuit SEN05035-01
D65EX, PX, WX-16 40-305 57

SEN05035-01

©2011 KOMATSU
All Rights Reserved
40-305 58
SEN05036-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Failure code [DKH1KA] Pitch angle sensor: Disconnection............................................................................ 4
Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................... 6
Failure code [DLT3KA] T/M out-speed sensor: Disconnection ....................................................................... 8
Failure code [DLT3KB] T/M out-speed sensor: Abnormal .............................................................................. 9
Failure code [DW5AKA] Pitch selector Sol.: Disconnection.......................................................................... 10
Failure code [DW5AKB] Pitch selector Sol.: Short circuit ..............................................................................11
Failure code [DW5AKY] Pitch selector Sol.: Short circuit ............................................................................. 12
Failure code [DW7BKA] Fan rev EPC: Disconnection.................................................................................. 14
Failure code [DW7BKB] Fan rev EPC: Short circuit ..................................................................................... 15
Failure code [DWN1KA] Hss EPC1: Disconnection...................................................................................... 16
Failure code [DWN1KB] Hss EPC1: Short circuit ......................................................................................... 17
Failure code [DWN1KY] Hss EPC1: Short circuit ......................................................................................... 18
Failure code [DWN2KA] Hss EPC2: Disconnection...................................................................................... 19
Failure code [DWN2KB] Hss EPC2: Short circuit ......................................................................................... 20
Failure code [DWN2KY] Hss EPC2: Short circuit ......................................................................................... 21
Failure code [DWN5KA] Fan pump solenoid: Disconnection........................................................................ 22
Failure code [DWN5KB] Fan pump solenoid: Short circuit ........................................................................... 23
Failure code [DWN5KY] Fan control solenoid: Short circuit ......................................................................... 24
Failure code [DXA0KA] TVC Sol.: Disconnection ......................................................................................... 26
Failure code [DXA0KB] TVC Sol.: Short circuit............................................................................................. 27
Failure code [DXA0KY] TVC Sol.: Short circuit............................................................................................. 28
D65EX, PX, WX-16 40-306 1

SEN05036-01
Failure code [DXH1KA] Lock-up ECMV: Disconnection ............................................................................... 29

Failure code [DXH1KB] Lock-up ECMV: Short circuit ................................................................................... 30
Failure code [DXH1KY] Lock-up ECMV: Short circuit ................................................................................... 32
Failure code [DXH4KA] 1st clutch ECMV: Disconnection ............................................................................. 34
Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................................................. 35
Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................................................. 36
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection............................................................................ 37
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................................... 38
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................................... 39
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection............................................................................. 40
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 41
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit ................................................................................ 42
Failure code [DXH7KA] R clutch ECMV: Disconnection ............................................................................... 43
Failure code [DXH7KB] R clutch ECMV: Short circuit................................................................................... 44
Failure code [DXH7KY] R clutch ECMV: Short circuit................................................................................... 46
Failure code [DXH8KA] F clutch ECMV: Disconnection................................................................................ 48
Failure code [DXH8KB] F clutch ECMV: Short circuit ................................................................................... 49
Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................................... 50
Failure code [DXJ4KA] Weq lock Sol.: Disconnection .................................................................................. 52
Failure code [DXJ4KB] Weq lock Sol.: Short circuit ...................................................................................... 53
40-306 2 D65EX, PX, WX-16

SEN05036-01
D65EX, PX, WX-16 40-306 3

SEN05036-01 Failure code [DKH1KA] Pitch angle sensor: Disconnection
Failure code [DKH1KA] Pitch angle sensor: Disconnection 1
Action code Failure code Pitch angle sensor: Disconnection

Trouble
E03 DKH1KA (Power train controller system)
Failure
• Signal voltage of pitch angle sensor is below 0.15 V.
description
Action of • Cannot sense pitch angle of machine.
Indication of • Gearshift shock is made on slope or steering shock is made on level ground.
• State of pitch angle sensor power can be checked with monitoring function.
Related
(Code: 60100 Pitch Angle Sensor)
information

2. Disconnect connector PT1 and connect T-adapter to female side.
supply system
Power
supply
2. Insert T-adapter into connector PT1.
Defective pitch angle sensor a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or
2 (Internal disconnection) or below), internal disconnection and ground fault cannot be identified. In this case,
ground fault
go to cause 4. If check result of cause 4 is normal, pitch angle sensor is defective.
Sensor
Between PT1 (female) (B) and (A) Voltage 0.2 – 4.8 V
output
2. Disconnect connectors STC1, STC3 and PT1, and connect T-adapters to female
side of them.
3 harness (Disconnection or Between STC3 (female) (16) and PT1 (female) (C)
defective contact)
Between STC1 (female) (21) and PT1 (female) (A)
Between STC1 (female) (8) and PT1 (female) (B) Resistance Max. 1 z
2. Disconnect connectors STC1 and PT1, and connect T-adapter to female side of
ground circuit) Between STC1 (female) (8) and (21), or between PT1
(female) (B) and (A)
PT1 (female) (B) and ground
controller
40-306 4 D65EX, PX, WX-16

Failure code [DKH1KA] Pitch angle sensor: Disconnection SEN05036-01
D65EX, PX, WX-16 40-306 5

SEN05036-01 Failure code [DKH1KB] Pitch angle sensor: Short circuit
Failure code [DKH1KB] Pitch angle sensor: Short circuit 1
Action code Failure code Pitch angle sensor: Short circuit

Trouble
E03 DKH1KB (Power train controller system)
Failure
• Signal voltage of pitch angle sensor is above 4.85 V.
description
Action of • Cannot sense pitch angle of machine.
Indication of • Gearshift shock is made on slope or steering shock is made on level ground.
• State of pitch angle sensor power can be checked with monitoring function.
(Code: 60100 Pitch Angle Sensor)
Related
information
tion, failure code [DKH1KA] is displayed.

2. Disconnect connector PT1 and connect T-adapter to female side.
supply system
Power
supply
2. Disconnect connector PT1.
Defective pitch angle sensor 3. Turn starting switch to ON position.
2 (Internal disconnection) or If failure code [DKH1KB] is not displayed but [DKHK1A] of disconnection is
ground fault displayed, pitch angle sensor is defective.
(If failure code [DKH1KB] is still displayed, it shows that wiring harness or power
train controller is defective.)
Hot short in wiring harness 2. Disconnect connector PT1 and connect T-adapter to female side.
3
Between PT1 (female) (B) and (A) or ground Voltage Max. 1 V
2. Disconnect connectors STC1 and PT1, and connect T-adapter to female side of
STC1.
Short circuit in wiring 3. Turn starting switch to ON position.
4
No continuity
(No sound is heard)
controller
40-306 6 D65EX, PX, WX-16

Failure code [DKH1KB] Pitch angle sensor: Short circuit SEN05036-01
D65EX, PX, WX-16 40-306 7

SEN05036-01 Failure code [DLT3KA] T/M out-speed sensor: Disconnection
Failure code [DLT3KA] T/M out-speed sensor: Disconnection 1
Action code Failure code T/M out-speed sensor: Disconnection

Trouble
E02 DLT3KA (Power train controller system)
Failure
• No power is input from transmission bevel speed (revolution) sensor.
description
Action of
• Recognizes that transmission bevel speed is 0 rpm.
controller
• Transmission bevel speed cannot be monitored.
Indication of
• Traction force cannot be calculated.
problem on
• Automatic shift down function may not operate correctly.
machine
• Transmission bevel speed can be checked with monitoring function.
Related (Code: 31400 T/M Out Speed)
information • Method of reproducing failure code: Turn starting switch to ON position and travel machine or run
tracks in the air with machine body put on the stands.

Defective transmission bevel 2. Disconnect connector BVRV and connect T-adapter to male side.
gear (output) speed sensor
1 500 –
(Internal disconnection or Between BVRV (male) (1) and (2) Resistance
1,000 z
short circuit)
Between BVRV (male) (1) and ground Resistance Min. 1 Mz
2 below 1 z, wiring harness has short circuit.
in wiring harness
500 –
1,000 z
Disconnection in wiring 2. Disconnect connectors STC2 and BVRV, and connect T-adapters to female side of
defective contact)
Between STC2 (female) (29) and BVRV (female) (2) Resistance Max. 1 z
Between STC2 (female) (30) and BVRV (female) (1) Resistance Max. 1 z
Hot short in wiring harness 2. Disconnect connectors BVRV, and connect T-adapter to female side.
Between BVRV (female) (1) and (2) Voltage 3–4V
Defective power train If cause is not found by the above checks, power train controller may be defective.
5
controller (Since trouble is in system, troubleshooting cannot be performed.)
40-306 8 D65EX, PX, WX-16

Failure code [DLT3KB] T/M out-speed sensor: Abnormal SEN05036-01
Failure code [DLT3KB] T/M out-speed sensor: Abnormal 1
Action code Failure code T/M out-speed sensor: Abnormal

Trouble
E02 DLT3KB (Power train controller system)
Failure
• No power is input from transmission bevel speed (revolution) sensor.
description
Action of
• Recognizes that transmission bevel speed is 0 rpm.
controller
• Transmission bevel speed cannot be monitored.
Indication of
• Traction force cannot be calculated.
problem on
• Automatic shift down function may not operate correctly.
machine
• Transmission bevel speed can be checked with monitoring function.
Related (Code: 31400 T/M Out Speed)
information • Method of reproducing failure code: Turn starting switch to ON position and travel machine or run
tracks in the air with machine body put on the stands.

Defective transmission bevel 2. Disconnect connector BVRV and connect T-adapter to male side.
gear (output) speed sensor
1 500 –
(Internal disconnection or Between BVRV (male) (1) and (2) Resistance
1,000 z
short circuit)
Between BVRV (male) (1) and ground Resistance Min. 1 Mz
2 below 1 z, wiring harness has short circuit.
in wiring harness
500 –
1,000 z
Ground fault of wiring 2. Disconnect connectors STC2 and BVRV, and connect T-adapter to female side of
ground circuit) Between STC2 (female) (30) or BVRV (female) (1) and
ground
4
D65EX, PX, WX-16 40-306 9

SEN05036-01 Failure code [DW5AKA] Pitch selector Sol.: Disconnection
Failure code [DW5AKA] Pitch selector Sol.: Disconnection 1
Action code Failure code Work equipment pitch select solenoid: Disconnection
Trouble
E02 DW5AKA (Power train controller system)
Failure
• Any current does not flow when power is output to the work equipment pitch select solenoid circuit.
description
Action of
• Stops output to pitch select solenoid circuit.
controller
Indication of
problem on • Blade pitch cannot be changed.
machine
• Output state (ON/OFF) to pitch select solenoid can be checked in monitoring function.
Related (Code 90803: Blade ON/OFF output 1 pitch selector sol.)
information • Method of reproducing failure code: Turn starting switch to ON position and operate pitch select
switch.

Defective work equipment 1. Turn starting switch to OFF position.
1 pitch select solenoid 2. Disconnect connector PTP and connect T-adapter to male side.
(Internal disconnection) Between PTP (male) (1) and (2) Resistance 18 – 28 z
2
Between STC3 (female) (28) and (3) Resistance 18 – 28 z
harness (Disconnection or 2. Disconnect connectors STC3 and PTP, and connect T-adapters to female side of
3 them.
connector) Between STC3 (female) (28) and PTP (female) (1) Resistance Max. 1 z
Between STC3 (female) (3) and PTP (female) (2) Resistance Max. 1 z
4
40-306 10 D65EX, PX, WX-16

Failure code [DW5AKB] Pitch selector Sol.: Short circuit SEN05036-01
Failure code [DW5AKB] Pitch selector Sol.: Short circuit 1
Action code Failure code Work equipment pitch select solenoid: Short circuit
Trouble
E02 DW5AKB (Power train controller system)
Failure
• Abnormal current flowed when power is output to work equipment pitch select solenoid circuit.
description
Action of
controller
Indication of
problem on • Blade pitch cannot be changed.
machine
switch.

Defective work equipment 2. Disconnect connector PTP and connect T-adapter to male side.
1 pitch select solenoid
Between PTP (male) (1) and (2) Resistance 18 – 28 z
(Internal short circuit)
Between PTP (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and PTP, and connect T-adapter to female side of
ground circuit) Between STC3 (female) (28) or PTP (female) (1) and
ground
2. Disconnect connectors STC3 and PTP and connect T-adapter to female side of
Short circuit in wiring either of them.
3
harness
Between STC3 (female) (28) and (3), or between PTP
4
D65EX, PX, WX-16 40-306 11

SEN05036-01 Failure code [DW5AKY] Pitch selector Sol.: Short circuit
Failure code [DW5AKY] Pitch selector Sol.: Short circuit 1
Action code Failure code Work equipment pitch select solenoid: Short circuit
Trouble
E02 DW5AKY (Power train controller system)
Failure
• Current flows constantly to work equipment pitch select solenoid circuit.
description
Action of
controller
Indication of
problem on • Only blade pitch can be changed and tilt cannot be changed.
machine
switch.

Defective work equipment 2. Disconnect connector PTP and connect T-adapter to male side.
1 pitch select solenoid
Between PTP (male) (1) and (2) Resistance 18 – 28 z
Between PTP (female) (1) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector PTP and connect T-adapter to female side.
Between PTP (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors STC3 and PTP and connect T-adapter to female side of
STC3.
a Check with tester in continuity mode.
a T-adapter for connector PL1 is not available, so check short circuit in connector
Short circuit in wiring PL1 as followings.
3
harness 1. Turn starting switch to OFF position.
2. Disconnect connectors STC1 to STC3 and PTP, and connect T-adapters to female
side of STC1 to STC3.
Between STC3 (female) (28) and each pin of STC1 No continuity
(female) (No sound is heard)
4
40-306 12 D65EX, PX, WX-16

Failure code [DW5AKY] Pitch selector Sol.: Short circuit SEN05036-01
D65EX, PX, WX-16 40-306 13

SEN05036-01 Failure code [DW7BKA] Fan rev EPC: Disconnection
Failure code [DW7BKA] Fan rev EPC: Disconnection 1
Action code Failure code Fan reverse EPC: Disconnection

Trouble
E01 DW7BKA (Power train controller system)
Failure
• When power is output to fan reverse solenoid circuit, no current flows.
description
Action of
• Stops output to fan reverse solenoid circuit.
controller
Indication of
problem on • Fan reverse function cannot be used.
machine
• Operating condition of fan reverse solenoid can be checked with monitoring function.
Related (Code: 40909 T/M Output 1)
information • Method of reproducing failure code: Turn starting switch to ON position and select fan reverse
mode.

Defective fan reverse 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector FAR and connect T-adapter to male side.
(Internal disconnection) Between FAR (male) (1) and (2) Resistance 34 – 44 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and FAR, and connect T-adapters to female side of
3 them.
connector) Between STC3 (female) (18) and FAR (female) (1) Resistance Max. 1 z
Between STC3 (female) (3) and FAR (female) (2) Resistance Max. 1 z
Hot short in wiring harness 2. Disconnect connector FAR and connect T-adapter to female side.
Between FAR (female) (1) and ground Voltage Max. 1 V
5
40-306 14 D65EX, PX, WX-16

Failure code [DW7BKB] Fan rev EPC: Short circuit SEN05036-01
Failure code [DW7BKB] Fan rev EPC: Short circuit 1
Action code Failure code Fan reverse EPC: Short circuit

Trouble
E01 DW7BKB (Power train controller system)
Failure
• When power was output to fan reverse solenoid circuit, abnormal current flowed.
description
Action of
• Stops output to fan reverse solenoid circuit.
controller
Indication of
problem on • Fan reverse function cannot be used.
machine
• Operating condition of fan reverse solenoid can be checked with monitoring function.
Related (Code: 40909 T/M Output 1)
information • Method of reproducing failure code: Turn starting switch to ON position and select fan reverse
mode.

Defective fan reverse 2. Disconnect connector FAR and connect T-adapter to male side.
1 solenoid
Between FAR (male) (1) and (2) Resistance 34 – 44 z
Between FAR (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and FAR and connect T-adapter to female side of
ground circuit) Between STC3 (female) (18) or FAR (female) (1) and
ground
2. Disconnect connectors STC3 and FAR and connect T-adapter to female side of
3
harness
Between STC3 (female) (18) and (3), or between FAR
4
D65EX, PX, WX-16 40-306 15

SEN05036-01 Failure code [DWN1KA] Hss EPC1: Disconnection
Failure code [DWN1KA] Hss EPC1: Disconnection 1
Action code Failure code HSS EPC1: Disconnection

Trouble
E03 DWN1KA (Power train controller system)
Failure
• When power is output to HSS right EPC solenoid circuit, no current flows.
description
Action of • Stops output to HSS right EPC solenoid circuit.
Indication of • Machine does not turn right.
• Output to HSS right EPC solenoid can be checked with monitoring function.
Related (Code: 50601 HSS Solenoid RH (F/B))
information • Method of reproducing failure code: Turn starting switch to ON position and operate PCCS lever
(Right steering).

Defective HSS right EPC 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector HSR and connect T-adapter to male side.
(Internal disconnection) Between HSR (male) (1) and (2) Resistance 4 – 15 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and HSR and connect T-adapters to female side of
3 them.
connector) Between STC3 (female) (35) and HSR (female) (1) Resistance Max. 1 z
Between STC3 (female) (13) and HSR (female) (2) Resistance Max. 1 z
4
40-306 16 D65EX, PX, WX-16

Failure code [DWN1KB] Hss EPC1: Short circuit SEN05036-01
Failure code [DWN1KB] Hss EPC1: Short circuit 1
Action code Failure code HSS EPC1: Short circuit

Trouble
E03 DWN1KB (Power train controller system)
Failure
• When power was output to HSS right EPC solenoid circuit, abnormal current flowed.
description
Indication of • Machine does not turn right.
(Right steering).

Defective HSS right EPC 2. Disconnect connector HSR and connect T-adapter to male side.
1 solenoid (Internal short
Between HSR (male) (1) and (2) Resistance 4 – 15 z
circuit)
Between HSR (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and HSR and connect T-adapter to female side of
ground circuit) Between STC3 (female) (35) or HSR (female) (1) and
ground
2. Disconnect connectors STC3 and HSR and connect T-adapter to female side of
3
harness
Between STC3 (female) (35) and (13), or between HSR
4
D65EX, PX, WX-16 40-306 17

SEN05036-01 Failure code [DWN1KY] Hss EPC1: Short circuit
Failure code [DWN1KY] Hss EPC1: Short circuit 1

Trouble
E04 DWN1KY (Power train controller system)
Failure
• Current flows constantly to HSS right EPC solenoid circuit.
description
Indication of • Machine continues to turn right.
machine • Once machine stops, machine does not travel.
(Neutral).

Defective HSS right EPC 2. Disconnect connector HSR and connect T-adapter to male side.
Between HSR (male) (1) and (2) Resistance 4 – 15 z
circuit)
Between HSR (female) (1) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector HSR and connect T-adapter to female side.
Between HSR (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors STC3 and HSR and connect T-adapter to female side of
STC3.
3
2. Disconnect connectors STC1 to STC3 and HSR, and connect T-adapter to female
4
40-306 18 D65EX, PX, WX-16

Failure code [DWN2KA] Hss EPC2: Disconnection SEN05036-01
Failure code [DWN2KA] Hss EPC2: Disconnection 1
Action code Failure code HSS EPC2: Disconnection

Trouble
Failure
• When power is output to HSS left EPC solenoid circuit, no current flows.
description
Action of • Stops output to HSS left EPC solenoid circuit.
Indication of • Machine does not turn left.
• Output to HSS left EPC solenoid can be checked with monitoring function.
Related (Code: 50600 HSS Solenoid LH (F/B))
(Left steering)

Defective HSS left EPC 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector HSL and connect T-adapter to male side.
(Internal disconnection) Between HSL (male) (1) and (2) Resistance 4 – 15 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and HSL, and connect T-adapters to female side of
3 them.
connector) Between STC3 (female) (25) and HSL (female) (1) Resistance Max. 1 z
Between STC3 (female) (23) and HSL (female) (2) Resistance Max. 1 z
4
D65EX, PX, WX-16 40-306 19

SEN05036-01 Failure code [DWN2KB] Hss EPC2: Short circuit
Failure code [DWN2KB] Hss EPC2: Short circuit 1

Trouble
Failure
• When power was output to HSS left EPC solenoid circuit, abnormal current flowed.
description
Indication of • Machine does not turn left.
(Left steering).

Defective HSS left EPC 2. Disconnect connector HSL and connect T-adapter to male side.
1 solenoid
Between HSL (male) (1) and (2) Resistance 4 – 15 z
Between HSL (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and HSL and connect T-adapter to female side of
ground circuit) Between STC3 (female) (25) or HSL (female) (1) and
ground
2. Disconnect connectors STC3 and HSL and connect T-adapter to female side of
3
harness
Between STC3 (female) (25) and (23), or between HSL
4
40-306 20 D65EX, PX, WX-16

Failure code [DWN2KY] Hss EPC2: Short circuit SEN05036-01
Failure code [DWN2KY] Hss EPC2: Short circuit 1

Trouble
Failure
• Current flows constantly to HSS left EPC solenoid circuit.
description
Indication of • Machine continues to turn left.
machine • Once machine stops, machine does not travel.
(Neutral).

Defective HSS left EPC 2. Disconnect connector HSL and connect T-adapter to male side.
Between HSL (male) (1) and (2) Resistance 4 – 15 z
circuit)
Between HSL (female) (1) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector HSL and connect T-adapter to female side.
Between HSL (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors STC3 and HSL and connect T-adapter to female side of
STC3.
3
2. Disconnect connectors STC1 to STC3 and HSL and connect T-adapters to female
4
D65EX, PX, WX-16 40-306 21

SEN05036-01 Failure code [DWN5KA] Fan pump solenoid: Disconnection
Failure code [DWN5KA] Fan pump solenoid: Disconnection 1
Action code Failure code Fan pump solenoid: Disconnection

Trouble
Failure
• When power is output to fan pump control solenoid circuit, no current flows.
description
Action of
• Stops output to fan pump control solenoid circuit.
controller
Indication of
problem on • Fan speed is kept at maximum.
machine
• Output to fan pump control solenoid can be checked with monitoring function.
Related
(Code: 31624 Fan pump Solenoid (F/B))
information

Defective fan pump control 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector FAC and connect T-adapter to male side.
(Internal disconnection) Between FAC (male) (1) and (2) Resistance 2 – 12 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and FAC, and connect T-adapters to female side of
3 them.
connector) Between STC3 (female) (36) and FAC (female) (1) Resistance Max. 1 z
Between STC3 (female) (3) and FAC (female) (2) Resistance Max. 1 z
4
40-306 22 D65EX, PX, WX-16

Failure code [DWN5KB] Fan pump solenoid: Short circuit SEN05036-01
Failure code [DWN5KB] Fan pump solenoid: Short circuit 1
Action code Failure code Fan pump solenoid: Short circuit

Trouble
Failure
• When power was output to fan pump control solenoid circuit, abnormal current flowed.
description
Action of
controller
Indication of
problem on • Fan speed is kept at maximum.
machine
Related
information

Defective fan pump control 2. Disconnect connector FAC and connect T-adapter to male side.
Between FAC (male) (1) and (2) Resistance 2 – 12 z
circuit)
Between FAC (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and FAC, and connect T-adapter to female side of
ground circuit) Between STC3 (female) (36) or FAC (female) (1) and
ground
2. Disconnect connectors STC3 and FAC and connect T-adapter to female side of
3
harness
Between STC3 (female) (36) and (3), or between FAC
4
D65EX, PX, WX-16 40-306 23

SEN05036-01 Failure code [DWN5KY] Fan control solenoid: Short circuit
Failure code [DWN5KY] Fan control solenoid: Short circuit 1
Action code Failure code Fan pump control solenoid: Short circuit
Trouble
Failure
• Current flows constantly to fan pump control solenoid circuit.
description
Action of
controller
Indication of
• Fan speed is kept at minimum.
problem on
• Machine may be overheat.
machine
Related
information

Defective fan pump control 2. Disconnect connector FAC and connect T-adapter to male side.
Between FAC (male) (1) and (2) Resistance 2 – 12 z
circuit)
Between FAC (female) (1) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector FAC and connect T-adapter to female side.
Between FAC (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors STC3 and FAC and connect T-adapter to female side of
STC3.
3
2. Disconnect connectors STC1 to STC3 and FAC, and connect T-adapters to
female side of STC1 to STC3.
4
40-306 24 D65EX, PX, WX-16

Failure code [DWN5KY] Fan control solenoid: Short circuit SEN05036-01
D65EX, PX, WX-16 40-306 25

SEN05036-01 Failure code [DXA0KA] TVC Sol.: Disconnection
Failure code [DXA0KA] TVC Sol.: Disconnection 1
Action code Failure code TVC solenoid: Disconnection

Trouble
E01 DXA0KA (Power train controller system)
Failure
• When power is output to work equipment-HSS pump TVC solenoid circuit, no current flows.
description
Action of
• Stops output to work equipment-HSS pump TVC solenoid circuit.
controller
Indication of
problem on • If engine is loaded while running at low speed, it stops.
machine
• Output to work equipment-HSS pump TVC solenoid can be checked with monitoring function.
Related
(Code: 01300 TVC Solenoid (F/B))
information

Defective work equipment- 1. Turn starting switch to OFF position.
1 HSS pump TVC solenoid 2. Disconnect connector TVC and connect T-adapter to male side.
(Internal disconnection) Between TVC (male) (1) and (2) Resistance 2 – 12 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and TVC, and connect T-adapters to female side of
3 them.
connector) Between STC3 (female) (7) and TVC (female) (1) Resistance Max. 1 z
Between STC3 (female) (23) and TVC (female) (2) Resistance Max. 1 z
4
Note: TVC solenoid means PC-EPC valve.
40-306 26 D65EX, PX, WX-16

Failure code [DXA0KB] TVC Sol.: Short circuit SEN05036-01
Failure code [DXA0KB] TVC Sol.: Short circuit 1
Action code Failure code TVC solenoid: Short circuit

Trouble
E01 DXA0KB (Power train controller system)
Failure • When power was output to work equipment-HSS pump TVC solenoid circuit, abnormal current
description flowed.
Action of
controller
Indication of
problem on • If engine is loaded while running at low speed, it stops.
machine
Related
information

Defective work equipment- 2. Disconnect connector TVC and connect T-adapter to male side.
1 HSS pump TVC solenoid
Between TVC (male) (1) and (2) Resistance 2 – 12 z
Between TVC (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and TVC, and connect T-adapter to female side of
ground circuit) Between STC3 (female) (7) or TVC (female) (1) and
ground
2. Disconnect connectors STC3 and TVC and connect T-adapter to female side of
3
harness
Between STC3 (female) (7) and (23), or between TVC
4
D65EX, PX, WX-16 40-306 27

SEN05036-01 Failure code [DXA0KY] TVC Sol.: Short circuit
Failure code [DXA0KY] TVC Sol.: Short circuit 1
Action code Failure code TVC solenoid: Short circuit

Trouble
E01 DXA0KY (Power train controller system)
Failure • When power was output to work equipment-HSS pump TVC solenoid circuit, abnormal current
description flowed.
Action of
controller
Indication of
• Turn radial may big.
problem on
• Work equipment speed may be lowered.
machine
Related
information

Defective work equipment- 2. Disconnect connector TVC and connect T-adapter to male side.
1 HSS pump TVC solenoid
Between TVC (male) (1) and (2) Resistance 2 – 12 z
Between TVC (female) (1) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector TVC and connect T-adapter to female side.
Between TVC (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors STC3 and TVC and connect T-adapter to female side of
STC3.
No continuity
(No sound is heard)
3
2. Disconnect connectors STC1 to STC3 and TVC, and connect T-adapters to
4
40-306 28 D65EX, PX, WX-16

Failure code [DXH1KA] Lock-up ECMV: Disconnection SEN05036-01
Failure code [DXH1KA] Lock-up ECMV: Disconnection 1
Action code Failure code Lock-up ECMV: Disconnection

Trouble
E02 DXH1KA (Power train controller system)
Failure
• When power is output to torque converter lockup clutch ECMV solenoid circuit, no current flows.
description
Action of
• Stops output to torque converter lockup clutch ECMV solenoid circuit.
controller
Indication of
problem on • Torque converter lockup function does not operate.
machine
• Output to torque converter lockup clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31642 L/U ECMV (F/B))
information
• Method of reproducing failure code: Start engine and drive reverse (in auto gearshift mode).

Defective lockup clutch 1. Turn starting switch to OFF position.
1 ECMV solenoid 2. Disconnect connector L SOL and connect T-adapter to male side.
(Internal disconnection) Between L SOL (male) (1) and (2) Resistance 3 – 13 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and L SOL, and connect T-adapters to female side
3 of them.
connector) Between STC3 (female) (17) and L SOL (female) (1) Resistance Max. 1 z
Between STC3 (female) (3) and L SOL (female) (2) Resistance Max. 1 z
4
D65EX, PX, WX-16 40-306 29

SEN05036-01 Failure code [DXH1KB] Lock-up ECMV: Short circuit
Failure code [DXH1KB] Lock-up ECMV: Short circuit 1
Action code Failure code Lock-up ECMV: Short circuit

Trouble
E02 DXH1KB (Power train controller system)
Failure • When power was output to torque converter lockup clutch ECMV solenoid circuit, abnormal current
description flowed.
Action of
• Stops output to torque converter lockup clutch ECMV solenoid circuit.
controller
Indication of
problem on • Torque converter lockup function does not operate.
machine
• Output to torque converter lockup clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31642 L/U ECMV (F/B))
information
• Method of reproducing failure code: Start engine and drive reverse (in auto gearshift mode).

Defective lockup clutch 2. Disconnect connector L SOL and connect T-adapter to male side.
1 ECMV solenoid
Between L SOL (male) (1) and (2) Resistance 3 – 13 z
Between L SOL (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and L SOL and connect T-adapter to female side of
ground circuit) Between STC3 (female) (17) or L SOL (female) (1) and
ground
2. Disconnect connectors STC3 and L SOL and connect T-adapter to female side of
3
harness
Between STC3 (female) (17) and (3), or between L SOL
4
40-306 30 D65EX, PX, WX-16

Failure code [DXH1KB] Lock-up ECMV: Short circuit SEN05036-01
D65EX, PX, WX-16 40-306 31

SEN05036-01 Failure code [DXH1KY] Lock-up ECMV: Short circuit
Failure code [DXH1KY] Lock-up ECMV: Short circuit 1
Action code Failure code Lock-up ECMV: Short circuit

Trouble
E03 DXH1KY (Power train controller system)
Failure
• Current flows constantly to torque converter lockup clutch ECMV solenoid circuit.
description
Action of • Stops output to torque converter lockup clutch ECMV solenoid circuit.
• Torque converter lockup function operates constantly.
Indication of
• Engine may stall during travel.
problem on
machine
• Output to lockup clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31642 L/U ECMV (F/B))
information • Method of reproducing failure code: Start engine and drive in auto gearshift mode (while lockup is in
operation).

Defective lockup clutch 2. Disconnect connector L SOL and connect T-adapter to male side.
1 ECMV solenoid
Between L SOL (male) (1) and (2) Resistance 3 – 13 z
Between L SOL (female) (1) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector L SOL and connect T-adapter to female side.
Between L SOL (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors STC3 and L SOL and connect T-adapter to female side of
STC3.
3
2. Disconnect connectors STC1 to STC3 and L SOL, and connect T-adapters to
4
40-306 32 D65EX, PX, WX-16

Failure code [DXH1KY] Lock-up ECMV: Short circuit SEN05036-01
D65EX, PX, WX-16 40-306 33

SEN05036-01 Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 1
Action code Failure code 1st clutch ECMV: Disconnection

Trouble
Failure
• When power is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
description
Action of • Stops output to transmission 1st clutch ECMV solenoid circuit.
Indication of • Auto shift-down function does not operate.
• Output to 1st clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31612 T/M Clutch 1st ECMV (F/B))
information
• Method of reproducing failure code: Start engine and set gear to F1 or R1.

Defective 1st clutch ECMV 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector 1 SOL and connect T-adapter to male side.
(Internal disconnection) Between 1 SOL (male) (1) and (2) Resistance 3 – 13 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and 1 SOL, and connect T-adapters to female side
3 of them.
connector) Between STC3 (female) (6) and 1 SOL (female) (1) Resistance Max. 1 z
Between STC3 (female) (23) and 1 SOL (female) (2) Resistance Max. 1 z
4
40-306 34 D65EX, PX, WX-16

Failure code [DXH4KB] 1st clutch ECMV: Short circuit SEN05036-01
Failure code [DXH4KB] 1st clutch ECMV: Short circuit 1
Action code Failure code 1st clutch ECMV: Short circuit

Trouble
Failure
• When power was output to transmission 1st clutch ECMV solenoid circuit, abnormal current flowed.
description
Related
information

Defective 1st clutch ECMV 2. Disconnect connector 1 SOL and connect T-adapter to male side.
1 solenoid
Between 1 SOL (male) (1) and (2) Resistance 3 – 13 z
Between 1 SOL (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and 1 SOL and connect T-adapter to female side of
ground circuit) Between STC3 (female) (6) or 1 SOL (female) (1) and
ground
2. Disconnect connectors STC3 and 1 SOL and connect T-adapter to female side of
3
harness
Between STC3 (female) (6) and (23), or between 1 SOL
4
D65EX, PX, WX-16 40-306 35

SEN05036-01 Failure code [DXH4KY] 1st clutch ECMV: Short circuit
Failure code [DXH4KY] 1st clutch ECMV: Short circuit 1
Action code Failure code 1st clutch ECMV: Short circuit

Trouble
Failure
• Current flows constantly to transmission 1st clutch ECMV solenoid circuit.
description
Related
information

Defective 1st clutch ECMV 2. Disconnect connector 1 SOL and connect T-adapter to male side.
1 solenoid
Hot short in wiring harness 2. Disconnect connector 1 SOL and connect T-adapter to female side.
Between 1 SOL (female) (1) and ground Voltage Max. 1 V
STC3.
No continuity
(No sound is heard)
3
2. Disconnect connectors STC1 to STC3 and 1 SOL, and connect T-adapters to
4
40-306 36 D65EX, PX, WX-16

Failure code [DXH5KA] 2nd clutch ECMV: Disconnection SEN05036-01
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 1
Action code Failure code 2nd clutch ECMV: Disconnection

Trouble
Failure
• When power is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
description
Action of • Stops output to transmission 2nd clutch ECMV solenoid circuit.
• Output to 2nd clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
information

Defective 2nd clutch ECMV 1. Turn starting switch to OFF position.
2
3 of them.
4
D65EX, PX, WX-16 40-306 37

SEN05036-01 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 1
Action code Failure code 2nd clutch ECMV: Short circuit

Trouble
Failure
• When power was output to transmission 2nd clutch ECMV solenoid circuit, abnormal current flowed.
description
Related
(Code: 31613 T/M Clutch 2nd ECMV (F/B))
information

Defective 2nd clutch ECMV 2. Disconnect connector 2 SOL and connect T-adapter to male side.
1 solenoid
ground
3
harness
Between STC3 (female) (16) and (13), or between
2 SOL (female) (1) and (2)
4
40-306 38 D65EX, PX, WX-16

Failure code [DXH5KY] 2nd clutch ECMV: Short circuit SEN05036-01
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit 1
Action code Failure code 2nd clutch ECMV: Short circuit

Trouble
Failure
• Current flows constantly to transmission 2nd clutch ECMV solenoid circuit.
description
Related
information

Defective 2nd clutch ECMV 2. Disconnect connector 2 SOL and connect T-adapter to male side.
1 solenoid
STC3.
3
4
D65EX, PX, WX-16 40-306 39

SEN05036-01 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 1
Action code Failure code 3rd clutch ECMV: Disconnection

Trouble
Failure
• When power is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
description
Action of • Stops output to transmission 3rd clutch ECMV solenoid circuit.
Indication of
problem on
machine
• Output to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31614 T/M Clutch 3rd ECMV (F/B))
information

Defective 3rd clutch ECMV 1. Turn starting switch to OFF position.
2
3 of them.
4
40-306 40 D65EX, PX, WX-16

Failure code [DXH6KB] 3rd clutch ECMV: Short circuit SEN05036-01
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 1
Action code Failure code 3rd clutch ECMV: Short circuit

Trouble
Failure
• When power was output to transmission 3rd clutch ECMV solenoid circuit, abnormal current flowed.
description
Indication of
problem on
machine
Related
information

Defective 3rd clutch ECMV 2. Disconnect connector 3 SOL and connect T-adapter to male side.
1 solenoid
ground
3
harness
3 SOL (female) (1) and (2)
4
D65EX, PX, WX-16 40-306 41

SEN05036-01 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit 1
Action code Failure code 3rd clutch ECMV: Short circuit

Trouble
Failure
• Current flows constantly to transmission 3rd clutch ECMV solenoid circuit.
description
Indication of
problem on
machine
Related
information

Defective 3rd clutch ECMV 2. Disconnect connector 3 SOL and connect T-adapter to male side.
1 solenoid
STC3.
3
4
40-306 42 D65EX, PX, WX-16

Failure code [DXH7KA] R clutch ECMV: Disconnection SEN05036-01
Failure code [DXH7KA] R clutch ECMV: Disconnection 1
Action code Failure code R clutch ECMV: Disconnection

Trouble
Failure
• When power is output to transmission R clutch ECMV solenoid circuit, no current flows.
description
Action of • Stops output to transmission R clutch ECMV solenoid circuit.
Indication of
problem on
• Once machine stops, travel is limited to F1.
machine
• Output to R clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31616 T/M Clutch R ECMV (F/B))
information
• Method of reproducing failure code: Start engine and set gear to R (Reverse).

Defective R clutch ECMV 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector R SOL and connect T-adapter to male side.
(Internal disconnection) Between R SOL (male) (1) and (2) Resistance 3 – 13 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and R SOL, and connect T-adapters to female side
3 of them.
connector) Between STC3 (female) (37) and R SOL (female) (1) Resistance Max. 1 z
Between STC3 (female) (13) and R SOL (female) (2) Resistance Max. 1 z
4
D65EX, PX, WX-16 40-306 43

SEN05036-01 Failure code [DXH7KB] R clutch ECMV: Short circuit
Failure code [DXH7KB] R clutch ECMV: Short circuit 1
Action code Failure code R clutch ECMV: Short circuit

Trouble
Failure
• When power was output to transmission R clutch ECMV solenoid circuit, abnormal current flowed.
description
Indication of
problem on
• Once machine stops, travel is limited to F1.
machine
Related
information

Defective R clutch ECMV 2. Disconnect connector R SOL and connect T-adapter to male side.
1 solenoid
Between R SOL (male) (1) and (2) Resistance 3 – 13 z
Between R SOL (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and R SOL and connect T-adapter to female side of
ground circuit) Between STC3 (female) (37) or R SOL (female) (1) and
ground
2. Disconnect connectors STC3 and R SOL and connect T-adapter to female side of
3
harness
R SOL (female) (1) and (2)
4
40-306 44 D65EX, PX, WX-16

Failure code [DXH7KB] R clutch ECMV: Short circuit SEN05036-01
D65EX, PX, WX-16 40-306 45

SEN05036-01 Failure code [DXH7KY] R clutch ECMV: Short circuit
Failure code [DXH7KY] R clutch ECMV: Short circuit 1
Action code Failure code R clutch ECMV: Short circuit

Trouble
Failure
• Current flows constantly to transmission R clutch ECMV solenoid circuit.
description
Indication of
problem on
• Once machine stops, machine does not travel.
machine
Related
information

Defective R clutch ECMV 2. Disconnect connector R SOL and connect T-adapter to male side.
1 solenoid
Between R SOL (male) (1) and (2) Resistance 3 – 13 z
Between R SOL (female) (1) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector R SOL and connect T-adapter to female side.
Between R SOL (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors STC3 and R SOL and connect T-adapter to female side of
STC3.
3
2. Disconnect connectors STC1 to STC3 and R SOL, and connect T-adapters to
4
40-306 46 D65EX, PX, WX-16

Failure code [DXH7KY] R clutch ECMV: Short circuit SEN05036-01
D65EX, PX, WX-16 40-306 47

SEN05036-01 Failure code [DXH8KA] F clutch ECMV: Disconnection
Failure code [DXH8KA] F clutch ECMV: Disconnection 1
Action code Failure code F clutch ECMV: Disconnection

Trouble
Failure
• When power is output to transmission F clutch ECMV solenoid circuit, no current flows.
description
Action of • Stops output to transmission F clutch ECMV solenoid circuit.
Indication of
problem on
• Once machine stops, travel is limited to R1.
machine
• Output to F clutch ECMV solenoid can be checked with monitoring function.
Related
(Code: 31622 T/M Clutch F ECMV (F/B))
information
• Method of reproducing failure code: Start engine and set gear to F (Forward).

Defective F clutch ECMV 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector F SOL and connect T-adapter to male side.
(Internal disconnection) Between F SOL (male) (1) and (2) Resistance 3 – 13 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and F SOL, and connect T-adapters to female side
3 of them.
connector) Between STC3 (female) (27) and F SOL (female) (1) Resistance Max. 1 z
Between STC3 (female) (23) and F SOL (female) (2) Resistance Max. 1 z
4
40-306 48 D65EX, PX, WX-16

Failure code [DXH8KB] F clutch ECMV: Short circuit SEN05036-01
Failure code [DXH8KB] F clutch ECMV: Short circuit 1
Action code Failure code F clutch ECMV: Short circuit

Trouble
Failure
• When power was output to transmission F clutch ECMV solenoid circuit, abnormal current flowed.
description
Indication of
problem on
• Once machine stops, travel is limited to R1.
machine
Related
information

Defective F clutch ECMV 2. Disconnect connector F SOL and connect T-adapter to male side.
1 solenoid
Between F SOL (male) (1) and (2) Resistance 3 – 13 z
Between F SOL (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and F SOL and connect T-adapter to female side of
ground circuit) Between STC3 (female) (27) or F SOL (female) (1) and
ground
2. Disconnect connectors STC3 and F SOL and connect T-adapter to female side of
3
harness
F SOL (female) (1) and (2)
4
D65EX, PX, WX-16 40-306 49

SEN05036-01 Failure code [DXH8KY] F clutch ECMV: Short circuit
Failure code [DXH8KY] F clutch ECMV: Short circuit 1
Action code Failure code F clutch ECMV: Short circuit

Trouble
Failure
• Current flows constantly to transmission F clutch ECMV solenoid circuit.
description
Indication of
problem on
• Once machine stops, machine does not travel.
machine
Related
information

Defective F clutch ECMV 2. Disconnect connector F SOL and connect T-adapter to male side.
1 solenoid
Between F SOL (male) (1) and (2) Resistance 3 – 13 z
Between F SOL (female) (1) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector F SOL and connect T-adapter to female side.
Between F SOL (female) (1) and ground Voltage Max. 1 V
2. Disconnect connectors STC3 and F SOL and connect T-adapter to female side of
STC3.
3
2. Disconnect connectors STC1 to STC3 and F SOL, and connect T-adapters to
4
40-306 50 D65EX, PX, WX-16

Failure code [DXH8KY] F clutch ECMV: Short circuit SEN05036-01
D65EX, PX, WX-16 40-306 51

SEN05036-01 Failure code [DXJ4KA] Weq lock Sol.: Disconnection
Failure code [DXJ4KA] Weq lock Sol.: Disconnection 1
Action code Failure code Work equipment lock solenoid: Disconnection

Trouble
E03 DXJ4KA (Power train controller system)
Failure
• When power is output to work equipment lock solenoid circuit, no current flows.
description
Action of • Stops output to work equipment lock solenoid circuit.
Indication of • Blade and ripper cannot be operated.
Related • Method of reproducing failure code: Turn starting switch to ON position and operate work equipment
information lock lever (Free).

Defective work equipment 1. Turn starting switch to OFF position.
1 lock solenoid 2. Disconnect connector WLK and connect T-adapter to male side.
(Internal disconnection) Between WLK (male) (1) and (2) Resistance 20 – 60 z
2
harness (Disconnection or 2. Disconnect connectors STC3 and WLK, and connect T-adapters to female side of
3 them.
connector) Between STC3 (female) (8) and WLK (female) (1) Resistance Max. 1 z
Between STC3 (female) (23) and WLK (female) (2) Resistance Max. 1 z
Hot short in wiring harness 2. Disconnect connector WLK and connect T-adapter to female side.
Between WLK (female) (1) and ground Voltage Max. 1 V
5
40-306 52 D65EX, PX, WX-16

Failure code [DXJ4KB] Weq lock Sol.: Short circuit SEN05036-01
Failure code [DXJ4KB] Weq lock Sol.: Short circuit 1
Action code Failure code Work equipment lock solenoid: Short circuit
Trouble
E03 DXJ4KB (Power train controller system)
Failure
• When power was output to work equipment lock solenoid circuit, abnormal current flowed.
description
Action of • Stops output to work equipment lock solenoid circuit.
Indication of • Blade and ripper cannot be operated.
Related • Method of reproducing failure code: Turn starting switch to ON position and operate work equipment
information lock lever (Free).

Defective work equipment 2. Disconnect connector WLK and connect T-adapter to male side.
1 lock solenoid
Between WLK (male) (1) and (2) Resistance 20 – 60 z
Between WLK (female) (1) and ground Resistance Min. 1 Mz
Ground fault of wiring 2. Disconnect connectors STC3 and WLK and connect T-adapter to female side of
ground circuit) Between STC3 (female) (8) or WLK (female) (1) and
ground
2. Disconnect connectors STC3 and WLK and connect T-adapter to female side of
3
harness
Between STC3 (female) (8) and (23), or between WLK
4
D65EX, PX, WX-16 40-306 53

SEN05036-01

©2010 KOMATSU
All Rights Reserved
40-306 54
SEN05037-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
400 Troubleshooting of electrical system

(E-mode)
Before troubleshooting of electrical system .................................................................................................... 3
Information in troubleshooting table................................................................................................................ 5
E-1 Engine does not start (starting motor does not turn) ................................................................................ 7
E-2 Preheater does not operate.................................................................................................................... 10
E-3 When starting switch is turned ON, machine monitor displays nothing.................................................. 16
E-4 When starting switch is turned ON (before starting engine), basic check item lights up ........................ 18
E-5 Precaution item lights up while engine is running .................................................................................. 20
E-6 Emergency stop item lights up while engine is running.......................................................................... 22
E-7 Engine coolant temperature gauge does not indicate normally ............................................................. 24
E-8 Fuel gauge does not indicate properly ................................................................................................... 26
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 29
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 30
E-11 Contents of display by machine monitor are different from applicable machine................................... 31
E-12 Machine monitor does not display some items .................................................................................... 31
E-13 Function switch does not work ............................................................................................................. 31
E-14 Operation mode does not change ........................................................................................................ 32
E-15 Gearshift mode does not change ......................................................................................................... 32
E-16 Customize function does not operate normally .................................................................................... 33
E-17 Customize memory function does not operate normally ...................................................................... 33
E-18 Alarm buzzer does not sound or does not stop.................................................................................... 34
E-19 When starting switch is turned OFF, service meter is not displayed .................................................... 34
D65EX, PX, WX-16 40-400 1

400 Troubleshooting of electrical system (E-mode)
SEN05037-01
E-20 Machine monitor cannot be set in service mode .................................................................................. 34

E-21 Horn does not sound or does not stop ................................................................................................. 35
E-22 Back-up alarm does not sound or does not stop .................................................................................. 36
E-23 Head lamp or rear lamp does not light up ............................................................................................ 38
E-24 Windshield wiper does not operate ...................................................................................................... 42
E-25 Window washer does not operate ........................................................................................................ 56
E-26 KOMTRAX system does not operate correctly..................................................................................... 61
40-400 2 D65EX, PX, WX-16

Before troubleshooting of electrical system SEN05037-01
Before troubleshooting of electrical system 1
Connection table of fusible link and fuse box

a This connection table shows the devices to which each power supply of fusible link and the fuse box
supplies power (An accessory power supply is a device which supplies power while the starting switch is
in the ON position and an unswitched power supply is a device which supplies power while the starting
switch is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fusible link and
and fuses to see if the power is supplied normally.
Fuse box (A)

1 20 Starting switch (B terminal)
FL2 [50 A] Unswitched 2 15 Monitor, power train controller
(FL2-4) power supply 3 30 Engine controller
4 15 Cab main circuit
5 15 Power train controller
7 5 Horn
8 5 Backup alarm
FL1 [120 A] Accessory 9 20 Electrical intake air heater, air suspension seat
(FL1-4) power supply 10 20 Spare
11 20 Head lamp
12 20 Rear lamp
13 20 Air conditioner
ACC power
— 6 5 Engine controller (ACC signal)
supply
Fuse box (B)

Unswitched
— 1 10 Radio memory
power supply
2 20 Additional lamp, rotation lamp
3 20 12 V converter
FL1 [50 A] Accessory Radio, room lamp, cigarettelighter, intermittent
4 20
(FL1-3) power supply wipper
5 10 Front wiper, rear wiper
6 10 LH and RH door wiper
Location of fusible link (FL1, FL2)
D65EX, PX, WX-16 40-400 3

SEN05037-01 Before troubleshooting of electrical system
Location of fuse and fuse No.
40-400 4 D65EX, PX, WX-16

Information in troubleshooting table SEN05037-01
Information in troubleshooting table 1
diagram. Before performing troubleshooting, understand that information fully.
Trouble Indication of problem on machine
Related
information
Probable causes • Procedure
• Measuring location
a “Between A - B” means “Measure voltage or resistance and so on between A
and B”.
• Standard value in normal condition to evaluate assumed cause if it is good condi-
tion or not.
1 Defective device or part
• Remarks required to evaluate the cause is correct
<Phenomenon of defective wiring harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness is disconnected.
harness
2 • Ground fault
A harness not connected to ground (earth) circuit contacts the ground (earth) cir-
cuit or machine.
• Hot short circuit
A harness not connected to the power (24V) circuit contacts the power (24V) cir-
cuit.
3 harness
• Short circuit
An independent wire in the harness abnormally contacts another wire.
(Defective insulation in connector or others.)
<Notes on troubleshooting>
4 (1) How to indicate connector number and handle T-branch
(Contact with 24V circuit)
For troubleshooting, insert or connect T-branch adapter as follows unless
• When “male” or “female” is not indicated with a connector number, discon-
nect the connector, and insert T-branch adapter in both male and female.
Short circuit in wiring • When “male” or “female” is indicated with a connector number, disconnect
5
harness the connector, and connect T-branch adapter only to either male or female
end.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect plus (+) and minus (–) leads as follows unless
6 Defective controller • Connect the plus (+) lead to a pin or harness indicated in the front.
• This is the excerpted circuit diagram related to troubleshooting.

• Connector No.: Indicates (model – number of pins) (color)
• Indication of “Connector No. and Pin No.” from the branch or junction point:
Indicates the branch destination or the splice location in the same harness
• Arrow ( ): Indicates the approximate mounting place on machine
• NO: Normally Open
• NC: Normally Closed
a See “Electrical circuit diagram” in chapter 90 for branch label in wiring harness.
D65EX, PX, WX-16 40-400 5

SEN05037-01 Information in troubleshooting table
40-400 6 D65EX, PX, WX-16

E-1 Engine does not start (starting motor does not turn) SEN05037-01
E-1 Engine does not start (starting motor does not turn) 1
Trouble Starting motor does not rotate and engine does not start
• Since the engine start circuit has the neutral safety function, the engine does not start unless the
work equipment lock lever and parking brake lever are in the lock position and the travel lever is in
the neutral position.
• Since KOMTRAX has the start lock function, the engine cannot be started unless the start lock func-
Related tion is canceled.
information • Before starting the troubleshooting, validate that the related failure code is not displayed.
(If the failure code [D110KB], [D130KA], [D130KB], [DD14KA] or [DD14KB] is displayed, trouble-
shoot them first.)
• In the case of “the battery relay does not make operating sound” when turning the starting switch
ON, perform E-1 also.

1
FS12-1 troubleshoot cause 10 first.
2
disconnection at terminal Check terminals of battery relay, alternator, starting motor, ground, ground 03 etc.
Battery voltage Min. 24 V
3 Insufficient battery capacity
Battery specific gravity Min. 1.26
Defective parking lever 1. Turn starting switch to ON position.
switch 2. Operate parking lever and troubleshoot.
4
(Internal defect or defective “P” display on machine Free position Other than “P” is displayed.
adjustment) monitor. Lock position “P” is displayed.
Defective work equipment 2. Operate work equipment lock lever and troubleshoot.
lock lever switch (Internal Symbol
5 Free position
disconnection or short “work equipment lock” symbol on lights off
circuit) machine monitor Symbol
Lock position
lights on
3. Disconnect connector KEY and connect T-adapter to male side.
4. Turn starting switch to ON, OFF and START positions and troubleshoot.
OFF Resistance Min. 1 Mz
6 Defective starting switch Between KEY (male) (1) and (5)
ON Resistance Max. 1 z
Between KEY (male) (3) and (5)
START Resistance Max. 1 z
START Resistance Max. 1 z
Defective neutral safety
2. Replace the neutral safety relay (NSF) with another one.
7 relay
3. Start the engine.
(Internal disconnection)
If the engine starts, the original neutral safety relay is defective.
Defective alternator 1. Turn starting switch to ON position.
8
(Internal short circuit) Terminal AL/R and ground Voltage Max. 12 V
2. Start the engine and troubleshoot.
Electric power supply: between terminal B and ground Voltage 20 – 30 V
Detective starting motor
9 Charge: between ST (2) and ground Voltage Max. 12 V
(Internal defect)
Starting: between ST (1) and ground Voltage 20 – 30 V
When each voltage of electric power supply, charging, and starting is normal but the
starting motor does not rotate, the starting motor is defective.
D65EX, PX, WX-16 40-400 7

SEN05037-01 E-1 Engine does not start (starting motor does not turn)

2. Remove connector RSD and connect T-adapter to diode.
a Measure in diode range of tester.
Defective diode RSD Between RSD (male) (5) (+) and (1) (–) Continues
10 (Internal disconnection or Between RSD (male) (2) (+) and (6) (–) No continuity
short circuit) Between RSD (male) (6) (+) and (2) (–) Continues
Between RSD (male) (7) (+) and (3) (–) Continues
Between RSD (male) (8) (+) and (4) (–) Continues
• Battery relay
Between terminal BRE and ground Resistance Max. 1 z
• Battery relay
3. Insert T-adapter into connector RSD.
Between RSD (5) or (6) and ground Voltage 20 – 30 V
Between RSD (1) or (3) and ground Voltage 20 – 30 V
Between terminal BRSW and ground Voltage 20 – 30 V
Between terminal BRC and ground Voltage 20 – 30 V
Disconnection of wiring • Alternator and starting motor
harness
3. Insert T-adapters into connectors KEY, NSF and ST.
5. Turn starting switch to START position and perform troubleshooting.
Between KEY (5) and ground Voltage 20 – 30 V
Between KEY (3) and ground Voltage 20 – 30 V
Between NSF (1) and ground Voltage 20 – 30 V
Between NSF (2) and ground Voltage Max. 1 V
Between ST (1) and ground Voltage 20 – 30 V
Between terminal AL/B and ground Voltage 20 – 30 V
Between terminal ST/B and ground Voltage 20 – 30 V
Defective battery relay If battery relay check result of cause 11 is normal and battery relay operation sound
12
(It does not turn ON) is not heard, battery relay is defective.
Ground fault of wiring 2. Disconnect ground cable.
13 harness (Contact with 3. Disconnect connectors KEY, NSF, STC1, CM01 and ST.
ground circuit) Between KEY (5) and ground Resistance Min. 1 Mz
Between KEY (3) or NSF (3) and ground Resistance Min. 1 Mz
Between NSF (5) or ST (1) and ground Resistance Min. 1 Mz
2. Disconnect terminal AL/R.
Between terminal AL/R (Wiring harness side) and
Voltage Max. 1 V
terminal AL/E
40-400 8 D65EX, PX, WX-16

E-1 Engine does not start (starting motor does not turn) SEN05037-01
D65EX, PX, WX-16 40-400 9

SEN05037-01 E-2 Preheater does not operate
E-2 Preheater does not operate 1
Trouble 1) Manual preheater does not operate.

a This troubleshooting describes the procedures to be followed when manual preheating does not
function to heat the electrical intake air heater mounting section.
• For preheating, both the “Automatic preheating function” and “Manual preheating function” are
available. When either function is performed, the preheating lamp lights up.
(When only the preheating does not light up, troubleshoot “3) While the preheater is operating, the
Related preheating monitor does not light up”)
information • If “the monitor panel does not light up” or “the battery relay does not make operating sound” when
turning the starting switch ON, the main electric power supply system is supposed to be defective.
So, troubleshoot E-3 and E-1.
• Before starting the troubleshooting, validate that the related failure code is not displayed.
(If the failure code [CA153], [CA154], [CA2555], [CA2556] or [D110KB] is displayed, firstly perform
these troubleshooting.)

If fuse FS12-1 is broken, circuit probably has ground fault. In this case, troubleshoot
1 Defective fuse FL2-1
cause 6 first.
2
disconnection at terminal Check terminals of heater relay, battery relay, etc.
Defective diode HTD 2. Remove connector HTD and connect T-adapter to diode.
3 (Internal disconnection or a Measure in diode range of tester.
short circuit) Between HTD (male) (1) (+) and (2) (–) No continuity
Between HTD (male) (2) (+) and (1) (–) Continues
Defective electrical intake air 1. Turn starting switch to OFF position.
4 heater 2. Disconnect terminal HT/A.
(Internal disconnection) Between terminal HT/A and ground Continues
5 Defective starting switch 4. Turn starting switch to ON and HEAT positions and troubleshoot.
HEAT Resistance Max. 1 z
2. Disconnect connectors KEY and CM01, and connect T-adapter to female side of
KEY.
Between KEY (female) (2) and ground Continues
Disconnection in or ground 1. Turn starting switch to OFF position.
6
fault of wiring harness 2. Turn starting switch to ON position.
Between terminal HT/B and ground Voltage 20 – 30 V
1. Turn starting switch to HEAT position (Connect R1).
a Check within 30 seconds after turning starting switch to HEAT position.
Between terminal HT/C and ground Voltage 20 – 30 V
Ground fault of wiring 2. Disconnect connectors KEY and CM01 and terminals HT/C and BRC.
Between terminal HT/B and ground Resistance Min. 1 Mz
ground circuit)
Between terminal HT/C (Wiring harness side) and
ground
Defective heater relay If cause 6 is not the cause for the trouble and heater relay operation sound is not
8
(It does not turn ON) heard, heater relay is defective.
40-400 10 D65EX, PX, WX-16

E-2 Preheater does not operate SEN05037-01
D65EX, PX, WX-16 40-400 11

Trouble 2) Automatic preheater does not operate.

• Automatic preheater operates when intake air (boost) temperature is below –5°C.
Related
• If automatic preheater does not operate, check if manual preheater operates.
information
• Engine controller troubleshoots primary (coil) side of preheater relay by failure codes [CA2555] and
[CA2556].

cause 5 first.
2. Replace preheater relay (connector: PHR) with backup alarm relay (connector:
Defective preheater relay
BKA).
2 (Internal disconnection or 3. Turn starting switch to ON position.
short circuit)
If automatic preheater operates when intake air (boost) temperature is below –5°C,
original preheater relay is defective.
3
in wiring harness below 1 Mz, wiring harness has short circuit.
a Preheater relay coil resistance.
Between CE02 (female) (40) and ground Resistance 300 – 600 z
2. Disconnect connectors PHR and CM01, and connect T-adapter to female side of
Disconnection in wiring PHR.
4 harness (Disconnection or 3. Remove fuse FS12-9.
defective contact)
Between PHR (female) (5) and ground Continues
Between PHR (female) (3) and FS12-9 Resistance Max. 1 z
Ground fault of wiring 2. Disconnect connectors PHR and CM01, and connect T-adapter to female side of
PHR.
ground circuit)
3. Remove fuse FS12-9.
Between PHR (female) (3) and ground Resistance Min. 1 Mz
40-400 12 D65EX, PX, WX-16

Trouble 3) While the preheater is operating, the preheating monitor does not light up.
Related • For preheating, there are two functions, that is, the “Automatic preheating function” and “Manual
information preheating function”. When either preheating is performed, the preheating monitor lights up.

Disconnection in wiring 2. Disconnect connectors PHR, KEY and CM01, and connect T-adapters to female
1 harness (Disconnection or side of them.
defective contact) Between PHR (female) (5) and CM01 (female) (16) Resistance Max. 1 z
Between KEY (female) (2) and CM01 (female) (16) Resistance Max. 1 z
Ground fault of wiring 2. Disconnect connectors PHR, CM01 and terminal HT/C, and connect T-adapter to
female side of CM01.
ground circuit)
Between CM01 (female) (16) and ground Resistance Min. 1 Mz
If cause not found by above checks, machine monitor is defective.
2. Insert T-adapter into connector CM01.
3 Defective machine monitor 3. Disconnect terminal HT/A.
a Disconnect so that current will not flow in heater when starting switch is turned to
HEAT position.
4. Turn starting switch to HEAT position.
D65EX, PX, WX-16 40-400 13

40-400 14 D65EX, PX, WX-16

D65EX, PX, WX-16 40-400 15

SEN05037-01 E-3 When starting switch is turned ON, machine monitor displays nothing
E-3 When starting switch is turned ON, machine monitor displays

nothing 1
Trouble • When starting switch is turned ON, machine monitor displays nothing.
• When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen of check before starting, screen to check setting of preset, and ordinary screen
in order.
Related • When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
information perature and the condition of the battery. In this case, the machine monitor goes off for a moment.
This phenomenon is not a failure, however.
• If “the battery relay does not make operating sound” when the starting switch is turned on, perform
E-1.

Defective fuse FL2-2, FS12- If fuse FL2-2, FS12-1 or FS12-2 is broken, circuit probably has ground fault. In this
1
1 or FS12-2 case, troubleshoot cause 8 first.
2
disconnection at terminal Check terminals of battery, battery relay, etc.
Battery voltage (2 pieces) Min. 24 V
3 Insufficient battery capacity
Battery electrolyte specific gravity Min. 1.26
a If machine monitor has not been replaced, this check is not required.
Wrong connection of wiring 1. Turn starting switch to OFF position.
4 harness (Numbers of pins of 2. Remove machine monitor.
CM01 and CM03 are same) Check that connectors CM01 (white) and CM03 (green) are matched to connector
colors of machine monitor unit.
Disconnection in or ground a If voltage is 0 V, wiring harness has disconnection or ground fault.
5 fault of wiring harness or Between CM01 (female) (1) and (3) Voltage 20 – 30 V
defective starting switch
Between CM01 (female) (2) and (4) Voltage 20 – 30 V
5. Turn starting switch to ON position (Connect ACC).
Between CM01 (female) (14) and (4) Voltage 20 – 30 V
6 Defective starting switch 4. Turn starting switch to ON and OFF positions and perform troubleshooting.
OFF No continuity Min. 1 Mz
OFF No continuity Max. 1 z
Disconnection in wiring Between CM01 (female) (3), (4) and ground
7 harness (Disconnection or Resistance Max. 1 z
a Check loose and rust at terminal GND11.
defective contact)
Between CM01 (female) (1), (2) and battery (+) Resistance Max. 1 z
5. Turn starting switch to ON position (Connect ACC with ground cable
disconnected).
Between CM01 (female) (14) and battery (+) Resistance Max. 1 z
40-400 16 D65EX, PX, WX-16

E-3 When starting switch is turned ON, machine monitor displays nothing SEN05037-01

8 harness (Contact with 4. Disconnect connector CM01 and connect T-adapter to female side.
ground circuit)
a Check that condition is normal when starting switch is turned to ON position (con-
necting ACC with ground cable disconnected).
9 Defective machine monitor a If cause is not found by the above checks, machine monitor is defective.
D65EX, PX, WX-16 40-400 17

SEN05037-01 E-4 When starting switch is turned ON (before starting engine), basic check item lights up
E-4 When starting switch is turned ON (before starting engine), basic

check item lights up 1
Trouble • When starting switch is turned ON (before starting engine), basic check item lights up.
• Basic check item is only water separator monitor.
Related (When water level in water separator goes up)
information • Water detection condition in water-in-fuel sensor can be checked in monitoring function.
(Code: 18800 Water in Fuel)

Rise of water level in water
1 separator (When system is Water level in water separator may be up. Check it and drain the water if necessary.
normal)
Defective water-in-fuel If cause 1 is not detected, water-in-fuel sensor system may be defective. Perform
2
sensor system troubleshooting for failure codes [CA144] and [CA145] about water-in-fuel sensor.
If causes 1 and 2 are not detected, machine monitor may be defective.
40-400 18 D65EX, PX, WX-16

E-4 When starting switch is turned ON (before starting engine), basic check item lights up SEN05037-01
D65EX, PX, WX-16 40-400 19

SEN05037-01 E-5 Precaution item lights up while engine is running
E-5 Precaution item lights up while engine is running 1
Trouble • Precaution item lights up while engine is running.

• Check item is only charge level monitor.
Related
• State of generation signal of alternator can be checked with monitoring function.
information
(Code: 04300 Battery Charge Volt)

1
disconnection at terminal Check terminals of alternator etc.
Defective alternator 1. Turn starting switch to OFF position.
2 (insufficient power 2. Start engine and troubleshoot while running engine at medium speed or higher.
generation) Between terminal AL/R and ground Voltage 20 – 30 V
Disconnection in wiring 3. Disconnect connectors CM01 and RSD, and connect T-adapter to female side of
3 harness (Disconnection or CM01.
defective contact) 4. Disconnect terminal AL/R.
Between CM01 (female) (11) and terminal R Resistance Max. 1 z
Between terminal AL/E and GND3 (ground) Resistance Max. 1 z
3. Disconnect connectors CM01, RSD, STC1 and ST, and connect T-adapter to
4 harness (Contact with female side of CM01.
ground circuit)
4. Disconnect terminal AL/R.
a If cause is not found by the above checks, machine monitor is defective.
5 Defective machine monitor 3. Insert T-adapter into connector CM01.
5. Start engine and perform troubleshoot while running engine at medium speed or
higher.
40-400 20 D65EX, PX, WX-16

E-5 Precaution item lights up while engine is running SEN05037-01
D65EX, PX, WX-16 40-400 21

SEN05037-01 E-6 Emergency stop item lights up while engine is running
E-6 Emergency stop item lights up while engine is running 1
Trouble 1) Engine coolant temperature monitor lights up.

• Signal voltage of engine coolant temperature sensor is input to engine controller and then the data
Related is transmitted to machine monitor through CAN communication system.
information • Engine coolant temperature can be checked with monitoring function.

Overheating of engine
1 coolant (when system is Engine coolant may be overheated. If it is overheated, remove cause.
normal)
Defective engine coolant If cause 1 is not detected, engine coolant temperature sensor system may be
2
temperature sensor system defective. Perform troubleshooting for failure codes [CA144] and [CA145].
Trouble 2) Engine oil pressure monitor lights up.

• Engine oil pressure switch signal (ON/OFF) is not monitored.
Related
• If engine oil pressure switch is turned ON while engine is running, the signal is transmitted as failure
information
code [B@BAZG] from engine controller to machine monitor by CAN communication.

Lowering of engine oil
Check the engine oil pressure as the drop of engine oil pressure is detected.
1 pressure (when system is
• Perform the troubleshooting for “S-12 The oil pressure drops.”
normal)
When the possible cause 1 is not the real cause, the engine oil pressure switch
Defective engine oil
2 circuit is supposed to be defective. So, perform troubleshooting for “Failure code
pressure sensor system
[CA435] Abnormal engine oil pressure switch.”
Trouble 3) Power train oil temperature monitor lights up.

• Signal voltage of torque converter oil temperature sensor is input to power train controller and then
Related
the data is transmitted to machine monitor through CAN communication system.
information
• Power train oil temperature can be checked with monitoring function.

Overheating of power train
1 Power train oil may be overheated. If it is overheated, remove cause.
oil (when system is normal)
Defective power train oil If cause 1 is not detected, power train oil temperature sensor system may be
2
temperature sensor system defective. Perform troubleshooting for failure codes [DGT1KA] and [DGT1KX].
40-400 22 D65EX, PX, WX-16

E-6 Emergency stop item lights up while engine is running SEN05037-01
Trouble 4) Hydraulic oil temperature monitor lights up.

Related • Hydraulic oil temperature can be checked with monitoring function.
information (Code: 04401 Hyd Oil Temperature)

Overheating of hydraulic oil
1 Hydraulic oil may be overheated. If it is overheated, remove cause.
(when system is normal)
Defective hydraulic oil
If cause 1 is not detected, hydraulic oil temperature sensor system or machine
2 temperature gauge system
monitor may be defective. Perform troubleshooting for failure code [DGS1KX].
or machine monitor
D65EX, PX, WX-16 40-400 23

SEN05037-01 E-7 Engine coolant temperature gauge does not indicate normally
E-7 Engine coolant temperature gauge does not indicate normally 1
1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).

Defective engine coolant Engine coolant temperature sensor system may be defective.
1
temperature sensor system Perform troubleshooting for failure codes [CA144] and [CA145].
If cause 1 is not detected, machine monitor may be defective.
3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble 4) Display of engine coolant temperature gauge is different from display of engine coolant tempera-
ture monitor.

a Turn starting switch ON or start engine and troubleshoot.
Engine coolant Coolant temperature
Color of monitor light (a)
temperature gauge level
105°C 6
Red
1 Defective machine monitor 102°C 5
100°C 4
85°C 3
Blue
60°C 2
30°C 1
Engine coolant temperature gauge and coolant temperature monitor
40-400 24 D65EX, PX, WX-16

E-7 Engine coolant temperature gauge does not indicate normally SEN05037-01
D65EX, PX, WX-16 40-400 25

SEN05037-01 E-8 Fuel gauge does not indicate properly
E-8 Fuel gauge does not indicate properly 1
Trouble 1) Fuel gauge does not indicate properly.

Related • The input state (voltage signal) from the fuel level sensor can be checked in monitoring function.
information (Code: 04200 Fuel level sensor volt)

Defective fuel level sensor 2. Disconnect connector FLV and connect T-adapter to male side.
1 (Internal disconnection or Between FLV (male) (1) and (2) FULL Resistance Approx. 4 z
short circuit) a Fuel level sensor characteristics EMPTY Resistance Approx. 85 z
Between FLV (male) (2) and ground Resistance Max. 1 z
2. Disconnect connector FLV and connect T-adapter to female side.
of wiring harness a Voltage of approx. 3.3 V is applied to fuel level sensor signal lines through resistor
inside power train controller.
Approx.
Between FLV (female) (1) and (2) Voltage
3.3 V
Disconnection or short circuit a Resistance accords with fuel level sensor characteristics table in cause 1.
3
Approx.
4 – 85 z
Disconnection in wiring 2. Disconnect connectors CM01 and FLV, and connect T-adapters to female side of
defective contact)
Between CM01 (female) (9) and FLV (female) (1) Resistance Max. 1 z
Between CM01 (female) (12) and FLV (female) (2) Resistance Max. 1 z
Ground fault of wiring 2. Disconnect connectors CM01 and FLV, and connect T-adapter to female side of
either of them.
ground circuit)
Between CM01 (female) (9) or FLV (female) (1) and
ground
2. Disconnect connectors CM01 and FLV, and connect T-adapter to female side of
Short circuit in wiring CM01.
harness
No continuity
Between CM01 (female) (9) and each pin other than (9)
(No sound is heard)
7 Defective machine monitor a If cause is not found by the above checks, machine monitor is defective.
40-400 26 D65EX, PX, WX-16

E-8 Fuel gauge does not indicate properly SEN05037-01
D65EX, PX, WX-16 40-400 27

SEN05037-01 E-8 Fuel gauge does not indicate properly
2) Display of fuel level gauge is different from actual fuel level.

Trouble
3) Display of fuel level gauge is different from display of fuel level monitor.
Related • Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel Level Sensor Volt)

Quantity of fuel Reading of fuel level gauge Color of monitor light (a)
376 l 6
297 l 5
219 l 4
Blue
140 l 3
102 l 2
Max. 61 l 1
Fuel level gauge and fuel level monitor
40-400 28 D65EX, PX, WX-16

E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally SEN05037-01
E-9 Power train oil temperature gauge (multi-gauge) does not indicate
normally 1
1) While power train oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
2) While power train oil temperature is stabilized normally, temperature gauge rises to red range (H).
• Signal voltage of power train oil temperature sensor is input to power train controller and then the
Related
data is transmitted to machine monitor through CAN communication system.
information
• Torque converter (power train) oil temperature can be checked with monitoring function.

Defective power train oil Power train oil temperature sensor system may be defective.
1
temperature sensor system Perform troubleshooting for failure codes [DGT1KA] and [DGT1KX].
3) Display of power train temperature gauge is different from actual power train oil temperature.
Trouble 4) Display of power train oil temperature gauge is different from display of power train oil temperature
monitor.
• Signal voltage of power train oil temperature sensor is input to power train controller and then the
Related
data is transmitted to machine monitor through CAN communication system.
information
• Torque converter (power train) oil temperature can be checked with monitoring function.

Power train oil
Power train oil temperature Color of monitor light (a)
temperature gauge level
130°C 6
Red
118°C 4
90°C 3
Blue
50°C 2
0°C 1
Power train oil temperature gauge and power train oil temperature monitor
D65EX, PX, WX-16 40-400 29

SEN05037-01 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate

normally 1
1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).

Perform troubleshooting for failure code [DGS1KX].
3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble 4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.

Reading of hydraulic oil
Hydraulic oil temperature Color of monitor light (a)
temperature gauge
105°C 6
Red
98°C 4
70°C 3
Blue
20°C 2
0°C 1
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
40-400 30 D65EX, PX, WX-16

E-11 Contents of display by machine monitor are different from applicable machine SEN05037-01
E-11 Contents of display by machine monitor are different from

applicable machine 1
Trouble • Contents of display by machine monitor are different from applicable machine.
Related
information

Machine monitor may be defective.
E-12 Machine monitor does not display some items 1
Trouble • Machine monitor does not display some items.

• The LCD panel sometimes has black points (points which are not lighted) and bright points (points
Related
which do not go off) for the reason of its characteristics. If the number of the bright points and black
information
points does not exceed 10, those points are not a failure or a defect.

a Turn starting switch ON and troubleshoot.
Defective machine monitor When following switches are operated, if all LCD panel is lighted up (all surface
1
(LCD panel) becomes white), LCD panel is normal.
• Operation of switches: [4] + [F2] (Press simultaneously)
Defective machine monitor If cause 1 is not detected, machine monitor may be defective.
2
(body) (Since trouble is in system, troubleshooting cannot be performed.)
E-13 Function switch does not work 1
Trouble • Function switch does not work.

Related
information

D65EX, PX, WX-16 40-400 31

SEN05037-01 E-14 Operation mode does not change
E-14 Operation mode does not change 1
Trouble 1) When operation mode switch is operated, display of operation mode monitor does not change.
Related • Check that related failure codes are not displayed and troubleshoot.
information (If failure codes [DAFRMC] and/or [DB2RKR] are displayed, troubleshoot them first.)

Trouble 2) When operation mode is changed, engine output is not changed.

• Engine output mode recognized by engine controller can be checked with monitoring function.
Related (Code: 17500 Engine Power Mode)
information • Check that related failure codes are not displayed and troubleshoot.
(If failure codes [DAFRMC] and/or [DB2RKR] are displayed, troubleshoot them first.)

Engine controller may be defective.
E-15 Gearshift mode does not change 1
Trouble 1) When gearshift mode switch is operated, display of speed mode section does not change.
• Check that related failure codes are not displayed and troubleshoot.
Related
(If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed, trou-
information
bleshoot them first.)

Trouble 2) When gearshift mode is changed, gearshift setting of power train is not changed.
• Check that related failure codes are not displayed and troubleshoot.
Related
(If failure codes [DAFRMC], [DK40KA], [DK40KB], [DLT3KA] and/or [DLT3KB] are displayed, trou-
information
bleshoot them first.)

Defective power train Power train controller may be defective.
2
40-400 32 D65EX, PX, WX-16

E-16 Customize function does not operate normally SEN05037-01
E-16 Customize function does not operate normally 1
Trouble 1) When customize switch is operated, customize screen is not displayed.

Related
information

Trouble 2) When setting is changed on customize screen, setting of machine is not changed.
Related
information

Defective engine controller
Engine controller or power train controller may be defective.
2 or defective power train
controller
E-17 Customize memory function does not operate normally 1
Trouble 1) When customize memory switch is operated, customize memory screen is not displayed.
Related
information

Trouble 2) When selection is changed on customize memory screen, setting of machine is not changed.
Related
information

Defective engine controller
Engine controller or power train controller may be defective.
2 or defective power train
controller
D65EX, PX, WX-16 40-400 33

SEN05037-01 E-18 Alarm buzzer does not sound or does not stop
E-18 Alarm buzzer does not sound or does not stop 1
Trouble • Alarm buzzer does not sound or does not stop.

Related
information

E-19 When starting switch is turned OFF, service meter is not displayed1
Trouble • When starting switch is turned OFF, service meter is not displayed.
• While starting switch is at OFF position, if following switches are operated, service meter is dis-
Related
played at top center of screen.
information
• Operation of switches: [4] + [1] (Press simultaneously)

When starting switch is turned ON, if machine monitor displays nothing, backup
Defective backup power
1 power supply system may be defective. In this case, perform troubleshooting for “E-3
supply system
When starting switch is turned ON, machine monitor displays nothing”.
E-20 Machine monitor cannot be set in service mode 1
Trouble • Machine monitor cannot be set in service mode.

Related • If following switches are operated, machine monitor is set in service mode.
information • Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order)

40-400 34 D65EX, PX, WX-16

E-21 Horn does not sound or does not stop SEN05037-01
E-21 Horn does not sound or does not stop 1
Trouble • Horn does not sound or does not stop.

• Troubleshoot for causes 1 – 7 and 9, when horn does not sound and for causes 2, 8 and 9 when
Related horn does not stop.
information • Troubleshooting at connector HRN (female) does not perform but perform at connector PRT
because T-adapter for connector HRN is not prepared.

cause 6 first.
2. Disconnect horn switch terminals (No polarity).
2 Defective horn switch 3. Turn horn switch ON/OFF and troubleshoot.
Between horn switch terminals
2. Disconnect connector PRT and connect T-adapter to female side.
3 Defective wiring harness 3. Turn starting switch to ON position.
4. Turn horn switch ON.
Between PRT (female) (3) and ground Voltage 20 – 30 V
Disconnection in wiring 2. Remove fuse FS12-7.
4
harness or horn 3. Turn horn switch ON.
Between FS12-7 and ground Continues
5 Disconnection in horn
2. Disconnect connector HRN.
Between HRN and ground Continues
If check of cause 4 is abnormal and check of cause 5 is normal, wiring harness is
disconnected.
defective contact)
2. Disconnect connector HRN and insert T-adapter into PRT.
3. Remove fuse FS12-7
ground circuit)
4. Turn horn switch ON.
Between PRT (female) (3) and ground Resistance Min. 1 Mz
Hot short in wiring harness 2. Disconnect connector HRN and insert T-adapter into PRT.
8
Between PRT (3) and ground Voltage Max. 1 V
Defective horn (Internal
9 If the cause cannot be found by above checks, horn may be defective.
defect)
D65EX, PX, WX-16 40-400 35

SEN05037-01 E-22 Back-up alarm does not sound or does not stop
E-22 Back-up alarm does not sound or does not stop 1
Trouble 1) Back-up alarm does not sound.

• When a failure occurs on the primary side (coil side) of the back-up alarm relay, relevant failure
Related
codes [D161KA], [D161KB] are displayed, but in case of failure on the secondary side (contact
information
side), no failure code is displayed.

cause 6 first.
Defective backup alarm 2. Replace backup alarm relay (connector: BKA) with another relay.
2 relay (Internal disconnection 3. Turn starting switch to ON position.
or short circuit) 4. Perform reverse travel operation.
If backup alarm sounds, original backup alarm relay is defective.
2. Disconnect connector BKAL and connect T-adapter to female side.
3 Defective wiring harness 3. Turn starting switch to ON position.
4. Perform reverse travel operation.
Between BKAL (1) and (2) Voltage 20 – 30 V
4 2. Disconnect connector BKA and connect T-adapter to female side.
harness or backup alarm
Between BKA (female) (5) and ground Continues
Disconnection in wiring 3. Disconnect connectors BKA and BKAL and connect T-adapters to female side of
defective contact) Between BKA (female) (5) and BKAL (female) (1) Resistance Max. 1 z
Between BKAL (female) (2) and ground Resistance Max. 1 z
Between BKA (female) (1), (3) and FS12-8 Resistance Max. 1 z
Ground fault of wiring 2. Remove fuse FS12-8.
6 harness (Contact with 3. Disconnect connectors BKA and BKAL and connect T-adapter to female side of
ground circuit) either of them.
Between BKA (female) (1) or (3) and ground Resistance Min. 1 Mz
Between BKA (female) (5) and ground Resistance Min. 1 Mz
Defective back-up alarm
7 If cause cannot be found by above checks, back-up alarm may be defective.
(Internal defect)
40-400 36 D65EX, PX, WX-16

E-22 Back-up alarm does not sound or does not stop SEN05037-01
Trouble 2) Back-up alarm does not stop.

Related
information

Defective backup alarm 2. Replace backup alarm relay (connector: BKA) with another relay.
1 relay (Internal disconnection a The above can be checked with backup alarm relay removed only.
or short circuit) 3. Turn starting switch to ON position.
If backup alarm stops, original backup alarm relay is defective.
Hot short in wiring harness 2. Disconnect connector BKAL and connect T-adapter to female side.
2
(Contact with 24 V circuit) Between BKAL (female) (1) and (2) Voltage Max. 1 V
Between BKAL (female) (1) and ground Voltage Max. 1 V
Defective back-up alarm
3 If cause cannot be found by above checks, back-up alarm may be defective.
(Internal defect)
D65EX, PX, WX-16 40-400 37

SEN05037-01 E-23 Head lamp or rear lamp does not light up
E-23 Head lamp or rear lamp does not light up 1
Trouble 1) Head lamp does not light up.

• If head lamp relay, head lamp switch, diode and left-and-right common wiring harness of head
Related lamps is defective, both of left-and-right head lamps don't light up (If either of head lamps light up,
information this check is not required).
• See Trouble 2) for related circuit diagram.

Defective head lamp
1 Since the head lamp may be defective, check its bulb for breakage.
(Breakage of bulb)
Defective fuse
2 If the fuse is broken, the circuit probably has a ground fault, etc.
(FLI-4, FS12-11)
Defective head lamp relay 2. Replace relay (connector: FLP) with backup alarm relay (connector: BKA).
short circuit) 4. Turn head lamp switch to ON position.
If head lamp lights up, original head lamp relay is defective.
2. Disconnect connector FLSW and connect T-adapter to male side.
3. Turn head lamp switch to ON/OFF positions, and troubleshoot.
4 Defective head lamp switch a ON position is located in both directions.
Between FLSW (male) (5) and (6)
2. Remove connector DIODE and connect T-adapter to diode.
Defective diode DIODE a Measure in diode range of tester.
5 (Internal disconnection or Between DIODE (male) (3) (+) and (7) (–) No continuity
short circuit) Between DIODE (male) (7) (+) and (3) (–) Continues
Between DIODE (male) (2) (+) and (6) (–) No continuity
Between DIODE (male) (6) (+) and (2) (–) Continues
a Check the location where voltage abnormality occurs and locate defective point of
wiring harness.
2. Disconnect connectors LHDR and LHDL, and connect T-adapters to female side
of them.
4. Turn head lamp switch to ON position.
Between LHDL (female) (1) and (2) Voltage 20 – 30 V
Between LHDR (female) (1) and (2) Voltage 20 – 30 V
a If no failure is detected by above checks, this check is not required.
Disconnection in or ground
fault of wiring harness 2. Disconnect connector FLP and connect T-adapter to female side.
4. Turn head lamp switch to ON position.
Between FLP (female) (1) and (2) Voltage 20 – 30 V
Between FLP (female) (3) and (2) Voltage 20 – 30 V
2. Disconnect connector FLSW and connect T-adapter to female side.
Between FLSW (female) (5) and (2) Voltage 20 – 30 V
40-400 38 D65EX, PX, WX-16

E-23 Head lamp or rear lamp does not light up SEN05037-01

3. Disconnect connectors FLSW, DIODE, FLP, LHDR, LHDL and KEY, and connect
T-adapters to female side of them.
Between LHDR (female) (2) and ground Resistance Max. 1 z
Between LHDL (female) (2) and ground Resistance Max. 1 z
Disconnection in wiring Between LHDR (female) (1) and FLP (female) (5) Resistance Max. 1 z
7 harness (Disconnection or Between LHDL (female) (1) and FLP (female) (5) Resistance Max. 1 z
defective contact)
Between FLP (female) (1) and DIODE (female) (2), (3) Resistance Max. 1 z
Between FLP (female) (2) and ground Resistance Max. 1 z
Between FLP (female) (3) and FS12-11 Resistance Max. 1 z
Between FLSW (female) (6) and DIODE (female) (6) Resistance Max. 1 z
Between FLSW (female) (4) and DIODE (female) (7) Resistance Max. 1 z
Between FLSW (female) (5) and KEY (female) (1) Resistance Max. 1 z
Between FLSW (female) (2) and ground Resistance Max. 1 z
Ground fault of wiring 3. Disconnect connectors DIODE, FLP, LHDR and LHDL, and connect T-adapter to
8 harness female side of FLP.
(Contact with ground circuit) Between FLP (female) (1) and ground Resistance Min. 1 Mz
Between FLP (female) (3) and ground Resistance Min. 1 Mz
Between FLP (female) (5) and ground Resistance Min. 1 Mz
D65EX, PX, WX-16 40-400 39

SEN05037-01 E-23 Head lamp or rear lamp does not light up
Trouble 2) Rear lamp does not light up.

Related
information

Defective rear lamp
1 Since the rear lamp may be defective, check its bulb for breakage.
(Breakage of bulb)
Defective fuse
2 If the fuse is broken, the circuit probably has a ground fault, etc.
(FLI-4, FS12-12)
Defective rear lamp relay 2. Replace relay (connector: RLP) with backup alarm relay (connector: BKA).
short circuit) 4. Turn rear lamp switch to ON position.
If rear lamp lights up, original rear lamp relay is defective.
2. Disconnect connector RLSW and connect T-adapter to male side.
3. Turn rear lamp switch to ON/OFF positions, and troubleshoot.
4 Defective rear lamp switch a ON position is located in both directions.
Between RLSW (male) (5) and (6)
a Check the location where voltage abnormality occurs and locate defective point of
wiring harness.
2. Disconnect connectors LREL, and connect T-adapter to female side.
4. Turn rear lamp switch to ON position.
Between LREL (female) (1) and (2) Voltage 20 – 30 V
Disconnection in or ground 2. Disconnect connector RLP and connect T-adapter to female side.
5
fault of wiring harness 3. Turn starting switch to ON position.
4. Turn rear lamp switch to ON position.
Between RLP (female) (1) and (2) Voltage 20 – 30 V
Between RLP (female) (3) and (2) Voltage 20 – 30 V
2. Disconnect connector RLSW and connect T-adapter to female side.
Between RLSW (female) (5) and (2) Voltage 20 – 30 V
3. Disconnect connectors RLSW, RLP, LREL and KEY, and connect T-adapters to
Between LREL (female) (2) and ground Resistance Max. 1 z
6 harness (Disconnection or Between LREL (male) (2) and ground Resistance Max. 1 z
defective contact) Between LREL (female) (1) and RLP (female) (5) Resistance Max. 1 z
Between RLP (female) (1) and RLSW (female) (6) Resistance Max. 1 z
Between RLP (female) (2) and ground Resistance Max. 1 z
Between RLP (female) (3) and FS12-12 Resistance Max. 1 z
Between RLSW (female) (5) and KEY (female) (1) Resistance Max. 1 z
Between RLSW (female) (2) and ground Resistance Max. 1 z
40-400 40 D65EX, PX, WX-16

E-23 Head lamp or rear lamp does not light up SEN05037-01

Ground fault of wiring 3. Disconnect connectors RLP and LREL, and connect T-adapter to female side of
7 harness RLP.
Between RLP (female) (1) and ground Resistance Min. 1 Mz
D65EX, PX, WX-16 40-400 41

SEN05037-01 E-24 Windshield wiper does not operate
E-24 Windshield wiper does not operate 1
Trouble 1) No windshield wiper operates continuously or intermittently.

• If any wiper operates, check of fuse FL1-3 and fuse 4 in fuse box is not required.
• Wiper intermittent switch supplies 24 V power to wiper intermittent units CB26 and CB27 during
both continuous and intermittent operations.
• T-adapter is not prepared for connectors of wiper intermittent units CB26 and CB27 (Troubleshoot
without T-adapter).
• Wiper intermittent units CB26 and CB27 have 2 wiper intermittent circuits respectively.
Explanation of pins in wiper intermittent unit
Related (1): GND1

information (2): Relay output 1 (Power supply 1 to wiper motor)
(3): Continuous 24 V input
(4): Intermittent 24 V input
(5): Relay output 2 (Power supply 2 to wiper motor)
(6): 24 V common input
(7): 24 V pulse input 2 from wiper motor
(9): GND2
• Since T-adapter is not used, check pins 1, 2, 3, 4, 6 and 9 for disconnection in wiring harness of
wiper intermittent unit in this troubleshooting.

If fuse shown at left is broken, circuit probably has ground fault. In this case,
troubleshoot cause 6 first.
• When fuse FL1-3 or fuse 4 in fuse box is defective
Defective fuse FL1-3 or fuse No windshield wiper operates.
1
4, 5 or 6 in fuse box • When fuse 5 in fuse box is defective
Front and rear wipers do not operate.
• When fuse 6 in fuse box is defective
Right and left door wipers do not operate.
2. Disconnect connector CB11 and connect T-adapter to male side.
3. Turn intermittent switch to ON and OFF positions, and troubleshoot.
Defective wiper intermittent OFF Resistance Max. 1 z
2
switch Between CB11 (male) (3) and (4)
ON Resistance Min. 1 Mz
Between CB11 (male) (5) and (6)
40-400 42 D65EX, PX, WX-16

E-24 Windshield wiper does not operate SEN05037-01

a If any wiper operates, this check is not required.
Between fuse box terminal B3 and ground Voltage 20 – 30 V
a If any wiper operates, this check is not required.
2. Disconnect connector CB11 and connect T-adapter to female side.
3. Remove fuse 4 in fuse box.
Between CB11 (female) (4), (5) and fuse 4 terminal in
Resistance Max. 1 z
fuse box.
• Wiper intermittent unit
2. Disconnect connectors CB11 – CB15, CB23 and CB24, and connect T-adapters to
a Since there are many diodes in internal circuit, take care of polarity of tester.
a If tester does not display “OFF” as resistance, judge that there is no disconnection
in wiring harness.
• Check of CB26 pins 1 and 3 for disconnection
Between CB11 (female) (3) (+) and CB14 (female) (3) Resistance 1 M – 50 Mz
(–)
defective contact)
(–)
(–)
(–)
• Wiper intermittent unit
2. Insert T-adapter into connectors CB23 and CB24.
4. Turn front and left wiper switches to ON position.
5. Turn intermittent switch to OFF position.
Voltage 20 – 30 V
Between CB23 (6) and ground
Voltage 20 – 30 V
Between CB24 (3) and ground
2. Remove fuses 2 – 6 in fuse box.
3. Disconnect connectors CB11, CB17, CB23, CB24, CB26, CB27 and CB37.
Ground fault of wiring Between fuse box terminal B3 and ground Resistance Min. 1 Mz
4 harness (Contact with Between fuse 4 terminal in fuse box and ground Resistance Min. 1 Mz
ground circuit)
Between fuse 5 terminal in fuse box and ground Resistance Min. 1 Mz
Between fuse 6 terminal in fuse box and ground Resistance Min. 1 Mz
Between CB11 (female) (3) and ground Resistance Min. 1 Mz
D65EX, PX, WX-16 40-400 43

40-400 44 D65EX, PX, WX-16

Trouble 2) Front wiper does not operate (Continuous/Intermittent operation is defective).

• If rear wiper does not operate either, see 1).
• Wiper motor detects wiping stroke end and makes 24 V voltage from fuse pulse.
• Even in continuous operation mode, wiper motor operates with power supplied from front and rear
wiper intermittent unit CB26.
• In intermittent operation mode, wiper motor operates by exchanging 24 V voltage pulses with front
and rear wiper intermittent unit CB26.
• Pins of wiper intermittent unit CB26 related to this trouble are as follows.
(1): GND1
Related (2): Relay output 1 (Power supply 1 to wiper motor)
information (3): Continuous (24 V) input
(4): Intermittent (24 V) input
• Check pins 2 and 8 for disconnection in wiring harness of wiper intermittent unit CB26 in this trou-
bleshooting. Other pins are checked for disconnection in contents of Trouble 1).

Defective front wiper motor
1 2. Disconnect connector CB23 and connect T-adapter to male side.
Between CB23 (6) and (1) Continues
a Check that right and left door wipers operate normally.
2. Disconnect connectors CB26 and CB27 and replace wiper intermittent units.
Defective front and rear 3. Turn starting switch to ON position.
2 (F, R) wiper intermittent unit 4. Turn front wiper switch to ON position.
(Internal disconnection) If front wiper becomes normal, original front and rear wiper intermittent unit is
defective.
• Reference: Between CB26 (male) (2) and (8) Resistance Max. 1 z
• Reference: Between CB26 (male) (2) and (6) Resistance Min. 1 Mz
3 Defective front wiper switch 4. Turn switch to ON and OFF positions, and troubleshoot.
• Ground
Between CB14 (female) (2) and ground Resistance Max. 1 z
• Wiper motor power supply H from fuse
Between CB23 (3) and (1) Voltage 20 – 30 V
4 harness (Disconnection or 2. Remove fuse 5 in fuse box.
defective contact) 3. Disconnect connector CB23 and connect T-adapter to female side.
a If no failure is detected in wiper motor power supply
H, this check is not required.
Resistance Max. 1 z
Between CB23 (female) (3) and fuse 5 terminal in
fuse box
H, this check is not required. Resistance Max. 1 z
Between CB23 (female) (1) and ground
Resistance Max. 1 z
Between CB23 (female) (2) and (6)
D65EX, PX, WX-16 40-400 45


Ground fault of wiring 2. Disconnect connectors CB23 and CB26 and connect T-adapter to female side of
5 harness (Contact with CB23.
ground circuit) Between CB23 (female) (2) and ground Resistance Min. 1 Mz
If cause is not found by above checks, front wiper motor is defective.
2. Insert T-adapter into connector CB23.
Defective front wiper motor 3. Turn starting switch to ON position.
6 (Defective detection function 4. Turn front wiper switch to ON position.
for wiping stroke end) a Voltage is applied when wiper is operated (Voltage is GND level at both wiping
stroke end and in OFF period in intermittent mode).
40-400 46 D65EX, PX, WX-16

D65EX, PX, WX-16 40-400 47

Trouble 3) Rear wiper does not operate (Continuous/Intermittent operation is defective).

• If front wiper does not operate either, see 1).
• Even in continuous operation mode, wiper motor operates with power supplied from front and rear
wiper intermittent unit CB26.
• In intermittent operation mode, wiper motor operates by exchanging 24 V voltage pulses with front
and rear wiper intermittent unit CB26.
Related (3): Continuous (24 V) input

information (4): Intermittent (24 V) input
(9): GND2
• See “Trouble 2)” for related circuit diagram.

Defective rear wiper motor
1 2. Disconnect connector CB23 and connect T-adapter to male side.
Between CB23 (6) and (1) Continues
a Check that right and left door wipers operate normally.
Defective front and rear 3. Turn starting switch to ON position.
2 (F, R) wiper intermittent unit 4. Turn rear wiper switch to ON position.
(Internal disconnection) If rear wiper becomes normal, original front and rear wiper intermittent unit is
defective.
3 Defective rear wiper switch 4. Turn switch to ON and OFF positions, and troubleshoot.
• Ground
Resistance Max. 1 z
fuse box
Resistance Max. 1 z
40-400 48 D65EX, PX, WX-16


If cause is not found by above checks, rear wiper motor is defective.
2. Insert T-adapter into connector CB37.
Defective rear wiper motor 3. Turn starting switch to ON position.
6 (Defective detection function 4. Turn rear wiper switch to ON position.
for wiping stroke end) a Voltage is applied when wiper is operated (Voltage is GND level at both wiping
D65EX, PX, WX-16 40-400 49

Trouble 4) Left door wiper does not operate (Continuous/Intermittent operation is defective).
• If right door wiper does not operate either, see 1).
• Even in continuous operation mode, wiper motor operates with power supplied from left door and
right door (LH, RH) wiper intermittent unit CB27.
• In intermittent operation mode, wiper motor operates by exchanging 24 V voltage pulses with left
door and right door (LH, RH) wiper intermittent unit CB27.
(1): GND1
Related (2): Relay output 1 (Power supply 1 to wiper motor)
(3): Continuous (24 V) input
information

Defective left door wiper 1. Turn starting switch to OFF position.
1 motor (Internal 2. Disconnect connector CB24 and connect T-adapter to male side.
disconnection) Between CB24 (3) and (1) Continues
a Check that front and rear wipers operate normally.
Defective left door and right 3. Turn starting switch to ON position.
door (LH, RH) wiper 4. Turn left door wiper switch to ON position.
2
intermittent unit
If left door wiper becomes normal, original left door and right door (LH, RH) wiper
intermittent unit is defective.
Defective left door wiper 3. Disconnect connector CB15 and connect T-adapter to male side.
3 4. Turn switch to ON and OFF positions, and troubleshoot.
switch
• Ground
Resistance Max. 1 z
fuse box
Resistance Max. 1 z
40-400 50 D65EX, PX, WX-16


Ground fault of wiring 2. Disconnect connectors CB24 and CB27 and connect T-adapter to female side.
ground circuit)
If cause is not found by above checks, left door wiper motor is defective.
Defective left door wiper 2. Insert T-adapter into connector CB24.
motor (Defective detection 3. Turn starting switch to ON position.
6 4. Turn left door wiper switch to ON position.
function for wiping stroke
end) a Voltage is applied when wiper is operated (Voltage is GND level at both wiping
D65EX, PX, WX-16 40-400 51

Trouble 5) Right door wiper does not operate (Continuous/Intermittent operation is defective).
• If left door wiper does not operate either, see 1).
• Even in continuous operation mode, wiper motor operates with power supplied from left door and
right door (LH, RH) wiper intermittent unit CB27.
• In intermittent operation mode, wiper motor operates by exchanging 24 V voltage pulses with left
door and right door (LH, RH) wiper intermittent unit CB27.
Related
information (3): Continuous (24 V) input
(9): GND2

Defective right door wiper 1. Turn starting switch to OFF position.
1 motor (Internal 2. Disconnect connector CB17 and connect T-adapter to male side.
disconnection) Between CB17 (3) and (1) Continues
a Check that front and rear wipers operate normally.
Defective left door and right 3. Turn starting switch to ON position.
door (LH, RH) wiper 4. Turn right door wiper switch to ON position.
2
intermittent unit
If right door wiper becomes normal, original left door and right door (LH, RH) wiper
intermittent unit is defective.
Defective right door wiper 3. Disconnect connector CB13 and connect T-adapter to male side.
switch
• Ground
Resistance Max. 1 z
fuse box
Resistance Max. 1 z
40-400 52 D65EX, PX, WX-16


If cause is not found by above checks, right door wiper motor is defective.
Defective right door wiper 2. Insert T-adapter into connector CB24.
motor (Defective detection 3. Turn starting switch to ON position.
6 4. Turn right door wiper switch to ON position.
function for wiping stroke
end) a Voltage is applied when wiper is operated (Voltage is GND level at both wiping
D65EX, PX, WX-16 40-400 53

40-400 54 D65EX, PX, WX-16

D65EX, PX, WX-16 40-400 55

SEN05037-01 E-25 Window washer does not operate
E-25 Window washer does not operate 1
Trouble 1) Front window washer does not operate.

• If wiper also does not operate, see E-24 1) or 3).
Related
• T-adapter is not prepared for window washer motor connector (Perform troubleshooting without T-
information
adapter).

a Check that rear window washer spouts water normally.
Defective front washer motor 2. Replace connector WSFR with WSRR.
1
(Internal disconnection) 3. Turn starting switch to ON position.
4. Turn front window washer switch to ON position.
If rear window washer spouts water, original front window washer motor is defective.
2 Defective front wiper switch 4. Turn switch to ON and OFF positions, and troubleshoot.
Disconnection in wiring Between CB14 (female) (6) and ground Continues
3 harness (Disconnection or 1. Turn starting switch to OFF position.
defective contact) 2. Remove fuse 5 in fuse box.
Between CB14 (female) (5) and fuse 5 in fuse box Resistance Max. 1 z
Ground fault of wiring 3. Disconnect connectors CB14 and WSFR, and connect T-adapter to female side of
ground circuit)
40-400 56 D65EX, PX, WX-16

E-25 Window washer does not operate SEN05037-01
D65EX, PX, WX-16 40-400 57

Trouble 2) Rear window washer does not operate.

Related • T-adapter is not prepared for window washer motor connector (Perform troubleshooting without T-
information adapter).

a Check that front window washer spouts water normally.
Defective rear washer motor 2. Replace connector WSFR with WSRR.
1
(Internal disconnection) 3. Turn starting switch to ON position.
4. Turn rear window washer switch to ON position.
If front window washer spouts water, original rear window washer motor is defective.
2 Defective rear wiper switch 4. Turn switch to ON and OFF positions, and troubleshoot.
Ground fault of wiring 3. Disconnect connectors CB12 and WSRR, and connect T-adapter to female side of
ground circuit)
40-400 58 D65EX, PX, WX-16

E-25 Window washer does not operate SEN05037-01
Trouble 3) Right door window washer does not operate.


a Check that left door window washer spouts water normally.
Defective right door washer 2. Replace connector WSLH with WSRH.
1 motor (Internal 3. Turn starting switch to ON position.
disconnection) 4. Turn right door window washer switch to ON position.
If left door window washer spouts water, original right door window washer motor is
defective.
Defective right door wiper 3. Disconnect connector CB13 and connect T-adapter to male side.
switch
Ground fault of wiring 3. Disconnect connectors CB13 and WSLH, and connect T-adapter to female side of
ground circuit)
D65EX, PX, WX-16 40-400 59

Trouble 4) Left door window washer does not operate.


a Check that right door window washer spouts water normally.
Defective left door washer 2. Replace connector WSLH with WSRH.
1 motor (Internal 3. Turn starting switch to ON position.
disconnection) 4. Turn left door window washer switch to ON position.
If right door window washer spouts water, original left door window washer motor is
defective.
Defective left door wiper 3. Disconnect connector CB15 and connect T-adapter to male side.
switch
Ground fault of wiring 3. Disconnect connectors CB15 and WSRH, and connect T-adapter to female side of
ground circuit)
40-400 60 D65EX, PX, WX-16

E-26 KOMTRAX system does not operate correctly SEN05037-01
E-26 KOMTRAX system does not operate correctly 1
Trouble KOMTRAX system does not operate correctly.

• Perform following troubleshooting if the administrator of KOMTRAX system requests to check
Related whether abnormality is occurring in the system on the machines.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Perform all the troubleshooting on service menu display of machine monitor.

2. Display “Terminal status” screen.
1 Defective communication 1
Check item:
Open
KOMTRAX communication
2. Display “GPS & Communication Status” screen.
N ###.##.## (Latitude)
Check item:
2 Defective GPS E ###.##.## (Longitude)
Positioning
In positioning
If latitude and longitude are not displayed within 5 minutes when the machine stays
outdoor where can view sky, contact KOMTRAX service hot line.
Check item:
Defective communication Satellite in View or No Satellite in View
3 Communication
environment
If Communication Status does never display “Satellite in View” within 15 minutes
when the machine stays outdoor where can view sky, check if connector of TH300 or
antenna on top of the cab are properly connected.
4 Defective communication 2
Check item:
0 – 60 (normally 0)
Number of message not yet sent
a Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from
KOMTRAX setting” in the service menu of the “12 Display of KOMTRAX setting” in the ser-
machine monitor. vice menu of the machine monitor.
D65EX, PX, WX-16 40-400 61

SEN05037-01

©2009 KOMATSU
All Rights Reserved
40-400 62
SEN05038-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
500 Troubleshooting of hydraulic and

mechanical system (H-mode)
Failure mode and cause table......................................................................................................................... 2
Contents of troubleshooting table ................................................................................................................... 4
H-1 There is no travel power (no drawbar pull)............................................................................................... 5
H-2 Machine does not move (at 2nd or 3rd speed) ........................................................................................ 6
H-3 Machine does not move at any gear speed ............................................................................................. 7
H-4 Machine travels only in one direction, forward or in reverse .................................................................... 8
H-5 When gear is shifted or travel direction is changed, large time lag is made ............................................ 9
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) ........................................... 10
H-7 Steering speed or power is low .............................................................................................................. 10
H- 8 Brake does not work ..............................................................................................................................11
H-9 Overheat of power train oil ..................................................................................................................... 12
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor .................. 13
H-11 All work equipment speeds are slow .................................................................................................... 13
H-12 Work equipment does not move .......................................................................................................... 14
H-13 Blade lift speed is slow or lacks power................................................................................................. 14
H-14 Blade tilt speed is slow or lacks power................................................................................................. 15
H-15 Ripper lift speed is slow or lacks power ............................................................................................... 15
H-16 Excessive hydraulic drift of blade lift .................................................................................................... 16
H-17 Excessive hydraulic drift of blade tilt .................................................................................................... 16
H-18 Excessive hydraulic drift of ripper lift .................................................................................................... 17
D65EX, PX, WX-16 40-500 1

500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN05038-00 Failure mode and cause table
Failure mode and cause table 1
Part causing problem Power train Brake
Transmission main relief valve

Transmission valve (ECMV)
Transmission clutch (*1)
Brake disc and plate

Brake pedal linkage
Power train pump
Torque converter
Parking brake
Transmission
Brake (drag)
Brake valve
Failure mode
There is no travel power (no drawbar pull) Q Q Q Q Q Q Q
Machine does not move (at 2nd or 3rd speed) Q Q Q Q Q Q
Machine does not move at any gear speed Q Q Q Q Q
Q Q Q Q
Related to travel
Machine travels only in one direction, forward or in reverse

When gear is shifted or travel direction is changed, large time lag is made Q Q Q Q Q
Machine cannot be steered (Machine does not turn leftward or rightward)
Steering speed or power is low
Brake does not work Q Q Q Q
Overheat of power train oil Q Q Q Q
Abnormal sound comes out from around HSS and work equipment pump or
HSS motor
All work equipment speeds are slow
Work equipment does not move
Work equipment
Blade lift speed is slow or lacks power

Blade tilt speed is slow or lacks power
Ripper lift speed is slow or lacks power
Excessive hydraulic drift of blade lift
Excessive hydraulic drift of blade tilt
Excessive hydraulic drift of ripper lift
40-500 2 D65EX, PX, WX-16

Q
Q
Engine
Hydraulic tank stainer
Q
Q
HSS pump
Q Q Q
Q Q
Q Q
HSS motor
motor
PTO
Pump and
Work equipment pump
D65EX, PX, WX-16

Q Q Q
Q Q Q
Q
Self pressure reducing valve (control circuit pressure)
Q Q
HSS main relief valve
Failure mode and cause table
Unload valve
Q Q
Work equipment main relief valve
Q
Q
Q Q Q
PPC valve
Blade lift control valve
Q Q
Q Q Q
Blade lift cylinder
Blade tilt control valve
Hydraulic system
Q Q
Q Q
Blade tilt cylinder
Ripper lift control valve
Ripper lift cylinder
Troubleshooting No.
H-2
H-1
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-11
Q Q H-18
H-17
H-16
Q Q H-15
H-14
H-13
H-12
H-10
(*1)
Gear speed
N
F3
F2
F1
R3
R2
R1
F
Q
Q
Q
Q
Q
1st
Q
Q
2nd
Used clutch
Q
Q
3rd
R
Q
Q
Q
40-500
3
SEN05038-00
SEN05038-00 Contents of troubleshooting table
Contents of troubleshooting table 1
a Troubleshooting lists contain the following information all together. Understand the contents carefully
and troubleshoot the machine.
Symptom of
Symptom of failure that has appeared in the machine
failure
General
Information related to troubles occurred or troubleshooting
information
Cause Standard value when normal and remarks for troubleshooting
2
Possible Cause by which a trouble
causes and the is assumed to be caused <Described contents>
standard values (The order number indi- • Standard value when normal required to judge the possible cause
when normal cates a serial number, not • Remarks required to judge whether the cause is right or not
a priority sequence.)
3
40-500 4 D65EX, PX, WX-16

H-1 There is no travel power (no drawbar pull). SEN05038-00
H-1 There is no travel power (no drawbar pull). 1
Symptom of
• There is no travel power (no drawbar pull).
failure
General
• Check that the power train oil level is normal before troubleshooting.
information

a Prepare with the starting switch OFF, and then run the engine at
high idle for troubleshooting.
1 Defective engine
Measurement conditions Engine speed
F3 stall 1,650 rpm
2 Defective power train pump The power train pump is assumed to be defective; visually check it.
Internally defective torque Torque converter Torque converter
3 PCCS lever
converter inlet pressure outlet pressure
Max. 0.98 MPa 0.39 – 0.78 MPa
Full neutral
{Max. 10 kg/cm2} {4 – 8 kg/cm2}
PCCS lever
pressure
Full neutral Min. 3.17 MPa {Min. 32.3 kg/cm2}
Defective set pressure or
4 internal defect of transmis- a Prepare with starting switch OFF and diagnose with starting
sion main relief valve switch still OFF.
Possible Visually check that the free length of spring and the number of
causes and the shims are normal and also that the spool rotates smoothly.
standard values • Free length of large spring: 128 mm
when normal • Free length of small spring: 108 mm
• Number of shims: 7
low idle for troubleshooting.
Transmission clutch Clutch pressure
Defective operation of trans- FWD Min. 2.60 MPa {Min. 26.5 kg/cm2}
5
mission valve (ECMV) REV Min. 2.99 MPa {Min. 30.5 kg/cm2}
1ST Min. 2.94 MPa {Min. 30.0 kg/cm2}
2ND Min. 2.16 MPa {Min. 22.0 kg/cm2}
3RD Min. 2.99 MPa {Min. 30.5 kg/cm2}
6 Defective brake valve Parking lever Brake pressure
2.55 – 2.94 MPa
Free
{26 – 30 kg/cm2}
If the result of the troubleshooting in cause 6 is abnormal, the park-
Parking lever or brake pedal
7 ing lever or brake pedal linkage is assumed to be out of adjustment;
linkage out of adjustment
visually check it.
Internally defective The transmission is assumed to be defective internally; visually
8
transmission check it.
D65EX, PX, WX-16 40-500 5

SEN05038-00 H-2 Machine does not move (at 2nd or 3rd speed)
H-2 Machine does not move (at 2nd or 3rd speed) 1
Symptom of
• Machine does not move (at 2nd or 3rd speed)
failure
General
Check that the transmission main relief pressure is normal before troubleshooting.
information
(See H-1 “There is no travel power”.)

1 PCCS lever
Max. 0.98 MPa 0.39 – 0.78 MPa
Full neutral
{Max. 10 kg/cm2} {4 – 8 kg/cm2}
Defective operation of trans- Transmission clutch Clutch pressure
Possible 2
mission valve (ECMV)
causes and the 2ND Min. 2.16 MPa {Min. 22.0 kg/cm2}
standard values 3RD Min. 2.99 MPa {Min. 30.5 kg/cm2}
when normal
Internally defective The transmission clutch (2nd or 3rd speed) is assumed to be defec-
3
transmission clutch tive internally; visually check it.
Defective operation of The parking brake operation is assumed to be defective (dragging);
4
parking brake (dragging) check the linkage valves.
a Move to a flat place (a hard road), and start the engine for trou-
Defective operation of brake bleshooting.
5
(dragging) If the machine does not run by low idle + F2 operation, brake drag-
ging occurs. (Carry out troubleshooting “H-8 Brake does not work“.)
Internally defective The transmission is assumed to be defective internally; visually
6
transmission check it.
40-500 6 D65EX, PX, WX-16

H-3 Machine does not move at any gear speed SEN05038-00
H-3 Machine does not move at any gear speed 1
Symptom of
• Machine does not move at any gear speed.
failure
General
information

PCCS lever
pressure
Defective set pressure or
2 internal defect of transmis- a Prepare with starting switch OFF and diagnose with starting
sion main relief valve switch still OFF.
Visually check that the free length of spring and the number of
shims are normal and also that the spool rotates smoothly.
• Free length of large spring: 128 mm
• Free length of small spring: 108 mm
Possible (Before this, check that the transmission main relief pressure is
normal.)
causes and the
standard values Transmission clutch Clutch pressure
when normal Defective operation of trans-
3 FWD Min. 2.60 MPa {Min. 26.5 kg/cm2}
REV Min. 2.99 MPa {Min. 30.5 kg/cm2}
Internally defective The transmission clutch is assumed to be defective internally; visu-
4
transmission ally check it.
a Move to a flat place, and run the engine at high idle for trouble-
shooting.
(Before this, check that the transmission main relief pressure is
normal.)
5 Defective brake valve Brake pedal Brake oil pressure (left/right)

Release 2.55 – 2.94 MPa {26 – 30 kg/cm2}
Depress 0 MPa {0 kg/cm2}
When the oil pressure is abnormal, carry out troubleshooting “H-8
Brake does not work”.
D65EX, PX, WX-16 40-500 7

SEN05038-00 H-4 Machine travels only in one direction, forward or in reverse
H-4 Machine travels only in one direction, forward or in reverse 1
Symptom of
• Machine travels only in one direction, forward or in reverse.
failure
General
information

1 The power train pump is assumed to be defective; visually check it.
pump
PCCS lever Transmission main relief pressure
Defective set pressure or a Prepare with starting switch OFF and diagnose with starting
2 internal defect of transmis- switch still OFF.
sion main relief valve
Visually check that the free length of spring and the number of
Possible
causes and the
standard values
when normal
(Before this, check that the transmission main relief pressure is
Defective operation of trans- normal.)
3
mission valve (ECMV) Transmission clutch Clutch pressure
FWD Min. 2.60 MPa {Min. 26.5 kg/cm2}
Defective transmission If the result of the troubleshooting in cause 3 is abnormal, the clutch
4
clutch seal seal is assumed to be defective; visually check it.
Internally defective The transmission clutch (forward or reverse) is assumed to be
5
transmission clutch defective internally; visually check it.
40-500 8 D65EX, PX, WX-16

H-5 When gear is shifted or travel direction is changed, large time lag is made SEN05038-00
H-5 When gear is shifted or travel direction is changed, large time lag
is made 1
Symptom of
• Time lag is excessive when shifting gear or changing direction.
failure
General
information

PCCS lever Transmission main relief pressure
Defective set pressure or a Prepare with starting switch OFF and diagnose with starting
2 internal defect of transmis- switch still OFF.
sion main relief valve
• Visually check that the free length of spring and the number of
Possible low idle for troubleshooting.
causes and the (Before this, check that the transmission main relief pressure is
standard values normal.)
when normal Transmission clutch Clutch pressure
Defective operation of trans-
3 FWD Min. 2.60 MPa {Min. 26.5 kg/cm2}
Defective transmission If the result of the troubleshooting in cause 3 is abnormal, the clutch
4
clutch seal seal is assumed to be defective; visually check it.
Internally defective The transmission clutch is assumed to be defective internally; visu-
5
transmission clutch ally check it.
a Move to a flat place (a hard road), and start the engine for trou-
Defective operation of brake bleshooting.
6
(Dragging) If the machine does not run by low idle + F2 operation, brake drag-
ging occurs. (Carry out troubleshooting “H-8 Brake does not work”.)
D65EX, PX, WX-16 40-500 9

SEN05038-00 H-6 Machine cannot be steered (Machine does not turn leftward or rightward)
H-6 Machine cannot be steered (Machine does not turn leftward or

rightward) 1
Symptom of
• Machine cannot be steered. (Machine does not turn leftward or rightward.)
failure
General
• Check that the hydraulic oil level is normal before troubleshooting.
information

a Prepare with the engine started, and then run the engine at high
Defective set pressure or idle for troubleshooting.
Possible defective operation
1 PCCS lever Basic pressure of control circuit
causes and the of self pressure reducing
standard values valve (PPC basic pressure) 3.97 ± 0.29 MPa
Neutral
when normal {40.5 ± 3.0 kg/cm2}
If an abnormal sound occurs in the HSS peripheral equipment, carry
Abnormal sound from HSS
2 out troubleshooting “H-10 Abnormal sound comes out from around
peripheral equipment
HSS and work equipment pump or HSS motor”.
H-7 Steering speed or power is low 1
Symptom of
• Steering speed or power is insufficient.
failure
General
information

a Prepare with the engine started, and then run the engine at high
Defective set pressure or idle for troubleshooting.
1 defective operation of HSS PCCS lever HSS relief pressure
main relief valve Min. 34.8 MPa
Left or right stroke end
Possible {355 kg/cm2}
causes and the a Prepare with the engine started, and then run the engine at high
standard values Defective set pressure or idle for troubleshooting.
when normal defective operation of self
2 PCCS lever Basic pressure of control circuit
pressure reducing valve
(PPC basic pressure) 3.97 ± 0.29 MPa
Neutral
{40.5 ± 3.0 kg/cm2}
If an abnormal sound occurs in the HSS peripheral equipment, carry
Abnormal sound from HSS
3 out troubleshooting “H-10 Abnormal sound comes out from around
peripheral equipment
HSS and work equipment pump or HSS motor”.
40-500 10 D65EX, PX, WX-16

H- 8 Brake does not work SEN05038-00
H- 8 Brake does not work 1
Symptom of
• Brake does not work.
failure
General
• Check that the transmission main relief pressure is normal before troubleshooting.
information
(See H-1 "There is no travel power")

Defective operation of brake Brake pedal Brake oil pressure
1
valve 2.55 – 2.94 MPa
Possible When released
{26 – 30 kg/cm2}
causes and the
standard values When depressed 0 MPa {0 kg/cm2}
when normal Brake pedal linkage out of If the result of the troubleshooting in cause 1 is abnormal, the brake
2
adjustment pedal linkage is assumed to be out of adjustment; visually check it.
If the result of the troubleshooting in cause 1 is abnormal, the brake
3 Defective brake seal
seal is assumed to be defective; visually check it.
Slip or abrasive wear of Slip or abrasive wear of the brake disc plate is suspected; visually
4
brake disc plate check it.
D65EX, PX, WX-16 40-500 11

SEN05038-00 H-9 Overheat of power train oil
H-9 Overheat of power train oil 1
Symptom of
• The power train oil overheats.
failure
• Check that the reading on the power train oil temperature gauge matches the actual oil temperature
General before troubleshooting. (If they do not match, carry out troubleshooting “Reading on power train oil
information temperature gauge is incorrect”.
• Check that the transmission main relief pressure is normal before troubleshooting.
(See H-1 "There is no travel power")

The engine cooling system is assumed to be defective or the engine
1 Defective engine system output is assumed to be increased; see the shop manual of engine
volume.
Defective power train pump
The power train pump is assumed to be defective or residual air
2 or residual air from suction
from the suction circuit is assumed to remain; visually check it.
circuit
Possible
causes and the 3 PCCS lever
standard values
when normal Max. 0.98 MPa 0.39 – 0.78 MPa
Full neutral
{Max. 10 kg/cm2} {4 – 8 kg/cm2}
Defective operation of trans- The transmission clutch is assumed to be defective internally (slip);
4
mission clutch (Slip) visually check it.
a Start the engine to diagnose.
1. Run the engine at low idle on a flat place (a hard road).
Defective operation of brake 2. Set the gearshift lever in F2.
5
(Dragging) 3. See if the machine moves (travels). If it does not move, brake
dragging occurs.
(Carry out troubleshooting “H-8 Brake does not work”.)
40-500 12 D65EX, PX, WX-16

H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor SEN05038-00
H-10 Abnormal sound comes out from around HSS and work equipment
pump or HSS motor 1
Symptom of
• Abnormal noise comes from around HSS and work equipment pump.
failure
General
information

1 Inappropriate oil The oil used is assumed to be inappropriate; visually check it.
Clogged hydraulic tank
2 The hydraulic tank strainer is assumed to be clogged; visually check it.
Possible strainer
causes and the Air is assumed to be inhaled in the suction circuit of the HSS and
standard values 3 Air inhaled in suction circuit
work equipment pump; visually check the pipes.
when normal
Internally defective HSS The HSS and work equipment pump is assumed to be defective
4
pump internally; visually check it.
Internally defective HSS
5 The HSS motor is assumed to be defective internally; visually check it.
motor
H-11 All work equipment speeds are slow 1
Symptom of
• All work equipment speeds are slow.
failure
General
• Check that the oil level in the hydraulic tank is normal before troubleshooting.
information

Defective PTO (pump drive
The PTO pump drive unit of the HSS and work equipment is
1 unit of HSS and work equip-
assumed to be defective; visually check it.
ment)
Defective HSS and work The HSS and work equipment pump is assumed to be defective;
2
equipment pump visually check it.
Defective operation
3 Work equipment control lever Unload pressure
of unload valve
3.23 – 4.9 MPa
Possible Full neutral
{33 – 50 kg/cm2}
causes and the
standard values
Defective set pressure or high idle for troubleshooting.
when normal
4 defective operation of main Work equipment control lever Main relief pressure
relief valve Min. 28.4 MPa
Stroke end
{Min. 290 kg/cm2}
Defective operation of high idle for troubleshooting.
5 self pressure reducing valve Work equipment control lever Basic pressure of control circuit
Full neutral
{40.5 ± 3.0 kg/cm2}
If the result of the troubleshooting in cause 5 is abnormal, the PPC
6 Internally defective PPC valve
valve is assumed to be defective internally; visually check it.
D65EX, PX, WX-16 40-500 13

SEN05038-00 H-12 Work equipment does not move
H-12 Work equipment does not move 1
Symptom of
• Work equipment does not move.
failure
General
information

Defective PTO (pump drive
The PTO pump drive unit of the HSS and work equipment is
1 unit of HSS and work equip-
assumed to be defective; visually check it.
ment)
Defective HSS and work The HSS and work equipment pump is assumed to be defective;
2
equipment pump visually check it.
Defective operation
3 Work equipment control lever Unload pressure
of unload valve
Possible 3.23 – 4.9 MPa
causes and the Full neutral
{33 – 50 kg/cm2}
standard values
when normal a Prepare with the starting switch OFF, and then run the engine at
Defective set pressure or high idle for troubleshooting.
4 defective operation of main Work equipment control lever Main relief pressure
relief valve Min. 28.4 MPa
Stroke end
{Min. 290 kg/cm2}
Defective operation of high idle for troubleshooting.
5 self pressure reducing valve Work equipment control lever Basic pressure of control circuit
Full neutral
{40.5 ± 3.0 kg/cm2}
H-13 Blade lift speed is slow or lacks power 1
Symptom of
• Blade lift speed is slow or lacks power.
failure
General • Check for modifications to the blade.
information • If the hydraulic drift of blade lift is also excessive, carry out the troubleshooting of "H-16 Excessive
hydraulic drift of blade lift" first.

Defective operation of PPC
Possible 1 Blade control lever PPC valve output pressure
valve
causes and the 3.19 – 4.17 MPa
standard values Lift stroke end
{32.5 – 42.5 kg/cm2}
when normal
Defective operation of blade The operation of the blade lift control valve spool is assumed to be
2
lift control valve (spool) defective; visually check it.
Residual air in blade lift cylin- Residual air is assumed to remain in the blade lift cylinder; bleed air
3
der and observe how the phenomenon changes.
40-500 14 D65EX, PX, WX-16

H-14 Blade tilt speed is slow or lacks power SEN05038-00
H-14 Blade tilt speed is slow or lacks power 1
Symptom of
• Blade tilt speed is slow or lacks power.
failure
information • If the hydraulic drift of blade tilt is also excessive, carry out the troubleshooting of "H-17 Excessive
hydraulic drift of blade tilt" first.

Possible 1 Blade control lever PPC valve output pressure
valve
causes and the 3.19 – 4.17 MPa
standard values Tilt stroke end
{32.5 – 42.5 kg/cm2}
when normal
Defective operation of blade The operation of the blade tilt control valve spool is assumed to be
2
tilt control valve (spool) defective; visually check it.
Residual air in blade tilt cylin- Residual air is assumed to remain in the blade tilt cylinder; bleed air
3
H-15 Ripper lift speed is slow or lacks power 1
Symptom of
• Ripper lift speed is slow or lacks power.
failure
General • Check for modifications to the ripper.
information • If the hydraulic drift of ripper lift is also excessive, carry out the troubleshooting of "H-18 Excessive
hydraulic drift of ripper lift" first.

1 Ripper control lever PPC valve output pressure
valve
3.19 – 4.17 MPa
Lift stroke end
Possible {32.5 – 42.5 kg/cm2}
causes and the Defective operation of ripper The operation of the ripper lift control valve spool is assumed to be
standard values 2
lift control valve (spool) defective; visually check it.
when normal
The operation of the suction valve of the ripper lift control valve is
Defective operation of ripper assumed to be defective; visually check it.
3
lift control valve (suction valve) a As one method, replace the suction valve at the head with the
one at the bottom, and observe how the phenomenon changes.
Residual air in ripper lift cylin- Residual air is assumed to remain in the ripper lift cylinder; bleed air
4
D65EX, PX, WX-16 40-500 15

SEN05038-00 H-16 Excessive hydraulic drift of blade lift
H-16 Excessive hydraulic drift of blade lift 1
Symptom of
• Excessive hydraulic drift of blade lift.
failure
information • Check for oil leaks in the hydraulic circuit of the work equipment before troubleshooting.

a Prepare with the engine started, and then stop the engine for
troubleshooting.
Possible 1. Raise the blade (approx. 800 mm).
Defective seal of blade lift 2. Disconnect the hose on the cylinder head side and block it.
causes and the 1
control valve (spool) 3. Measure hydraulic drift of the tip of blade cutting edge.
standard values
when normal Blade lift Hydraulic drift
Block blade lift circuit 35 mm/5 min
Defective seal of blade lift The seal of the blade lift cylinder is assumed to be defective; visu-
2
cylinder ally check it.
H-17 Excessive hydraulic drift of blade tilt 1
Symptom of
• Excessive hydraulic drift of blade tilt.
failure

troubleshooting.
Possible 1. Fully extend the blade tilt cylinder.
Defective seal of blade tilt 2. Disconnect the hose on the cylinder bottom side and block it.
causes and the 1
control valve (spool) 3. Measure hydraulic drift of the tip of blade cutting edge.
standard values
when normal Blade tilt Hydraulic drift
Block blade tilt circuit 70 mm/5 min
Defective seal of blade tilt The seal of the blade tilt cylinder is assumed to be defective; visu-
2
40-500 16 D65EX, PX, WX-16

H-18 Excessive hydraulic drift of ripper lift SEN05038-00
H-18 Excessive hydraulic drift of ripper lift 1
Symptom of
• Excessive hydraulic drift of ripper lift.
failure
General • Check for modifications to the ripper.

troubleshooting.
Possible 1. Pull out the shank pin and raise the ripper to the maximum.
Defective seal of ripper lift
causes and the 1 2. Disconnect the hose on the cylinder head side and block it.
control valve (spool)
standard values
when normal Ripper lift Hydraulic drift
Block ripper lift circuit 35 mm/5 min
Defective seal of ripper lift The seal of the ripper lift cylinder is assumed to be defective; visu-
2
D65EX, PX, WX-16 40-500 17

SEN05038-00

©2009 KOMATSU
All Rights Reserved
40-500 18
SEN05039-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
600 Troubleshooting of engine (S-mode)

Method of using troubleshooting charts .......................................................................................................... 3
S-1 Starting performance is poor. ................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) .................................................. 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (water, fuel in oil) ............................................................................................................ 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
D65EX, PX, WX-16 40-600 1

SEN05039-00
40-600 2 D65EX, PX, WX-16

Method of using troubleshooting charts SEN05039-00
Method of using troubleshooting charts 1
The troubleshooting chart consists of the “ques-

tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E.
(If no items have other marks and the causes cannot be narrowed, however, you may apply them.)
D65EX, PX, WX-16 40-600 3

SEN05039-00 Method of using troubleshooting charts
<Example of troubleshooting> Exhaust smoke is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
40-600 4 D65EX, PX, WX-16

Method of using troubleshooting charts SEN05039-00
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
D65EX, PX, WX-16 40-600 5

SEN05039-00 S-1 Starting performance is poor.
S-1 Starting performance is poor. 1
General causes why starting performance is poor Cause
Stuck and seized fuel supply pump plunger

Clogged air breather hole in fuel tank cap
• Defective electrical system
• Insufficient supply of fuel
Defective contact of valve, valve seat
Defective alternator (generator unit)

Leakage, clogging, air in fuel piping
Defective alternator (regulator unit)

Defective intake air heater system
• Insufficient intake of air
Defective or deteriorated battery

• Improper selection of fuel
Clogged air cleaner element
Clogged fuel filter, element
Defective electric lift pump

Worn piston ring, cylinder
a With the common rail fuel injection system (CRI), the fuel injec-
tion timing is recognized electrically, so even when the starting
Defective injector
operation is carried out, the engine may not start until the
crankshaft has completed two rotations. However, this does
not indicate any abnormality.
Confirm recent repair history

Degree of use of
Operated for long period E E E
machine
Gradually became worse Q w w Q
Ease of starting
Starts when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation & Maintenance Manual w w Q Q
Engine oil must be added more frequently w
Preheating monitor does not work normally during preheating or in low temperatures
w
(when monitor is installed)
Charging monitor shows abnormality in charging while driving (when monitor is installed) w w
Dust indicator lamp is red (when indicator is installed) w
Air breather hole in fuel tank cap is clogged w
Leakage of fuel from fuel piping w Q
Starting motor cranks engine slowly w
When engine is No fuel comes out even when fuel filter air bleed plug is removed w Q
cranked with starting When hose at collection portion for spill flow from fuel injector is
motor w
disconnected, spill flow is small
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
w
ders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Check air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Check fuel filter, strainer directly q
Troubleshooting
Carry out troubleshooting for code display “Supply pump pressure no signal (*1)“ q
Carry out troubleshooting for code display “Defective electric lift pump (*2)“ q
Engine speed does not change when operation of certain cylinders is stopped in reduced cylin-
q
der mode
Intake air heater mount does not become warm during operation of preheating q
Is voltage between alternator terminal B and terminal E with engine at low idle? Yes q
(20 – 30V) No q
When specific gravity of electrolyte or voltage of battery is measured, it is found to be low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Action
*1: Failure code of code display [CA559] and [CA2249]

40-600 6 D65EX, PX, WX-16

S-2 Engine does not start SEN05039-00
S-2 Engine does not start 1
a) Engine does not turn Causes
Defective connection of battery terminal
Defective starting motor (motor section)

General causes why engine does not turn
• Seized parts inside engine:

See "S-4 Engine stops during operations"
Defective steering circuit wiring

• Defective electrical system
• Problem in power train
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E

Condition of horn when Horn does not sound Q Q w
starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w

Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch Makes grating noise w w
is turned to START, start-
ing pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting in H-mode

Carry out troubleshooting in E-mode
When specific gravity of electrolyte and voltage of battery are measured, they are low q
There is not voltage (20 – 30 V) between battery relay terminal B and
q
terminal E
Troubleshooting
When terminal B and terminal C of starting switch are connected,

q
engine starts
Turn starting switch OFF,
When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry q
engine starts
out troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are connected,
q
engine does not start
When terminal at safety switch and terminal B at starting motor are
q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
—
—
Remedy
D65EX, PX, WX-16 40-600 7

SEN05039-00 S-2 Engine does not start
b) Engine turns but no exhaust smoke comes out Cause
Defective actuation of fuel overflow valve (does not close)

General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
Defective fuel supply pump IMV solenoid

Seized, abnormally worn fuel feed pump
Stuck, seized fuel supply pump plunger
Defective common rail pressure limiter

Broken fuel supply pump shaft

Clogged fuel filter, element

Insufficient fuel in tank
Defective fuel injector

Improper fuel used
Degree of use of
Questions
Operated for long period E E

machine
Exhaust smoke suddenly stops coming out (when starting again) w Q w w E
Replacement of filters has not been carried out according to Operation & Mainte-
w E Q
nance Manual
Fuel tank is found to be empty w
Air breather hole in fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is no fuel in filter w w Q
Check items
There is a leakage from fuel piping w
When engine is No fuel comes out even when fuel filter air bleed plug is removed Q Q w Q Q
cranked with start- When hose at collection portion for spill flow from fuel injector is
ing motor Q w w w Q
disconnected, spill flow is small
When air is bled from fuel system, air comes out q

Check fuel filter directly q
Check fuel feed pump directly q
Troubleshooting
Carry out troubleshooting for code display “Supply pump pressure no signal (*1)“ q q
Carry out troubleshooting for code display “Abnormality in IMV solenoid (*2)“ q
Check fuel overflow valve directly q
Possible to start in reduced cylinder mode q
When pressure limiter return pipe is removed, fuel comes out q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Action
Add

*2: Failure code of code display [CA2311]
40-600 8 D65EX, PX, WX-16

S-2 Engine does not start SEN05039-00
c) Exhaust smoke comes out but engine does not start Cause
(Fuel is being injected)
Defective coolant temperature sensor, defective wiring harness

General causes why exhaust smoke comes out but engine does not
start
Worn dynamic valve system (valve, rocker lever, etc.)

• Lack of rotating force due to defective electrical system


Leakage, clogging, air in fuel system
Defective intake air heater system

Clogged injector, defective spray
Worn piston ring, cylinder liner

Improper fuel used
Clogged fuel filter

Degree of use of
Operated for long period E E E
machine
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used w Q Q

Replacement of filters has not been carried out according to Operation & Maintenance Manual w w
Preheating monitor does not work normally during preheating or in low temperatures
w
(when monitor is installed)
Air breather hole in fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is no fuel in filter w Q
Starting motor cranks engine slowly w
When engine is cranked, abnormal noise is heard from around cylinder head w
Q w Q
Check items
When engine is No fuel comes out even when fuel filter air bleed plug is removed
cranked with starting When hose at collection portion for spill flow from fuel injector is dis-
motor w
connected, spill flow is small
w
ders is low

Check dynamic valve system directly q
When compression pressure is measured, it is found to be low q
When air is bled from fuel line, air comes out q
Troubleshooting
Check fuel filter directly q

Possible to start in reduced cylinder mode q
When specific gravity of electrolyte or voltage of battery is measured, it is found to be low. q
Defective coolant temperature gauge display (when coolant temperature gauge is installed) q
Intake air heater mount does not become warm during preheating q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Action

D65EX, PX, WX-16 40-600 9

SEN05039-00 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Cause

Defective contact of valve and valve seat


Seized turbocharger, interference
• Abnormal fuel injection condition
Clogged injector, defective spray


• Controller controlled by derate mode
Improper valve clearance

(The injection amount (output) is limited because a failure has occurred in
the electrical system.)
Clogged fuel filter

Degree of use of
Operated for long period E E E E
machine
Questions
Engine pick-up suddenly becomes poor w Q Q Q

Non-specified fuel is being used w w w
Rust and water are found when fuel in fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some cyl-
Q w
inders is low
Color of exhaust Blue under light load w

Check items
gas Black w Q w w
When engine is running, abnormal noise is heard from around cylinder head w
When engine is running, noise of interference is heard from around turbocharger w
High idle speed is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Check valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

When air is bled from fuel line, air comes out q
q
der mode
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Action
40-600 10 D65EX, PX, WX-16

S-4 Engine stops during operations SEN05039-00
S-4 Engine stops during operations 1
General causes why engine stops Cause
Broken dynamic valve system (valve, rocker lever, etc.)
Broken auxiliary equipment (pump, compressor, etc.)

• Internal part of engine seized
Failure in power train mounted on the machine

• Engine overheating
• Problem in power train

Broken, seized piston, connecting rod
Broken, seized crankshaft bearing
Broken, seized fuel feed pump

Broken fuel supply pump shaft
Clogged, leaking fuel piping
Broken, seized gear train
Clogged fuel filter

Degree of use of machine Operated for long period E
Abnormal noise was heard and engine stopped suddenly w w w w Q w Q w w
Engine overheated and stopped w Q Q
Questions
Condition when engine

stopped Engine stopped slowly w Q
There was hunting and engine stopped w Q Q Q
Replacement of filters has not been carried out according to Operation & Maintenance Manual w
Fuel level monitor indicates low fuel remaining (when monitor is installed) w
Rust and water are found when fuel in fuel tank is drained w
Metal particles are found when oil in oil pan is drained w w w Q
Check items
Does not turn at all w w
When it is attempted to turn Turns in opposite direction w

engine by hand Moves amount of backlash w w
Fuel supply pump shaft does not run w
Engine rotates but stops when load is applied to machine w
q
Check dynamic valve system directly
Check piston and connecting rod directly q
Check crankshaft bearing directly q
Troubleshooting
Check gear train directly q

Check fuel feed pump directly q
When auxiliary equipment (pump, air compressor, etc.) is removed, engine turns q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Action
Add
D65EX, PX, WX-16 40-600 11

SEN05039-00 S-5 Engine does not rotate smoothly
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Cause
Defective Bkup speed sensor, defective wiring harness

• Air in fuel system
Defective Ne speed sensor, defective wiring harness

Clogged fuel injector, defective spray (dirt caught)
• Speed sensor is not normal (abnormality not big enough to generate failure display

Clogged fuel filter

Degree of use of
Operated for long period E
machine
Questions
Occurs at a certain speed range Q Q

Occurs at low idle Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Check items

Rust and water are found when fuel in fuel tank is drained Q
q
Troubleshooting
Check fuel filter, strainer directly

Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode q
Carry out troubleshooting for code display “Abnormality in Ne speed sensor (*1)“ q
Carry out troubleshooting for code display “Abnormality in Bkup speed sensor (*2)“ q
Replace
Replace
Replace
Replace
Correct
Clean
Action
Add

40-600 12 D65EX, PX, WX-16

S-6 Engine lacks output (or lacks power) SEN05039-00
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Cause
Defective boost pressure sensor, defective wiring harness

Defective mount of boost pressure sensor (air leakage)
Clogged fuel injector, defective spray (dirt caught)


Defective contact of valve and valve seat
Defective injector drive (signal, solenoid)

• Engine overheating:

See “S-14 Coolant temperature becomes too high (over-

heating)“
Clogged, leaking fuel piping

Leakage in air intake piping

Clogged fuel spill piping

(The injection amount (output) is limited because a failure
Clogged fuel filter

has occurred in the electrical system.)
Degree of use of
machine
Questions
Suddenly Q w Q Q Q Q
Power was lost
Gradually Q Q Q Q Q Q
Engine oil must be added more frequently Q Q
Dust indicator lamp is red (when indicator is installed) w w
Power is lacking after short stop in operations w
Black w w
Color of exhaust gas
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is
w w
low

Check items
High idle speed of engine is high Q
High idle speed is normal, but speed suddenly drops when load is applied Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w
Check air intake piping directly q
When boost pressure is measured, it is found to be low q q q

Troubleshooting
Check fuel piping q
Check spill port check valve directly q
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder
q q
mode
Check mounting of boost pressure sensor directly q
Carry out troubleshooting for code display “Abnormality in boost pressure sensor (*2)“ q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Action

D65EX, PX, WX-16 40-600 13

SEN05039-00 S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion) 1
General causes why exhaust smoke is black Cause
Leakage of air between turbocharger and cylinder head

• Engine overheating:
Defective coolant temperature sensor,

See “S-14 Coolant temperature becomes too high
Defective contact of valve, valve seat

(overheating)“
Defective fuel injection pressure

Defective fuel injection timing

Clogged, seized fuel injector
(The injection amount (output) is limited because a failure has
Crushed, clogged muffler
defective wiring harness

occurred in the electrical system.)
Worn fuel injector

Degree of use of
machine
Suddenly became black w w Q Q Q
Questions
Color of exhaust gas Gradually became black w Q Q

Non-specified fuel is being used Q Q
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Leakage of air between turbocharger and cylinder head, loose clamp w
Operates in low-temperature mode even at normal temperatures Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some cyl-
Q w
inders is low
Check items
Rotation speed of torque converter stall and pump relief is high (excessive injection of fuel) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
When hose from injector to spill collection portion is disconnected, spill flow is found to be
w
abnormally high

Troubleshooting

When muffler is removed, exhaust color returns to normal q
q
der mode
Carry out troubleshooting for code display “Abnormality in coolant temperature sensor (*2)“ q
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Clean
Action
*1:Failure code of code display [CA559] and [CA2249]

*2:Failure code of code display [CA114] and [CA145]
40-600 14 D65EX, PX, WX-16

S-8 Oil consumption is excessive (or exhaust smoke is blue) SEN05039-00
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Cause
Turbocharger
• Abnormal combustion of oil
Leakage from oil pan, cylinder head, etc.

• The engine has been run at low or high idle for a long time
Worn, broken valve (stem, guide, seal)

continuously
Dust stucked in from intake system

(more than 20 minutes continuous operation is not allowed)
Clogged breather, breather hose

• External leakage of oil
Worn seal at the side of turbine

Worn seal at the side of blower

• Wear of lubrication system
Leakage from oil drain plug

Worn, broken rear oil seal
Leakage from oil cooler
Leakage from oil piping

Leakage from oil filter
Broken piston ring
Broken oil cooler

Degree of use of
E E E E
Questions
Operated for long period

machine
Oil consumption suddenly increased w Q
Engine oil must be added more frequently w Q
Oil gets contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
Loose piping clamp in air intake system w
Inside of turbocharger air supply pipe is dirty with oil w
Inside of turbocharger exhaust pipe is dirty with oil Q w
Check items
There is oil in engine coolant w

Oil level in damper chamber rises w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be extremely dirty q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather, breather hose directly q
Check rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Action
D65EX, PX, WX-16 40-600 15

SEN05039-00 S-9 Oil becomes contaminated quickly
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Cause
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
Clogged breather, breather hose

• Improper oil used
Defective oil filter safety valve

• Operation under excessive load
Exhaust smoke color is poor

Worn valve, valve guide
Clogged oil cooler

Clogged oil filter
Questions
Degree of use of machine Operated for long period E E E

Non-specified fuel is being used Q Q
Metal particles are found when oil inside oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather, breather hose directly q
See S-7
Check oil cooler directly q
Check oil filter directly q
Spring of oil filter safety valve catching or broken q
Check turbocharger drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
—
Action
40-600 16 D65EX, PX, WX-16

S-10 Fuel consumption is excessive SEN05039-00
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Cause
Defective coolant temperature sensor, defective wiring harness

• Leakage of fuel
• Improper condition of fuel injection (injection pressure, injection timing)
• Excessive injection of fuel
External leakage from fuel piping, fuel filter
Defective common rail fuel pressure
Defective actuation of fuel injector

Leakage of fuel inside head cover
Defective fuel feed pump oil seal

Defective supply pump plunger
Defective fuel injection timing

Defective fuel injector spray
Degree of use of
E E E
Questions

machine
Is more than for other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
There is irregular combustion w
Engine oil level rises and smells of diesel fuel w w
w
ders is low
Check items
Low idle speed is high Q

Rotation speed of torque converter stall and pump relief is high Q
Color of exhaust Black Q Q Q Q

gas White Q
Remove head cover and check directly q

Check fuel feed pump oil seal directly q
q
Troubleshooting
Carry out troubleshooting for code display “Supply pump pressure no signal (*1)”
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder
q
mode
When flow of oil from fuel injector at spill return collection portion is measured, it is found to be
q
excessive
Carry out troubleshooting for code display “Abnormality in coolant temperature sensor (*2)” q
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Action

D65EX, PX, WX-16 40-600 17

SEN05039-00 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)1
General causes why oil is in coolant Causes
Broken hydraulic oil cooler or power train

• Internal leakage in lubrication system
oil cooler on applicable machine side

• Internal leakage in cooling system
Broken cylinder head, head gasket
Broken oil cooler core, O-ring

Cracks inside cylinder block
Holes caused by pitting
Degree of use of
E E
Questions

machine
Suddenly rose Q Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
w
Check items
There are excessive air bubbles in radiator, coolant spurts back

Hydraulic oil or power train oil is milky w
When hydraulic oil or power train oil is drained, water is found w
Carry out troubleshooting

Pressure-tightness test of cylinder head shows there is leakage q
Troubleshooting
in H-mode
Inspect cylinder block, liner directly q q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Remedy
40-600 18 D65EX, PX, WX-16

S-12 Oil pressure drops SEN05039-00
S-12 Oil pressure drops 1
General causes why oil pressure drops Cause
Defective oil level sensor, defective wiring harness

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
Leaking, crushed, clogged hydraulic piping

• Selection of oil by the temperature etc. specified in the Operation and Main-
tenace Manual is not observed.
• Deterioration of oil due to overheating
Clogged, broken pipe inside oil pan

Clogged strainer inside oil pan
Defective regulator valve

Worn bearing journal
Defective oil pump

Lack oil in oil pan
Clogged oil filter

Water, fuel in oil
Degree of use of
E E E
Questions

machine
Oil level monitor indicates drop in oil pressure (when monitor is installed) Q w
Non-specified oil is being used Q Q
indicates oil pressure drop at low idle w
Oil pressure moni- indicates oil pressure drop at low idle and high idle Q w w w Q
tor (when monitor
is installed) indicates oil pressure drop on slopes w
sometimes indicates oil pressure drop w Q
Oil level monitor indicates low amount of oil (when monitor is installed) w w
Oil level in oil pan is low w
There is crushing, external leakage from hydraulic piping w
Check items
Oil is cloudy white and smells of diesel oil w

Metal particles are found when oil in oil pan is drained w
Metal particles are found when oil inside oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Check oil pan strainer and pipe directly q q

See S-13
Oil pump rotation is heavy, there is play q

Deterioration, damage of valve, spring in regulator valve q
Check oil filter directly q
When oil level sensor is replaced, oil level monitor displays normally q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
—
Action
Add
D65EX, PX, WX-16 40-600 19

SEN05039-00 S-13 Oil level rises (water, fuel in oil)
S-13 Oil level rises (water, fuel in oil) 1
General causes why oil level rises Cause
Defective auxiliary equipment seal (pump, air compressor)

• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the coolant, carry out troubleshooting for “S-11 Oil is in coolant“.
Defective part inside fuel supply pump

Broken oil cooler core, O-ring

Cracks inside cylinder block
Worn, broken rear oil seal

Broken injector O-ring
Holes made by pitting

Questions
Degree of use of
machine
Fuel consumption has increased w w
Coolant must be added more frequently Q Q
There is oil in engine coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is cloudy white Q Q
After engine is started, drops of water come from muffler Q
When radiator cap is left open and engine is running at low idle, an abnormal number of bubbles
w Q
Check items
appear, or water spurts back

Exhaust smoke is white Q
Oil level goes down in damper chamber w
Oil level goes down in hydraulic tank w

Remove injector and check O-ring q
Troubleshooting
Check cylinder block, liner directly q q

Check rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove supply pump and check directly q
Check auxiliary equipment seal directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Action
40-600 20 D65EX, PX, WX-16

S-14 Coolant temperature becomes too high (overheating) SEN05039-00
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too high Cause
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

• Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature

• Drop in heat dissipation efficiency
Defective actuation of thermostat
Fan belt slipping, worn fan pulley

• Defective cooling circulation system
Clogged, crushed radiator fins

• Rise in oil temperature in power train
Clogged, broken oil cooler

Holes made by pitting
Clogged radiator core

Broken water pump
Lack of coolant
Degree of use of
machine
Condition of over- Suddenly overheated Q w Q

Questions
heating Always tends to overheat Q w w Q

Coolant tempera- Rises quickly Q w
ture gauge
(when coolant
temperature Does not go down from red range w
gauge is installed)
Radiator coolant level monitor indicates low coolant level (when monitor is installed) w
Engine oil level has risen, oil is cloudy white w Q
Fan belt tension is loose w
There is play when fan pulley is rotated w
Cloudy white oil is floating on coolant w
Excessive air bubbles inside radiator, water spurts back w
When light bulb is held behind radiator, no light passes through w
Check items
Radiator shroud, inside of underguard are clogged with dirt or mud w w

Water is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than coolant temperature (when oil
w
and coolant temperature gauges are installed)

Check cylinder liner directly q

Check oil cooler directly q
Temperature difference between top and bottom radiator tanks is excessive q
Troubleshooting
When function test is carried out on thermostat, it does not open even at cracking tem-
q
perature
Temperature difference between top and bottom radiator tanks is small q
Check radiator core directly q
When function test is carried out on radiator cap, cracking pressure is found to be low q
Check fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Action
Add
D65EX, PX, WX-16 40-600 21

SEN05039-00 S-15 Abnormal noise is made
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Cause
Defective fuel injection timing (abnormal coolant temperature

• Abnormality due to defective parts
Leakage of air between turbocharger and cylinder head

• Abnormal combustion
Broken dynamic valve system (valve, rocker lever, etc.)

• Air sucked in from intake system
Defect inside muffler (dividing board out of position)
low temperature sensor, boost temperature sensor)

a Judge if the noise is an internal one or an external one.
Excessive wear of piston ring, cylinder liner

a
Deformed fan, loose fan belt, interference

If the engine is not thoroughly warmed up, the engine sound
becomes slightly louder because it is operated in the low tem-
perature mode, but this is not an abnormality.

a When the engine is accelerated, it enters the acceleration
Improper gear train backlash
Clogged, seized fuel injector

mode and the engine noise is a little bit higher for 3 seconds at
Dirt caught in fuel injector

Missing, seized bushing

a maximum, but this is not an abnormality.

Degree of use of
Operated for long period E
machine
Questions
Condition of abnor- Gradually occurred Q Q

mal noise Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil inside oil filter is drained w w
Leakage of air between turbocharger and cylinder head w
When engine is running, abnormal noise is heard from around cylinder head w w
When engine is running, vibrating noise is heard from around muffler w
Check items
w Q
ders is low
Color of exhaust Blue under light load w

gas Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when accelerating Q Q Q Q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Check gear train directly q q
Check fan, fan belt directly q
q q
der mode
Abnormal noise is made only when starting q
Confirm with monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Action
40-600 22 D65EX, PX, WX-16

S-16 Vibration is excessive SEN05039-00
S-16 Vibration is excessive 1
General causes why vibration is excessive Cause
Misalignment between engine and equipment on the machine

Defective fuel injection timing (abnormal coolant temperature,
• Defective parts (abnormal wear, breakage, etc,)
• Improper alignment with machine
• Abnormal combustion
Stuck dynamic valve system (valve, rocker lever, etc.)

a If there is abnormal noise together with the vibration, carry out troubleshoot-
Loose engine mounting bolts, broken cushion

ing also for “S-15 Abnormal noise is made“.
Broken part inside output shaft and damper

Worn main bearing, connecting rod
Improper gear train backlash
boost temperature sensor)

Worn cam bushing
Degree of use of
E E E
Questions

machine
Condition of vibra- Suddenly increased Q Q

tion Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil inside oil filter is drained w w
Metal particles are found when oil in oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Check main bearing, connecting rod bearing directly q
Troubleshooting
Check gear train directly q

Check camshaft bushing directly q
Confirm with monitoring function q
Check engine mounting bolts, cushions directly q
When face runout and radial runout are inspected, they are found to be incorrect q
Check inside of output shaft and damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Action
D65EX, PX, WX-16 40-600 23

SEN05039-00

©2009 KOMATSU
All Rights Reserved
40-600 24
SEN05110-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
50 Disassembly and assembly 50
100 General information on disassembly

and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 17
D65EX, PX, WX-16 50-100 1

100 General information on disassembly and assembly
SEN05110-01 How to read this manual
How to read this manual (Rev. 2009.01)1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
6 : Amount of oil or coolant to be drained
model. They have a new part num-
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each Installation
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
50-100 2 D65EX, PX, WX-16

How to read this manual SEN05110-01
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
6 : Amount of oil or coolant drained
2) Distinction of new and existing special
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively.
q In “Assembly” section, the work procedures,
R: Tools made available by redesign-
precautions and know-how to do the work, and
ing the existing tools which were
the amount of oil and coolant to be replenished
developed for other models. Each
are described.
of them has a new part number
q Common tools that are necessary for assem-
assigned by setting forward the
bly are described as [1], [2]••• etc. and their
part number of the existing tool.
part numbers, part names and quantities are
Blank : Tools already available for other
not described.
models. They can be used without
q The meanings of the symbols used in “Assem-
any modification.
bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre-
: Precautions related to work safety
sented in the section of “Sketches of
a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
79 T- - :
5
* *** ****
means that they are not available : Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
D65EX, PX, WX-16 50-100 3

SEN05110-01 Coating materials list
Coating materials list (Rev. 2009.02)1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060 • Used to stick and seal metal, glass, and plas-
Adhesive: 1 kg
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8 tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
50-100 4 D65EX, PX, WX-16

Coating materials list SEN05110-01
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
disulfide lubricant
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A • Feature: Lithium grease with extreme pressure
G0-LI SYG2-160LI
Various Various lubrication performance.
*: For cold dis- SYGA-160CNLI
trict SYG0-400LI-A (*) • General purpose type.
SYG0-160CNLI
(*)
• Used for parts under heavy load.
400 g x • Caution:
Bellows- • Do not apply grease to rolling bearings like
Molybdenum SYG2-400M 10
type con-
disulfide grease SYG2-400M-A 400 g x swing circle bearings, etc. and spline.
tainer
Grease
LM-G (G2-M) SYGA-16CNM 20 • The grease should be applied to work equipment

Can
16 kg pins at their assembly only, not applied for
greasing afterwards.
Hyper White • Seizure resistance, heat resistance and water

SYG2-400T-A Bellows- resistance higher than molybdenum disulfide
Grease G2-T, 400 g
SYG2-16CNT type con-
G0-T (*) grease.
SYG0-400T-A (*) tainer
*: For cold dis- 16 kg • Not conspicuous on machine since color is
SYG0-16CNT (*) Can
trict white.
Biogrease
SYG2-400B
G2-B, G2-BT (*) Bellows- • Since this grease is decomposed by natural bac-
SYGA-16CNB 400 g
*: For use at type con-
SYG2-400BT (*) teria in short period, it has less effects on micro-
high tempera- tainer
SYGA-16CNBT 16 kg organisms, animals, and plants.
ture and under Can
(*)
high load
D65EX, PX, WX-16 50-100 5

SEN05110-01 Coating materials list
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
• Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass con-
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
tainer
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass con-
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 tainer
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR side.
Glass con-
Primer
PAINT PRIMER 22M-54-27230 20 ml

tainer (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
435-41 (Using limit: 4 months after date of manu-
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass con-
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
tainer
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season

PENGUINE Polyethyl- and “W” for low-temperature season as
SEAL 580 417-926-3910 320 ml ene con- adhesive for glass.
SUPER “S” or tainer (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
Polyethyl- • Used as adhesive for glass.

Sika Japan,
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manu-
Sikaflex 256HV
Adhesive for cab glass
tainer facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Polyethyl- • Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manu-
SEAL No. 2505 tainer facture)
Caulking material
SEKISUI Polyethyl- • Used to seal front window.

SILICONE 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manu-
SEALANT tainer facture)
• Used to seal joint of glasses.
GE TOSHIBA Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
TOSSEAL 381 (Using limit: 12 months after date of manu-
facture)
50-100 6 D65EX, PX, WX-16

Special tool list SEN05110-01
Special tool list 1
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”)
New/remodel
Necessity
Sketch
Q'ty
Item Symbol Part No. Part name Nature of work, remarks
Removal and
installation of fuel supply
pump assembly, fuel
1 795-799-1131 Gear t 1 Cranking
injector assembly, engine
front oil seal, and cylinder
head assembly
Removal and installation Removal, installation of
of fuel supply pump 2 795-799-1390 Remover t 1 fuel supply pump drive
assembly gear
Removal and 3 795-799-6700 Puller t 1
installation of fuel injector Removal of fuel injector
assembly and cylinder A assembly
head assembly 4 795-799-8150 Remover q 1
Removal and
Installation of engine front
installation of engine front 5 795-799-8120 Oil seal driver q 1 N
oil seal
oil seal
Removal and 795-799-1150 Repair stand q 1
installation of engine rear 6 Fitting of engine assembly
oil seal 795-799-2280 Adapter q 1
Removal and
Tightening of cylinder head
installation of cylinder 7 790-331-1120 Wrench (angle) q 1
bolt
head assembly
790-101-5401 Push tool kit (C) t 1
Disconnection and 790-101-5431 • Plate 1
connection of power train 1 Installation of oil seal
unit assembly 790-101-5421 • Grip 1
01010-51240 • Bolt 1
2 790-201-2720 Spacer t 1 Installation of bearing
790-101-5201 Push tool kit (B) t 1
790-101-5231 • Plate 1
D 3
790-101-5221 • Grip 1
Disassembly and assem- 01010-51225 • Bolt 1
bly of PTO assembly 790-101-5201 Push tool kit (B) t 1 Press fitting of bearing
790-101-5331 • Plate 1
4
790-101-5221 • Grip 1
01010-51225 • Bolt 1
5 796-430-1110 Push tool t 1
D65EX, PX, WX-16 50-100 7

SEN05110-01 Special tool list
New/remodel
Necessity
Sketch
Q'ty
6 794T-422-1110 Push tool t 1 Q

7 794T-413-1120 Push tool t 1 Q
790-101-5401 Push tool kit (C) t 1
Disassembly and assem- Press fitting of bearing
790-101-5491 • Plate 1
bly of torque converter 8
assembly 790-101-5421 • Grip 1
01010-51240 • Bolt 1
Wrench Removal and installation of
9 792-213-1110 t 1
assembly nut
791T-415-5300 Puller assembly t 1 Q
10 791T-415-5310 • Plate 1 Q Installation of snap ring
01010-82040 • Bolt 1
Operation check of clutch
11 799-301-1600 Oil leak tester kit t 1
piston
790-101-5201 Push tool kit (B) t 1
790-101-5311 • Plate 1
12
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5401 Push tool kit (C) t 1
D 790-101-5461 • Plate 1
13
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5201 Push tool kit (B) t 1
Disassembly and
assembly of transmission 790-101-5281 • Plate 1
assembly 14
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Press fitting of bearing
790-101-5001 Push tool kit (A) t 1
790-101-5081 • Plate 1
15
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5471 • Plate 1
16
790-101-5421 • Grip 1
01010-51240 • Bolt 1
17 790-201-2760 Spacer t 1
18 793T-615-1170 Push tool t 1 Q
19 790-201-2830 Spacer t 1
20 791T-415-5210 Push tool t 1 Q
50-100 8 D65EX, PX, WX-16

New/remodel
Necessity
Sketch
Q'ty
Removal, installation of
1 791T-422-1320 Hanger q 1 Q
brake and carrier assembly
Removal, installation of
2 790-302-1500 Wrench kit q 1
bevel pinion nut
Wrench
3 796-730-2300 q 1
assembly
Commercially
Torque wrench
available or q 1
set Adjustment of preload on
795-630-1803
bevel gear shaft and bevel
• Torque gear assembly
4 795-630-1810 1
wrench
795-630-1830 • Adapter 1
790-101-5201 Push tool kit (B) t 1

790-101-5261 • Plate 1
5 Removal of bevel pinion
790-101-5221 • Grip 1
01010-51225 • Bolt 1
6 794T-422-1110 Push tool t 1 Q
Disassembly and 790-101-5401 Push tool kit (C) t 1
assembly of HSS E
assembly 790-101-5481 • Plate 1
7
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5491 • Plate 1
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
9 793T-659-1110 Push tool t 1 Q
10 796T-467-2160 Push tool t 1 Q Press fitting of bearing
11 790-201-2730 Push tool t 1
790-101-5201 Push tool kit (B) t 1
790-101-5221 • Grip 1
12 01010-51225 • Bolt 1
790-101-5271 • Plate 1
790-101-5311 • Plate 1
790-101-5001 Push tool kit (A) t 1
790-101-5091 • Plate 1
13
790-101-5021 • Grip 1
01010-50816 • Bolt 1
D65EX, PX, WX-16 50-100 9

New/remodel
Necessity
Sketch
Q'ty
790-337-1032 Lifting tool t 1

Removal and
Lifting up of final drive
installation of final drive 1 791-427-1090 Plate t 1
assembly
assembly
01010-51635 Bolt t 2
Remover
791-427-1100 t 1
assembly
Separation of sprocket hub
2
790-101-2102 Puller t 1 assembly and bearing
790-101-1102 Pump t 1
3 792-520-2121 Installer t 1 Installation of floating seal
Installer
791-427-1200 t 1
assembly
Press fitting of sprocket
4
Disassembly and 790-101-2102 Puller t 1 hub bearing
assembly of final drive 790-101-1102 Pump t 1
assembly
790-101-5201 Push tool kit (B) t 1
790-101-5321 • Plate 1
5 Installation of oil seal
790-101-5221 • Grip 1
01010-51225 • Bolt 1
6 790-201-2330 Plate t 1
7 790-201-2460 Plate t 1 Press fitting of bearing
8 790-101-5431 Plate t 1
Removal and installation J
of final drive assembly 791T-527-1110 Plate t 1 Slinging of final drive
9
(Planetary gear installed 01010-81680 Bolt t 2 assembly
inside of sprocket type)
01643-31645 Washer t 6
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
Separation of sprocket hub
10 790-101-2470 Adapter (M20) t 2
assembly and bearing
790-101-2450 Adapter (M12) t 2
790-201-2680 Plate t 1
Disassembly and assem-
bly of final drive (Plane- 790-101-2102 Puller t 1
tary gear installed inside 790-101-1102 Hydraulic pump t 1
of sprocket type)
791-520-4140 Screw t 1
791-112-1180 Nut t 1
01643-22460 Washer t 1
11 790-101-2420 Adapter (M16) t 1 Installation of bearing
790-201-2840 Spacer t 1
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
50-100 10 D65EX, PX, WX-16

New/remodel
Necessity
Sketch
Q'ty
790-431-1031 Block t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
01643-22460 Washer t 2 Press fitting of sprocket
12
791T-527-1130 Plate t 1 N Q hub bearing
791T-527-1120 Push tool t 1 N Q
790-101-2102 Puller t 1
13 791-580-8110 Installer t 1 Installation of floating seal
790-101-5201 Push tool kit t 1
Disassembly and assem-
bly of final drive (Plane- 790-101-5321 • Plate t 1
J
tary gear installed inside 14 790-101-5311 • Plate t 1
of sprocket type)
790-101-5221 • Grip t 1
01010-51225 • Bolt t 1
Installation of oil seal,
790-101-5441 • Plate t 1
Press fitting of bearing
15 790-101-5431 • Plate t 1
790-101-5421 • Grip t 1
01010-51240 • Bolt t 1
790-101-5630 Plate t 1 N
16 790-101-5421 Grip t 1
01010-51240 Bolt t 1
Disassembly and
assembly of idler 1 791-515-1520 Installer t 1
assembly
Disassembly and
assembly of track roller 2 791-530-1520 Installer t 1 Installation of floating seal
assembly
Disassembly and L
assembly of carrier roller 3 796-230-1110 Installer t 1
assembly
Disassembly and
assembly of idler
4 791-601-1000 Oil pump t 1 Supply of oil
assembly and track roller
assembly
Compressor of
791-685-8005 t 1
type B
791-635-3160 Extension t 1
Disassembly and
assembly of recoil spring M 790-201-2780 Spacer t 1 Disassembly, assembly of
recoil spring assembly
assembly 790-201-2790 Spacer t 1
790-101-1102 Pump t 1
790-101-1600 Cylinder t 1
Remover
791-450-1100 t 1
assembly
N Pulling out of center pin
of equalizer bar assembly 790-101-2102 Puller t 1
790-101-1102 Pump t 1
D65EX, PX, WX-16 50-100 11

New/remodel
Necessity
Sketch
Q'ty
Installer
791-430-1200 t 1
assembly
P Press fit ring
of pivot shaft assembly 790-101-2102 Puller t 1
790-101-1102 Pump t 1
Removal of pin plug of
1 790-646-7531 Remover t 1
track link
2 791-660-7460 Brush t 1 Cleaning of pin of track link
791-432-1110 Push tool t 1
Installation of pin of track
3 791-646-7550 Bar t 1
link (for large plug)
Whole disassembly and 791-646-7560 Guide t 1
whole
assembly of track shoe 791-932-1110 Push tool t 1
R
assembly Installation of pin of track
4 791-646-7523 Bar t 1
(Conventional type track link (for small plug)
shoe) 791-646-7590 Guide t 1
Check of track link for
5 790-701-3000 Checker t 1
airtightness
Installation of seal of track
6 791-432-1120 Installer t 1
link
7 791-601-1000 Oil pump t 1 Supply of track link oil
791-932-1110 Push tool t 1
Installation of pin of track
4 791-646-7523 Bar t 1
link (for small plug)
791-646-7590 Guide t 1
Check of track link for air-
5 790-701-3000 Checker t 1
tightness
Push tool
791T-532-1100 t 1 Q
assembly
Whole disassembly and 791T-532-1110 • Adapter 1 Q
whole assembly of track 791T-532-1130 • Ring 1 Q
R
shoe assembly 791T-532-1140 • Plate 1 Q
(PLUS type track shoe)
791T-532-1150 • Ring 1 Q
791T-532-1160 • Push tool 1 Q Installation of wedge ring
18
791T-532-1170 • Adapter 1 Q (For large plug side)
791T-532-1180 • Spring 1 Q
791T-532-1190 • Spring 1 Q
791T-532-1210 • Bolt 1 Q
791T-632-5730 • Bar 1 Q
01580-11210 • Nut 1
01252-60610 • Bolt 4
50-100 12 D65EX, PX, WX-16

New/remodel
Necessity
Sketch
Q'ty
Push tool
791T-532-1200 t 1 Q
assembly
791T-532-1120 • Adapter 1 Q
791T-532-1130 • Ring 1 Q
791T-532-1140 • Plate 1 Q
791T-532-1150 • Ring 1 Q
791T-532-1160 • Push tool 1 Q Installation of wedge ring
R 19
791T-532-1170 • Adapter 1 Q (For small plug side)
791T-532-1180 • Spring 1 Q
Whole disassembly and 791T-532-1190 • Spring 1 Q
assembly of one link
(PLUS type track shoe) 791T-532-1220 • Bolt 1 Q
791T-632-5730 • Bar 1 Q
01580-11210 • Nut 1
01252-60610 • Bolt 4
Push tool
791T-532-1300 t 2 Q
assembly
20 791T-532-1310 • Push tool 2 Q Press fitting of wedge ring
R
791T-632-5730 • Bar 2 Q
01580-11210 • Nut 2
21 791T-432-1130 Push tool t 1 Q Press fitting of oil seal
791-432-1110 Push tool t 1
Installation of pin plug of
3 791-646-7550 Bar t 1
track link (for large plug)
791-646-7560 Guide t 1
791-932-1110 Push tool t 1
Installation of pin plug of
4 791-646-7523 Bar t 1
track link (for small plug)
791-646-7590 Guide t 1
Installation of seal of track
6 791-432-1120 Installer t 1
link
791-635-3110 Frame t 1
Field disassembly and 791-635-3160 Extension t 1
assembly of one link
R 791-635-3170 Nut t 4
(Conventional type track
shoe) 8 791-635-3180 Screw t 2
791-635-3190 Screw t 1 Pulling out of pin
791-645-3510 Adapter t 1
791-646-3260 Pusher t 1
790-101-1102 Pump t 1
9
790-101-1300 Cylinder t 1
Jack
790-105-2300 t 1
10 (196 kN {20 ton} Connection of link
790-101-1102 Pump t 1
791-645-3520 Adapter t 1
11 Press fitting of bushing
791-432-1210 Spacer t 1
D65EX, PX, WX-16 50-100 13

New/remodel
Necessity
Sketch
Q'ty
12 791-645-3540 Guide t 1
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
791-635-3190 Screw t 1 Press fitting of pin
13
791-645-3510 Adapter t 1
791-645-3520 Adapter t 1
791-645-3530 Pusher t 1
791-432-1210 Spacer t 1
791-432-1220 Spacer t 1
791-635-3110 Frame t 1
Field disassembly and
assembly of one link 791-635-3160 Extension t 1
R
(Conventional type track 791-635-3170 Nut t 4
shoe)
791-635-3180 Screw t 2
14 Press fitting of bushing
791-635-3190 Screw t 1
791-645-3520 Adapter t 1
791-645-3540 Guide t 1
791-645-3550 Pusher t 1
15 791-646-3270 Guide t 1 Connection of link
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
16 Press fitting of pin
791-635-3180 Screw t 2
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
50-100 14 D65EX, PX, WX-16

New/remodel
Necessity
Sketch
Q'ty
1 790-101-1102 Pump assembly t 1

Jack (196 kN {20 Expansion of
2 790-105-2300 t 1
ton}) link
Remover &
1 791-532-2201 t 1
installer
• Cylinder (980
2 790-101-1300 1
kN {100 ton})
3 791-532-2210 • Plate 1
4 791-532-2220 • Plate 1
5 791-532-2230 • Block 1
6 791-532-2240 • Stud bolt 2
Field disassembly and Disassembly
assembly of one link 7 791-532-2390 • Rod 2 and
R 17
(PLUS type 8 791-532-2260 • Plate 1 assembly of
track shoe) link
3 9 791-532-2270 • Boss 2
10 791-532-2280 • Boss 2
11 791-532-2290 • Plate 1
12 01582-12722 • Nut 4
13 791-532-2380 • Washer 2
14 01252-61645 • Bolt 4
15 02205-12437 • Nut 4
16 791-532-2370 • Plate 1
Press fitting
17 791-532-2340 • Push tool 2 of wedge
ring
790-502-1003 Repair stand t 1 Disassembly and assembly
1 hydraulic cylinder
790-101-1102 Pump t 1 assembly
Wrench Removal and installation of
2 790-330-1100 t 1
assembly cylinder head
Socket (Width
790-302-1270 across flats: 50 t 1
mm)
Socket (Width
Removal and installation of
3 790-102-1330 across flats: 75 t 1
nut
mm)
Socket (Width
Disassembly and 790-302-1340 across flats: 80 t 1
assembly of hydraulic U mm)
cylinder assembly
4 790-720-1000 Expander t 1 Expansion of piston ring
796-720-1650 Ring t 1 For blade lift
07281-01029 Clamp t 1 cylinder
796-720-1660 Ring t 1 For blade
angle
07281-01159 Clamp t 1 cylinder Installation of
5
796-720-1670 Ring t 1 For blade tilt piston ring
cylinder,
blade pitch
07281-01279 Clamp t 1 cylinder,
ripper lift
cylinder
D65EX, PX, WX-16 50-100 15

New/remodel
Necessity
Sketch
Q'ty

790-101-5021 • Grip 1
01010-50816 • Bolt 1
For blade lift
790-201-1781 • Push tool 1
cylinder
For blade tilt Press fitting
6 cylinder, of bushing
blade pitch
790-201-1811 • Push tool 1
cylinder,
ripper lift
cylinder
For blade
790-201-1791 • Push tool 1 angle
Disassembly and cylinder
assembly of hydraulic U
cylinder assembly 790-201-1500 Push tool kit 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
For blade lift
790-201-1590 • Plate 1
cylinder
For blade tilt Press fitting
7 cylinder, of dust seal
blade pitch
790-201-1620 • Plate 1
cylinder,
ripper lift
cylinder
For blade
790-201-1610 • Plate 1 angle
cylinder
Removal and
installation of Lifter (Suction
X 1 793-498-1210 t 2 Installation of window glass
operator’s cab glass cup)
(Stuck glass)
50-100 16 D65EX, PX, WX-16

Sketches of special tools SEN05110-01
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D6 Push tool
D7 Push tool
D65EX, PX, WX-16 50-100 17

SEN05110-01 Sketches of special tools
D10 Puller assembly
D10 Plate
50-100 18 D65EX, PX, WX-16

D18 Push tool
D20 Push tool
D65EX, PX, WX-16 50-100 19

E1 Hanger
E6 Push tool
50-100 20 D65EX, PX, WX-16

E9 Push tool
E10 Push tool
D65EX, PX, WX-16 50-100 21

J9 Plate (Planetary gear installed inside of sprocket type)
J12 Push tool (Planetary gear installed inside of sprocket type)
50-100 22 D65EX, PX, WX-16

J12 Plate (Planetary gear installed inside of sprocket type)
R18 Push tool assembly
D65EX, PX, WX-16 50-100 23

R18 Adapter
R18, R19 Ring
50-100 24 D65EX, PX, WX-16

R18, R19 Plate
R18, R19 Ring
D65EX, PX, WX-16 50-100 25

R18, R19 Push tool
R18, R19 Adapter
50-100 26 D65EX, PX, WX-16

R18, R19 Spring
R18, R19 Spring
D65EX, PX, WX-16 50-100 27

R18 Bolt
R18, R19, R20 Bar
50-100 28 D65EX, PX, WX-16

R19 Adapter
D65EX, PX, WX-16 50-100 29

R19 Bolt
50-100 30 D65EX, PX, WX-16

R20 Push tool
R21 Push tool
D65EX, PX, WX-16 50-100 31

SEN05110-01

©2011 KOMATSU
All Rights Reserved
50-100 32
SEN05111-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 7
Removal and installation of cylinder head assembly .................................................................................... 17
Removal and installation of radiator assembly ............................................................................................. 32
Removal and installation of aftercooler assembly......................................................................................... 35
Removal and installation of hydraulic oil cooler assembly ............................................................................ 37
Removal and installation of power train oil cooler assembly ........................................................................ 39
Removal and installation of cooling fan drive assembly ............................................................................... 42
Removal and installation of cooling fan motor assembly .............................................................................. 44
Removal and installation of main body of coolant preheater (subextremely cold weather spec).................. 46
Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.) ....................... 50
Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.) ............... 52
Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.)............. 56
Removal and installation of damper assembly ............................................................................................. 65
Removal and installation of engine front oil seal........................................................................................... 68
Removal and installation of engine rear oil seal ........................................................................................... 72
Removal and installation of engine hood assembly ...................................................................................... 80
Removal and installation of fuel tank assembly ............................................................................................ 82
D65EX, PX, WX-16 50-200 1

SEN05111-01 Removal and installation of fuel supply pump assembly
Removal and installation of fuel 5. Remove 2 air conditioner hose clamps (3).
supply pump assembly 1
6. Remove air hose clamp (4) and disconnect air
Special tools hose (5). [*1]
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
1 795-799-1131 Gear t 1
A
2 795-799-1390 Remover t 1
Removal
k Stop the machine on a level place and
apply the parking brake.
k Lower the work equipment to the ground
and stop the engine. 7. Remove 3 wiring harness clamps (6).
k Disconnect the cable from the negative (–)
terminal of the battery. 8. Disconnect wiring harness connectors CN-AC
(7) and CN-ACG (8) and ground cable (9).
1. Open fuel tank lower cover (1a).
9. Remove air conditioner compressor (10). For
2. Turn the fuel valve at the fuel tank bottom to details, see Testing and adjusting, “Testing and
the “CLOSE” position. adjusting air conditioner compressor belt ten-
sion”. [*2]
a Fix air conditioner compressor (10) to the
machine with a rope.
3. Open left engine side cover (1) and lock it.

a Lock the cover securely.
4. Remove cover (2). 10. Disconnect wiring harness connector (11) from
the fuel supply pump.
11. Remove hose clamp (12).
12. Disconnect overflow tube (13). [*3]
50-200 2 D65EX, PX, WX-16

Removal and installation of fuel supply pump assembly SEN05111-01
13. Remove the fuel scatter prevention caps at 15. To remove the air conditioner hose clamp,
both ends and disconnect fuel high-pressure remove the following covers.
pipe (14). [*4] 1) Remove cover (18).
14. Disconnect fuel hoses (15), (16) and (17) 2) Remove left step cover (19).
according to the following procedure. [*5] a Remove the cover in order to remove
1) While pushing part (a) of fuel hose (15) in air conditioner hose clamp.
the direction of the arrow, pull part (b) in
the direction of the arrow to disconnect the
fuel hose.
2) Disconnect fuel hoses (16) and (17) simi-
larly.
17. Disconnect wiring harness connector CN-

AC05 (21).
18. Remove receiver drier and bracket assembly

(22).
a Fix receiver drier and bracket assembly
(22) to the machine.
D65EX, PX, WX-16 50-200 3

19. Remove cap (23) from the flywheel housing

and install engine cranking tool A1 (See the
special tool table).
a See Testing and adjusting, “Adjusting
valve clearance”.
24. Remove bracket (27).
25. Remove 4 mounting nuts (28) and fuel supply

pump assembly (29).
20. Loosen and remove cap (24).

a Use a filter wrench etc. to remove cap
(24).
21. Using tool A1, rotate the crankshaft forward

(counterclockwise seeing from the flywheel
side) and set stamp (M) of drive gear (GY) to
the TDC (Top Dead Center). (See the special
tool table)
a Use a mirror to check the stamp etc.
valve clearance”.
22. Remove mounting nut (25) and washer (26)

from fuel supply pump shaft (SH).
a When removing mounting nut (25) and
washer (26), take care not to drip them
into the case.
23. Tighten tool A2 evenly to disconnect shaft (SH)

of the fuel supply pump from drive gear (GY).
50-200 4 D65EX, PX, WX-16

Removal and installation of fuel supply pump assembly SEN05111-01
Installation 4. Install washer (26) and tighten mounting nut

q Install the fuel supply pump assembly accord- (25).
ing to the following procedure. a When installing mounting nut (25) and
washer (26), take care not to drip them
1. Install fuel supply pump assembly (29) while into the case.
matching projection (P) of its shaft (SH) to 3 Mounting nut (25):
groove (G) of gear (GY). 180 ± 13 Nm {18.4 ± 1.3 kgm}
2. Install bracket (27) to fuel supply pump assem-

bly (29).
3 Mounting bolt (27a):
65 ± 6 Nm {6.6 ± 0.6 kgm}
3 Mounting bolt (27b):
77 ± 12 Nm {7.9 ± 1.2 kgm}
3. Install 4 mounting nuts (28).

2 Mounting nut (28): Adhesive (LT-2)
3 Mounting nut (28):
43 ± 6 Nm {4.4 ± 0.6 kgm}
q Carry out the following installation in the

reverse order to removal.
[*1]
a Push in air hose (5) to the stopper of the tube
securely.
3 Air hose mounting clamp (4):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
a Install the air conditioner compressor. For
detail, see Testing and adjusting, “Testing and
adjusting air conditioner compressor belt ten-
sion” and “Removal and installation of air con-
ditioner compressor”.
[*3]
3 Overflow tube (13) mounting joint bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
D65EX, PX, WX-16 50-200 5

[*4]
q Install fuel high-pressure pipe (14) and install
the fuel scatter prevention caps to both ends.
a Tighten the sleeve nut of fuel high-pressure
pipe (14) with the fingers at first, and then
tighten them permanently.
3 Fuel high-pressure pipe (14) sleeve nut:
37.3 ± 4 Nm {3.8 ± 0.4 kgm}
[*5]
k Since the internal parts of the installed por-
tions of fuel hoses (15), (16) and (17) may
have been damaged, replace those hoses
with new ones.
q Checking for fuel leakage (Fuel system)

Check the fuel system for leakage. For details,
see Testing and adjusting, “Checking fuel sys-
tem for leakage”.
q Bleeding air (Fuel system)

Bleed air from the fuel circuit. For details, see
Testing and adjusting, “Bleeding air from fuel
circuit”.
50-200 6 D65EX, PX, WX-16

Removal and installation of fuel injector assembly SEN05111-01
Removal and installation of fuel 5. Remove U-bolt (2) and mounting bolt (3). [*1]
injector assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
1 795-799-1131 Gear t 1
A 3 795-799-6700 Puller t 1
4 795-799-8150 Remover q 1
Removal 6. Lift off muffler assembly (4).

k Stop the machine on a level place and 4 Muffler assembly (4): 30 kg
and stop the engine.
terminal of the battery.
1. Open cover (1) under the fuel tank.
2. Turn the fuel valve at the fuel tank bottom to

the “CLOSE” position.
7. Remove 3 air conditioner hose clamps (5).
3. Remove the engine hood assembly. For

details, see “Removal and installation of
engine hood assembly”.
4. Sling the muffler assembly temporarily.
D65EX, PX, WX-16 50-200 7

SEN05111-01 Removal and installation of fuel injector assembly
8. Remove wiring harness clamp (6). 15. Remove plate (23).
9. Disconnect wiring harness connectors CN-AC

10. Remove air conditioner compressor assembly

(10). For details, see Testing and adjusting,
“Testing and adjusting air conditioner compres-
sor belt tension”. [*2]
a Fix air conditioner compressor assembly
(10) to the machine with a rope.
16. Remove hose clamp (24) and disconnect air

hose (25). [*3]
11. Remove tube clamp (11) and muffler water

drain tube (12).
17. Disconnect wiring harness connectors CN-C8

(26) and CN-C17 (27).
18. Disconnect air tube (29). [*4]
13. Remove wiring harness clamps (14), (15) and

(16).
14. Disconnect the following wiring harness con-

nectors.
(17): CN-HTD (Disconnect from clamp)
(18): CN-WIF
(19): CN-HT/B
(20): CN-HT/A
(21): CN-HT/C
(22): Ground
50-200 8 D65EX, PX, WX-16

19. Remove left step cover (30). 25. Remove fuel filter and corrosion resistor
a Remove the left step cover to remove the assembly (36).
air conditioner hose clamp.

AC05 (32).

(33).
26. Disconnect wiring harness connector CN-C4

(37).
a To disconnect wiring harness connector
CN-C4 (37), slide lock (e) in the direction
of the arrow and pull the connector toward
you while pressing lock (f).
a Even if lock (f) is pressed, the connector
cannot be pulled out if part (g) does not
float. In this case, float part (g) with a flat-
head screwdriver while pressing lock (f)
23. Disconnect 2 heater hoses (34). and pull out the connector toward you to
disconnect.
24. Disconnect 2 fuel hoses (35). [*5]
a While pushing part (c) of fuel hose (35) in
the direction of the arrow, pull part (d) in
fuel hose.
D65EX, PX, WX-16 50-200 9

31. Remove the fuel scatter prevention caps at

both ends and disconnect 6 fuel high-pressure
pipes (43). [*6]
32. Remove hose clamp (44) and disconnect 2

blow-by hoses (45).
28. Remove wiring harness clamp (39).
29. Disconnect 3 fuel injector wiring harness con-

nectors CN-C9 (41).
33. Remove cylinder head cover (46). [*7]
50-200 10 D65EX, PX, WX-16

34. Loosen 2 capture nuts (47) at the fuel injector

head and disconnect fuel injector wiring har-
ness (48).
a Loosen the capture nuts alternately.
a The capture nuts are not removable from
the wiring harness.
a Installed position of wiring harness
Cable color Cylinder No.
p Yellow May be installed
1, 3, 5
q Orange reversely
r Red May be installed
2, 4, 6
s Brown reversely
37. Remove retainer (53) and inlet connector (54).

35. Loosen locknut (49) and loosen adjustment a Before removing retainer (53), remove all
screw (50) by 2 – 3 turns. dirt and sand sticking to and around the
a Loosen the adjustment screw so that an retainer.
excessive force will not be applied to the a Tool A4 (remover) is set for removing inlet
pushrod when the rocker arm is installed. connector (54). (See the special tool table)
36. Remove mounting bolts (51) and rocker arm

and crosshead assembly (52).
38. Remove 2 fuel injector holder mounting bolts

(55).
39. Using tool A3, remove fuel injector holder (56)

and fuel injector assembly (57) together.
a Take care that dirt and foreign matter will
not enter the mounting portion of fuel
injector assembly (57).
a Never hold the solenoid valve at the fuel
injector top with pliers etc.
a Record the installed position and direction

(shapes of holes (a) and (b)) of the cross-
h e a d . ( I n s ta l l t h e c r o s s h e a d i n t h e
recorded direction)
D65EX, PX, WX-16 50-200 11

Installation 3. Insert fuel injector assembly (57) in the cylin-

q Fuel injector assembly der head with its fuel inlet hole directed toward
a Check that the fuel injector installation hole is the intake manifold.
free from flaw and dirt.
a When replacing the fuel injector assembly with 4. Finger-tighten mounting bolts (55) of fuel injec-
new one, be sure to replace the inlet connector holder (56) 3 – 4 turns.
tor, too.
a Check the inlet connector visually for the fol-
lowing defects. If it has any of those defects,
replace it with new one.
(a): There are burrs or deformation at the inlet
or outlet of the inlet connector.
(b): The edge filter is clogged or dirty. If there is
sediment in it, it must not be reused.
(c): The O-ring is cracked or deteriorated.
(d): The outlet seal surface is worn or has a
trace of bad contact or leakage.
a If high-pressure fuel leaks, the seat surface is
eroded and fine streaks or cracks are made. In
this case, replace the inlet connector and fuel
injector assembly with new ones. 5. Install inlet connector (54) with retainer (53)
temporarily.
2 O-ring of inlet connector (54) and
mounting hole on cylinder head side:
3 Retainer (53):
15 ± 5.0 Nm {1.5 ± 0.5 kgm}
6. Tighten mounting bolts (55) of fuel injector

holder (56) alternately.
3 Fuel injector holder mounting bolt (55):
10 ± 2 Nm {1.0 ± 0.2 kgm}
a The top of fuel injector holder (56) must be
in parallel with the top of the cylinder
head.
1. Install gasket (58) and O-ring (59) to fuel injec- Max. allowance: 2.4°
tor assembly (57).
2 O-ring (59) and fuel injector mounting
hole: Engine oil (EO15W-40)
2. Install fuel injector holder (56) to fuel injector

assembly (57).
a Match the convex (A) and concave (B)
parts.
50-200 12 D65EX, PX, WX-16

7. Install inlet connector (54) with retainer (53) 8. Install crosshead (58) and rocker arm assem-
permanently. bly (59) and finger-tighten mounting bolts (51).
3 Retainer (53): a Check that the ball of adjustment screw
41 ± 4 Nm {4.1 ± 0.4 kgm} (50) is fitted in the push rod socket
2 Retainer (53) and hatched part (t) of cyl- securely.
inder head shown below: Caulking (GE a Check that the rocker arm cap on the
TOSHIBA SILICONE TOSSEAL 381) crosshead side is in flat contact with the
crosshead.
a Before installing, clean the oil holes of
mounting bolts (51).
2 Mounting bolt (51) and seat:
9. Tighten mounting bolts (51) permanently.

64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}

and install engine cranking tool A1 (See the
special tool table).
a Check which one is at the top position, No.
q Rocker arm and crosshead assembly 1 cylinder or No. 6. For details, see Test-
a The shapes of holes (a) and (b) of the cross- ing and adjusting, “Adjusting valve clear-
head are different. When reusing the cross- ance”.
head, install it to the original intake and
exhaust valves in the original direction. (A new
crosshead may be installed in either direction)
a Check that 2 valves are inserted in holes (a)
and (b).

a Use a filter wrench etc. to use cap (63).
D65EX, PX, WX-16 50-200 13


tool table)
valve clearance”.
a Install fuel injector wiring harness terminal

(60) so that it will not interfere with rocker
arm (59) when the latter moves up and
down.
13. Adjust the valve clearance. For details, see

Testing and adjusting, “Adjusting valve clear-
ance”.
3 Locknut (49):
24 ± 4 Nm {2.45 ± 0.41 kgm}
14. Install fuel injector wiring harness (48).

3 Capture nut (47):
1.25 ± 0.25 Nm {0.10 ± 0.03 kgm}
a Tighten the capture nuts alternately.
the wiring harness.
1, 3, 5
q Orange reversely
2, 4, 6
s Brown reversely
50-200 14 D65EX, PX, WX-16

a Install fuel injector wiring harness (48) so [*2]

that it will not come in strong contact with a Install the air conditioner compressor. For
the inside wall of rocker arm housing (61), detail, see Testing and adjusting, “Testing and
will not come off guides (u), and will not be adjusting air conditioner compressor belt ten-
bent more sharply. sion” and “Removal and installation of air con-
[*3]
a Push in air hose (25) to the stopper of the tube.
3 Air hose (23) mounting clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
3 Air tube (29) mounting clamp:
8 ± 1 Nm {0.8 ± 0.1 kgm}
3 Air tube (29) mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*5]
q Carry out the following installation in the q Fuel hose (35)
reverse order to removal. k Since the internal parts of the installed por-
tions of fuel hose (35) may have been dam-
[*1] aged, replace the hose with new one.
a Install the muffler and bracket according to the
following procedure. [*6]
1) Tighten mounting bolts (2a) and (2b) per- q Fuel high-pressure pipe
manently. k Do not reuse the fuel high-pressure pipe by
2) Tighten mounting bolt (2c) and mounting bending it.
nut (2d) temporarily. k Be sure to use genuine fuel high-pressure
3) Tighten mounting bolt (2e) and mounting pipe clamps and tighten them to the speci-
nuts (2f) and (2g) permanently. fied torque.
4) Tighten mounting bolt (2c) permanently. k Install the wiring harnesses at least 10 mm
5) Tighten mounting nut (2d) permanently. apart from the high-pressure pipe.
a Tighten both mounting nuts (2f) and (2g) a If the tape seal portion of a fuel high-pressure
evenly. pipe joint has any of the following problems,
a When performing steps 4) and 5), take care replace the fuel high-pressure pipe with new
not to install the exhaust elbow and muffler one.
forcibly. 1) Visible longitudinal slit (b) or pit (c) in
3 U-bolt mounting nuts (2f) and (2g): range (a) of 2 mm from end.
9.8 – 14.7 Nm {1.0 – 1.5 kgm} 2) Level difference caused by fatigue which
is felt with nail in taper seal end part (d) of
2 mm from end.
D65EX, PX, WX-16 50-200 15

a Install the fuel high-pressure pipe between the

common rail and fuel injector according to the
1) Finger-tighten 6 fuel high-pressure pipes
(43).
2) Tighten 6 fuel high-pressure pipes (43)
permanently.
3 Fuel high-pressure pipe (43):
37.3 ± 4 Nm {3.8 ± 0.4 kgm}
3) Install the fuel scatter prevention caps to
both ends of the fuel high-pressure pipe.
a Direct the slit of the fuel scatter prevention cap
on the fuel injector side down and direct that
on the common rail side toward the opposite
side of cylinder block.
a The fuel scatter prevention caps are installed
so that fuel will not spout over the hot parts of
the engine and catch fire when it leaks for
some reason.
[*7]
3 Cylinder head cover (46) mounting bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}

tem for leakage”.

circuit”.
50-200 16 D65EX, PX, WX-16

Removal and installation of cylinder head assembly SEN05111-01
Removal and installation of 4. Drain the engine coolant from the radiator.
cylinder head assembly 1 6 Radiator: 36 l
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
1 795-799-1131 Gear t 1
3 795-799-6700 Puller t 1
A
4 795-799-8150 Remover q 1
7 790-331-1120 Wrench (angle) q 1
Removal 5. Remove the engine hood assembly. For

k Stop the machine on a level place and details, see “Removal and installation of
apply the parking brake. engine hood assembly”.
and stop the engine. 6. Sling the muffler assembly.
terminal of the battery. 7. Remove U-bolt (2) and mounting bolt (3). [*1]
k If the radiator coolant temperature is high,
wait until it decreases to avoid getting
scalded and then drain the coolant.

8. Lift off muffler assembly (4).

4 Muffler assembly (4): 30 kg
3. Remove inspection cover (1a) of the engine

undercover.
D65EX, PX, WX-16 50-200 17

SEN05111-01 Removal and installation of cylinder head assembly
9. Remove 3 air conditioner hose clamps (5). 15. Remove wiring harness clamps (14), (15) and
(16).

nectors.
(17): CN-HTD (Disconnect from clamp)
(18): CN-WIF
(19): CN-HT/B
(20): CN-HT/A
(21): CN-HT/C
(22): Ground
17. Remove plate (23).


18. Remove hose clamp (24) and disconnect air

hose (25). [*3]
13. Remove tube clamp (11) and muffler water

drain tube (12).
50-200 18 D65EX, PX, WX-16

19. Disconnect wiring harness connectors CN-C8 25. Disconnect 2 heater hoses (34).
(26) and CN-C17 (27).
26. Disconnect 2 fuel hoses (35). [*5]
20. Disconnect air tube (29). [*4] a While pushing part (c) of fuel hose (35) in
the direction of the arrow, pull part (d) in
fuel hose.
27. Remove fuel filter and corrosion resistor

assembly (36).
21. Remove left step cover (30).

a Remove the left step cover to remove the
air conditioner hose clamp.

AC05 (32). 28. Disconnect wiring harness connector CN-C4
(37).
24. Remove receiver drier and bracket assembly a To disconnect wiring harness connector
(33). CN-C4 (37), slide lock (e) in the direction
a Fix receiver drier and bracket assembly of the arrow and pull the connector toward
(33) to the machine. you while pressing lock (f).
a Even if lock (f) is pressed, the connector
cannot be pulled out if part (g) does not
float.
In this case, float part (g) with a flat-head
screwdriver while pressing lock (f) and pull
out the connector toward you to discon-
nect.
D65EX, PX, WX-16 50-200 19

33. Remove tube clamp (45) and fuel scatter pre-

vention caps at both ends and disconnect 6
fuel high-pressure pipes (46) and (47). [*6]
34. Remove the fuel scatter prevention caps at

both ends and disconnect fuel tube (48).
35. Remove bracket (49) and disconnect 3 fuel

hoses (50). [*7]
36. Remove common rail assembly (51). [*8]
37. Remove tube clamp (52) and disconnect lubri-

cation tube (53). [*] Torque
31. Disconnect 3 fuel injector wiring harness con-

nectors CN-C9 (41).
50-200 20 D65EX, PX, WX-16

38. Remove hose clamp (54) and disconnect 2 43. Remove 3 heat insulation plates (64).
blow-by hoses (55).
44. Disconnect lubrication hose (65) and drain

39. Remove U-bolt (56) from the right side of the hose (66). [*14]
engine and remove bracket (57). [*10]
40. Remove clamp (58) and disconnect air tube

(59). [*11]
41. Remove clamp (60) and disconnect exhaust

tube (61). [*12]
45. Sling turbocharger and exhaust manifold

assembly (67) and remove all mounting bolts
(68). [*15]
42. Disconnect water hose (62) and radiator upper

hose (63). [*13]
D65EX, PX, WX-16 50-200 21

46. Lift off turbocharger and exhaust manifold 49. Loosen 2 capture nuts (72) at the fuel injector
assembly (67). head and disconnect fuel injector wiring har-
4
ness (73).
Turbocharger and exhaust manifold
a Loosen the capture nuts alternately.
assembly (67): 25 kg
the wiring harness.
1, 3, 5
q Orange reversely
2, 4, 6
s Brown reversely
50. Loosen locknut (74) and loosen adjustment

screw (75) by 2 – 3 turns.
a Loosen the adjustment screw so that an
excessive force will not be applied to the
47. Remove wiring harness clamp (69) and dis- pushrod when the rocker arm is installed.
connect water tube (70).
51. Remove mounting bolts (76) and rocker arm
and crosshead assembly (77).
48. Remove cylinder head cover (71). [*16]
50-200 22 D65EX, PX, WX-16

a Record the installed position and direction

(shapes of holes (a) and (b)) of the cross-
h e a d . ( I n s ta l l t h e c r o s s h e a d i n t h e
recorded direction)
55. Remove push rods (83).
56. Remove spacer (84).
52. Remove retainer (78) and inlet connector (79). 57. Remove the spacers from other cylinders, too.
a Before removing retainer (78), remove all
dirt and sand sticking to and around the 58. Remove rocker arm housing (85).
retainer.
a Tool A4 (remover) is set for removing inlet
connector (79). (See the special tool table)
59. Remove 26 cylinder head mounting bolts and

lift off cylinder head assembly (86).
4 Cylinder head assembly (86): 85 kg
53. Remove 2 fuel injector holder mounting bolts
(80).
60. Remove cylinder head gasket (87).
54. Using tool A3, remove fuel injector holder (81)
and fuel injector assembly (82) together.
a Take care that dirt and foreign matter will
not enter the mounting portion of fuel
injector assembly (82).
a Never hold the solenoid valve at the fuel
injector top with pliers etc.
D65EX, PX, WX-16 50-200 23

Installation 3. Before installing the cylinder head mounting

q Cylinder head assembly bolts, check the following conditions. If a bolt
a Check that the cylinder head mounting face satisfies either or both of the following condi-
and inside of the cylinders are free from dirt tions, do not reuse it but replace.
and foreign matter. q Number of tightening time of bolt is 6
(Number of punch marks to indicate num-
1. Set cylinder head gasket (87) to the cylinder ber of tightening time on bolt head is 5).
block. q Bolt stem length (a) is 162.6 mm or longer.
a Match the holes of cylinder head gasket
(87) to those of the cylinder block.
a When installing the cylinder head gasket,
ensure that the grommet is not peeled off
and has not come off.
4. Install the cylinder head mounting bolts

1) Install cylinder head mounting bolts and
finger-tighten them in the order of [1] –
[26].
2. Sling cylinder head assembly (86) and set it to 2 Cylinder head mounting bolt:
the cylinder block. Engine oil (EO15W-40)
4
2) Tighten the cylinder head mounting bolts
Cylinder head assembly (86): 85 kg in the order shown below.
a Hit the valve stem lightly with a plastic 1] 50 ± 7 Nm {5.0 ± 0.7 kgm}
hammer to check that the half collet is fit- 2] 150 ± 10 Nm {15.3 ± 1.0 kgm}
ted to the valve stem groove securely. 3] Return all bolts 360°
a Check that the holes of cylinder head gas- 4] 115 ± 5 Nm {11.7 ± 0.5 kgm}
ket (87) are matched to those of the cylin- 5] Check torque of 115 ± 5 Nm {11.7 ±
der block. 0.5 kgm}
6] Retighten 120 ± 5°
a Tool A7 (See the special tool table) is set
for angle tightening.
50-200 24 D65EX, PX, WX-16

q When not using tool A7 8. Install spacer (84).

1) Make marks on the cylinder head and
each mounting bolt with paint etc. (See
the figure below)
2) Tighten the cylinder head mounting bolt
120 ± 5°.
a When using a new mounting bolt, do not
make a punch mark.
q Rocker arm housing assembly

5. Install push rods (83).
a Check that the push rod is securely in the
tappet hole.
2 Push rod socket:
6. Fit the gasket and install rocker arm housing q Fuel injector assembly
(85). a Check that the fuel injector installation hole is
free from flaw and dirt.
7. Tighten rocker arm housing mounting bolts in a When replacing the fuel injector assembly with
the order of [1] – [7] shown below. new one, be sure to replace the inlet connec-
3 Rocker arm housing mounting bolt: tor, too.
24 ± 4 Nm {2.4 ± 0.4 kgm} a Check the inlet connector visually for the fol-
lowing defects. If it has any of those defects,
replace it with new one.
(a): There are burrs or deformation at the inlet
or outlet of the inlet connector.
(b): The edge filter is clogged or dirty. If there is
sediment in it, it must not be reused.
(c): The O-ring is cracked or deteriorated.
(d): The outlet seal surface is worn or has a
trace of bad contact or leakage.
D65EX, PX, WX-16 50-200 25

a If high-pressure fuel leaks, the seat surface is 12. Finger-tighten mounting bolts (80) of fuel injec-
eroded and fine streaks or cracks are made. tor holder (81) 3 – 4 turns.
In this case, replace the inlet connector and
fuel injector assembly with new ones.
13. Install inlet connector (79) with retainer (78)

temporarily.
2 O-ring of inlet connector (79) and
mounting hole on cylinder head side:
3 Retainer (78):
15 ± 5.0 Nm {1.5 ± 0.5 kgm}
9. Install gasket (88) and O-ring (89) to fuel injec-

tor assembly (82).
2 O-ring (89) and fuel injector mounting
hole: Engine oil (EO15W-40)
10. Install fuel injector holder (81) to fuel injector

assembly (82). 14. Tighten mounting bolts (80) of fuel injector
a Match the convex (A) and concave (B) holder (81) alternately.
parts. 3 Fuel injector holder mounting bolt (80):
10 ± 2 Nm {1.0 ± 0.2 kgm}
11. Insert fuel injector assembly (82) in the cylin- a The top of fuel injector holder (81) must be
der head with its fuel inlet hole directed toward in parallel with the top of the cylinder
the intake manifold. head.
Max. allowance: 2.4°
50-200 26 D65EX, PX, WX-16

15. Install inlet connector (79) with retainer (78) 16. Install crosshead (90) and rocker arm assem-
permanently. bly (91) and finger-tighten mounting bolts (76).
2 Retainer (78) and hatched part (t) of cyl- a Check that the ball of adjustment screw
inder head shown below: Caulking (GE (75) is fitted in the push rod socket
TOSHIBA SILICONE TOSSEAL 381) securely.
3 Retainer (78): a Check that the rocker arm cap on the
41 ± 4 Nm {4.1 ± 0.4 kgm} crosshead side is in flat contact with the
crosshead.
a Before installing, clean the oil holes of
mounting bolts (76).
2 Mounting bolt (76) and seat:
17. Tighten mounting bolts (76) permanently.

64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}

and install engine barring tool A1 (See the spe-
cial tool table).
a Check which one is at the top position, No.
q Rocker arm and crosshead assembly 1 cylinder or No. 6. For details, see Test-
a The shapes of holes (a) and (b) of the cross- ing and adjusting, “Adjusting valve clear-
head are different. When reusing the cross- ance”.
head, install it to the original intake and
exhaust valves in the original direction. (A new
crosshead may be installed in either direction)
a Check that 2 valves are inserted in holes (a)
and (b).

a Use a filter wrench etc. to remove cap
(93).
D65EX, PX, WX-16 50-200 27


tool table)
valve clearance”.
a Install fuel injector wiring harness termi-

nals (94) so that they will not interfere with
rocker arm (91) when the latter moves up
and down.
21. Adjust the valve clearance. For details, see

Testing and adjusting, “Adjusting valve clear-
ance”.
3 Locknut (74):
24 ± 4 Nm {2.45 ± 0.41 kgm}
22. Install fuel injector wiring harness (73).

3 Capture nut (72):
1.25 ± 0.25 Nm {0.10 ± 0.03 kgm}
a Tighten the capture nuts alternately.
the wiring harness.
1, 3, 5
q Orange reversely
2, 4, 6
s Brown reversely
50-200 28 D65EX, PX, WX-16

a Install fuel injector wiring harness (73) so [*2]

that it will not come in strong contact with a Install the air conditioner compressor. For
the inside wall of rocker arm housing (85), detail, see Testing and adjusting, “Testing and
will not come off guides (u), and will not be adjusting air conditioner compressor belt ten-
bent more sharply. sion” and “Removal and installation of air con-
[*3]
a Push in air hose (25) to the stopper of the tube.
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
3 Air tube (29) mounting clamp:
8 ± 1 Nm {0.8 ± 0.1 kgm}
3 Air tube (29) mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*5]
q Fuel hose (35)
q Carry out the following installation in the k Since the internal parts of the installed por-
reverse order to removal. tions of fuel hose (35) may have been dam-
aged, replace the hose with new one.
[*1]
a Install the muffler and bracket according to the [*6]
following procedure. q Fuel high-pressure pipe
1) Tighten mounting bolts (2a) and (2b) per- k Do not reuse the fuel high-pressure pipe by
manently. bending it.
2) Tighten mounting bolts (2c) and mounting k Be sure to use genuine fuel high-pressure
nuts (2d) temporarily. pipe clamps and tighten them to the speci-
3) Tighten mounting bolts (2e) and mounting fied torque.
nuts (2f) and (2g) permanently. k Install the wiring harnesses at least 10 mm
4) Tighten mounting bolts (2c) permanently. apart from the high-pressure pipe.
5) Tighten mounting nuts (2d) permanently. a If the tape seal portion of a fuel high-pressure
a Tighten both mounting nuts (2f) and (2g) pipe joint has any of the following problems,
evenly. replace the fuel high-pressure pipe with new
a When performing steps 4) and 5), take one.
care not to install the exhaust elbow and 1) Visible longitudinal slit (b) or pit (c) in
muffler forcibly. range (a) of 2 mm from end.
3 U-bolt mounting nuts (2f) and (2g): 2) Level difference caused by fatigue which
9.8 – 14.7 Nm {1.0 – 1.5 kgm} is felt with nail in taper seal end part (d) of
2 mm from end.
D65EX, PX, WX-16 50-200 29

a Install the fuel high-pressure pipe between the 3) Install the fuel pressure relief valve.
common rail and fuel injector according to the Apply clean gear oil (#90) to the threads.
following procedure. 3 Tightening torque:
1) Finger-tighten 6 fuel high-pressure pipes 100 ± 4 Nm {10.2 ± 0.4 kgm}
(47). 4) Start the engine and check that there is no
2) Tighten 6 fuel high-pressure pipes (47) leakage.
permanently. a For the testing procedure, refer to
3 Fuel high-pressure pipe (47) sleeve "Testing and adjusting".
nut: 37.3 ± 4 Nm {3.8 ± 0.4 kgm}
3) Install the fuel scatter prevention caps to [*9]
both ends of the fuel high-pressure pipe. 3 Lubrication tube (53) mounting bolt:
a Direct the slit of the fuel scatter prevention cap 24 ± 4 Nm {2.45 ± 0.41 kgm}
on the fuel injector side down and direct that
on the common rail side toward the opposite [*10]
side of cylinder block. 3 U-bolt (56): 18.6 ± 7.8 Nm {1.9 ± 0.8 kgm}
a The fuel scatter prevention caps are installed
so that fuel will not spout over the hot parts of [*11]
the engine and catch fire when it leaks for 3 Clamp (58): 7 ± 1.1 Nm {0.7 ± 0.1 kgm}
some reason.
[*12]
[*7] 3 Clamp (60): 6.9 – 8.8 Nm {0.7 – 0.9 kgm}
q Fuel hose (50)
k Since the internal parts of the installed por- [*13]
tions of fuel hose (50) may have been dam- 3 Radiator upper hose (6) mounting clamp:
aged, replace the hose with new one. 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
a For the installed positions of water hose (62)
[*8] and radiator upper hose (63), see the following
3 Common rail assembly (51) mounting bolt: figure.
43 ± 6 Nm {4.4 ± 0.6 kgm} q Cylinder head side
q Handling fuel pressure sensor and fuel
pressure relief valve
1. Fuel pressure sensor
Do not remove the sensor except for its
replacement. The sensor removed from the
common rail must be replaced with the new
one.
1) Check the sensor connector for cracks,
damages, broken seal. Also, check the
pins for foreign matter, corrosion, bents, or
breakage.
2) Install the new sensor.
Apply clean gear oil (#90) to the threads.
3 Tightening torque:
70 ± 5 Nm {7.1 ± 0.5 kgm}
3) Connect the engine harness. At this time,
pay attention to polarity of the connector.
4) Start the engine and check that there is no
leakage.
a For the testing procedure, refer to
"Testing and adjusting".
2. Fuel pressure relief valve
1) Do not reuse a fuel pressure relief valve
whose leakage rate has exceeded the
specified value.
2) Check that the high-pressure seal sur-
faces of the fuel pressure relief valve and
rail are not damaged.
50-200 30 D65EX, PX, WX-16

[*14] q Bleeding air (Fuel system)

3 Lubrication hose (65) sleeve nut: Bleed air from the fuel circuit. For details, see
36 ± 4 Nm {3.7 ± 0.4 kgm} Testing and adjusting, “Bleeding air from fuel
3 Drain hose (66) mounting bolt: circuit”.
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*15]
q Install the turbocharger and exhaust manifold
assembly mounting bolts (68) according to the
1) Tighten all the bolts in the order of [1] –
[12] shown below.
3 24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Retighten bolts [1] – [4] only shown below
in the order of their numbers.
3 24 ± 4 Nm {2.4 ± 0.4 kgm}
3) Tighten all the bolts in the order of [1] –
[12] shown below.
3 43 ± 6 Nm {4.4 ± 0.6 kgm}
4) Retighten bolts [1] – [4] only shown below
in the order of their numbers.
3 43 ± 6 Nm {4.4 ± 0.6 kgm}
[*16]
3 Cylinder head cover (71) mounting bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}
q Refilling with coolant (Radiator)

Add engine coolant through the coolant filler to
the specified level. Run the engine to circulate
the coolant through the system. Then, check
the coolant level again.
5 Radiator (Engine coolant): 36 l (For
details, see “Table of fuel, coolant
and lubricants”.)

tem for leakage”.
D65EX, PX, WX-16 50-200 31

SEN05111-01 Removal and installation of radiator assembly
Removal and installation of 7. Remove 5 wiring harness clamps (3).

radiator assembly 1
8. Remove 3 hose clamps (4).
Removal
k Stop the machine on a level place and 9. Disconnect water hose (5). [*1]
k Lower the work equipment to the ground,
stop the engine, and loosen the hydraulic
tank cap gradually to release the pressure
inside the hydraulic tank.
1. Remove inspection cover (1) of the engine

undercover.
2. Drain the engine coolant from the radiator.

6 Radiator: 36 l
10. Disconnect radiator lower hose (6). [*2]
3. Remove cover (2) under the hydraulic tank.
4. Drain the hydraulic oil from the hydraulic tank. 11. Sling the radiator assembly.
6 Hydraulic tank: 82 l 12. Remove 4 radiator mounting bolts (7).

6. Remove the hydraulic oil cooler assembly. For

hydraulic oil cooler assembly”.
50-200 32 D65EX, PX, WX-16

Removal and installation of radiator assembly SEN05111-01
14. Lift off radiator assembly (9). [*3] Installation

4 Radiator assembly (9): 25 kg q Carry out installation in the reverse order to
removal.
[*1]
3 Water hose (5) mounting clamp:
4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}
a For the installed positions of the hoses, see the
following figure.
q Upper side of radiator
[*2]
3 Radiator lower hose (6) mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
following figure.
q Lower side of radiator
D65EX, PX, WX-16 50-200 33

SEN05111-01 Removal and installation of radiator assembly
q Oil cooler inlet side q Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic tank (Hydraulic oil): 82 l (For
and lubricants”.)
[*3]
a Check that projections (a) at the radiator bot-
tom are securely in mounting holes (b).

and lubricants”.)
50-200 34 D65EX, PX, WX-16

Removal and installation of aftercooler assembly SEN05111-01
Removal and installation of 7. Disconnect aftercooler outlet air hose (3). [*1]
aftercooler assembly 1
Removal

undercover.
8. Sling the aftercooler assembly.
6 Radiator: 36 l 9. Remove 2 aftercooler mounting bolts (4).
4. Drain the hydraulic oil from the hydraulic tank. 11. Lift off aftercooler assembly (6). [*2]
6 Hydraulic tank: 82 l 4 Aftercooler assembly (6): 25 kg


D65EX, PX, WX-16 50-200 35

SEN05111-01 Removal and installation of aftercooler assembly
Installation q Refilling with coolant (Radiator)

q Carry out installation in the reverse order to Add engine coolant through the coolant filler to
removal. the specified level. Run the engine to circulate
[*1] the coolant level again.
3
5
Aftercooler outlet air hose (3) mounting Radiator (Engine coolant): 36 l (For
clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} details, see “Table of fuel, coolant
a When installing the hose, direct up white mark and lubricants”.)
(a) at its end.
a For the installed positions of the hoses, see the q Refilling with oil (Hydraulic tank)
following figure. Add oil through the oil filler to the specified
q Aftercooler outlet side through the system. Then, check the oil level
again.
and lubricants”.)
[*2]
a Check that projections (b) at the aftercooler
bottom are securely in mounting holes (c).
50-200 36 D65EX, PX, WX-16

Removal and installation of hydraulic oil cooler assembly SEN05111-01
Removal and installation of 6. Disconnect the following hoses.

hydraulic oil cooler assembly 1
(3): Aftercooler inlet air hose and tube [*1]
(4): Aeration hose
Removal (5): Radiator reservoir hose
k Stop the machine on a level place and (6): Radiator upper hose [*2]

undercover.

6 Radiator: 36 l
7. Remove radiator reservoir tank and bracket

assembly (7).
8. Remove radiator upper bracket (8).
4. Drain the hydraulic oil from the hydraulic tank.

6 Hydraulic tank: 82 l
9. Remove 4 fixing brackets (9) and air condi-
tioner condenser assembly (10).
a Fix air conditioner condenser assembly

D65EX, PX, WX-16 50-200 37

SEN05111-01 Removal and installation of hydraulic oil cooler assembly
10. Remove hose clamps (11). q Turbocharger side
11. Disconnect hydraulic hoses (12) and (13).

a Plug the hoses and adapters to prevent
the oil from flowing out.
12. Remove hydraulic oil cooler assembly (14) and

frame (15) together.
[*2]
3 Radiator upper hose (6) mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
following figure.
q Upper side of radiator
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Aftercooler inlet air hose (3) mounting
clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
following figure.
q Aftercooler side

and lubricants”.)
q Refilling with oil (Hydraulic tank)

again.
and lubricants”.)
50-200 38 D65EX, PX, WX-16

Removal and installation of power train oil cooler assembly SEN05111-01
Removal and installation of power 6. Remove the hydraulic oil cooler assembly. For
train oil cooler assembly 1
Removal
k Stop the machine on a level place and 7. Remove the radiator assembly. For details,
apply the parking brake. see “Removal and installation of radiator
k Lower the work equipment to the ground, assembly”.
tank cap gradually to release the pressure 8. Remove the aftercooler assembly. For details,
inside the hydraulic tank. see “Removal and installation of aftercooler
k Disconnect the cable from the negative (–) assembly”.
9. Remove engine underguard (1).
1. Remove inspection cover (1a) of the engine a Install wire ropes etc. to the bottom of
undercover. engine underguard (1) and hang down.
4 Engine underguard (1): 130 kg
6 Radiator: 36 l
10. Sling radiator guard and power train oil cooler

assembly (2).
3. Remove cover (1b) under the hydraulic tank.
11. Remove 5 upper mounting bolts (3).

D65EX, PX, WX-16 50-200 39

SEN05111-01 Removal and installation of power train oil cooler assembly
12. Disconnect power train oil cooler outlet air 15. Disconnect 2 hydraulic hoses (7).
hose (4). [*1] a Plug the hoses and adapters to prevent
13. Remove 3 lower mounting bolts (5).
17. Lift off radiator guard and power train oil cooler
assembly (2).
4 Radiator guard and power train oil
cooler assembly (2): 100 kg
14. Remove 2 radiator guard lower mounting bolts

(6) on the right and left sides from below.
18. Remove power train oil cooler assembly (9)

from radiator guard and power train oil cooler
assembly (2).
50-200 40 D65EX, PX, WX-16

Removal and installation of power train oil cooler assembly SEN05111-01
Installation
removal.
[*1]
3 Power train oil cooler outlet hose (4) mount-
ing clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
a When installing, see the following.
q Power train oil cooler side

and lubricants”.)

again.
and lubricants”.)
q Refilling with oil (Power train case)

again.
5 Power train case (Power train oil): Addi-
tion only (For details, see “Table of
fuel, coolant and lubricants”.)
D65EX, PX, WX-16 50-200 41

SEN05111-01 Removal and installation of cooling fan drive assembly

cooling fan drive assembly 1
6. Disconnect wiring harness connector CN-FAR
Removal (5).
apply the parking brake. 7. Disconnect hydraulic tube (6) and hydraulic
k Lower the work equipment to the ground, hoses (7) and (8).
stop the engine, and loosen the hydraulic a Plug the hoses and adapters to prevent
tank cap gradually to release the pressure the oil from flowing out.
k Disconnect the cable from the negative (–) 8. Remove cooling fan guard (9).

9. Sling the cooling fan drive assembly.
10. Remove 2 upper mounting bolts (10) and 2

lower mounting bolts (11).
3. Remove the mounting bolts and lift off radiator

grille (2).
4 Radiator grille (2): 40 kg
50-200 42 D65EX, PX, WX-16

Removal and installation of cooling fan drive assembly SEN05111-01
11. Lift off cooling fan drive assembly (12). Installation

a When removing cooling fan drive assem- q Carry out installation in the reverse order to
bly (12), take care that it will not interfere removal.
with parts around it.
4 Cooling fan drive assembly (12): 50 kg q Refilling with oil (Hydraulic tank)
again.
and lubricants”.)
D65EX, PX, WX-16 50-200 43

SEN05111-01 Removal and installation of cooling fan motor assembly
Removal and installation of 5. Loosen nut (3). [*2]

cooling fan motor assembly 1
a Leave nut (3) screwed in by 2 – 3 turns.
Removal

6 Hydraulic tank: 82 l 6. Using puller [1], disconnect fan (4) from the fan
motor shaft.
7. Remove nut (3) described above and remove

fan (4).
3. Remove the cooling fan drive assembly. For

details, see “Removal and installation of cool-
ing fan drive assembly”.
4. Remove mounting bolt (1) and lock plate (2). 8. Remove the 4 mounting bolts and fan motor
[*1] assembly (5). [*3]
50-200 44 D65EX, PX, WX-16

Removal and installation of cooling fan motor assembly SEN05111-01
Installation
removal.
[*1], [*2]
3 Mounting nut (3):
132 – 157 Nm {13.5 – 16.0 kgm}
a Install lock plate (2) according to the following

procedure.
1) Align the mounting bolt holes on both front
and reverse sides of lock plate (2).
2) From the above result, select either side
which needs less adjustment and
retighten until the hole of nut (3) is
matched.
3) Tighten mounting bolt (1).
2 Mounting bolt (1): Adhesive (LT-2)
[*3]
a Wipe the fitting portions of the fan motor shaft
and fan boss clean and degrease them.

again.
and lubricants”.)
D65EX, PX, WX-16 50-200 45

SEN05111-01 Removal and installation of main body of coolant preheater (subextremely cold weather spec)
Removal and installation of main 4. Remove coolant preheater cover (5).

body of coolant preheater 4 Coolant preheater cover: 20 kg
(subextremely cold weather spec)1 a Bolt (6): M12 (five pieces)
Removal
k Place the machine on a level ground and
k Disconnect the cable from the negative (-)

undercover.
2. Drain engine coolant from the radiator.
6 Radiator: 37 L
5. Remove heat insulation cover (7).

Bolt (8): M6 (one piece)
3. Lock it after opening engine right side cover

(2), remove fuel tank cap (3) of coolant pre-
heater, and pull out rubber plate (4).
6. Remove heat insulation cover assembly (9).
Remove M6 bolts (10) (two pieces) and pull
out heat insulation cover assembly (9) as
assembly.
Heat insulation cover assembly (9)

9a: Heat insulation material
9b: Iron portion
Z: Obverse side
Y: Reverse side
50-200 46 D65EX, PX, WX-16

Removal and installation of main body of coolant preheater (subextremely cold weather spec) SEN05111-01
7. Remove clamp (11) and band (12) of exhaust 9. Remove coolant preheater water pipes (two
duct, and separate it off from main body of places).
coolant preheater. 1) With engine right side cover opened,
a Bolt (13): M10 (one piece) loosen clamp (16) and pull the hose out.
a Use socket of width across flats 9.5mm
(necessary)
2) With engine right side cover opened,

reach your hand behind the coolant pre-
8. Check the fuel valve (14) of coolant preheater heater to loosen clamp (17) and pull the
is CLOSE, and loosen the fuel hose on coolant hose out.
preheater side (portion A).
a Oil remained in the hose may flow out.
Prepare an oil container or a plug in
advance to prevent oil from flowing.
a Width across flats of hose (15): 19mm
D65EX, PX, WX-16 50-200 47

SEN05111-01 Removal and installation of main body of coolant preheater (subextremely cold weather spec)
10. Remove bolt (18) fixing water pipe 12. Disconnect wiring harness connectors (24)
tube.Coolant preheater assembly cannot be (three places).
removed because the water pipe tube is fixed Disconnect wring harness connectors (24)
to the fender. Be sure to remove it. (three places) by reaching hand through the
a Bolt (18): M10 (one piece) space where the engine right side under cover
(19) was removed.
11. Remove the engine right side under cover

(19). 13. Remove wiring harness clamps (25) (two
q Remove grommets (20), (two piece) and places).
remove two bolts (two piece) in it. The harness is clamped to additional fender
a Bolt: M12 (two pieces) (26), so remove bolts (27) (two pieces).
a Bolt (27): M10 (two pieces)
q Grasp the handle(21) of engine right side

under cover (19), and move it to the rear 14. Remove bolts (29) of rubber mount portion in
side of the machine, remove lock pin (23), main body of coolant preheater (28).
and then lift the cover up and remove Remove bolts (29) (four pieces) fixing on cool-
them. ant preheater assembly (28).
a Bolt (29): M12 (four pieces)
50-200 48 D65EX, PX, WX-16

Removal and installation of main body of coolant preheater (subextremely cold weather spec) SEN05111-01
15. Remove coolant preheater assembly.

4 Coolant preheater assembly:
25 kg
Installation
q Perform installation in the reverse order to
removal.
D65EX, PX, WX-16 50-200 49

SEN05111-01 Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.)
Removal and installation of 3. Loosen drain plug (6) of fuel tank and drain the
oil.
coolant preheater fuel tank q Prepare an oil container, and place it on
(Subextremely cold weather the shoe for drained oil under the fuel tank
spec.) 1 drain plug (6).
Removal Fuel tank capacity: 4 L
k Place the machine on a level ground and q Use a wrench [1] of width across flats 22
apply the parking brake. mm horizontally from notch of additional
k Lower the work equipment to the ground, fender, and loosen it.
1. Open engine right side cover (1) and lock it,

remove fuel tank cap (2) of coolant preheater,
and pull out rubber plate (3).
2. Remove coolant preheater cover (4).

4 Coolant preheater cover:
20 kg
a Bolt (5): M12 (five pieces)
4. Disconnect fuel hose (8).

a Loosen hose shown in the figure below
(portion B).
a Hose (8) width across flats: 19mm
50-200 50 D65EX, PX, WX-16

Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.) SEN05111-01
5. Remove fuel tank mounting bolts (9).

Bolt (9): M12 (four pieces)
6. Fuel tank assembly (10).

6: Drain plug
10a: Fuel gauge
10b: Fuel cap
10c: Strainer
10d: Strainer
Installation
removal.
D65EX, PX, WX-16 50-200 51

SEN05111-01 Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)
Removal and installation of 4. Remove coolant preheater cover (5)

coolant preheater exhaust duct. 4 Coolant preheater cover:
(Subextremely cold weather 17 kg
spec.) 1
a Bolt (6): M12 (five pieces)
Removal
1. Remove the inspection cover (1) of engine

under cover.
2. Drain engine coolant from the radiator.
6 Radiator: 37 L
5. Remove heat insulation cover (7).

Bolt (8): M6 (one piece)
3. Open engine right side cover (2) and lock it,

remove fuel tank cap (3) of coolant preheater,
and pull out rubber plate (4).
6. Remove heat insulation cover assembly (9).
Remove M6 bolts (10) (two pieces) and pull
out heat insulation cover assembly (9) as
assembly.
Heat insulation cover assembly (9):

9a: Heat insulation material
9b: Iron portion
Z: Obverse
Y: Reverse
50-200 52 D65EX, PX, WX-16

Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.) SEN05111-01
7. Remove clamp (11) and band (12) of exhaust 9. Remove engine right side under cover (17).
duct, and separate it off from main body of q Remove grommets (18) (two pieces) and
coolant preheater. remove two bolts in it.
a Bolt (13): M10 (one piece) a Grommet bolts: M12 (two pieces)
a Use socket of width across flats 9.5mm.
(Necessary)
q Grasp engine right side under cover (17)

handle, and move it to the rear side of the
8. Remove coolant preheater water pipes (14) machine, remove lock pin (20), and then
(two places). lift the cover up and remove them.
1) With engine right side cover opened, 10. Disconnect harness connector (21) (one
loosen clamp (15) and pull the hose out. piece).
Reach your hand through the space where the
en gine righ t sid e u nde r co ver (1 7) wa s
removed, and disconnect the wring harness
connector (21) (one place) which is the lowest
of three vertical lined.
2) With engine right side cover opened,

reach your hand behind the coolant pre-
heater to loosen clamp (16) and pull the
hose out.
D65EX, PX, WX-16 50-200 53

SEN05111-01 Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)
11. Install hook to additional fender assembly (22)

and sling it temporarily.
a Install M12 eyebolts to portion a and b.
a Install sling hook to f20 sling hook install-
ing port of portion C.
a Sling additional fender assembly (22) by
slinging it at three points.
13. Remove the undercover.

a Hold the bottom of engine underguard
(24) with wire rope etc. and sling it down.
12. Remove the additional fender assembly (22).

4 Additional fender assembly (22): 60 kg
Remove the following bolts (23) (four pieces)
a Bolts 23 (a to d): M12 (two pieces)
a Bolts 23 (e to h): M16 (six pieces)
14. Loosen clamp (27) on engine oil pan cover

(26) side of exhaust duct (25), and remove the
exhaust duct.
50-200 54 D65EX, PX, WX-16

Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.) SEN05111-01
15. Loosen intermediate clamp bolt of exhaust

duct (25).
a Clamp mounting bolt: M12 (three pieces)
16. Remove exhaust duct (25) with the clamp

installed to the duct, by pulling it upward from
the engine right side cover.
Installation
removal.
q Use a new exhaust duct (25) when installing it.
Do not reuse the old one.
(The heat insulation material used on the sur-
face of exhaust duct is hardened. It can be bro-
ken while being removed. If it is broken,
insulation will be no longer effective. Be sure to
install new part.)
D65EX, PX, WX-16 50-200 55

SEN05111-01 Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.)
Removal and installation of oil 3. Remove exhaust duct mounting bolts (5) (four
pieces).
pan cover of coolant preheater a Mounting bolt (5): M12 (four pieces)
(subextremely cold weather
spec.) 1
Removal
1. Removal of under cover.

a Hold the bottom of engine underguard (1)
with wire rope etc. and sling it down.
4. Remove exhaust duct (2).

4 Exhaust duct assembly: 10 kg
2. Remove exhaust duct (2) from oil pan cover (4)

by loosening clamp (3) of exhaust duct (2).
Installation
removal.
50-200 56 D65EX, PX, WX-16

Removal and installation of engine assembly SEN05111-01
Removal and installation of 4. Remove inspection cover (1a) of the engine

engine assembly 1
undercover.
Removal 5. Drain the engine coolant from the radiator.

k
6
Stop the machine on a level place and
Radiator: 36 l
q Precautions for handling refrigerant
k Collect refrigerant (R134a) beforehand.
a Ask professional traders for collecting and
filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere. 6. Remove cover (2) under the hydraulic tank.
k If the refrigerant (R134a) gets inside
ones eyes, it may cause blindness. 7. Drain the hydraulic oil from the hydraulic tank.
Therefore, make sure to wear protec- 6 Hydraulic tank: 82 l
tive glasses when collecting or filling
the refrigerant. Collecting and filling
work must be conducted by a qualified
person.
1. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit. [*1]
q Quantity of refrigerant: 900 ± 50 g



10. Remove the radiator assembly. For details,

see “Removal and installation of radiator
assembly”.
11. Remove the aftercooler assembly. For details,

see “Removal and installation of aftercooler
assembly”.
12. Sling the muffler assembly.
D65EX, PX, WX-16 50-200 57

SEN05111-01 Removal and installation of engine assembly
13. Remove U-bolt (3) and mounting bolt (4). [*2] 16. Remove wiring harness clamp (7).


14. Lift off muffler assembly (5).

4 Muffler assembly (5): 30 kg
19. Remove the fuel prefilter assembly according

1) Disconnect wiring harness (12) from relay
(13).
2) Remove 3 wiring harness clamps (14) and
2 wiring harness clamps (15).
3) Disconnect wiring harness connector CN-
15. Remove 3 air conditioner hose clamps (6). WIF (16).
50-200 58 D65EX, PX, WX-16

4) Remove 2 hose clamps (17). 2) Alternator assembly (28)

5) Disconnect 2 fuel hoses (18). 1] Disconnect wiring connectors CN-AL/
6) Remove 2 mounting bolts (19) and fuel E (23), CN-AL/B (24) and CN-AL/R
prefilter and bracket assembly (20). (25).
2] Remove mounting bolts (26) and (27)
and alternator assembly (28).
21. Disconnect power train oil cooler outlet hose

(29) from the engine. [*4]
20. Remove the alternator assembly according to

a Remove the alternator assembly to
remove the front right mounting bolt of the
engine.
1) Alternator belt (21) 22. Remove wiring harness clamp (30) and dis-
1] Set wrench [1] to part (A) (width connect starting motor (31).
across flats: 12.7 mm) of tensioner
assembly (22). 23. Disconnect wiring harness connectors CN-
2] Turn wrench [1] in the unwinding EG1 (32) and CN-EG2 (33).
direction to decrease the tension of
alternator belt (21) and remove alter-
nator belt (21).
k Set wrench [1] securely to part (A) of
tensioner assembly (22) before turning
it. (The spring of tensioner assembly
(22) is strong. If the wrench is set
incompletely and turned, it comes off
and that is very dangerous.)
k After removing alternator belt (21),
return tensioner assembly (22) slowly
and carefully.
k Take care not to catch your finger
between the pulley and belt (21) during
work.
D65EX, PX, WX-16 50-200 59

24. Disconnect 2 heater hoses (34) and remove 2) Remove inspection cover (38) of the floor
bracket (35). plate.
25. Remove right and left step plates (36). 3) Disconnect wiring harness connector CN-
PAC (39) from the underside of the floor
plate.
26. Remove the floor plate assembly according to

1) Remove floor mat (37) from inside of the 4) Disconnect the turnbuckle of brake rod
ROPS cab. (40). For details, see Testing and adjust-
ing, “Adjusting brake pedal”. [*5]
5) Lift off floor plate assembly (41)
4 Floor plate assembly (41): 30 kg
a Since a crane cannot be used inside
the ROPS cab, use a bar etc. to lift off
floor plate assembly (41).
50-200 60 D65EX, PX, WX-16

27. Remove hose clamp (42). 2) Remove wiring harness clamps (46) and
(47).
28. Remove wiring harness clamp (43) and dis- 3) Remove wiring harness clamp (48) and
connect wiring harness connector CN-AC05 bracket (49).
(44). a The figure shows the clamp position
after the ROPS cab is removed.
(44a).
(44a) to the machine.
4) Sling the engine hood mounting bracket.

5) Remove right and left engine hood mount-
ing bracket mounting bolts (50).
30. Remove the engine hood mounting bracket at

the front of the ROPS cab according to the fol-
lowing procedure.
1) Remove 2 hose clamps (45) from the
under side of the floor.
6) Lift off engine hood mounting bracket (51).

4 Engine hood mounting bracket
(51): 50 kg
D65EX, PX, WX-16 50-200 61

31. Remove the drive shaft assembly according to 32. Disconnect engine ground cable (55) from the
the following procedure. right rear of the engine.
1) Remove undercover (52) under the power
train. 33. Remove 1 engine rear mounting bolt (56) each
on the right and left sides. [*7]
2) Sling the drive shaft assembly.

3) Remove all drive shaft mounting bolts (53) 34. Remove 1 engine front mounting bolt (57)
from the underside of the power train. [*6] each on the right and left sides. [*8]
4) Lift off drive shaft assembly (54). 35. Lift off engine assembly (58).
a Ensure that all the wiring and piping are
4 Drive shaft assembly (54): 25 kg
disconnected before lifting off the engine
assembly.
4 Engine assembly (58): 1,000 kg
50-200 62 D65EX, PX, WX-16

Installation [*2]
q Carry out installation in the reverse order to a Install the muffler and bracket according to the
removal. following procedure.
1) Tighten mounting bolts (2a) and (2b) per-
[*1] manently.
a When installing the air conditioner hoses, take 2) Tighten mounting bolts (2c) and mounting
care that dirt, dust, water, etc. will not enter nuts (2d) temporarily.
them. 3) Tighten mounting bolts (2e) and mounting
a When installing each joint of the air conditioner nuts (2f) and (2g) permanently.
hose, check that O-ring (70) is fitted to it. 4) Tighten mounting bolts (2c) permanently.
a Check that O-ring (70) is free from flaw and 5) Tighten mounting nuts (2d) permanently.
deterioration. a Tighten both mounting nuts (2f) and (2g)
a When connecting the refrigerant piping, apply evenly.
compressor oil for new refrigerant (R134a) a When performing steps 4) and 5), take care
(DENSO: ND-OIL8) to O-ring (70). not to install the exhaust elbow and muffler
3 Thread size (M16 x 1.5) (Width across flats: forcibly.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm} 3 U-bolt mounting nuts (2f) and (2g):
3 Thread size (M22 x 1.5) (Width across flats: 9.8 – 14.7 Nm {1.0 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
3 Thread size (M24 x 1.5) (Width across flats:
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
3 Receiver tank refrigerant tube mounting bolt
(M6 x 1.0) (Width across flats: 10 mm):
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
3 Air conditioner compressor refrigerant tube
mounting bolt (M6 x 1.0) (Width across flats:
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
[*3]
a Install the air conditioner compressor. For
detail, see Testing and adjusting, “Testing and
adjusting air conditioner compressor belt ten-
sion” and “Removal and installation of air con-
D65EX, PX, WX-16 50-200 63

[*4] q Refilling with oil (Hydraulic tank)

3 Power train outlet hose (29) mounting Add oil through the oil filler to the specified
clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} level. Run the engine to circulate the oil
a For the installed positions of the hoses, see the through the system. Then, check the oil level
following figure. again.
5
q Engine side
Hydraulic tank (Hydraulic oil): 82 l (For
and lubricants”.)

tem for leakage”.

circuit”.
[*5]
a Install the turnbuckle of brake rod (40). For
details, see Testing and adjusting, “Adjusting
brake pedal”.
[*6]
2 Drive shaft mounting bolt (53):
Adhesive (LT-2)
98 – 123 Nm {10.0 – 12.5 kgm}
[*7]
2 Engine rear mounting bolt (56):
Adhesive (LT-1A)
[*8]
2 Engine front mounting bolt (57):
Adhesive (LT-1A)
q Charging with refrigerant (R134a)

Charge the air conditioner circuit with refriger-
ant (R134a).
a Quantity of refrigerant: 900 ± 50 g
q Adding of compressor oil

For details, see Air conditioner, “Handling of
compressor oil”.

and lubricants”.)
50-200 64 D65EX, PX, WX-16

Removal and installation of damper assembly SEN05111-01
Removal and installation of 6. Remove the ROPS cab assembly. For details,
damper assembly 1
see “Removal and installation of ROPS cab
assembly”.
Removal
k Stop the machine on a level place and 7. Remove the power train and lubricating oil
apply the parking brake. pump assembly. For details, see “Removal and
k Lower the work equipment to the ground installation of power train and lubricating oil
and stop the engine. pump assembly”.
terminal of the battery. 8. Remove the drive shaft assembly according to
k If the radiator coolant temperature is high, the following procedure.
wait until it decreases to avoid getting 1) Remove undercover (2) under the power
scalded and then drain the coolant. train.
the atmosphere.
ones eyes, it may cause blindness.
Therefore, make sure to wear protec-
person.
1. Collect the refrigerant (air conditioner gas: 2) Sling the drive shaft assembly.
R134a) from the air conditioner circuit. [*1] 3) Remove all drive shaft mounting bolts (3)
q Quantity of refrigerant: 900 ± 50 g from the underside of the power train. [*2]

undercover.

6 Radiator: 36 l
4. Drain the fuel through the fuel valve at the fuel

tank bottom.
6 Fuel tank: 415 l
5. Remove the fuel tank assembly. For details,

see “Removal and installation of fuel tank
assembly”.
D65EX, PX, WX-16 50-200 65

SEN05111-01 Removal and installation of damper assembly
4) Lift off drive shaft assembly (4). 12. Using guide bolts [2], remove damper assem-
4 Drive shaft assembly (4): 25 kg bly (8). [*5]
9. Remove drain plug (5) to drain the oil from the

damper case. [*3]
Installation
6 Damper case: 1.7 l q Carry out installation in the reverse order to
removal.
10. Remove coupling (6).
[*1]
a When installing the air conditioner hoses, take
care that dirt, dust, water, etc. will not enter
them.
a When installing each joint of the air conditioner
hose, check that O-ring (70) is fitted to it.
a Check that O-ring (70) is free from flaw and
deterioration.
a When connecting the refrigerant piping, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8) to O-ring (70).
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
11. Using guide bolts [1], remove damper cover 24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
(7). [*4] 3 Thread size (M24 x 1.5) (Width across flats:
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
4 Damper cover (7): 20 kg 3 Receiver tank refrigerant tube mounting bolt
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
50-200 66 D65EX, PX, WX-16

Removal and installation of damper assembly SEN05111-01
[*2] q Refilling with oil (Power train case)

2 Drive shaft mounting bolt (53): Add oil through the oil filler to the specified
Adhesive (LT-2) level. Run the engine to circulate the oil
3 Drive shaft mounting bolt (53): through the system. Then, check the oil level
98 – 123 Nm {10.0 – 12.5 kgm} again.
[*3]
3
Drain plug (5): 58.8 – 78.5 Nm {6 – 8 kgm}
[*4]
q Refilling with oil (Damper case)
a Using guide bolts [1], sling and install damper
cover (7).
2 Damper cover (7) mounting face:
Gasket sealant (LG-7)
3 Damper cover (7) mounting bolt:
again.
98 – 123 Nm {10.0 – 12.5 kgm} 5 Damper case (Power train oil):
1.7 l (TO30)
q Refilling with fuel (Fuel tank)

5 Fuel tank (Diesel fuel): 415 l (For
and lubricants”.)

tem for leakage”.

[*5]
3
Damper assembly (8) mounting bolt:
circuit”.
98 – 123 Nm {10.0 – 12.5 kgm}

ant (R134a).

compressor oil”.

and lubricants”.)
D65EX, PX, WX-16 50-200 67

SEN05111-01 Removal and installation of engine front oil seal
Removal and installation of 3. Remove cover (2) under the hydraulic tank.
engine front oil seal 1
Special tools 6 Hydraulic tank: 82 l
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
1 795-799-1131 Gear t 1
A
5 795-799-8120 Oil seal driver q 1
Removal
stop the engine, and loosen the hydraulic 5. Remove the engine hood assembly. For
tank cap gradually to release the pressure details, see “Removal and installation of
k
Disconnect the cable from the negative (–)
k
If the radiator coolant temperature is high, details, see “Removal and installation of
wait until it decreases to avoid getting hydraulic oil cooler assembly”.
7. Remove the radiator assembly. For details,
see “Removal and installation of radiator
1. Remove inspection cover (1a) of the engine assembly”.
undercover.
2. Drain the engine coolant from the radiator. see “Removal and installation of aftercooler
6 Radiator: 36 l assembly”.
50-200 68 D65EX, PX, WX-16

Removal and installation of engine front oil seal SEN05111-01
9. Remove the alternator belt (3) according to the 10. Remove 4 mounting nuts (5) and crankshaft
following procedure. pulley and vibration damper assembly (6). [*1]
1) Set wrench [1] to part (A) (width across a Lock the crankshaft with engine cranking
flats: 12.7 mm) of tensioner assembly (4). tool A1 (see the special tool table). For
2) Turn wrench [1] in the unwinding direction details, see “Removal and installation of
to decrease the tension of alternator belt fuel supply pump assembly”.
(3) and remove alternator belt (3). a Make match marks on crankshaft pulley
k Set wrench [1] securely to part (A) of and vibration damper assembly (6) and
tensioner assembly (4) before turning the front cover. (Make the match marks
it. since there is the stamp of 1-6TOP on the
(The spring of tensioner assembly (4) crankshaft pulley)
is strong. If the wrench is set incom-
pletely and turned, it comes off and
that is very dangerous.)
k After removing alternator belt (3),
return tensioner assembly (4) slowly
and carefully.
k Take care not to catch your finger
between the pulley and belt (3) during
work.
11. Remove 6 mounting nuts (7) and oil seal car-

rier (8).
12. Remove dust seal (9) and engine front oil seal
(10) from oil seal carrier (8).
D65EX, PX, WX-16 50-200 69

SEN05111-01 Removal and installation of engine front oil seal
Installation 6. Install oil seal carrier (8) to the front cover.

1. Remove the foreign matter sticking to the 2 Flange surface of oil seal carrier (8):
crankshaft flange with clean cloth. Gasket seal (LG-7)

a Apply gasket seal (LG-7) to (b) around 5
2. Set engine front oil seal (10) to tool A5 from stud bolts (11) and nut (7) thread (c) as
the pilot [3] side. well as the flange surface.
a Since pilot [3], which is plastic part, inside 3 Mounting nut (7):
engine front oil seal (10) is used as a 9.8 ± 2 Nm {1 ± 0.2 kgm}

guide to the crankshaft, do not remove it a Tighten mounting nuts (7) in the order of
from the engine front oil seal (10). [1] – [5] shown below.
a Pilot [3] is installed to spare engine front a Check again that installed dimension (a)
oil seal (10). described above is 0.5 – 1.0 mm.
7. Install dust seal (9).

a Push in dust seal (9) until it touches
engine front oil seal (10) described above.
3. Install engine front oil seal (10) which is set to

tool 5A from the inside of oil seal carrier (8).
a Install engine front oil seal (10) flush with
the inside plane of oil seal carrier (8).
a Installed dimension (a) from outside of oil
seal carrier (8): 0.5 – 1.0 mm
4. Put pilot [3] to the crankshaft and push it in

together with oil seal carrier (8) with the hands.
5. Remove pilot [3].
50-200 70 D65EX, PX, WX-16

Removal and installation of engine front oil seal SEN05111-01
q Carry out the following installation in the

reverse order to removal.
[*1]
3 Mounting bolt (5):
200 ± 10 Nm {20.4 ± 1 kgm}
a Lock the crankshaft with engine barring tool A1
(see the special tool table). For details, see
“Removal and installation of fuel supply pump
assembly”.

and lubricants”.)

again.
and lubricants”.)
D65EX, PX, WX-16 50-200 71

SEN05111-01 Removal and installation of engine rear oil seal
Removal and installation of 2. Open cover (1) under the fuel tank.
engine rear oil seal 1
Special tools the “CLOSE” position.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
795-799-1500 Repair stand t 1

A 6
795-799-2280 Adapter q 1
Removal
stop the engine, and loosen the hydraulic 4. Remove inspection cover (1a) of the engine
tank cap gradually to release the pressure undercover.
k Disconnect the cable from the negative (–) 5. Drain the engine coolant from the radiator.
6
terminal of the battery. Radiator: 36 l
the atmosphere.
person. 6. Remove cover (2) under the hydraulic tank.
1. Collect the refrigerant (air conditioner gas: 7. Drain the hydraulic oil from the hydraulic tank.
R134a) from the air conditioner circuit. [*1] 6 Hydraulic tank: 82 l
50-200 72 D65EX, PX, WX-16

Removal and installation of engine rear oil seal SEN05111-01
8. Remove the engine hood assembly. For 16. Remove the flywheel housing according to the
details, see “Removal and installation of following procedure.
engine hood assembly”. 1) Disconnect wiring harness (6) from fly-
wheel housing (5).
9. Remove the hydraulic oil cooler assembly. For 2) Set a block under the engine oil pan to
details, see “Removal and installation of float flywheel housing (5).
hydraulic oil cooler assembly”. 3) Sling flywheel housing (5).
4) Remove mounting bolts (7).
10. Remove the radiator assembly. For details, 5) Lift off flywheel housing (5). [*4]
see “Removal and installation of radiator 4 Flywheel housing (5): 70 kg
assembly”.

see “Removal and installation of aftercooler
assembly”.
12. Remove the engine assembly. For details, see

“Removal and installation of engine assembly”.
13. Remove the drain plug to drain the oil from the
damper case. [*2]
6 Damper case: 1.7 l
14. Remove the damper assembly. For details,

see “Removal and installation of damper 17. Remove the engine rear oil seal according to
assembly”. the following procedure.
1) Remove rear cover (8).
15. Remove the flywheel assembly according to a When separating the engine oil pan
the following procedure. gasket from the bottom of rear cover
1) Using blocks [1], fix the engine assembly. (8), take care not to damage it.
a Tool A6 (Repair stand, adapter) is set. a Insert a gauge etc. in the clearance
(See the special tool table) between the bottom of rear cover (8)
2) Sling flywheel assembly (3). and the engine oil pan gasket and
3) Remove mounting bolts. move it forward and backward to sep-
4) Using guide bolts [2], lift off flywheel arate the gasket.
assembly (3). [*3] a When engine oil pan gasket is dam-
4 Flywheel assembly (3): 55 kg aged, [*5]
1] Drain the engine oil from the engine
oil pan.
6 Engine oil pan: 33 l
2] Remove the engine oil pan.
a Replace the engine oil pan gasket.
2) Remove engine rear oil seal (9) from rear
cover (8).
D65EX, PX, WX-16 50-200 73

Installation 5. Using alignment tool [4], push engine rear oil

1. Clean, degrease and dry the gasket contact seal (9) into a proper depth of rear cover (8).
faces of the rear cover and cylinder block. a Alignment tool [4] is attached to the
engine rear oil seal.
2. Clean, degrease and dry the engine rear oil
seal contact face of the crankshaft. 6. Remove alignment tool (4).
3. Apply neutral detergent to the outside of the 7. Apply gasket sealant according to the following
engine rear oil seal. procedure.
a Since pilot [3], which is plastic part, inside 1) Apply gasket sealant to thick line part (a)
the engine rear oil seal is used as a guide on the underside of rear cover (8).
to the crankshaft, do not remove it from 2 Apply string 3 mm in diameter to
the engine rear oil seal. thick line part (a) on underside of
rear cover (8):
4. Install engine rear oil seal (9) to rear cover (8). Gasket sealant (LG-7)
50-200 74 D65EX, PX, WX-16

2) Apply gasket sealant thickly to 2 hatched 15. Remove alignment tool [4].
parts (b) shown below.
2 Hatched part (b):
8. Install guide pin [5] to the cylinder block.
9. Install gasket (10) while positioning it with

guide pin [5].
10. Put pilot [3] to the crankshaft and push it in

together with rear cover (8) with the hands.
a Cut gasket (10) so that projection dimen-
sion (c) into the engine oil pan face will be
as follows.
Projection dimension (c): Max. 0.25 mm
16. Install the flywheel housing.
2 Apply string 1 – 3 mm in diameter
11. Remove pilot [3].
around bolt holes on cylinder block side
shown below: Gasket sealant (LG-6)
3 Flywheel housing mounting bolt:
77 ± 12 Nm {7.9 ± 1.2 kgm}
a Tighten the mounting bolts in the order
shown below.
12. Install alignment tool [4] again and ensure that

engine rear oil seal (9) is pushed into a proper
depth.
a Do not remove alignment tool [4] but keep
it installed.
13. Remove guide pin [5] described above. q Carry out installation in the reverse order to
removal.
14. Tighten the 8 mounting bolts of rear cover (8)
in the order shown below.
3 Rear cover (8) mounting bolt:
12.7 ± 2.0 Nm {1.3 ± 0.2 kgm}
D65EX, PX, WX-16 50-200 75

[*1] a Fix the flywheel and flywheel housing with bar

a When installing the air conditioner hoses, take [6].
them.
deterioration.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm} a Tighten the mounting bolts in the order shown
3 Receiver tank refrigerant tube mounting bolt below.
(M6 x 1.0) (Width across flats: 10 mm): 2 Flywheel mounting bolt:
3.9 – 6.9 Nm {0.4 – 0.7 kgm} Engine oil (EO15W-40)
3 Air conditioner compressor refrigerant tube 3 Flywheel mounting bolt:
mounting bolt (M6 x 1.0) (Width across flats: 137 ± 7 Nm {14.0 ± 0.7 kgm}
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
a Measure the facial runout and radial runout of

[*2] the flywheel.
3 Drain plug: 58.8 – 78.5 Nm {6 – 8 kgm} q Radial runout: Max. 0.13 mm
q Facial runout: Max. 0.24 mm
[*3]
a Using guide bolts [2], sling and install flywheel q Measurement of radial runout
assembly (3). 1) Install dial gauge [7] to the flywheel
4
housing.
Flywheel assembly (3): 55 kg
2) Set dial gauge [7] probe perpendicu-
lar to the faucet joint portion (d) or
outside of the flywheel.
3) Set the dial gauge [7] pointer to “0”.
4) Rotate the crankshaft 1 turn and mea-
sure the difference between the maxi-
mum and minimum readings of dial
gauge [7].
a Check that the dial gauge [7] pointer
stops at the starting point after rotat-
ing 1 turn.
50-200 76 D65EX, PX, WX-16

q Measurement of facial runout

1) Similarly to the setting for the radial
runout measurement, set the dial
gauge [7] probe perpendicular to the
outermost part of the end face of the
flywheel.
a When measuring, bring the
crankshaft to the front or rear
side so that an error will not be
caused by the end play.
gauge [7]. q Measurement of facial runout
1) Similarly to the setting for the radial
runout measurement, set the dial
gauge [7] probe perpendicular to the
end face of the flywheel housing.
a When measuring, bring the
crankshaft to the front or rear
side so that an error will not be
caused by the end play.
gauge [7].
[*4]
a Measure the facial runout and radial runout of
the flywheel housing.
q Radial runout: Max. 0.20 mm
q Facial runout: Max. 0.20 mm
q Measurement of facial runout

1) Install dial gauge [7] to the crankshaft
end face.
2) Set dial gauge [7] probe perpendicu-
lar to the faucet joint portion of the fly-
wheel housing.
gauge [7].
a Check that the dial gauge [7]
pointer stops at the starting point
after rotating 1 turn.
D65EX, PX, WX-16 50-200 77

[*5]
a If the engine oil pan was removed, install it
1) Apply gasket sealant to cylinder block por-
tion (f).
2 Cylinder block portion (f):
Gasket seal (LG-7)
4)Apply gasket sealant to hatched part (j) of

the mounting face on the bed plate side of
gasket (13).
2 Hatched part (j) of mounting face on
bed plate side of gasket (13):
2) Apply gasket sealant to the mounting face 5)Install gasket (14) to the end flange and
on the cylinder block side of bed plate install suction tube (15).
(12). 2 End flange: Gasket sealant (LG-7)
2 Straight portion (g) and periphery 3 Flange mounting bolt:
(h) of bolt hole: Gasket seal (LG-7) 7.8 ± 2 Nm {0.8 ± 0.2 kgm}
Straight portion (g) between bolt
holes: String 3 mm in diameter
Periphery (h) of bolt hole:
String 1 mm in diameter
a Since the gasket sealant strings of
different diameters are different, con-
nect straight portion (g) and periphery
(h) of the bolt hole smoothly.
3) Install bed plate (12) to cylinder block (11).
50-200 78 D65EX, PX, WX-16


ant (R134a).

compressor oil”.

6)Apply gasket sealant to hatched part (k) of 5 Radiator (Engine coolant): 36 l (For
the mounting face of engine oil pan (17). details, see “Table of fuel, coolant
2 Hatched part (k) of mounting face of and lubricants”.)
engine oil pan (17):
Gasket sealant (LG-7) q Refilling with oil (Engine oil pan)
7) Install engine oil pan (17) to the cylinder level. Run the engine to circulate the oil
block. through the system. Then, check the oil level
again.
5 Engine oil pan (Engine oil): 33 l (For
and lubricants”.)
q Refilling with oil (Damper case)

again.
5 Damper case (Power train oil):
1.7 l (TO30)
8) Tighten the mounting bolts in the numeri- q Refilling with oil (Hydraulic tank)
cal order shown below. Add oil through the oil filler to the specified
3 Engine oil pan (17) mounting bolt: level. Run the engine to circulate the oil
24 ± 4 Nm {2.4 ± 0.4 kgm} through the system. Then, check the oil level
again.
and lubricants”.)

tem for leakage”.

circuit”.
D65EX, PX, WX-16 50-200 79

SEN05111-01 Removal and installation of engine hood assembly
Removal and installation of 4. Remove right and left covers (4).

engine hood assembly 1
Removal
1. Open right and left engine side covers (1) and

lock them.
a Lock the covers securely.
2. Remove right and left covers (2). 5. Disconnect air hose (5) from the right side of
the engine. [*1]
3. Remove radiator top cover (3).

6. Sling engine hood assembly (6).
7. Remove the engine hood mounting bolts and

lift off engine hood assembly (6).
4 Engine hood assembly: 150 kg
50-200 80 D65EX, PX, WX-16

Removal and installation of engine hood assembly SEN05111-01
Installation
removal.
[*1]
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
D65EX, PX, WX-16 50-200 81

SEN05111-01 Removal and installation of fuel tank assembly
Removal and installation of fuel 4. Open battery cover (3) on the left side of the
tank assembly 1
machine and lock it.
Removal
1. Remove cover (1) under the fuel tank.

tank bottom.
6 Fuel tank: 415 l
5. Disconnect wiring harness connector CN-FTK

(4) for the fuel level sensor.
6. Disconnect fuel return hose (5).

a Plug the hose and adapter to prevent the
fuel from flowing out.
3. Disconnect fuel outlet hose (2).

a Plug the hose and adapter to prevent the
fuel from flowing out.
7. Sling the fuel tank assembly.
8. Remove 3 fuel tank mounting bolts (6) each on

the right and left sides from the bottom of the
rear fenders of the machine.
50-200 82 D65EX, PX, WX-16

Removal and installation of fuel tank assembly SEN05111-01
9. Lift off fuel tank assembly (7). Installation

disconnected before lifting off the engine q Carry out installation in the reverse order to
assembly. removal.
4 Fuel tank assembly:
240 kg (when empty) q Refilling with fuel (Fuel tank)
and lubricants”.)

tem for leakage”.

circuit”.
D65EX, PX, WX-16 50-200 83

SEN05111-01

© 2012 KOMATSU
All Rights Reserved
50-200 84
SEN05112-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
300 Power train

Removal and installation of power train unit assembly ................................................................................... 2
Separation and connection of power train unit assembly ............................................................................... 6
Disassembly and assembly of PTO assembly ...............................................................................................11
Disassembly and assembly of torque converter assembly ........................................................................... 16
Disassembly and assembly of transmission assembly ................................................................................. 27
Disassembly and assembly of HSS assembly.............................................................................................. 54
Removal and installation of final drive assembly .......................................................................................... 74
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)............. 76
Disassembly and assembly of final drive assembly...................................................................................... 78
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type) ........ 86
D65EX, PX, WX-16 50-300 1

300 Power train
SEN05112-02 Removal and installation of power train unit assembly
Removal and installation of power

train unit assembly 1
Removal
scalded and then drain the coolant. 6. Remove the ROPS cab assembly. For details,
q Precautions for handling refrigerant see “Removal and installation of ROPS cab
k Collect refrigerant (R134a) beforehand. assembly”.
filling the refrigerant (R134a). 7. Remove the HSS motor assembly. For details,
a Never release the refrigerant (R134a) to see “Removal and installation of HSS motor
the atmosphere. assembly”.
k If the refrigerant (R134a) gets inside a Remove the HSS motor to remove the
ones eyes, it may cause blindness. HSS case bevel gear shaft cover and cap
Therefore, make sure to wear protec- on the right side.
the refrigerant. Collecting and filling 8. Remove undercover (1) under the power train.
person.


tank bottom.
6 Fuel tank: 415 l

assembly”.
9. Sling the drive shaft assembly.
10. Remove all drive shaft mounting bolts (2) from
5. Drain the hydraulic oil from the hydraulic tank. the underside of the power train. [*2]
50-300 2 D65EX, PX, WX-16

300 Power train
Removal and installation of power train unit assembly SEN05112-02
11. Lift off drive shaft assembly (3). 18. Disconnect 2 power train oil filter hoses (12).
4 Drive shaft assembly (3): 25 kg
12. Disconnect pressure pickup pilot hose (4).

19. Remove 5 wiring harness clamps (13).
13. Disconnect wiring harness connector CN-RFD
(5).
a Fix wiring harness (15) to the machine.
14. Disconnect HSS case oil feed pipe (6). [*3]

21. Remove hose clamp (16) from the left side of
the transmission.
22. Disconnect 2 hydraulic hoses (17).
16. Disconnect suction hose (8). [*4]
17. Disconnect hydraulic hoses (9), (10) and (11).
D65EX, PX, WX-16 50-300 3

300 Power train
SEN05112-02 Removal and installation of power train unit assembly
23. Remove right and left covers (18) from the 26. Loosen right and left clamps (22) and move
inside of the sprocket. [*5] seals (23) out. [*6]
24. Using forcing screws [1], pull out right and left 27. Sling the power train unit assembly.
drive shafts (19) until their spline portions
come off. 28. Remove right and left power train front mount-
a If drive shafts (19) do not come off, apply a ing bolts (24). [*7]
hydraulic jack etc. to the track shoe
grouser and adjust the grouser position
finely.
29. Lift off power train unit assembly (25). [*8]

25. Remove right and left HSS case bevel gear assembly.
4
shaft cap covers (20) and caps (21).
Power train unit assembly (25):
1,700 kg
50-300 4 D65EX, PX, WX-16

300 Power train
Removal and installation of power train unit assembly SEN05112-02
Installation [*6]
q Carry out installation in the reverse order to a Install seal (23) with the stamp (UP) up.
removal. a Ensure that clamp (22) is clamping all periph-
ery of the coupling securely.
[*1] 3 Seal mounting clamp (22):
a When installing the air conditioner hoses, take 4.9 – 8.3 Nm {0.50 – 0.85 kgm}
them.
deterioration.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm} [*7]
3 Receiver tank refrigerant tube mounting bolt 2 Power train mounting bolt (24):
(M6 x 1.0) (Width across flats: 10 mm): Adhesive (LT-1A)
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
[*8]
a Install seals (23) of the right and left bevel gear
shafts, taking care not to damage them.
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
ant (R134a).

compressor oil”.

again.
5
[*2]
Hydraulic tank (Hydraulic oil): 82 l (For
details, see “Table of fuel, coolant and
Adhesive (LT-2)
3
lubricants”.)
Drive shaft mounting bolt (2):
98 – 123 Nm {10.0 – 12.5 kgm} q Refilling with fuel (Fuel tank)
Fuel tank (Diesel fuel): 415 l (For details, see
[*3]
3
“Table of fuel, coolant and lubricants”.)
HSS case oil feed pipe (6) mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} q Checking for fuel leakage (Fuel system)
[*4] see Testing and adjusting, “Checking fuel sys-
3 Suction hose (8) mounting clamp: tem for leakage”.
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5] Bleed air from the fuel circuit. For details, see
3 Cover (18) mounting bolt: Testing and adjusting, “Bleeding air from fuel
98 – 123 Nm {10.0 – 12.5 kgm} circuit”.
D65EX, PX, WX-16 50-300 5

300 Power train
SEN05112-02 Separation and connection of power train unit assembly
Separation and connection of 4. Disconnect brake rod (2).

power train unit assembly 1
5. Disconnect parking brake cable (3). [*1]
Special tools a Check and record the installed dimen-
sions of parking brake cable (3).
New/Remodel
Necessity
Symbol
6. Remove the hose clamps and disconnect
Sketch
Q’ty
Part No. Part name hydraulic hoses (4), (5), (6) and (7).
7. Remove plate (8).

790-101-5401 Push tool kit (C) t 1
790-101-5431 • Plate 1
D 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Separation
1. Set the power train unit assembly horizontally
with blocks etc.
2. Drain the oil from the power train case.

6 Power train case: 53 l
3. Remove the mounting bolts and HSS and cool- 8. Remove the hose clamp and disconnect
ing fan pump assembly (1). hydraulic hose (9).
a Check and record the installed dimen-
4 HSS and cooling fan pump assembly sions of each branched hose.
(1): 130 kg
9. Remove the wiring harness clamp and discon-
nect wiring harness (10).
a Check and record the installed dimen-
sions of each branched wiring harness.
q Locations of wiring harness connectors
(See figure below)
(10a): CN-FAC
(10b): CN-TVC
(10c): CN-RFD
(10d): CN-L SOL
(10e): CN-L SW
(10f): CN-HHP
(10g): CN-R SW
(10h): CN-R SOL
(10j): CN-3 SOL
(10k): CN-3 SW
(10m): CN-1 SW
(10n): CN-1 SOL
(10p): CN-BVRV
(10q): CN-2 SW
(10r): CN-2 SOL
(10s): CN-F SW
(10t): CN-F SOL
(10u): CN-TCT
(10v): CN-TIP
50-300 6 D65EX, PX, WX-16

300 Power train
Separation and connection of power train unit assembly SEN05112-02
11. Sling HSS assembly (12).

disconnected.
12. Remove all transmission mounting bolts (13).

[*2]
13. Using 2 forcing screws [1], separate the trans-

mission assembly and HSS assembly (12).
a Use transmission mounting bolts (13)
described above as forcing screws [1].
10. Disconnect hydraulic hose (11).
14. Lift off HSS assembly (12).

4 HSS assembly (12): 750 kg
D65EX, PX, WX-16 50-300 7

300 Power train
15. Remove 2 brackets (13). a Set a block etc. under the transmission
assembly to stabilize before removal.
16. Disconnect PTO lubrication tube (14). [*3]
22. Set the transmission assembly on block [2]

17. Remove power train filter relief valve (15A) and with PTO assembly (19) up.
hose (15B) (subextremely cold weather spec.)
23. Remove oil strainer assembly (20).
24. Remove coupling (21). [*6]
25. Remove side block (22) for the torque con-

verter.
18. Disconnect hydraulic tube (15). [*4]
19. Remove the mounting bolts and lift off power

train and lubrication pump assembly (16). [*5]
4 Power train and lubrication pump
assembly (16): 20 kg 26. Remove 2 sleeves (25).
a Hook a wire etc. to the hole of sleeve (25)
20. Remove the mounting bolts and scavenging to pull out.
pump assembly (17).
21. Remove right and left transmission mounting

brackets (18).
50-300 8 D65EX, PX, WX-16

300 Power train
Separation and connection of power train unit assembly SEN05112-02
27. Using forcing screw [3], remove retainer 30. Lift off PTO assembly (27). [*8]
assembly (23). a The torque converter assembly is left on
the transmission side.
28. Remove oil seal (24) from retainer assembly 4 PTO assembly (27): 210 kg
(23). [*7]
31. Remove 9 mounting bolts (28) and lift off

torque converter assembly (29). [*9]
4 Torque converter assembly (29): 140 kg
29. Remove all mounting bolts (26).
32. Sling transmission assembly (30) and remove

it.
4 Transmission assembly (30): 380 kg
D65EX, PX, WX-16 50-300 9

300 Power train
Connection [*8]
q Carry out connection in the reverse order to 3 PTO assembly mounting bolt (26):
separation. 98 – 123 Nm {10.0 – 12.5 kgm}
[*1] [*9]
a If parking brake cable (3) was disconnected, 2 Torque converter assembly mounting bolt
adjust it. For details, see Testing and adjusting, (28): Adhesive (LT-2)
“Testing and adjusting parking brake cable”. 3 Torque converter assembly mounting bolt
(28): 98 – 123 Nm {10.0 – 12.5 kgm}
[*2]
3 Transmission mounting bolt (13):
245 – 309 Nm {25.0 ± 31.5 kgm} q Refilling with oil (Power train case)
[*3] level.
3
5
PTO lubrication tube (14) joint bolt: Power train case (Power train oil): 53 l
19.6 – 29.4 Nm {2.0 – 3.0 kgm} (For details, see “Table of fuel, cool-
ant and lubricants”.)
[*4]
3 Hydraulic tube (15) hose mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
3 Power train and lubrication pump assembly
(16) mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
[*6]
2 O-ring between coupling (21) and shaft end:
Grease (G2-LI)
2 Coupling (21) mounting bolt:
Adhesive (LT-2)
3 Coupling (21) mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
[*7]
a Using tool D1, press fit oil seal (24) to retainer
(23).
2 Oil seal (24) lip: Grease (G2-LI)
2 Outside of oil seal (24) press fitting face
and inside of hole on retainer (23) side:
a Wipe off projected gasket sealant.
50-300 10 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of PTO assembly SEN05112-02
Disassembly and assembly of 2) Drive gear assembly (2) out of cover

PTO assembly 1
assembly (1).
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
2 790-201-2720 Spacer t 1
790-101-5201 Push tool kit (B) t 1
790-101-5231 • Plate 1
3
790-101-5221 • Grip 1
01010-51225 • Bolt 1
D
790-101-5201 Push tool kit (B) t 1 3) Remove bearings (3a) and (3b) from gear
(2a).
790-101-5331 • Plate 1
4
790-101-5221 • Grip 1
01010-51225 • Bolt 1
5 796-430-1110 Push tool kit t 1
Disassembly
1. Cover assembly
1) Remove the mounting bolts and then
remove cover assembly (1) by using forc-
ing screws [1].
2. Idle gear
1) Remove mounting bolt (4) and plate (5).
D65EX, PX, WX-16 50-300 11

300 Power train
SEN05112-02 Disassembly and assembly of PTO assembly
2) Remove the mounting bolts and then 3) Remove bearing (14).

remove shaft (6) by using forcing screws
[2].
a Support gear (7) which may fall.
4. Input shaft bearing

Remove bearing (15).
3) Remove bearings (8a) and (8b) from gear

(7).
4) Remove outer races (10a) and (10b).
a When reusing bearings and outer
races (10a) and (10b), keep them
without changing their combinations.

1) Remove snap rings (11) and (12).
2) Drive gear (13) from the snap ring side.
50-300 12 D65EX, PX, WX-16

300 Power train
Assembly 2) Using tool D2, support the inner race of

q Precautions for assembly bearing (14).
a Clean each part thoroughly and check it is free 3) Press fit gear (13).
from dirt and flaw.
a Apply power train oil (For details, see “Table of
fuel, coolant and lubricants”) to the sliding sur-
faces of each part before installing.
a After press fitting each bearing, drip power
train oil (For details, see “Table of fuel, coolant
and lubricants”) onto its rotating parts and
rotate it about 10 turns.
a Confirm that the snap ring is securely in the
groove.
1. Input shaft bearing

Press fit bearing (15).
4) Install snap rings (12) and (11).

1) Using tool D3, press fit bearing (14).
3. Idle gear
1) Fit the O-ring to shaft (6) and install them
to the case.
D65EX, PX, WX-16 50-300 13

300 Power train
SEN05112-02 Disassembly and assembly of PTO assembly
2) Reverse the case and install bearing (8a). 5) Install plate (5) and mounting bolt (4).
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
3) Using tool D4, press fit outer races (10a)

and (10b) to gear (7).
4. Cover assembly
1) Using tool D5, install bearings (3a) and
(3b) to gear (2a).
4) Install gear (7) and bearing (8b).

a When reusing bearings and outer
races (10a) and (10b), do not change
their combinations. (See the above)
a Press fit the inner race side of bearing
2) Fit the O-ring to cover (1a).
(8b).
3) Install gear assembly (2) to cover (1a).
50-300 14 D65EX, PX, WX-16

300 Power train
4) While meshing the idle gear and the PTO

gear, install cover assembly (1)
D65EX, PX, WX-16 50-300 15

300 Power train
SEN05112-02 Disassembly and assembly of torque converter assembly
Disassembly and assembly of 3) Sling and remove housing and turbine

torque converter assembly assembly (3).
4 Housing and turbine assembly (3):
1
Special tools 85 kg
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
6 794T-422-1110 Push tool t 1 Q

7 792T-413-1120 Push tool t 1 Q
790-101-5401 Push tool kit (C) t 1
D 790-101-5491 • Plate 1
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
9 792-213-1110 Wrench assembly t 1
2. Gear and input shaft assembly
1) Remove 20 mounting bolts (4).
Disassembly
1. Housing and turbine assembly
1) Sling and set torque converter assembly
(1).
4 Torque converter assembly (1):
140 kg
2) Remove 24 mounting bolts (2) from the
lower section.
2) Using forcing screws [1], remove gear and

input shaft assembly (5).
50-300 16 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of torque converter assembly SEN05112-02
3) Remove inner race (6) from gear and 2) Using puller [2], remove clutch housing
input shaft assembly (5). assembly (10) from turbine and gear
assembly (9).
3. Housing assembly
1) Remove snap ring (7) and spacer (8). 3) Remove turbine and gear assembly (9).
4) Remove 36 mounting bolts (39a).
D65EX, PX, WX-16 50-300 17

300 Power train
5) Sling and remove clutch housing (11). 8) Remove 2 seal rings (15) from clutch
housing (11).
6) Remove piston (12) from clutch housing

(11). 9) Remove 2 seal rings (16) from piston (12).
7) Remove bearing (13) from clutch housing 10) Remove 1 disc (18) from housing (17).
(11).
a Snap ring (14) is attached to bearing
(13).
50-300 18 D65EX, PX, WX-16

300 Power train
4. Stator assembly 5. Pump and stator shaft assembly

1) Remove stator assembly (20) from pump 1) Using tool D9, remove nut (27) from pump
and stator shaft assembly (19). and stator shaft assembly (19).
a Using a bar or others, lock housing
(28).
2) Remove snap ring (21) from stator (20a)

and remove freewheel assembly (22).
3) Remove outer race (23), 2 bushings (24),
2 balls (25), and freewheel (26) from free-
wheel assembly (22).
a Take care not to lose balls (25).
2) Reverse pump and stator shaft assembly

(19) and set it to block [3].
3) Remove the mounting bolts and then
remove stator shaft (29) by using forcing
screws [4].
4) Remove housing (28).
5) Remove inner races (30a) and (30b) from
stator shaft (29).
D65EX, PX, WX-16 50-300 19

300 Power train
8) Remove snap ring (34) from bearing cage

assembly (33) and remove bearing (35).
6) Remove seal ring (31) from housing (28).
7) Remove the mounting bolts and remove

bearing cage assembly (33) from pump
assembly (32).
50-300 20 D65EX, PX, WX-16

300 Power train
Assembly 3) Install bearing cage assembly (33) to

q Precautions for assembly pump (32).
a Clean each part thoroughly and confirm that it 2 Bearing cage assembly (33)
is free from dirt and flaw. mounting bolt: Adhesive (LT-2)
a Apply power train oil (For details, see “Table of 3 Bearing cage assembly (33)
fuel, coolant and lubricants”) to the sliding sur- mounting bolt:
faces of each part before installing. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Confirm that the snap ring is securely in the
groove.
1. Pump and stator shaft assembly

1) Using tool D8, press fit bearing (35) to
bearing cage (33).
2) Install snap ring (34).
4) Install seal ring (31) to housing (28).

a When installing seal ring (31), take
care not to open its abutment joint too
wide.
3 Seal ring (31): Grease (G2-LI)
D65EX, PX, WX-16 50-300 21

300 Power train
5) Install stator shaft (29) to housing (28). 9) Install nut (27) to pump and stator shaft
2 Stator shaft (29) mounting bolt: assembly (19) and tighten it with tool D9.
Adhesive (LT-2) 3 Nut (27):
3 Stator shaft (29) mounting bolt: 441.3 – 490.3 Nm {45 – 50 kgm}
98 – 123 Nm {10.0 – 12.5 kgm} a Using a bar or others, lock housing
(28).
6) Reverse housing (28) and install inner

race (30b) to stator shaft (29).
7) Install pump (32) and inner race (30a) to
stator shaft (29).
8) Using tool D6, press fit inner race (30a).
2. Stator assembly
1) Install freewheel (26), 2 balls (25) and 2
bushings (24) to outer race (23).
a When installing freewheel (one-way
clutch) (26), set arrow (b) on the front
face of the bearing cage toward the
input side and confirm the rotation
direction of the stator.
Clockwise direction: Free rotation
Counterclockwise direction: Lock
a Do not remove sprag (d).
a When inserting, take care that drag
clips (c) on the periphery of freewheel
(26) will not be hitched in the ball
grooves of the outer race.
2) Install freewheel assembly (22) to stator
(20a) and install snap ring (21).
50-300 22 D65EX, PX, WX-16

300 Power train
2 Freewheel assembly (22): 3) Install stator assembly (20) to pump and

Power train oil (For details, see stator shaft assembly (19).
“Table of fuel, coolant and lubri-
cants”)
3. Housing assembly
1) Set turbine and gear assembly (9) to cylin-
der [5].
2) Install housing (17) and 1 disc (18) to tur-

bine and gear assembly (9).
D65EX, PX, WX-16 50-300 23

300 Power train
3) Install 2 seal rings (15) to clutch housing 6) Sling and install clutch housing (11).
(11). a When installing the clutch housing,
4) Install 2 seal rings (16) to clutch housing match the holes (3 places) on the pis-
(12). ton top to the projections on the
2 Seal rings (15) and (16): clutch housing.
Grease (G2-LI) 4 Clutch housing (11): 25 kg
a Install seal rings (15) and (16) in the 2 Mounting bolt (39a):
direction shown below. Adhesive (LT-2)
3 Mounting bolt (39a):
59 – 74 Nm {6.0 – 7.5 kgm}
5) Install piston (12).

clutch housing (11).
a Snap ring (14) is attached to bearing
(13).
50-300 24 D65EX, PX, WX-16

300 Power train
8) Install spacer (8) and snap ring (7). 2) Install gear and input shaft assembly (5)
and install mounting bolts (4).
98 – 123 Nm {10.0 – 12.5 kgm}
5. Housing and turbine assembly

1) Sling and install housing and turbine
assembly (3).
a Match the drain plug mounting hole to
the oil groove of the housing.
4 Housing and turbine assembly (3):
85 kg
4. Gear and input shaft assembly

1) Press fit inner race (6) to gear and input
shaft assembly (5).
D65EX, PX, WX-16 50-300 25

300 Power train
2) Install mounting bolts (2) to torque con-

verter assembly (1) from below.
49.0 – 58.8 Nm {5.0 – 6.0 kgm}
3 2 drain plugs:
5.9 – 8.8 Nm {0.6 – 0.9 kgm}
50-300 26 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of transmission assembly SEN05112-02
Disassembly and assembly of Disassembly

transmission assembly 1 a Keep the removed discs and plates on a flat
place so that they will not distort.
Special tools
1. Related parts
New/Remodel
1) Sling and set transmission assembly (1) to
Necessity
Symbol
Sketch
block [1].
Q’ty
4 Transmission assembly (1): 380kg
Part No. Part name
791T-415-5300 Puller assembly t 1 Q

10 791T-415-5310 • Plate 1 Q
01010-82040 • Bolt 1
Oil leak tester kit
11 799-301-1600 t 1
(A)
790-101-5201 Push tool kit (B) t 1
790-101-5311 • Plate 1
12
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5461 • Plate 1
13 2) Remove the mounting bolts then sling and
790-101-5421 • Grip 1 remove transmission control valve assem-
01010-51240 • Bolt 1 bly (2).
790-101-5201 Push tool kit (B) t 1 4 Transmission control valve assem-
bly (2): 25 kg
D 790-101-5281 • Plate 1
14
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5001 Push tool kit (A) t 1
790-101-5081 • Plate 1
15
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5471 • Plate 1
16
790-101-5421 • Grip 1
01010-51240 • Bolt 1
17 790-201-2760 Spacer t 1
18 793T-615-1170 Push tool t 1 Q 3) Using tool [2], remove 5 sleeves (3).
19 790-201-2830 Spacer t 1
20 791T-415-5210 Push tool t 1 Q
D65EX, PX, WX-16 50-300 27

300 Power train
SEN05112-02 Disassembly and assembly of transmission assembly
4) Remove main relief valve assembly (4) 3. Transmission case

and plate (5). 1) Sling and set transmission assembly (9)
5) Remove sleeve (6). vertically to block [3].
a Hook a wire or others to the hole of 4 Transmission assembly (9): 350 kg
sleeve (6) to pull out.
2) Sling transmission case (10) temporarily

and remove 11 through bolts (11).
a When loosening through bolts (11),
do not use an impact wrench which
can damage the vibration control
sleeve.
2. Snap ring
Remove snap ring (8) from output shaft (7).
a This is preparatory work for removing out-
put shaft (7).
3) Sling and remove transmission case (10).

4 Transmission case (10): 120 kg
50-300 28 D65EX, PX, WX-16

300 Power train
4. Input shaft, front cover and No. 1 carrier 5. Disassembly of input shaft, front cover and
assembly No. 1 carrier assembly
1) Remove remaining 3 through bolts (12). 1) Remove snap ring (14), No. 2 sun gear
a When loosening through bolts (12), (15) and snap ring (16).
do not use an impact wrench which 2) Remove snap ring (17) and No. 1 sun
can damage the vibration control gear (18).
sleeve.
3) Remove snap ring (19).

2) Sling and remove input shaft, front cover,
and No. 1 carrier assembly (13).
4 Input shaft, front cover, and No. 1
carrier assembly (13): 35 kg
4) Set front cover (20) to blocks [4].

5) Using tool D20, remove input shaft and
No. 1 carrier assembly (21) and spacer
(21a).
D65EX, PX, WX-16 50-300 29

300 Power train
6) Remove snap ring (22) and remove No. 1 6. Disassembly of No. 1 carrier assembly
carrier assembly (24) from input shaft Remove 4 shafts (28), ball (29), 2 thrust wash-
(23). ers (30), bearing (31) and planetary gear (32)
from No. 1 carrier assembly (24).
a Take care not to lose ball (29).
7) Remove 2 seal rings (35) and (36) each,

snap rings (37) and (38a) and bearing (38)
from input shaft (23). 7. Disassembly of front cover
1) Remove snap ring (33) from front cover
(20) and remove bearing (34).
2) Remove seal ring (34a).
8) Remove snap ring (25) from No. 1 carrier

assembly (24) and remove No. 1 ring gear
(26).
8. No. 1 disc, plate and spring
1) Remove 5 springs (39).
2) Remove the following alternately.
Plate (40): 6 pieces
Disc (41): 5 pieces
3) Remove 5 guide pins (42).
50-300 30 D65EX, PX, WX-16

300 Power train
9. No. 1 piston 2) Remove seal rings (46) and (47) from No.
1) Remove No. 1 piston (43). 1 housing (45).
2) Remove seal ring (44) from No. 1 piston 11. No. 2 piston
(43). 1) Remove No. 2 piston (48).
10. No. 1 housing 2) Remove seal ring (49) from No. 2 piston
1) Sling and remove No. 1 housing (45). (48).
4 No. 1 housing (45): 25 kg
D65EX, PX, WX-16 50-300 31

300 Power train
12. No. 2 disc, plate and spring 13. No. 2 housing and No. 2 carrier assembly
1) Remove 5 springs (50). 1) Remove snap ring (58).
Disc (52): 7 pieces
2) Sling and remove No. 2 housing and No. 2

carrier assembly (59).
4 No. 2 housing and No. 2 carrier
4) Remove 14 through bolt vibration control
sleeves (55) from No. 2 housing (54).
a Confirm and record slit position (a) of
each vibration control sleeve (55)
5) Remove lubricating oil relief valve (56)
and spring (57).
3) Set No. 2 housing and No. 2 carrier

assembly to blocks [5].
4) Remove snap ring (60) and remove No. 2
carrier assembly (61) from No. 2 housing
(62).
50-300 32 D65EX, PX, WX-16

300 Power train
5) Remove spacer (61a) and No. 2 ring gear

(61b) from No. 2 carrier assembly (61).
14. Disassembly of No. 2 housing

Remove snap ring (71), bearing (72) and seal
ring (73) from No. 2 housing (62).

Disc (76): 4 pieces
15. Disassembly of No. 2 carrier and No. 1 ring
gear assembly
1) Remove 5 shafts (64), ball (65), 2 thrust
washers (66), bearing (67) and planetary
gear (68) from No. 2 carrier assembly
(61).
2) Using pins [6], push out snap ring (69) and
remove No. 1 ring gear (70).
a Insert 2 pins [6] in 2 of the 4 holes at
the diagonal positions on the periph-
ery of No. 1 ring gear (70).
D65EX, PX, WX-16 50-300 33

300 Power train
17. Output shaft and No. 3 carrier assembly 18. Disassembly of No. 3 carrier assembly
1) Remove No. 3 carrier assembly (78). 1) Remove 3 seal rings (83) from No. 3 car-
rier assembly (79).
2) Remove snap ring (84) and bearing (85).
gear (90) from No. 3 carrier assembly
(79).
2) Remove output shaft (80).
19. No. 3 ring gear and No. 4 carrier assembly

Sling and remove No. 3 ring gear and No. 4
carrier assembly (91).
3) Remove snap ring (81) from output shaft

(80).
20. Disassembly of No. 3 ring gear and No. 4

carrier assembly
1) Using pins [7], push out snap ring (92) and
remove No. 3 ring gear (93).
a Insert 2 pins [7] in 2 of the 4 holes at
the diagonal positions on the periph-
ery of No. 3 ring gear (93).
50-300 34 D65EX, PX, WX-16

300 Power train
2) Remove seal ring (104) from No. 3 piston

(103).
2) Remove 4 shafts (95), pin (96), 2 thrust

gear (99) from No. 4 carrier assembly 22. No. 3 housing
(91). 1) Sling and remove No. 3 housing (105).
a Take care not to lose pin (96).
3) Remove snap ring (100) and remove
bearing (101) and spacer (102) as an
assembly.
4) Remove bearing (101) from spacer (102).
2) Remove seal ring (106) from No. 3 hous-

ing (105).
21. No. 3 piston

1) Remove No. 3 piston (103).
D65EX, PX, WX-16 50-300 35

300 Power train
23. No. 4 disc, plate, and spring

Disc (109): 4 pieces
2) Remove snap ring (118) from No. 5 carrier

assembly (112) and remove No. 4 ring
gear (119).
a If the above No. 5 carrier assembly is
not removed first, snap ring (118) pre-
24. No. 5 carrier and No. 4 ring gear assembly vents it from being removed.
1) Remove 4 hexagon socket head bolts
(110).
2) Remove No. 5 carrier and No. 4 ring gear
assembly (111).
26. No. 4 piston

25. Disassembly of No. 5 carrier and No. 4 ring

gear assembly
washers (115), bearing (116), and plane-
tary gear (117) from No. 5 carrier assem-
bly (112).
50-300 36 D65EX, PX, WX-16

300 Power train
2) Remove seal ring (121) from No. 4 piston 28. No. 5 disc, plate and spring
(120). 1) Remove 5 springs (124).
27. No. 4 housing

1) Sling and remove No. 4 housing (122).
29. No. 5 piston


ing (122).
2) Remove seal ring (129) from No. 5 piston

(128).
D65EX, PX, WX-16 50-300 37

300 Power train
30. No. 5 ring gear and No. 5 sun gear 3) Remove seal rings (137) and (138) from
1) Remove No. 5 ring gear (130) and No. 5 bearing cage (135).
sun gear (131).
4) Remove bearing (136) from bearing cage

31. Disassembly of No. 5 housing assembly (135).
1) Remove snap ring (133) and spacer (134)
from No. 5 housing assembly (132).
5) Reverse No. 5 housing assembly (132)

and remove snap ring (139).
2) Using puller [8], remove bearing cage 4 No. 5 housing assembly (132):
(135) and bearing (136) as an assembly. 30 kg
50-300 38 D65EX, PX, WX-16

300 Power train
6) Using push tool [9], remove spacer (140) Assembly

and bearing (141) as an assembly from q Precautions for assembly
No. 5 housing assembly (132). a Clean each part thoroughly and confirm that it
is free from dirt and flaw.
a Apply power train oil (For details, see “Table of
fuel, coolant and lubricants”) to the sliding sur-
faces of each part before installing.
a Check that the snap ring is securely in the
groove.
a When installing piston seal ring (a), set pres-
sure receiving side (b) toward housing (c) as
shown in the figure.
a When installing the metallic seal ring, apply
7) Remove bearing (141) from spacer (140). grease (G2-LI) to it and install evenly, taking
care not to shift it in any direction.

ing (132). 1. Assembly of No. 5 housing assembly
1) Set No. 5 housing (132) to blocks [10].
4 No. 5 housing (132): 30 kg
D65EX, PX, WX-16 50-300 39

300 Power train
2) Using tool D12, press fit bearing (141) to 7) Using tool D18, press fit bearing cage
spacer (140). assembly (135) to No. 5 housing (132).
a Press fit the inner race side of the
bearing.
3) Using the push tool, press fit spacer (140)

and bearing (141) as an assembly to No. 5
housing (132). 8) Set spacer (134) to No. 5 housing assem-
4) Install snap ring (139). bly (132) and install snap ring (133).
5) Using tool D13, press fit bearing (136) to 9) Install seal ring (142) to No. 5 housing
bearing cage (135). (132).
6) Install seal rings (137) and (138) to bear- 2 Seal ring (142): Grease (G2-LI)
ing cage (135). a When Installing the seal ring, confirm
2 Seal rings (137) and (138): its pressure receiving side.
Grease (G2-LI) (See “• Precautions for assembly”)
50-300 40 D65EX, PX, WX-16

300 Power train
2. No. 5 piston 4. No. 4 Housing

1) Install seal ring (129) to No. 5 piston (128). 1) Install seal ring (123) to No. 4 housing
2 Seal ring (129): Grease (G2-LI) (122).
a When installing the seal ring, confirm 2 Seal ring (123): Grease (G2-LI)
its pressure receiving side. a When installing the seal ring, confirm
(See “• Precautions for assembly”) its pressure receiving side.
(See “• Precautions for assembly”)
2) Install No. 5 piston (128) and No. 5 ring

gear (130). 2) Sling and install No. 4 housing (122).
a Check that the spring is securely in
the piston groove.

1) Install 5 guide pins (127).
2) Install the following alternately.
3) Install 5 springs (124).
a Spring free length: 59 mm
D65EX, PX, WX-16 50-300 41

300 Power train
5. No. 4 piston 2) Install bearing (116) to planetary gear

1) Install seal ring (121) to No. 4 piston (120). (117), set thrust washers (115) on its both
2 Seal ring (121): Grease (G2-LI) sides, and set it to No. 5 carrier (112).
a When installing the seal ring, confirm 3) Set ball (114) to shaft (113) and install it to
its pressure receiving side. No. 5 carrier (112). (4 places)
7. No. 5 carrier and No. 4 ring gear assembly

2) Install No. 4 piston (120). 1) Using guide bolts [11], install No. 5 carrier
and No. 4 ring gear assembly (111).
2) Tighten 4 hexagon socket head bolts
(110).
2 Hexagon socket head bolt (110):
Adhesive (LT-2)
3 Hexagon socket head bolt (110):
27– 34 Nm {2.8 – 3.5 kgm}
6. Assembly of No. 5 carrier and No. 4 ring

gear assembly
1) Set No. 4 ring gear (119) to No. 5 carrier
(112) and install snap ring (118).
8. No. 5 sun gear

Install No. 5 sun gear (131).
50-300 42 D65EX, PX, WX-16

300 Power train
9. No. 4 disc, plate and spring 11. No. 3 piston

1) Install the following alternately. 1) Install seal ring (104) to No. 3 piston (103).
Plate (108): 5 pieces 2 Seal ring (103): Grease (G2-LI)
Disc (109): 4 pieces a When installing the seal ring, confirm
2) Install 5 springs (107). its pressure receiving side.
a Spring free length: 59 mm (See “• Precautions for assembly”)
10. No. 3 housing 2) Install No. 3 piston (103).

1) Install seal ring (106) to No. 3 housing
(105).
a When installing the seal ring, confirm
its pressure receiving side.
12. Assembly of No. 3 ring gear and No. 4 car-

rier assembly
spacer (102).
2) Sling and install No. 3 housing (105).

a Confirm that the spring is securely in
the piston groove.
D65EX, PX, WX-16 50-300 43

300 Power train
2) Using the push tool, press fit bearing (101) 14. Output shaft
and spacer (102) as an assembly to No. 4 1) Install snap ring (81) to output shaft (80).
carrier (91). 2 Splined section of output shaft (80):
3) Install snap ring (100). Grease (LM-G) or molybdenum
4) Install bearing (98) to planetary gear (99), disulfide lubricant (LM-P)
set thrust washers (97) on its both sides,
and set it to No. 4 carrier (91).
5) Install shaft (95) to No. 4 carrier (91) and
drive pin (96). (4 places)
(91) and install snap ring (92).
2) Install output shaft (80) to No. 3 ring gear

and No.4 carrier assembly (91).
13. No. 3 ring gear and No. 4 carrier assembly

Sling and install No. 3 ring gear and No. 4 car-
rier assembly (91).
50-300 44 D65EX, PX, WX-16

300 Power train
15. Assembly of No. 3 carrier assembly 17. No. 3 disc, plate and spring
1) Install bearing (89) to planetary gear (90), 1) Install 5 guide pins (53).
set thrust washers (88) on its both sides, 2) Install the following alternately.
and set it to No. 3 carrier (79). Plate (75): 5 pieces
2) Set ball (87) to shaft (86) and install it to Disc (76): 4 pieces
No. 3 carrier (79). (4 places) 3) Install 5 springs (74).
3) Using tool D15, press fit bearing (85). a Spring free length: 59 mm
5) Install 3 seal rings (83) to No. 3 carrier
assembly (79).
18. Assembly of No. 2 housing

No. 2 housing (62).
2) Install seal ring (73).
16. No. 3 carrier assembly

Install No. 3 carrier assembly (78). 3) Install snap ring (71).
D65EX, PX, WX-16 50-300 45

300 Power train
19. Assembly of No. 2 carrier and No. 1 ring 2) Set No. 2 carrier assembly (61) to cylinder
gear assembly [12].
1) Set No. 1 ring gear (70) to No. 2 carrier 3) Install No. 2 housing assembly (62).
(61) and install snap ring (69). 4) Using tool D17, press No. 2 housing
2) Install bearing (67) to planetary gear (68), assembly (62).
set thrust washers (66) on its both sides, a Press fit the inner race side of the
and set it to No. 2 carrier (61). bearing.
3) Set ball (65) to shaft (64) and install it to
No. 2 carrier (61). (4 places)
21. No. 2 housing and No. 2 carrier assembly

20. Assembly of No. 2 housing and No. 2 car- 1) Sling and install No. 2 housing and No. 2
rier assembly carrier assembly (59).
1) Install spacer (61a) and No. 2 ring gear 4 No. 2 housing and No. 2 carrier
(61b) to No. 2 carrier assembly (61). assembly (59): 45 kg
a Check that the spring is securely in
the piston groove.
50-300 46 D65EX, PX, WX-16

300 Power train
2) Put tool D10 in groove (b) of No. 2 carrier 4) Install 14 through bolt vibration control
assembly (78) and rotate it about 90° to sleeves (55) to No. 2 housing (54).
part (c). a Set slit (a) of vibration control sleeve
a Set tool D10 so that its both ends will (55) to the position recorded when
be securely fixed in groove (d) on the removed.
inside wall of No. 2 carrier assembly 5) Install spring (57) and lubricating oil relief
(78). valve (56).
3) Tighten the bolt of tool D10 to pull up No.
2 carrier assembly (78), and then install
snap ring (58).

Disc (52): 7 pieces
a Spring free length: 77 mm
D65EX, PX, WX-16 50-300 47

300 Power train
23. No. 2 piston 2) Sling and install No. 1 housing (45).

1) Install seal ring (49) to No. 2 piston (48). 4 No. 1 housing (45): 25 kg
2 Seal ring (49): Grease (G2-LI) a Confirm that the spring is fitted to pis-
a When installing the seal ring, confirm ton groove securely.
25. No. 1 piston

1) Install seal ring (44) to No. 1 piston (43).
2) Install No. 2 piston (48). 2 Seal ring (44): Grease (G2-LI)
24. No. 1 housing

1) Install seal rings (46) and (47) to No. 1
housing (45).
2 Seal rings (46) and (47): 2) Install No. 1 piston (43).
Grease (G2-LI)
50-300 48 D65EX, PX, WX-16

300 Power train
26. Assembly of No. 1 carrier assembly

1) Install bearing (31) to planetary gear (32),
set thrust washers (30) on its both sides,
and set it to No. 1 carrier (24).
2) Set ball (29) to shaft (28) and install it to
No. 1 carrier (24). (4 places)
4) Install input shaft (23) to No. 1 carrier

assembly (24) and install snap ring (22).
27. Assembly of input shaft and No. 1 carrier

assembly
assembly (24) and install snap ring (25).
5) Install No. 1 sun gear (18) and snap ring

(17) to input shaft (23).
6) Install snap ring (16), No. 2 sun gear (15)
and snap ring (14).
2) Install bearing (38) to input shaft (23).

3) Install 2 seal rings (35) and (36) each and
snap rings (38a) and (37).
2 Seal rings (35) and (36):
Grease (G2-LI)
2 Transmission side spline portion
(e):
Grease (LM-G) or molybdenum
disulfide lubricant (LM-P)
a Do not coat grease to the torque con-
verter side spline portion (f).
D65EX, PX, WX-16 50-300 49

300 Power train
28. Input shaft and No. 1 carrier assembly 30. Assembly of front cover
Install input shaft and No. 1 carrier assembly 1) Using tool D19, press fit bearing (34) to
(21). front cover (20).
2) Install snap ring (33) to front cover (20).
3) Install seal ring (34a).
2 Seal ring (34a): Grease (G2-LI)

Disc (41): 5 pieces
a Spring free length: 69.5mm
31. Front cover

1) Install spacer (21a).
50-300 50 D65EX, PX, WX-16

300 Power train
2) Install front cover (20).

a Confirm that the spring is securely in
the piston groove.
3) Install 3 through bolts (12).
a Push in through bolts (12) with the
hand until they reach the tap hole so
that they will not damage the vibration
control sleeves.
a Use an impact wrench only after the
threads are engaged completely.
3 Through bolt (12):
157 – 177 Nm {16 – 18 kgm}
32. Operation check of piston

Using tool D11, check the operating condition
and stroke of the piston.
Piston Stroke (mm)
No.1 5
No.2 7
No.3 4
No.4 4
No.5 4
4) Install snap ring (19) according to the fol-

lowing procedure.
1] Using tool [13], sling input shaft (23)
slightly.
a At this time, ensure that the
mounting groove of snap ring
(19) is out completely.
2] Install snap ring (19).
33. Transmission case

1) Sling and install transmission case (10).
4 Transmission case (10): 120 kg
D65EX, PX, WX-16 50-300 51

300 Power train
2) Install 11 through bolts (11) to transmis- 35. Related parts

sion case (10). 1) Install sleeve (6).
a Push in through bolts (11) with the 2) Install the O-ring to the groove and install
hand until they reach the tap hole so plate (5) and main relief valve assembly
that they will not damage the vibration (4).
control sleeves. 3 Main relief valve assembly (4)
a Use an impact wrench only after the mounting bolt:
threads are engaged completely. 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
3 Through bolt (11):
157 – 177 Nm {16 – 18 kgm}
34. Snap ring

1) Sling and set transmission assembly hori-
zontally.
4 Transmission assembly: 350 kg
2) Install snap ring (8) to output shaft (7).
3) Using tool [2], install 5 sleeves (3).
50-300 52 D65EX, PX, WX-16

300 Power train
4) Install the O-ring to the groove and sling

and install transmission control valve
assembly (2).
4 Transmission control valve assem-
bly (2): 25 kg
D65EX, PX, WX-16 50-300 53

300 Power train
SEN05112-02 Disassembly and assembly of HSS assembly

HSS assembly 1 1. Transmission speed sensor
Remove transmission speed sensor cover (1),
Special tools and then pull out and remove transmission
speed sensor (2).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
1 791T-422-1320 Hanger q 1 Q
2 790-302-1500 Wrench kit q 1
3 796-730-2300 Wrench assembly q 1
Commercially
Torque wrench
available or q 1
set
4 795-630-1803
795-630-1810 • Torque wrench 1
795-630-1830 • Adapter 1
790-101-5201 Push tool kit (B) t 1
790-101-5261 • Plate 1 Remove brake valve assembly (4).
5
790-101-5221 • Grip 1
01010-51225 • Bolt 1
6 794T-422-1110 Push tool t 1 Q
790-101-5401 Push tool kit (C) t 1
790-101-5481 • Plate 1
7
790-101-5421 • Grip 1
E 01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5491 • Plate 1
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
9 793T-659-1110 Push tool t 1 Q
3. Cover assembly
10 796T-467-2160 Push tool t 1 Q 1) Using eyebolts [1], remove cover assem-
11 790-201-2730 Push tool t 1 bly (5).
790-101-5201 Push tool kit (B) t 1
790-101-5221 • Grip 1
12 01010-51225 • Bolt 1
790-101-5271 • Plate 1
790-101-5311 • Plate 1
790-101-5001 Push tool kit (A) t 1
790-101-5091 • Plate 1
13
790-101-5021 • Grip 1
01010-50816 • Bolt 1
50-300 54 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of HSS assembly SEN05112-02
2) Remove 5 sleeves (24) and 2 pieces of 3] Remove bearing (10) from gear (9).
(25) from the HSS case.
2) Intermediate gear
4. Disassembly of cover assembly 1] Remove tube (11).
1) Input gear assembly
1] Remove snap ring (12).
2] Remove the bolt and holder (13).

3] Drive out shaft (14) from the bolt side
2] Using puller [2], pull out gear assem- and remove gear (15).
bly (6) and cage (7) together, and a Take care not to lose the ball.
then remove gear assembly (6) from
cage (7).
D65EX, PX, WX-16 50-300 55

300 Power train
4] Remove bearing (17) and spacer 4] Remove snap ring (23), then remove
(17a) from gear (15). bearing (28) from cover (32).
5] Remove outer race (29) from cover
(32).
3) Left carrier driver gear

1] Remove bolt (19) and holder (20).
2] Remove gear (22). 6] Remove bearing (26) from shaft (21).
3] Using gear puller [3], push out shaft 4) Remove the plug, spring (30), and valve
(21). (31).
50-300 56 D65EX, PX, WX-16

300 Power train
5. Removal of brake and carrier assembly 4) Remove bearing (60) from cover (41).
Remove the mounting bolt, then remove brake
and carrier assembly (34) with tool E1.
a Do not remove 4 hexagon socket head
bolts.
5) Remove spring (42).

6) Using eyebolts [5], remove piston (43).
6. Disassembly of brake assembly

1) Remove flange (36).
2) Remove snap ring (37) and spacer (38).
7) Push up and remove cage (51), taking

care not to damage the disc.
8) Remove seal rings (53) and (27) from
cage (51).
9) Using eyebolts [7], remove drum (45),
3) Set puller [4] and loosen 4 hexagon discs, and plates as a unit.
socket head bolts and remove cover (41).
a The inner race side of the bearing
comes out.
a Do not remove bolts (40) until cover
(41) comes off.
D65EX, PX, WX-16 50-300 57

300 Power train
10) Remove discs (46), plates (47), and 13) Remove bushing (60) from hub (39).
springs (48) from drum (45). 14) Remove snap ring (58), then remove stop-
per (56) from the hub.
11) Remove snap ring (59) and bearing (57).

a Pry up the bearing from the cut of the 7. Disassembly of carrier assembly
hub. 1) Turn over the hub and carrier assembly
and remove bolts (89), then remove car-
rier assembly (64) from hub (54).
12) Remove 18 mounting bolts, then remove

hub (39) from hub (54).
2) Remove hub (92) from carrier assembly
(64), then remove snap ring (50) and gear
(52).
50-300 58 D65EX, PX, WX-16

300 Power train
3) Drive roll pin (65) into the shaft. 3) Using the bearing race puller, remove
4) Pull out shaft (66) and remove gear (52), bearing (74).
thrust washer (67), and bearing (69). 4) Remove collar (71).
a Pull roll pin (65) out of the shaft. 5) Remove snap ring (93).
a Only the right side of the machine.
5) Remove bushing (91) from carrier (90).

9. Bevel pinion assembly
8. Sun gear 1) Remove the mounting bolts.
1) Remove snap ring (70) and collar (73). 2) Using guide bolts [9] and forcing screws
[10], remove bevel pinion assembly (95)
and shim (96).
a Check and record the quantity and
thickness of the shims.
2) Using gear puller [8], remove sun gear

(72) and bearing (98).
3) Disassembly of bevel pinion assembly

1] Remove bolt (97), plate (99), and pin
(100).
D65EX, PX, WX-16 50-300 59

300 Power train
2] Secure the pinion with a press and 10. Bevel gear shaft and bevel gear
remove nut (101) with tool E2. 1) Sling bevel gear and shaft assembly (75)
3] Using tool E5, remove bevel pinion temporarily.
(102) from cage (103). 2) Remove cage assemblies (76) and (86).
a Check and record the thickness,
quantity, and positions of shims (77).
a Since both cages are different from
each other, make marks on them.
4] Remove bearing (104).

5] Remove outer races (105) and (107)
from cage (103).
3) Move bevel gear and shaft assembly (75)

to the left end and remove bearing (78)
with puller [12].
a Remove only the bearing on the left
side of the machine.
6] Remove bearing (106) and spacer

(108) from bevel pinion (102).
50-300 60 D65EX, PX, WX-16

300 Power train
4) Sling bevel gear (79) and remove mount- Assembly

ing nut (80) and pull out bevel gear shaft q Precautions for assembly
assembly (81) to the right side of the a Clean the all parts and check them for dirt
machine. or damage before installing.
a Drop power train oil (refer to the section
“Fuel, coolant and lubricants” for detail)
onto the rotating parts of each bearing and
rotate it several turns.
a Coat the sliding parts with power train oil
(refer to the section “Fuel, coolant and
lubricants” for detail) before installing.
a Apply grease (G2-LI) to each piston seal
ring and install it evenly with the pressure
receiving side directed to the housing.
2 Rotary seal ring:
Fix each seal ring with grease (G2-
LI) and install it very carefully not to
catch it in the parts.
5) Remove bearing (78) from bevel gear a Check that the snap rings are fitted
shaft (82). securely in the grooves.
6) Remove bolts (83).
7) Remove outer race (84) from cage (76).
1. Suction tube
Install suction tube (55).
8) Remove seal rings (85) from bevel gear
shaft (81).
D65EX, PX, WX-16 50-300 61

300 Power train
2. Bevel gear shaft and bevel gear assembly 5) Insert bevel gear shaft (81) in bevel gear
1) Install bolt (83) to bevel gear shaft (82). (79) slung at the center of the case from
2) Heat bearing (78) with a bearing heater, the right side of the machine.
etc. and install it to the right side of the a Tighten mounting nut (80) temporarily
bevel gear shaft by shrink fit. in advance.
a If the bearing temperature is raised
too high, the hardness of the heat-
treated part lowers. Accordingly, do
not raise the bearing temperature
more than 120ºC.
a After installing the bearing, drop
power train oil (refer to the section
“Fuel, coolant and lubricants” for
detail) onto its rotating parts and
a Check that the clearance at the bear-
ing end is 0.03 mm or less.
3) Install outer race (84) to cages (76) and (86).
6) Heat bearing (78) with a bearing heater,

etc. and install it to the left side of the
bevel gear shaft by shrink fit.
a If the bearing temperature is raised
too high, the hardness of the heat-
treated part lowers. Accordingly, do
not raise the bearing temperature
more than 120ºC.
a After installing the bearing, drop
power train oil (refer to the section
detail) onto its rotating parts and
4) Install seal rings (85) to bevel gear shaft a Check that the clearance at the bear-
(81). ing end is 0.03 mm or less.
50-300 62 D65EX, PX, WX-16

300 Power train
7) Install cages (76) and (86) to bevel gear

and shaft assembly (75).
a Since both cages are different from each
other, take care not to mistake them.
a Install shims (77) of the thickness and
quantity recorded when removed.
q Standard shim thickness: 1.5 mm
q Varieties of shim thickness:
0.2 mm, 0.3 mm, 0.5 mm
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
8) Tighten the bevel gear mounting nut
securely.
a Place a plastic hammer, etc. between
the bevel gear. 3. Bevel pinion assembly
3 Mounting nut: 1) Assembly of bevel pinion
245 – 309 Nm {25.0 – 31.5 kgm} 1] Using tool E6, press fit bearing (106)
to bevel pinion (102) and install
spacer (108).
9) Adjusting pre-load
a Adjust the pre-load with the bevel pin-
ion assembly removed.
1] Rotate the bevel gear and shaft
assembly several turns to fit the bear-
ing.
2] Install tool E3 to the end of bevel gear
shaft (81) and measure the rotation
torque with tool E4 (torque wrench).
q Standard rotation torque:
10.3 – 14.7 Nm {1.05 – 1.50 kgm}
a If the rotation torque is lower than the
standard value, reduce the quantity of
shims (77) in step 7). If the former is
higher, increase the latter.
D65EX, PX, WX-16 50-300 63

300 Power train
2] Using tools E7 and E8, press fit outer 4] Using tool E9, press fit bearing (104)
races (105) and (107) to cage (103). to cage (103).
3] Place bevel pinion (102) on the press 5] Secure the pinion with the press and
stand and set cage (103). tighten locknut (101) with tool E2.
2 Locknut: Adhesive (LT-2)
3 Locknut:
392 – 441 Nm {40 – 45 kgm}
6] After tightening the nut, return it until
1 o f i ts p i n h o l e s ( 8 p l a c e s ) i s
matched to 1 of the pin holes of the
pinion shaft (5 places).
a Return the nut by 0 – 9°.
a Tighten the nut, turning the cage.
a After tightening the nut, check
that the bevel pinion rotates
smoothly.
7] Install pin (100), plate (99), then

tighten bolt (97).
3 Bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
50-300 64 D65EX, PX, WX-16

300 Power train
2) Using guide bolt [9], install shims (96) and a Adjust the backlash by increasing or
bevel pinion assembly (95). decreasing the thickness of both
a Install shims of the thickness and shims. Do not change the total thick-
quantity recorded when removed. ness of both shims so that the pre-
q Standard shim thickness: 2 mm load will not change. (If the thickness
q Varieties of shim thickness: of the shim on one side is increased,
0.2 mm, 0.3 mm, 1.0 mm decrease the thickness of the other
side, and vice versa.)
q When backlash is insufficient
Decrease the thickness of the shim
on the right side of the machine body
and increase the thickness on the left
side by the same quantity. (Move the
bevel gear in direction (A).)
4. Adjusting backlash and tooth contact

1) Adjusting backlash
Apply the probe of dial gauge [13] to the
tooth tip at the end of the bevel gear at
right angles. Fix the bevel pinion and
move the bevel gear forward and back-
ward, and read the value at this time.
a Standard backlash: 0.2 – 0.28 mm q When backlash is too large
a Measure the backlash diagonally at 3 Decrease the thickness of the shim
or more places. on the left side of the machine body
and increase the thickness on the
q If the measured backlash is out of the right side by the same quantity. (Move
standard range, adjust it according to the bevel gear in direction (B).)
D65EX, PX, WX-16 50-300 65

300 Power train
2) Adjusting tooth contact Adjusting

Testing If the tooth contact pattern is not proper,
Apply red lead thinly to the tooth surfaces adjust the tooth contact according to the
of the bevel gear and turn the bevel gear following procedure.
in the forward and reverse directions, then 1] If the bevel pinion is too far from the
check the tooth contact pattern on the center line of the bevel gear, the con-
bevel gear. tact is at the small end of the bevel
1] Check that tooth tip (A), bottom (B), gear tooth faces curved outward and
small end (C), and large end (D) of at the large end of the bevel gear
the teeth do not have any strong tooth tooth faces curved inward.
contact. q In this case, adjust the tooth contact
Adjust the thickness of the shims on
the bevel pinion side to move the
bevel pinion in direction (A). Move the
bevel gear in direction (B), then check
the tooth contact pattern and back-
lash again.
2] The tooth contact must be as follows.

(The standard distance is measured
from the tooth tip of the bevel pinion.)
a) Center of tooth contact (a):
20 – 40% of face width
b) Width of tooth contact (b):
30 – 50% of face width
c) Center of tooth contact (c): 2] If the bevel pinion is too close to the
35 – 65% of tooth depth center line of the bevel gear, contact
d) Width of tooth contact (d): is at the large end of the bevel gear
60 – 80% of tooth depth tooth faces curved outward and the
a If the bevel gear and bevel pinion are small end of the bevel gear tooth
adjusted in this way, their teeth come faces curved inward.
in contact with each other correctly q In this case, adjust the tooth contact
when they are loaded. according to the following procedure.
a (C) shows the small end and (D) Adjust the thickness of the shims on
shows the large end. the bevel pinion side to move the
bevel pinion in direction (A). Move the
bevel gear in direction (B), then check
the tooth contact pattern and back-
lash again.
a Do not change the total thickness of
the shims on both sides.
50-300 66 D65EX, PX, WX-16

300 Power train
3] When adjustment is finished, tighten 4) Install sun gear (72).

the mounting bolts of the cage and 5) Using tool E11, press fit bearing (98).
bevel pinion assembly to the speci- a Press fit the inner race and outer race
fied torque. simultaneously.
3 Mounting bolts of cage and
bevel pinion assembly:
98 – 123 Nm {10.0 – 12.5 kgm}
5. Sun gear
1) Install snap ring (93) to the shaft.
a Perform this work for only right side of
the machine.
2) Install collar (71).
3) Using tool E10, install bearing (74).
6) Install collar (73) and snap ring (70).
6. Assembly of carrier assembly

1) Install bushing (91) to carrier (90).
2) Install bearing (69) to gear (52). Fit thrust

washers (67) to top and bottom of the
bearing, then set them to the carrier.
3) Install shaft (66), matching the inside of
the thrust washers and bearing to the
shaft hole of the carrier.
a Match the roll pin hole accurately.
D65EX, PX, WX-16 50-300 67

300 Power train
4) Install roll pin (65). 7. Assembly of brake assembly

1) Install stopper (56) to the hub, then install
snap ring (58).
2) Install bushing (60) to hub (39).
5) Set hub (92) to ring gear (52) and install

snap ring (50).
6) Install hub (92) to carrier assembly (64).
3) Install hub (39) to hub (54) with 18 mount-
ing bolts.
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
7) Install hub and carrier assembly (64) to

hub (54) and tighten bolts (89).
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
4) Install bearing (57) to hub (39).
50-300 68 D65EX, PX, WX-16

300 Power train
6) Set brake drum (45) to hub (39).

7) Install discs (46), plates (47), and springs
(48).
11) Install spring (42).

12) Install guide bolt [14] to cage (51).
13) Install bearing (60) to cover (41).
8) Install seal rings (27) and (53) and cage
(51).
a Roughly match the oil holes on the
cage to the 4 oil holes on the drum.
a Press fit the cage to the outer race
side of the bearing.
14) Using eyebolts [15] and matching to the

guide bolt, set cover (41).
a Check that the spring is fitted securely
to both of the piston and case.
15) Compressing the spring with forcing
screws [17] and nuts [16], press fit the
9) Install the seal ring to piston (43). inner race side of the bearing to the hub
10) Install piston (43) to the drum, while set- assembly.
ting match mark (a) of the former to the
center of 13.5 mm hole (c) of the latter.
(b): Spot facing of piston
(d): Opposite side to side hole of drum
D65EX, PX, WX-16 50-300 69

300 Power train
16) Install spacer (38) and snap ring (37). 9. Assembly of cover assembly
17) Install flange (36). 1) Install valve (31) and spring (30) to the
cover, then install the plug.
18) Remove the bolts and nuts used to com-

press the spring, then install 4 bolts (40). 2) Left carrier drive gear
1] Using tool E11, press fit bearing (26)
to shaft (21).
8. Installation of brake and carrier assembly

1) Set the seal rings on the carrier side to
equalize the projection from the shaft.
2) Using tool E1, install brake and carrier
assembly (34).
50-300 70 D65EX, PX, WX-16

300 Power train
2] Using tool E12, press outer race (29) 5] Install gear (22).
to cover (32). 6] Install holders (20) and tighten bolts
3] Using tool E12, press fit bearing (28) (19).
to cover (32), then install snap ring 3 Mounting bolt:
(23). 98 – 123 Nm {10.0 – 12.5 kgm}
3) Intermediate gear assembly

1] Using tool E12, press fit bearing (17)
to gear (15) and install spacer (17a).
4] Press fit shaft (21) to the inner race

side of bearing (28).
D65EX, PX, WX-16 50-300 71

300 Power train
2] Using tool E13, press fit shaft (14) to 4] Install tube (11).
the inner race side of bearing (17). Fit
ball (16) halfway and press fit com-
pletely.
a Before the shaft enters the cover,
position the ball accurately.
4) Input gear assembly

1] Install bearings (10) to gear (9).
2] Install gear assembly (6).

3] Install cage (7) and ball (8), matching
them to the hole for ball (8).
3] Install holder (13) and tighten bolt 4] Install snap ring (12).
(12).
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
50-300 72 D65EX, PX, WX-16

300 Power train
10. Installation of cover assembly 12. Transmission speed sensor

1) Install 2 sleeves (25) and 5 sleeves (24) to Install transmission speed sensor (2) and
the HSS case. cover (1). For details, see Testing and adjust-
ing, “Adjusting transmission output shaft speed
sensor (Replacement procedure)”.
2) Using eyebolts [1], install cover assembly

(5).
2 Mating face of cover:
a Apply gasket sealant to both mating
faces of the case and cover.
a Apply gasket sealant to each mating
face without breakage.

Install brake valve assembly (4).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
D65EX, PX, WX-16 50-300 73

300 Power train
SEN05112-02 Removal and installation of final drive assembly
Removal and installation of final 5. Remove cover (2). [*2]

drive assembly 1
6. Use extraction bolt [3] to pull drive shaft (3) out
Special tools to a position where spline portion comes out.
a If drive shaft (3) cannot be pulled out,
New/Remodel
apply a jack etc. to the track shoe grouser
Necessity
Symbol
Sketch
and pull out the drive shaft while adjusting
Q’ty
Part No. Part name
its position finely.
7. Leave 2 or 3 of 11 inside mounting bolts (4)

and 9 outside mounting bolts in position at top,
J 1 791-427-1090 Plate t 1 and remove remaining mounting bolts. [*3]
01010-51635 Bolt t 2
Removal
1. Remove track shoe assembly. For details,
“Removal and installation of track shoe assem-
bly”.
2. Using jack, jack up chassis, then set stands [1]
and [2] under front frame and steering case.
k Set the stands in position securely.
3. Drain oil from final drive case.

6 Final drive case: D65EX-16: 24 l
D65EX-16 PAT: 27 l
D65PX-16: 27 l
D65WX-16: 27 l
4. Remove bracket (1). [*1]
50-300 74 D65EX, PX, WX-16

300 Power train
Removal and installation of final drive assembly SEN05112-02
8. Remove 2 cover mounting bolts from final drive Installation

case, then set tool J1 and lever block in posi- q Carry out installation in the reverse order to
tion, and sling final drive assembly (5). [*4] removal.
9. Remove the remaining bolts and move the [*1]

final drive assembly outward to remove it from 2 Thread of bracket (1) mounting bolt:
the case. Adhesive (LT-2)
a While operating the lever block and keep-
ing the clearance between the final drive [*2]
case assembly and the case even, pry off a Be careful not to damage the seal when install-
the final drive assembly with a bar, etc. ing.
3 Cover (2) mounting bolt:
4 Final drive assembly: 850 kg
98 – 123 Nm {10.0 – 12.5 kgm}
10. Remove sprocket (6).

[*3]
3 Final drive assembly mounting bolt:
490.3 – 608.0 Nm {50 – 62 kgm}
[*4]
3 Cover mounting bolt:
245.2 – 308.9 Nm {25.0 – 31.5 kgm}
q Refilling with oil

5 Final drive case:
Power train oil (refer to the section
detail)
D65EX-16: 24 l
D65EX-16 PAT: 27 l
D65PX-16: 27 l
D65WX-16: 27 l
D65EX, PX, WX-16 50-300 75

300 Power train
SEN05112-02 Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)
Removal and installation of final drive assembly (Planetary gear

installed inside of sprocket type) 1
a special tools 4. Remove bracket (1). [*1]
New/Redesign
Necessity
Sketch
Sym
Q'ty
Part number Part name
bol

791T-527-1110 Plate t 1 N Q
J 9
01010-81680 Bolt t 2
01010-31645 Bolt t 2
Removal
1. Separate track shoe assembly. For details,
see "Separation and connection of track
shoe assembly". 5. Remove cover (2). [*2]
2. Using jacks, lift up the machine body and set 6. Using forcing screws [3], draw out drive shaft
stands [1] and [2] under the front frame and (3) until the spline portion is pull out.
steering case. a If drive shaft (3) cannot be pulled out,
k Set the stand securely. push up the track shoe grouser by using a
jack etc. and fine-adjust the position
where the shaft can be pulled out easily.
7. Remove eleven inner mounting bolts (4) and
nine outer mounting bolts, but leave two to
three upper bolts installed. [*3]
3. Drain oil from the final drive case.

6 Final drive case
D65EX-17: 21 l(*1)
D65EX-17 PAT,D65PX-17,D65WX-17: 25 l
*1: Indicates the oil level except for power
angle and power tilt dozer.
8. Remove three cover mounting bolts (4a) of assembly (5). [*4]

the final drive case. Set tool J9 and the lever
block onto sling tap (P), and sling final drive
50-300 76 D65EX, PX, WX-16

300 Power train
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type) SEN05112-02
Installation
removal.
1)
[*1]
2 Threaded portion of mounting bolt for
bracket (1):
Adhesive (LT-2)
[*2]
3 Cover (2) mounting bolt:
98 - 123 Nm {10.0 - 12.5 kgm}
[*3]
3 Final drive assembly mounting bolt :
490.3 - 608.0 Nm {50 - 62 kgm}
[*4]
3 Cover mounting bolt:
245.2 - 308.9 Nm {25.0 - 31.5 kgm}
q Refilling of oil
5 Final drive case: Power train oil (For details,
see "List of lubricant and water")
D65EX-17: 21 l(*1)
D65EX-17 PAT,D65PX-17,D65WX-17: 25 l
*1: Indicates the oil level except for power
angle and power tilt dozer.
9. Remove the remaining bolts, and slide
outward to remove from the case.
a Set guide bolt [1], and use forcing taps [2]
(set at two places diagonally) to remove
the final drive case assembly.
4 Final drive assembly:
850 kg
D65EX, PX, WX-16 50-300 77

300 Power train
SEN05112-02 Disassembly and assembly of final drive assembly
Disassembly and assembly of 2. Disassembly of carrier assembly

final drive assembly 1
1) Remove lock plates (2).
2) Using forcing screws [2], remove plate (3)
Special tools together with gear assembly (4).
3) Remove gear assembly (4) from plate (3).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
791-427-1100 Remover assembly t 1

2 790-101-2102 Puller t 1
790-101-1102 Pump t 1
3 792-520-2121 Installer t 1
791-427-1200 Installer assembly t 1
4 790-101-2102 Puller t 1
790-101-1102 Pump t 1
J
790-101-5201 Push tool kit (B) t 1
a If gear assembly (4) remains in posi-
790-101-5321 • Plate 1 tion when the plate remains, use
5
790-101-5221 • Grip 1 puller [3] to remove it.
01010-51225 • Bolt 1
6 790-201-2330 Plate t 1
7 790-201-2460 Plate t 1
8 790-101-5431 Plate t 1
Disassembly
1. Carrier assembly
1) Remove cover.
2) Remove mounting bolts, and using eye-
bolts [1], remove carrier assembly (1).
4) Support gear (5), then push shaft (6) and

remove bearing (7).
50-300 78 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of final drive assembly SEN05112-02
5) Remove bearing (7) from shaft (6). 5. Sprocket, hub assembly

6) Remove outer race (8) from gear (5). 1) Fit eyebolts, pull out sprocket and hub
assembly (15) with tool J2, and remove.
a Bearing (19) will come out at the
same time.
3. Shaft
Using eyebolt [4], remove shaft (9).
4. Ring gear, housing assembly

1) Remove holder (10).
2) Remove floating seal (16).

a If it is to be used again, be careful not
to damage the seal surface and keep
2) Using eyebolts [5], remove ring gear and
it in a safe place.
hub assembly (11).
3) Remove outer race (18).
3) Remove snap ring (12), then remove ring
gear (14) from hub (13).
D65EX, PX, WX-16 50-300 79

300 Power train
6. Cover assembly 7. Gear assembly

1) Tighten forcing screws [6] to pull cover 1) Using eyebolts [9], remove gear assembly
assembly (21) out of case (22). Then, (24) from case.
using eyebolts [7], remove cover assem- 2) Using puller [10], remove bearing (26)
bly (21). from gear assembly (25).
a Although the cover assemblies of
D65EX-16, D65PX-16 and D65WX-
16 have different shapes, they can be
removed similarly.
8. Output shaft
Remove output shaft (27).
9. Pinion assembly
1) Using forcing screws [11], remove cage
a If it is to be used again, be careful not
(28).
to damage the seal surface and keep
a Check and record the number and
it in a safe place.
thickness of the shims.
3) Using forcing screw [8], remove spacer
(20) and bearing (19) from cover.
2) Remove pinion assembly (29).

3) Remove bearing (31) from pinion (30).
50-300 80 D65EX, PX, WX-16

300 Power train
4) Remove outer race (32) and oil seal (33) Assembly

from cage (28). a Clean all parts, and check for dirt or damage.
5) Remove outer race (34) from case. Coat the sliding surfaces of all parts with power
train oil (refer to the section “Fuel, coolant and
lubricants” for detail) before installing.
1. Pinion assembly
1) Using tool J5, press fit oil seal (33) to cage
(28).
2 Lip of oil seal: Grease (G2-LI)
2) Install outer race (32) to cage (28).

3) Install outer race (34) to case.
D65EX, PX, WX-16 50-300 81

300 Power train
4) Install bearings (31) to pinion (30).

5) Install pinion assembly (29).
a Install so that the part with the small
outside diameter is facing the outside.
2. Output shaft
Install output shaft (27).
3. Gear assembly
6) Assemble shim, then install cage (28).
1) Using tool J6, press fit bearing (26) to
gear (25).
a Select the shim thickness to be

assembled as follows.
1] Install pinion without fitting O-ring
to cage.
2] Hold cage down by hand, and
use a thickness gauge to mea-
sure clearance between gauge
and case at 2 places on the cir-
cumference.
3] Select shim from thickness of
measured clearance (a).
Shim thickness: (a) + 0 – 0.1 mm
a If clearance (a) is 0, ensure
that the rotation torque of
the pinion is 0.98 Nm {0.1
kgm} or less.
50-300 82 D65EX, PX, WX-16

300 Power train
2) Install thrust washer (35) to case. 4) Using eyebolts [7], install cover assembly
3) Using eyebolts [9], install gear assembly (21) to case, then tighten mounting bolts.
(24).
5. Sprocket, hub assembly

4. Cover assembly 1) Using tool J7, press fit outer race (18) to
1) Install spacer (20) to cover (36). hub (13).
2) Using tool J4, press fit bearing (19). 2) Using tool J3, install floating seal (16).
a A press can be used instead of the a Remove all oil and grease from the
puller. O-ring and O-ring contact surface,
3) Using tool J3, install floating seal. and dry before installing.
a Remove all oil and grease from the a After installing the floating seal, check
O-ring and O-ring contact surface, that the angle of the seal is less than
and dry before installing. 1 mm.
a After installing the floating seal, check
that the angle of the seal is less than
1 mm.
D65EX, PX, WX-16 50-300 83

300 Power train
3) Check that there is no dirt or dust on slid- 8) Set holder (10) in position.
ing surface of floating seal, then coat a The bearings are set parts, so there is
thinly with power train oil (refer to the sec- no need to adjust them, but in order to
tion “Fuel, coolant and lubricants” for check that there are no defective
detail). parts, measure the preload as fol-
4) Using eyebolts [13], set sprocket and hub lows.
assembly (15) in cover. 1] With no preload given to the
bearings, measure the rotating
torque of the sprocket hub, and
take this rotating torque as (b).
a Measure the sliding resis-
tance of the floating seal
first.
2] Rotate the sprocket and tighten
the plate holder bolt to 245.2 –
308.9 Nm {25.0 – 31.5 kgm}.
3] After tightening the bolt, check
that the rotating torque is (b) + 0
to 61.8 Nm {0 to 6.3 kgm}.
5) Using tool J4, rotate sprocket and hub

assembly, and press fit bearing (19).
a Press fit to a point which does not
give any preload.
6) Set hub (13) to ring gear (14), and install

snap ring (12).
7) Using eyebolts [5], install ring gear and
hub assembly (11).
50-300 84 D65EX, PX, WX-16

300 Power train
6. Shaft 4) Expand fit shaft (6).

Using eyebolts [4], install shaft (9). a Leave in dry ice for approx. 30 minutes.
5) Install lock plates (2).
7. Carrier assembly 3 Mounting bolt:
1) Using tool J8, press fit outer race (8) to 98 – 123 Nm {10.0 – 12.5 kgm}
planetary gear (5).
a The bearing is set parts, so be careful
not to change the combination.
6) Using eyebolts [1], install carrier assembly

(1).
3 Mounting bolt:
245.2 – 308.9 Nm {25.0 – 31.5 kgm}
7) Install cover.
2) Assemble 2 bearings (7) to gear (5), and

set to carrier (17).
a Center with the shaft hole.
3) Align with dowel pin and install plate (3).
3 Mounting bolt:
490.3 – 608.0 Nm {50 – 62 kgm}
D65EX, PX, WX-16 50-300 85

300 Power train
SEN05112-02 Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type)
Disassembly and assembly of final drive assembly (Planetary gear

installed inside of sprocket type) 1
Special tools Disassembly

1. Shaft
New/Redesign
Necessity
1) Set the final drive assembly on the blocks
Sketch
Symb
Q'ty
Part number Part name with the sprocket side up.
ol
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
10 790-101-2470 Adapter (M20) t 2
790-101-2450 Adapter (M12) t 2
790-201-2680 Plate t 1
790-101-2102 Puller t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 1
01643-22460 Washer t 1
3) Using eyebolts, remove shaft (2).
11 790-101-2420 Adapter (M16) t 1
790-201-2840 Spacer t 1
790-101-2102 Puller t 1
790-431-1031 Black t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
J
01643-22460 Washer t 2
12
791T-527-1130 Plate t 1 N Q
791T-527-1120 Push tool t 1 N Q
790-101-2102 Puller t 1
13 791-580-8110 Installer t 1
790-101-5201 Push tool kit t 1 2. Sprocket hub assembly
790-101-5321 • Plate t 1 1) Remove mounting bolts (3) and plate (4).
14 790-101-5311 • Plate t 1
790-101-5221 • Grip t 1
01010-51225 • Bolt t 1
790-101-5441 • Plate t 1
15 790-101-5431 • Plate t 1
790-101-5421 • Grip t 1
01010-51240 • Bolt t 1
790-101-5630 Plate t 1 N
16 790-101-5421 Grip t 1
01010-51240 Bolt t 1
50-300 86 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type) SEN05112-02
2) Remove shim (5). 3. Cover assembly

1) Remove spacer (11).
3) Using tool 2, disconnect sprocket hub

assembly (6) and bearing (7).
4) Using eyebolts, remove sprocket hub 3) Sling and remove cover assembly (13).
assembly (6).

6) Remove bearing outer race (9).
7) Reverse sprocket hub assembly (6) and
remove bearing outer race (10).
D65EX, PX, WX-16 50-300 87

300 Power train
5) Set two bars [2] under bearing (15) and pull 4. Carrier assembly
out bearing (15) about 5 mm by using flange 1) Using three eyebolts, remove carrier
(P) of the cover as a fulcrum. assembly (19).
a Pull out the bearing evenly by a couple of
worker.
2) Remove bolts (20) to remove holder (21).

3) Pull out planetary gear shaft (22) and remove
6) Using puller [3], pull out bearing (15). planetary gear (23) and bearings (25a) and
(25b).
a Take care of spacer (25d) between the
bearings.
7) Reverse cover assembly (13) and remove

four lock plates (16).
8) Remove ring gear (18).
50-300 88 D65EX, PX, WX-16

300 Power train
4) Remove two bearing outer races (25c) from 3) Using eyebolts, remove gear (29).
the planetary gear.
4) Remove mounting bolts (30) and plate (31).

5. Hub and case assembly
1) Remove thrust washer (26) and sun gear
(27).
5) Using tool J10, separate hub assembly (32)

from the case.
2) Remove gear mounting bolts (28).
D65EX, PX, WX-16 50-300 89

300 Power train
6) Remove bearing (33). 10)Use puller [3], remove bearing (35).

7) Using the eyebolts, remove hub assembly
(32).
6. Cage assembly
1) Reverse the case and remove mounting
8) Remove bearing outer race (33a) from the bolts (38) of cage assembly (37).
hub assembly. 2) Using forcing screws [4], remove cage
assembly (37) from the case.
9) Remove spacer (34).

3) Remove shim (39).
50-300 90 D65EX, PX, WX-16

300 Power train
4) Remove outer race (41) and oil seal (42) from 8. Case
cage (40). 1) Remove outer race (47) and oil seal (48) from
the case.
7. Gear assembly
1) Remove gear assembly (43).
2) Using puller [5], remove bearings (44) and

(45) from gear (46).
D65EX, PX, WX-16 50-300 91

300 Power train
Assembly 3) Using push tool [6], press fit bearings (44)

a Clean the all parts and check them for dirt or and (45) to gear (46).
damage before installing. q Press fitting force of bearing: 6 to 19 kN
a Coat the sliding surfaces of the all parts with {0.6 to 2.0 ton}
engine oil before installing. 4) Install gear assembly (45).
a Lower and install the gear assembly grad-
1. Gear assembly ually so that the oil seal lip will not be dam-
1) Using J13, install oil seal (48) to case (49). aged.
a When installing the oil seal, take care of its
direction.
a Apply the liquid gasket thinly to the inside
of the housing hole and wipe off the pro-
jected part.
2 Oil seal lip:
Grease(G2-LI)
2 Between oil seal lips (part G):
rease (G2-LI) (Filling rate 40 to 60 %)
2 Oil seal press-fitting portion:
Liquid gasket (LG-5)
2. Cage assembly
1) Using tool J14, install oil seal (42) to cage
(40).
a When installing the oil seal, take care of its
direction.
2 Between oil seal lips (part G):
Grease (G2-LI) (Filling rate 40 to 60 %)
a Apply the liquid gasket thinly to the inside
of the housing hole and wipe off the pro-
jected part.
2 Oil seal lip:
2) Using tool J15, press fit bearing outer race Grease(G2-LI)
(47) to the case. 2 Oil seal press-fitting surface:
q Press fitting force of bearing: 0 to 8 kN {0 Liquid gasket (LG-5)
to 0.9 ton}
50-300 92 D65EX, PX, WX-16

300 Power train
2) Using tool J15, press fit bearing outer race

(41) to cage (40).
q Press fitting force of bearing: 0 to 8 kN {0
to 0.9 ton}
Table 1
a + b (mm) Combination of shims Total
14X-27- 14X-27- 14X-27- shim
Larger
Below 11260 11270 11280 thickness
3) Install the O-ring to cage assembly (37) and than
(t = 0.2) (t = 0.3) (t = 1.0) δ (mm)
adjust shim (39). 0.98 1.18 2 1 0.70
1.18 1.38 1 2 0.80
1.38 1.58 3 0.90
1.58 1.78 1 1.00
1.78 1.98 1 3 1.10
1.98 2.18 1 1 1.20
2.18 2.38 1 1 1.30
2.38 2.58 2 1 1.40
2.58 2.78 1 1 1 1.50
2.78 2.98 2 1 1.60
2.98 3.18 2 1 1 1.70
3.18 3.38 1 2 1 1.80
3.38 3.58 3 1 1.90
3.58 3.78 2 2.00
4) Adjustment of shim
3.78 3.98 1 3 1 2.10
q Adjust the clearance of the pinion bearing
3.98 4.18 1 2 2.20
Tighten cage (40) mounting bolts B, C, E, 4.18 4.38 1 2 2.30
and F evenly. 4.38 4.58 2 2 2.40
3 Mounting bolt:
4.58 4.78 1 1 2 2.50
20 Nm {2 kgm} 4.78 4.98 2 2 2.60
1] Using feeler gauges under this condition, 4.98 5.18 2 1 2 2.70
measure clearance a and b between 5.18 5.38 1 2 2 2.80
cage (40) and case (49). 5.38 5.58 3 2 2.90
2] Referring to Table 1, set shim quantity c 5.58 5.78 3 3.00
from the total of clearances a and b.
3] Install set shim (39) to cage (40) and
tighten the six cage mounting bolts
evenly.
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
D65EX, PX, WX-16 50-300 93

300 Power train
3. Hub and case assembly 5) Set the bearing to the shaft.

1) Using tool J11, press fit bearing (35) to case
(49).
q Press fitting force of bearing: 12 to 34 kN
{1.3 to 3.4 ton}
2) Install spacer (34).
6) Using tool J11, press fit bearing (33) to case

(49).
{1.3 to 3.4 ton}
3) Using tool J14, press fit two bearing outer

races (33a) to hub (32).
{0.1 to 1.0 ton}
7) Install plate (31).

Adhesive (LT-2)
230 - 289 Nm {23.5 - 29.5 kgm}
4) Using eyebolts, set hub assembly (31) to the
shaft.
50-300 94 D65EX, PX, WX-16

300 Power train
8) Using eyebolts, install gear (29). 4. Carrier assembly

a Match the identification marks of the inner
race, outer race and spacer when assem-
bling because the bearings for the plane-
tary gears are kept in matched set.
1) Using tool J13, press fit bearing outer race
(25C) to planetary gear (24).
{0.4 to 1.6 ton}
9) Tighten gear mounting bolts (28).

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 - 123 Nm {10.0 - 12.5 kgm}
2) Install bearings (25A) and (25B) and spacer

(25D) to planetary gear (24).
10)Install sun gear (27) and thrust washer (26).
3) Set the planetary gear assembly to the

carrier and press fit shaft (23).
a Aligning the holes of the bearing and
spacer, press-fit the shaft gradually.
D65EX, PX, WX-16 50-300 95

300 Power train
4) Install bolts (21) and holders (22). 2) Install spacer (15a).

2 Mounting bolt: 3) Using tool J12, press fit bearing (15). Press
Adhesive (LT-2) fitting force of bearing: 11 to 39 kN {1.2 to
3 Mounting bolt: 3.9 ton}
230 - 289 Nm {23.5 - 29.5 kgm}
4) Using eyebolts, install the O-ring to cover

5) Using 3 eyebolts, install carrier assembly
assembly (13), and then install them to the
(19).
case assembly.
a Check that there is no dent, rust, oil,
grease, or water on the mating surfaces of
the case and cover.
5. Cover assembly
1) Install ring gear (18) and tighten four lock
plates (16).
5) Tighten mounting bolts (12).
3 Mounting bolt:
230 - 289 Nm {23.5 - 29.5 kgm}
6) Install spacer (11).
50-300 96 D65EX, PX, WX-16

300 Power train
7) Using tool J13, press fit floating seal (14). 2) Install sprocket teeth (10) to the sprocket
a Remove oil and grease completely from hub.
the O-ring and O-ring contact surface, and 3 Mounting bolt:
dry before installing. 931 ± 98 Nm {95 ± 10 kgm}
a After installing the floating seal, check that
its leaning is less than 1 mm.
3) Using tool J13, press fit floating seal (7).

a Remove oil and grease completely from
the O-ring and O-ring contact surface, and
6. Sprocket hub assembly dry before installing.
1) Using tool J16, press fit bearing outer race (9). a After installing the floating seal, check that
q Press fitting force of bearing: 7 to 32 kN its leaning is less than 1 mm.
{0.7 to 3.2 ton}
D65EX, PX, WX-16 50-300 97

300 Power train
4) Using eyebolts, install sprocket hub

assembly (6) to the cover assembly.
a Check that the sliding surface of the float-
ing seal is free from dirt and apply engine
oil to it lightly.
5) Set bearing (7).
δA + δB (mm) Quantity of shims

Total shim
14X-27 14X-27 thickness
Larger
Below -51370 -51380
than δ (mm)
(t = 0.5) (t = 0.2)
0.00 0.50 0 0 0.0
0.50 0.90 0 1 0.2
6) Using tool [3], press fit bearing (6). 0.90 1.10 0 2 0.4
a Rotate the sprocket hub assembly while 1.10 1.50 1 0 0.5
performing the press fitting. 1.50 1.90 1 1 0.7
q Press fitting force of bearing: 11 to 39 kN 1.90 2.10 1 2 0.9
{1.2 to 3.9 ton} 2.10 2.50 2 0 1.0
7) Install plate (4) and secure it with the

mounting bolts.
a Tighten the nine bolts evenly.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
230 - 289 Nm {23.5 - 29.5 kgm}
a Adjust the clearance between the end

face of cover (3) and bearing (6) accord-
ing to the following procedure.
1] Seat the bearing perfectly and
measure the level difference between
the bearing inner race and cover end
face at two diagonal places on the
circumference.
2] Determine quantity δ of the shim to be
inserted according to Table 2.
(If shrink fit is applied, measure after
cooling.)
50-300 98 D65EX, PX, WX-16

300 Power train
7. Shaft
Install the O-ring to the sprocket hub assembly
side. Using eyebolts, install shaft (2).
3 Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
q Refilling of oil
Tighten the drain plug and supply oil through
the oil filler port to the specified level.
a After installing the final drive assembly to the

chassis, check the oil level finally.
5 Final drive case
D65EX-17: 21 l
D65PX-17: 25 l
3 Oil filler and drain plug:
127 - 176 Nm {13 - 18 kgm}
3 Oil level detection port plug:
58.8 - 76.4 Nm {6 - 8 kgm}
D65EX, PX, WX-16 50-300 99

SEN05112-02

© 2012 KOMATSU
All Rights Reserved
50-300 100
SEN05113-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Removal and installation of track frame assembly.......................................................................................... 2
Removal and installation of idler assembly ..................................................................................................... 4
Removal and installation of idler assembly (Without idler support automatic thrust adjustment) ................... 6
Disassembly and assembly of idler assembly ................................................................................................ 8
Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment) ............. 12
Removal and installation of recoil spring assembly ...................................................................................... 17
Disassembly and assembly of recoil spring assembly.................................................................................. 18
Removal and installation of track roller assembly ......................................................................................... 22
Disassembly and assembly of track roller assembly .................................................................................... 23
Removal and installation of carrier roller assembly ...................................................................................... 27
Disassembly and assembly of carrier roller assembly .................................................................................. 28
Expansion and installation of track shoe assembly (Conventional type track shoe)..................................... 31
Expansion and installation of track shoe assembly (PLUS type track shoe) ................................................ 34
Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe) .............. 35
Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe) ......................... 49
Field disassembly and assembly of one link (Conventional type track shoe) ............................................... 61
Field disassembly and assembly of one link (PLUS type track shoe)........................................................... 68
Removal and installation of pivot shaft assembly ......................................................................................... 73
Removal and installation of equalizer bar assembly ..................................................................................... 74
Disassembly and assembly of equalizer bar side bushing ........................................................................... 76
D65EX, PX, WX-16 50-400 1

SEN05113-02 Removal and installation of track frame assembly
Removal and installation of track 4. Remove pivot shaft cover (3).

frame assembly 1
a The diagram shows the D65EX-16.
Removal
1. Remove track shoe assembly. For details, see
“Expansion and installation of track shoe
assembly”.
2. Using jack, jack up chassis, then set stands [1]

and [2] under front frame and steering case.
k Set the stands securely.
3. Remove pitch or tilt cylinder hose protection

cover and disconnect hoses (1) and (2).
6. Sling the track frame assembly.
7. Remove lock (5) and pull out pin (6). [*1]
50-400 2 D65EX, PX, WX-16

Removal and installation of track frame assembly SEN05113-02
8. Remove bolts (7) and plate (8), then lift off Installation
track frame assembly (9). [*2] q Carry out installation in the reverse order to
a Oil will leak from the pivot shaft case, so removal.
prepare a container to catch it.
4
[*1]
k
Track frame assembly:
When aligning the pin holes, never insert
1,600 kg (D65EX-16) your fingers in them.
1,800 kg (D65PX-16)
1,800 kg (D65WX-16) [*2]
a When inserting in the pivot shaft, apply power
6 Pivot shaft case: 4.5 l train oil (TO30) to face (a) of track frame (9).
3 Plate mounting bolt:
455 – 565 Nm {46.5 – 58.0 kgm}
5 Pivot shaft case (power train oil):
4.5 l (TO30)
a Fill the pivot shaft case with oil up to a point
100 mm from the oil filler plug.
(See the following figure )
D65EX, PX, WX-16 50-400 3

SEN05113-02 Removal and installation of idler assembly
Removal and installation of idler 6. Remove spring (6) and seat (7).
assembly 1
Removal
k Never stand in front of the idler assembly to
prevent danger.
1. Remove the blade assembly. For details, see

“Removal and installation of blade assembly”.
2. Expand the track shoe assembly. For details,

see “Expansion and installation of track shoe
assembly”.
3. Loosen mounting bolts (2) and spring seat 7. Remove yoke (8).
clamping bolts (3) and remove support (1).
8. Lift off idler assembly (4).

4. Pass wires through the hanging holes of idler
assembly (4). Sling idler assembly (4) and
slide it out forward along the top of the track
frame.
4 Idler assembly: 200 kg
5. Remove guide plate (5).
50-400 4 D65EX, PX, WX-16

Removal and installation of idler assembly SEN05113-02
Installation
removal.
a Install the idler assembly to the chassis
with the oil filler plug on the left side of the
chassis.
a Adjustment of shims
Adjust the shims so that clearance (a)
between idler support (1) and guide plate
(5) will be 2 mm at every point.
D65EX, PX, WX-16 50-400 5

SEN05113-02 Removal and installation of idler assembly (Without idler support automatic thrust adjustment)
Removal and installation of idler 4. Sling and pull out the idler assembly and
assembly (Without idler support remove the mounting bolts of support (5) and
yoke (6).
automatic thrust adjustment) 1
5. Sling and remove idler assembly (7).
4
Removal
Idler assembly:
1. Separate the track shoe assembly. For details,
see SEPARATION AND CONNECTION OF 200 kg
TRACK SHOE ASSEMBLY.
2. Remove lock plate (1) to remove lubricator (2).
k Negative pressure is applied inside the
recoil spring. When the yoke and idler
support are disconnected, if the lubri-
cator is not removed, the yoke is pulled
back toward the cylinder.
k Do not allow anyone to remain in front
of the idler yoke assembly during the
work for safety reasons.
3. Remove right and left guide plates (3). [*1]

a Remove shims (4), note the location and
the quantity of shims for installation pur-
pose, and keep them.
50-400 6 D65EX, PX, WX-16

Removal and installation of idler assembly (Without idler support automatic thrust adjustment) SEN05113-02
Installation
removal.
[*1]
a Standard shim thickness: 4 mm
a Adjust clearance "a" between the track frame
and guide plate (3) to 0.5 to 1.0 mm by
increasing or decreasing the shim.
2 Thread portion of the guide plate mount-
ing bolt:
Adhesive (LT-2)
D65EX, PX, WX-16 50-400 7

SEN05113-02 Disassembly and assembly of idler assembly
Disassembly and assembly of 5. Using push puller [1], pull support (8) out of
idler assembly 1
idler (7).
Special tools 6. Remove floating seal (9) from support (8).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 791-515-1520 Installer t 1
L
2 791-601-1000 Oil pump t 1
Disassembly
1. Remove the oil filler plug and drain the oil.

6 Idler: 0.24 – 0.26 l 7. Sling idler (7) and pull it out of shaft and sup-
port assembly (10).
2. Set idler (1) to a block. a When hanging the idler with sling rope [2],
prevent sling rope [2] from opening with
3. Remove mounting bolts (2), then remove sup- wires or ropes [3].
port (3).
a Record the number of the removed shims. 8. Remove floating seals (11) and (12) from idler
(7).
4. Remove nut (4) and drive out bolt (5) from the
nut side.
50-400 8 D65EX, PX, WX-16

Disassembly and assembly of idler assembly SEN05113-02
9. Remove floating seal (13) from shaft and sup- Assembly

port assembly (10).
1. Using push tool [4], press fit 2 bushings (18) to
idler (7).
10. Remove nut (14) and drive out bolt (15) from
the nut side.
2. Install the O-ring to shaft (17), and then install
11. Similarly to step 5, using push puller [1], pull them to support (16).
shaft (17) out of support (16). a When installing shaft (17), match its
groove to the groove of the support.
a Install the shaft with the opposite end of
the oil filler ahead.
3. Drive bolt (15) and tighten nut (14).

3 Mounting nut:
230.4 – 308.9 Nm {23.5 – 31.5 kgm}
12. Remove 2 bushings (18) from idler (7).
D65EX, PX, WX-16 50-400 9

SEN05113-02 Disassembly and assembly of idler assembly
4. Using tool L1, install floating seal (9) to shaft 5. Fit the O-ring to the shaft.
and support assembly (6).
6. Using tool L1, install floating seal (8) to idler
(3).
a For the method of installation, see step 4.
a When installing floating seals, thoroughly

clean, degrease, and dry the contact sur-
faces of the O-rings and floating seals
(hatched parts). Take care that dirt will not 7. Sling and install idler (3) to shaft and support
stick to the floating seal contact surfaces. assembly (6).
a After installing the floating seals, check a Secure sling rope [3] with a wire or a rope.
the followings. (Part A)
Slant of seal: less than 1 mm
Projection (a) of seal: 7 – 11 mm.
50-400 10 D65EX, PX, WX-16

Disassembly and assembly of idler assembly SEN05113-02
8. Refill the idler with oil.

a The idler may be refilled with oil at this
time. For the ordinary method of refilling
with oil, see “Refilling with oil”.
5 Idler: Approx. 0.24 – 0.26 l
3 Oil filler plug:
98.0 – 137.2 Nm {10 – 14 kgm}
9. Using tool L1, install floating seal (9) to support

(8).
a Degrease the O-ring and O-ring fitting sur-
faces thoroughly and dry them before
installing.
its slant is less than 1 mm. 14. Refilling with oil
q Ordinary method of refilling with oil
Remove plug (20) from shaft (17), add oil
through the oil filler, and tighten plug (20).
3 Oil filler plug:
98.0 – 137.2 Nm {10 – 14 kgm}
10. Install support (8) to idler (7).

a When installing shaft (17), match its
groove to the groove of the support.

3 Mounting nut:
230.4 – 308.9 Nm {23.5 – 31.5 kgm} q Filling with oil by evacuation
1) Remove plug (20) from shaft (17).
2) Using tool L2, add oil through the oil filler
and tighten plug (2).
3 Oil filler plug:
98.0 – 137.2 Nm {10 – 14 kgm}
12. Set the shim (3a) and install support mounting

bolts (3).
13. Install spring seat clamping bolts (2).
D65EX, PX, WX-16 50-400 11

SEN05113-02 Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment)
Disassembly and assembly of 7. Sling and pull idler (7) out of "shaft and support
idler assembly (Without idler assembly (10)".
a When slinging the idler by using sling rope
support automatic thrust [2], fix sling rope [2] with a wire or rope [3].
adjustment) 1
8. Remove floating seals (11) and (12) from idler
Special tools (7).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 791-515-1520 Installer t 1
L
2 791-601-1000 Oil pump t 1
Disassembly
1. Remove oil filler plug to drain oil.
6 Idler:
0.24 to 0.26 liters
2. Place idler assembly (1) on the block. 9. Remove floating seal (13) from "shaft and sup-
3. Remove mounting bolts (2) to remove support port assembly" (10).
(3).
a Note the quantity of shims for installation
purpose.
4. Remove nut (4) and drive out bolt (5) from the
nut side.
5. Using push puller [1], pull support (8) out of

idler (7).
6. Remove floating seal (9) from support (8).
50-400 12 D65EX, PX, WX-16

Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment) SEN05113-02
10. Remove nut (14) and drive out bolt (15) from Assembly
the nut side. 1. Using push tool [4], press fit two bushings (18)
11. Similarly to step 5, using push puller [1], pull to idler (7).
shaft (17) out of support (16).
2. Fit the O-ring to shaft (17) and install them to

12. Remove two bushings (18) from idler (7). support (16).
a When installing shaft (17), match the
grooves on it and the support.
a Install the shaft with the end having no oil
filler port ahead.
3 Mounting nut:
230.4 to 308.9 Nm {23.5 to 31.5 kgm}
D65EX, PX, WX-16 50-400 13

4. Using tool L1, install floating seal (9) to "shaft 5. Fit the O-ring to the shaft.
and support assembly (6)". 6. Using tool L1, install floating seal (8) to idler
(3).
a For the installation procedure, see step 4.
a When installing the floating seal, clean,

degrease and completely dry the contact
faces of the O-ring and floating seal 7. Sling and install idler (3) to "shaft and support
(hatched parts). assembly (6)".
Take care that dirt or other foreign matter a Fix sling rope [3] with a wire or a rope.
does not stick to the contact face of the (Part A)
floating seal.
a After inserting the floating seal, check the
following.
Leaning of seal: Max. 1 mm
Protrusion of seal (a): 7 to 11 mm
50-400 14 D65EX, PX, WX-16

Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment) SEN05113-02
8. Supply oil to the idler. 12. Install shims (3a) and install support mounting
a You may supply oil at this time. For the bolts (3).
normal method of refilling with oil, see 13. Install spring seat lock bolts (2).
REFILLING WITH OIL.
5 Idler:
0.24 to 0.26 liters
3 Oil filler plug:
98.0 to 137.2 Nm {10 to 14 kgm}
9. Using tool L1, install floating seal (9) to support
(8).
a Install the floating seal after degreasing
and drying the O-ring and O-ring contact
surface completely.
its leaning is less than 1 mm.
14. Refilling with oil

q Normal method of refilling with oil
Remove plug (20) from shaft (17), supply
oil through the oil filler port, and install
plug (20).
5 Idler:
0.24 to 0.28 liters
3 Oil filler plug:
98.0 to 137.2 Nm {10 to 14 kgm}
10. Install support (8) to idler (7).

a When installing shaft (17), match the
grooves on it and the support.
3 Mounting nut:
230.4 to 308.9 Nm {23.5 to 31.5 kgm}
D65EX, PX, WX-16 50-400 15

q Filling with oil by evacuation

1) Remove plug (20) from shaft (17).
2) Using tool L2, supply oil through the oil
filler port, and install plug (20).
5 Idler:
0.24 to 0.26 liters
3 Oil filler plug:
98.0 to 137.2 Nm {10 to 14 kgm}
50-400 16 D65EX, PX, WX-16

Removal and installation of recoil spring assembly SEN05113-02
Removal and installation of recoil Installation

spring assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove idler assembly. For details, see [*1]
“Removal and installation of idler assembly”. a Install recoil spring assembly (1) into the track
frame according to the following procedure.
2. Lift off recoil spring assembly (1). [*1] 1) Using lever block [1], sling the end of
4 Recoil spring assembly: 500 kg recoil spring assembly (1) and set the
recoil spring assembly in a horizontal posi-
tion.
2) Push in recoil spring assembly (1) and set
it to the track frame.
D65EX, PX, WX-16 50-400 17

SEN05113-02 Disassembly and assembly of recoil spring assembly
Disassembly and assembly of 3) Using push tool [1], remove piston (11)
recoil spring assembly 1
from yoke (10) with press.
a If cylinder (19) has not been dam-
Special tools aged, or nut (16) at the tip of the shaft
has not fallen off, disassemble as fol-
New/Remodel
lows.
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
Compressor of
791-685-8005 t 1
type B
791-635-3160 Extension t 1
M 790-201-2780 Spacer t 1
790-201-2790 Spacer t 1
790-101-1102 Pump t 1
790-101-1600 Cylinder t 1
Disassembly 3. Remove holder (13) from case (12) of recoil

1. Remove yoke and piston assembly (2) from spring.
k To prevent danger, never stand in front
recoil spring assembly (1).
of or behind the recoil spring assem-
bly.
4. Disassembly of holder
1) Remove cover (14) from holder (13).
2. Disassembly of yoke, piston assembly

1) Remove snap ring (3), then remove ring
(4), packing (5), and rings (6).
2) Remove bolt (7), then remove plate (8)
and washer (9).
2) Remove seal (15) from holder (13).
50-400 18 D65EX, PX, WX-16

Disassembly and assembly of recoil spring assembly SEN05113-02
5. Set recoil spring assembly (1) to tool M. k If cylinder (19) has been damaged, or nut
k The recoil spring is under a high (16) at the tip of shaft has fallen off, there is
installed load, so be careful to set it danger that the recoil spring may fly off to
correctly. the front when mounting bolts (21) of
a Installed load of recoil spring: holder (13) are removed. For this reason,
193.2 kN {19,700 kg} disassemble as follows.
k When disconnecting holder (13) and case
(12), do not stand in front of or behind the
recoil spring assembly until safety has
been confirmed and the recoil spring has
been removed.
1) Set recoil spring assembly (1) to tool M.
k The recoil spring is under a high
installed load, so be careful to set
it correctly.
a Installed load of recoil spring:
193.2 kN {19,700 kg}
2) Apply hydraulic pressure slowly and
secure recoil spring assembly.
3) Maintain condition in Step 2), and remove
6. Apply hydraulic pressure slowly, compress mounting bolts (21) of holder (13).
recoil spring, and tighten nut (16) until spacer 4) Gradually release hydraulic pressure to
(17) comes out, then take out spacer (17) and remove tension of recoil spring.
remove nut (16).
7. Gradually release hydraulic pressure to

remove tension of recoil spring.
8. Remove recoil spring (18) and cylinder (19)
from case (12), then remove bushing (20) from
cylinder (19).
D65EX, PX, WX-16 50-400 19

SEN05113-02 Disassembly and assembly of recoil spring assembly
Assembly 3. Apply hydraulic pressure slowly to compress

1. Press fit bushing (20) to cylinder (19) and recoil spring, and set so that installed length of
assemble case (12), recoil spring (18) and cyl- the recoil spring is the standard value.
inder (19) temporarily. a When compressing the spring, be careful
not to damage the thread. Use lever block
2. Set recoil spring assembly (1) assembled tem- [2] and carry out centering while com-
porarily to tool M. pressing the recoil spring.
k Since the recoil spring is very danger- a Installed length of recoil spring: 580 mm
ous because of its large installed load,
set each part securely.
4. Install nut (16), then install spacer (17).
5. Gradually release hydraulic pressure to com-

pletely remove tension of recoil spring, then
remove recoil spring assembly (1) from tool M.
50-400 20 D65EX, PX, WX-16

Disassembly and assembly of recoil spring assembly SEN05113-02
6. Assembly of holder 2) Assemble washer (9) and plate (8), and

Assemble seal (15) to holder (13), then install tighten bolt (7).
cover (14). a Bend the plate securely.
2 Lip of seal: Grease (G2-LI) 3) Fit rings (6), packing (5), and ring (4), and
install snap ring (3).
7. Install holder (13) to case (12) of recoil spring.
9. Assemble yoke and piston assembly (2) to

recoil spring assembly (1).
8. Assembly of yoke, piston assembly

1) Using push tool [2], press fit piston (11) to
yoke (10).
D65EX, PX, WX-16 50-400 21

SEN05113-02 Removal and installation of track roller assembly
Removal and installation of track Installation

roller assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Loosen track shoe tension. For details, see [*1]
“Expansion and installation of track shoe 2 Thread of roller guard mounting bolt:
assembly”. Adhesive (LT-2)
2. Remove mounting bolts of track roller guard [*2]

2
(1). [*1] Thread of track roller mounting bolt:
Adhesive (LT-2)
3 Track roller mounting bolt:
3. Remove track roller mounting bolts (2).
343 – 427 Nm {35.0 – 43.5 kgm}
a Install so that the oil plug is on the outside
of the chassis.
4. Start engine, and operate blade and hydraulic

jack to jack up machine.
k After jacking up the machine, set
blocks on top of the track shoes and
lock the work equipment control levers
and brake lock lever.
5. Remove track roller assembly (3). [*2]

4 Track roller assembly:
Single flange: 55 kg
Double flange: 65 kg
50-400 22 D65EX, PX, WX-16

Disassembly and assembly of track roller assembly SEN05113-02
Disassembly and assembly of 5. Remove floating seal (6) from track roller
track roller assembly 1
assembly (1).
Special tool
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
2 791-530-1520 Installer t 1
L
4 791-601-1000 Oil pump t 1
Disassembly
1. Remove the oil filler plug and drain the oil.
6 Track roller: 0.34 l 6. Sling roller (7) and pull it out of shaft (8).
2. Set track roller assembly (1) on block [1].
3. Using push puller [2], push in collar (3), and

then remove lock (4) and collar (3).
7. Remove floating seal (9) and bushing (10) (1

on each side) from roller (7).
4. Remove floating seal (5) from collar (3).
D65EX, PX, WX-16 50-400 23

SEN05113-02 Disassembly and assembly of track roller assembly
8. Remove floating seal (11) from shaft assembly Assembly

(8). 1. Using push tool [3], press fit 2 bushings (10) to
roller (7).
9. Remove lock pin (12), and then remove collar
(14) from shaft (13).
2. Using tool L2, install floating seal (15) to collar

(14).
a When installing floating seals, thoroughly

clean, degrease, and dry the contact sur-
(hatched parts). Take care that dirt will not
stick to the floating seal contact surfaces.
a After installing the floating seals, check
the followings.
Slant of the seal: less than 1 mm
Projection (a) of the seal: 7 – 11 mm.
50-400 24 D65EX, PX, WX-16

Disassembly and assembly of track roller assembly SEN05113-02
3. Fit the O-ring to shaft (13) and install collar (14) 6. Sling roller (7) and install it to shaft assembly
and lock pin (12). (8).
4. Using tool L2, install floating seal (11) to shaft 7. Using tool L2, install floating seal (6) to roller
(8). assembly (1).
a For the method of installation, see step 2. a For the method of installation, see step 2.
5. Using tool L2, install floating seal (9) to roller 8. Using tool L2, install floating seal (5) to collar
(7). (3).
a For the method of installation, see step 2. a For the method of installation, see step 2.
D65EX, PX, WX-16 50-400 25

SEN05113-02 Disassembly and assembly of track roller assembly
9. Set track roller assembly (1) to block [1].
10. Fit the O-ring to the shaft and install collar (3).
Using push puller [2], push in collar (3) and
install lock (4).
11. Refilling with oil

1) Remove plug (16). Using tool L4, add oil
through the oil filler.
5 Track roller (Gear oil):
0.34 l (GO140)
2) Tighten plug (16).
3 Plug:
98.0 – 137.2 Nm {10 – 14 kgm}
50-400 26 D65EX, PX, WX-16

Removal and installation of carrier roller assembly SEN05113-02
Removal and installation of 4. Sling carrier roller assembly (2) and pull and
carrier roller assembly 1
remove it out of support (3).
4 Carrier roller assembly: 30 kg
a The figures in this section show D65EX-16.
Removal
1. Loosen the track shoe assembly. For details,
see “Expansion and installation of track shoe
assembly”.
2. Using hydraulic jack [1], raise the track shoe.
Installation
removal.
q Adjust the track shoe assembly tension. For

track shoe assembly tension”.
3. Remove mounting bolts (1) of the carrier roller
assembly.
D65EX, PX, WX-16 50-400 27

SEN05113-02 Disassembly and assembly of carrier roller assembly
Disassembly and assembly of 4. Set carrier roller assembly (6) on block [1].
carrier roller assembly 1
5. Using push tool [2] and a press, pull out shaft
Special tools assembly (7).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
L 3 796-230-1110 Installer t 1
Disassembly
1. Remove oil filler plug (1) and drain the oil.
6 Carrier roller: 0.24 l
2. Remove snap ring (2) and cover (3).

6. Remove bearing (9) and 2 outer races (10)
from roller (8).
3. Remove bolt (4) and spacer (5).

7. Remove collar (12), floating seal (13), and
bearing (14) from shaft (11).
50-400 28 D65EX, PX, WX-16

Disassembly and assembly of carrier roller assembly SEN05113-02
Assembly a When installing floating seals, thoroughly

1. Press fit 2 outer races (10) to roller (8). clean, degrease, and dry the contact sur-
(hatched parts). Take care that dirt will not
stick to the floating seal contact surfaces.
a After installing the floating seals, check
the followings.
Slant of the seal: less than 1 mm
Projection (a) of the seal: 7 – 11 mm.
2. Using push tool [3], press fit collar (12) to shaft

(11).
4. Install floating seal (13) to the shaft.

a For precautions for installation, see step 3.
5. Using push tool [4], press fit bearing (14) to the
shaft.
3. Using tool L3, install floating seal (15) to collar

(12).
6. Set shaft assembly (7) to block [5] and install

roller (8).
D65EX, PX, WX-16 50-400 29

SEN05113-02 Disassembly and assembly of carrier roller assembly
7. Using push tool [6], press fit bearing (9). 10. Fit the O-ring to cover (3) and install them to
a While turning roller (8), press fit the bear- the roller, and then install snap ring (2).
ing.
11. Tighten plug (1).
8. Install spacer (5) and tighten bolt (4).

3 Bolt: 245 – 309 Nm {25.0 – 31.5 kgm}
9. Supply oil to the carrier roller.

5 Carrier roller (Gear oil): 0.24 l (GO140)
50-400 30 D65EX, PX, WX-16

Expansion and installation of track shoe assembly (Conventional type track shoe) SEN05113-02
Expansion and installation of Expansion of track shoe assembly

track shoe assembly (Ordinary)
(Conventional type track shoe) 1 a If any abnormality is not detected by “Check
before expanding track shoe assembly,” per-
Check before expanding track shoe form the following procedure.
assembly 1. Set master link (3) above the idler (a little after
k Since it may be very dangerous to expand the center of the idler) moving the machine for-
the track shoe assembly, check the follow- ward or in reverse.
ing items in advance. a Set blocks [1] and [2] between the front
k Do not loosen the lubricator more than 1 side of the idler and carrier roller so that
turn. If the grease is not discharged well, the mating part of the master link will not
move the machine forward and in reverse. open until the master bolt is pulled out.
1. Remove cover (1) and loosen lubricator (2) of

the adjustment cylinder to discharge the
grease.
k Do not loosen the lubricator more than
1 turn.
2. Loosen the track shoe. [*1]

k Do not loosen lubricator (2) more than
1 turn.
a If the track shoe is not loosened after the
lubricator is loosened, move the machine
forward and in reverse.
2. After the shoe is loosened, perform “Expansion
of track shoe assembly (Ordinary)”.
3. If the track shoe is not loosened by the above

work, perform “Expansion of track shoe
assembly (When track frame has internal trou-
ble)”.
a The track frame may have an internal
trouble (damage of the recoil spring or
recoil spring set bolt, fall of the shaft end
nut, etc.).
D65EX, PX, WX-16 50-400 31

SEN05113-02 Expansion and installation of track shoe assembly (Conventional type track shoe)
3. Remove track shoe (4). [*2] Expansion of track shoe assembly

a Do not loosen and pull out 4 mounting (When track frame has internal trouble)
bolts (5) one by one, but loosen them by 1 a If any abnormality is detected by “Check
– 2 turns each and check that they can be before expanding track shoe assembly,” per-
rotated lightly, and then pull them out. form the following procedure.
k If the track shoe is removed while the track
a If the bolts are rotated forcibly while they
are still tight, the threads of them and frame has an internal trouble, it may spring
master link (3) may be damaged. back. Even if the track shoe is removed, the
idler may jump out, and that can cause a
serious result. Accordingly, expand the
track shoe according to the following pro-
cedure.
1. Loosen the track shoe. [*1]

k Do not loosen lubricator (2) more than
1 turn.
a If the track shoe is not loosened after the
lubricator is loosened, move the machine
forward and in reverse.
a Check that the all grease has been dis-
charged.
4. Sling the front end of master link (3) and move

the machine slowly in reverse to expand track
shoe assembly (5).
a Length of track shoe: Approx. 9.5 m
50-400 32 D65EX, PX, WX-16

Expansion and installation of track shoe assembly (Conventional type track shoe) SEN05113-02
2. Move the machine slowly forward against large Installation

block [3] or a wall (or the blade of another q Carry out installation in the reverse order to
machine of the similar size of the machine to expansion (ordinary).
be repaired, if available) to press the track
shoe on the idler side. When the recoil spring [*1]
and track shoe are distorted, stop and apply a Adjust the track shoe tension. For details, see
the brake. Testing and adjusting, “Testing and adjusting
a Set master link (3) between the idler and track shoe tension”.
front carrier roller.
a For safe work, apply lever block [4] [*2]
between the carrier roller support and link. a Tighten the shoe mounting bolts for the master
link in the following order.
3. Remove track shoe (4) and disconnect master a Tighten the all 4 bolts with fingers until the
link (3). [*2] master link mating faces are fitted.
a Do not loosen and pull out the 4 mounting a If the bolts are tightened forcibly before the
bolts one by one, but loosen them by 1 – 2 master link mating faces are fitted, the threads
turns each and check that they can be of them and master link may be damaged.
rotated lightly, and then pull them out. 2 Shoe mounting bolt:
a If the bolts are rotated forcibly while they Molybdenum disulfide lubricant (LM-P)
3 Shoe mounting bolt:
are still tight, the threads of them and
master link (3) may be damaged. 1st time: 343 ± 39 Nm {35 ± 4 kgm}
2nd time:
4. Move the machine slowly in reverse to expand 180 (+10/-20)° (Angle tightening)
the track shoe assembly.
D65EX, PX, WX-16 50-400 33

SEN05113-02 Expansion and installation of track shoe assembly (PLUS type track shoe)
Expansion and installation of a Tighten the master link shoe bolts according to
track shoe assembly (PLUS type the following procedure.
q Tighten all 4 shoe bolts (3) with the fingers
track shoe) 1
until master link mating faces (a) are fitted.
a In this section, the points different from the q If shoe bolts (3) are tightened forcibly
conventional type track shoe are described. before master link mating faces (a) are fit-
ted, their threads and master link threads
may be damaged.
Expansion
q Tighten 4 shoe bolts (3) in the following
a For details of expansion and installation of the
order.
2 Shoe bolt (Master link):
track shoe assembly, see “Expansion and
installation of track shoe assembly (conven-
Molybdenum disulfide lubricant (LM-P)
3 Shoe bolt (Master link)
tional type track shoe) which is also applicable
to the track shoe assembly of the PLUS type
track shoe. Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
Retightening angle: 180 (+0/-20) °
Installation
a Install the master link shoe according to the fol-
lowing procedure.
Set and install the shoe so that master link (1)
and shoe grouser (2) will be positioned as
shown below.
50-400 34 D65EX, PX, WX-16

Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe) SEN05113-02
Whole disassembly and whole

assembly of track shoe assembly
(Conventional type track shoe) 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
1 791-646-7531 Remover t 1
2 791-660-7460 Brush t 1
791-432-1110 Push tool t 1
3 791-646-7550 Bar t 1 2. Disassembly of link
791-646-7560 Guide t 1 1) Set the link assembly on a link press and
hit it with a hammer so that the bushing
R 791-932-1110 Push tool t 1
will be fitted to jaw [1].
4 791-646-7523 Bar t 1 a If the link tread, outside of the bush-
791-646-7590 Guide t 1 ing, etc. are worn, adjust the height of
5 790-701-3000 Checker t 1 jaw [1] or guide plate and align the pin
and bushing with the left and right dis-
6 791-432-1120 Installer t 1
assembly jigs [2], [3] so that the link
7 791-601-1000 Oil pump t 1 hole will not be damaged during dis-
assembly work.
Whole disassembly a If the pin and bushing are not aligned
well, the link hole may be damaged
1. Removal of shoe and the pin and bushing may be bro-
Sling the shoe assembly and set it with the ken during disassembly work.
shoe up on the floor and remove the shoe by
using a shoe bolt impact wrench.
a If a shoe bolt is not loosened after it is
unscrewed by 1 turn (If its torque is not
reduced to 0), loosen the other bolts first,
and it will be removed smoothly.
a If a shoe bolt is turned forcibly while its
torque is not 0, bolt and link will adhere to
each other and they will need to be
repaired.
a When moving the shoe assembly, take
care not to damage the master link.
a If it is obliged to cut a shoe nut with gas,
keep the seal temperature below 80ºC to
prevent thermal deterioration of the seal
and take measures to prevent the spatters
from entering through the clearances
among the links.
D65EX, PX, WX-16 50-400 35

SEN05113-02 Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)
a Using tool R1, drive the small plug of 4) Return the right cylinder and take out the
the pin inward after the disassembly links, pins, bushings, and spacers on both
work so that the workplace will not sides and feed the next 1 set of the link
become dirty. assembly to the jaw.
a If the bushing ends and sealing sur-
faces are damaged, oil will leak.
Accordingly, handle them carefully.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simulta-
neously.
a Check the pulling out force of the pin 3. Inspection
and bushing to see if the necessary Check the parts for the following items to see if
press fitting force for the pin and they can be used for a lubricated track or a
bushing can be obtained when grease-filled track, then examine them gener-
reversed and assembled again. ally and determine to use them for a lubricated
track or grease-filled track.
a For judgment of reuse of the parts, see
“Guidance for reusable parts, Lubricated
tracks”.
1) Check the parts visually for damage. If a
part seems to be damaged, check it by
dye penetrant test or magnaflux inspec-
tion. If it has any crack, it cannot be used
again. Discard it.
3) Return the left cylinder and operate the

right cylinder to pull out the pin and bush-
ing from the right link simultaneously.
50-400 36 D65EX, PX, WX-16

2) Measure the outside diameter of the press

fitting parts of the pin and bushing and the
inside diameter of the pin and bushing fit-
ting parts of the link with a micrometer and
a cylinder gauge to see if the allowable fit-
ting allowance is obtained. When using
the pin, bushing, and link for a lubricated
track, however, secure the standard fitting
allowance between the pin and link.
a If the allowable fitting allowance is not
obtained, replace the parts with new
ones.
a For the dimensional criteria, see
Structure, function and maintenance
standard, “Track shoe”.
a Precautions for storage

1) Store the seal without removing it from the
link so that the counterbore portion will not
be rusted and take care not to damage the
seal lip.
2) Apply rust-preventive oil to the pin and
bushing fitting parts, shoe mating surface,
and master link mating surface of the link.
3) When storing, apply rust-preventive oil to
the all surfaces of the pin, bushing, and
spacer. Take care not to damage the ends
of the bushing in particular.
D65EX, PX, WX-16 50-400 37

Whole assembly 3) If the link, pin, bushing, and spacer are

a Before performing the following procedure, see dirty, clean them. Remove the nodules
“Guidance for reusable parts, procedure for sticking to the link and bushing with the
turning lubricated track”. grinder, too.
a Since these parts rust easily, clean
When recycling for lubricated track them just before assembling them.
a Do not polish the bushing ends. If
1. Preparation work
they are polished, oil may leak.
1) Cleaning seal assembly
4) If large plug (3) was pulled out of the pin,
Remove the seal assembly from the link
drive it in according to the following proce-
and divide it into seal ring (1) and load ring
dure.
(2), then clean them.
1] Using tool R2, clean the pin hole.
a Since the seal ring and load ring are
deteriorated easily by the cleaning liq-
uid (trichloroethylene etc.), clean
them quickly. After cleaning them,
wipe off the cleaning agent from
them.
2] Insert large plug (3) in the plug inser-

tion window of the guide of tool R3.
a Coat the large plug with oil
(GO90) and install it with the small
diameter end on the pin side.
3] Push the bar of tool R3 with the hand
2) When reusing the pin, chamfer its end cor-
until the large plug stops.
ners smoothly with a grinder. Remove the
4] Push the large plug with the bar to
nodules sticking to the press fitting parts
press the guide against pin (4).
with the grinder, too.
5] Drive in the bar with a hammer.
a If the ends are worn and sharpened,
a Driving distance (a) from pin end:
they may scuff the press fitting parts
6 ± 2 mm
and cause oil leakage.
a If the chamfered part of the pin
hole has been worn, chamfer it
with a small-sized grinder (grind-
stone tip angle: 45º – 60º) so that
the large plug will not be damaged.
50-400 38 D65EX, PX, WX-16

5) Installation of seal assembly a Set the link receiving face of jaw [4]
Clean and degrease parts (b) indicated vertically.
with thick lines (the counterbore portion of a Wear plate [5] should be a replace-
the link and seal assembly) carefully. able one, if possible.
Then, using tool R6, push in the seal
assembly to the bottom.
a If oil or grease is sticking to the coun-
terbore portion of the link or seal
assembly, the seal will turn and its
s e a l i n g p e r f o r m a n c e w i l l l o w e r.
Accordingly, do not apply any oil or
grease to that portion.
7) Adjust the relief pressure of the link press

so that the pressing force of the press will
not exceed the standard value.
a If the pressing force is too strong, the
spacer will be pressed forcibly against
the bushing. As a result, the spacer
may be broken and it and bushing
may be worn abnormally.
6) Adjust the dimensions of the press fitting a Pushing force of pin and bushing:
jig of the link press to keep the projection 539 kN {55 tons}
of the pin and bushing constant and keep Pushing force 1.8 x Average pres-
the installed dimensions of the seal within sure
the standard range. (Adjust the relief pressure of the link
q Dimension c: 3 mm press to set the press cutting force.)
d: 3 mm
e: 49.7 mm 2. Assembly of link
a If the pin end (part f) or link sides 1) Apply oil (GO90) to the mating surfaces of
(parts g and h) are worn, add the the pin and bushing with a clean brush
dimensions of the worn parts when and assemble them, then set them before
adjusting the standard dimensions so the jaw of the link press.
that the projections of the pins and a When reusing (reversing) the bush-
bushings on both sides will be even. ing, set the worn outside surface of
the bushing on the shoe fitting side of
the link (set the bushing with the worn
outside surface up on the link press).
D65EX, PX, WX-16 50-400 39

2) Press fit the master links on both bushing 5) Measure the projections of the bushing on
sides to the bushing with the shoe fitting both sides with a depth gauge.
faces up. a Adjust the press fitting jig of the link
a At this time, use the master links on press so that the projections on both
the pin side as supports. sides will be even.
a Press fitting force for bushing:
98 – 147 kN {10 – 15 tons}
6) Send the master links and set the next pin

and bushing.
3) Using the shoe bolt hole pitch gauge, a When reusing a pin, install it so that
press fit the master links until the distance its side hole (i) will be the link tread
between the shoe bolt holes of both links side similarly to a new one.
is the standard value. a If it is not installed so, its strength may
a Remove the all steel chips caused by be lowered. Accordingly, indicate the
press fitting of the bushing with com- direction of the side hole on the end
pressed air. face to prevent a mistake.
4) Turn over the master links and check that
they are press fitted in parallel.
50-400 40 D65EX, PX, WX-16

7) Set the right link and install the spacer to 9) Using spacer [6] for fine adjustment, press
the pin. fit the pin and bushing until the pin end is
a Check that the seal surface and bush- fitted to the bottom of the receiving jig.
ing end are free from dirt and apply oil a Adjust the depth of the receiving jig
(GO90) to them with a clean cloth or hole so that the projections of the pin
brush. on both sides will be even.
a When installing the spacer, wipe it
with a clean cloth.
10) Set the left link and install the spacer to

the pin.
8) Set the right jig on the receiving side and a Apply oil similarly to the right link.
the left one on the pushing side and press
fit the pin and bushing simultaneously.
a If the pin and bushing have play when
they are press fitted, the seal may
come off the link. To prevent this,
press fit smoothly.
a If the seal comes off the link, stop
press fitting and set the seal to the
link correctly, then start press fitting
again.
a Press fitting force for pin and bushing:
245 – 343 kN {25 – 35 tons}
11) Set the left jig on the receiving side and

the right one on the pushing side and
press fit the left link.
a When press fitting, take care that both
seals and spacers will not come off.
Press fitting force for link:
245 – 343 kN {25 – 35 tons}
D65EX, PX, WX-16 50-400 41

12) Press fit until the link, spacer, and bushing 14) After each link is assembled, bleed air
are fitted together. from the pin by using tool R5 and check
a Actually, you cannot see from outside the sealing performance.
if the above parts are fitted. Accord- a Keep the degree of vacuum inside the
ingly, control the hydraulic pressure of pin at 91 – 95 kPa {680 – 710 mmHg}
the link press. Set the relief pressure for 5 seconds and check that the
to a proper level and heighten the pressure does not change. If the
hydraulic pressure to that level. pressure changes, disassemble and
a For setting of the relief pressure, see check the seal. If the seal is free from
“1. Preparation work”. abnormality, assemble again.
a Check that adjacent 2 links can turn
around each other.
15) Using tool R7, supply oil (GO90) until the

oil supply pressure rises to 196 – 294 kPa
13) Using a shoe bolt hole pitch gauge, mea- {2 – 3 kg/cm2}.
sure the distance between the shoe bolt a In a cold or very cold district, supply
holes and check that the result is within Komatsu genuine oil (150-09-19270
the standard range. or 195-32-61990) having better low-
a If the distance between the shoe bolt temperature characteristics instead of
holes is longer than the standard GO90.
range, disassemble and check for a If the oil pressure is heightened too
abnormality, then press fit again. much, it has bad effects on the seal.
a If the distance between the shoe bolt Take care.
holes is shorter than the standard
range and the shoe cannot be
installed, the spacer or bushing end
may be worn more than the allowable
limit. In this case, disassemble and
replace the parts.
50-400 42 D65EX, PX, WX-16

a Supply oil so that depth (j) of the hol- 3. Installation of shoe

low between the top of pin (4) and top 1) Set the link assembly on the bed and
of the oil level will be in the following install the shoe with a shoe bolt impact
range when the link is left with large wrench and a torque wrench.
plug (3) side up (with the link assem- 2 Shoe bolt:
bly on its side) for 30 minutes. Lubricant containing molybde-
q Dimension (j): 50 – 80 mm num disulfide (LM-P)
3 Shoe bolt (Regular link)
Initial torque:
539 ± 49 Nm {55 ± 5 kgm}
Retightening angle: 120º ± 10º
16) After supplying oil, drive in the small plug

to the following specified position, using
tool R4.
a For the method of driving the small
plug, see the large plug side [1. Prep- 2) When installing a double track, place the
aration work, step 4)]. assembled double shoes on a level place
a Apply oil (GO90) around the small in 1 line with the shoe side up.
plug. 3) Pull pin-side master link (5) and bushing-
q Driving depth from end: 2.5 ± 1 mm side master link (6) together and set them
to each other by the mating faces.
4) Place shoe (7) on the links and fit the mat-
ing faces of the links.
5) Check that shoe bolts (8) can be tightened
easily, then connect the links with the
master bolts.
17) Assemble the master link on the pin side

at last.
a Check that the master links on both
sides are press fitted in parallel.
2 Shoe bolt:
Lubricant containing molybde-
num disulfide (LM-P)
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
–0º
Retightening angle: 180º –20º
D65EX, PX, WX-16 50-400 43

a Tighten the bolts in the order of [1] – 3) Using tools R3 and R4, drive in the large
[4]. and small plugs.
q Tool R3 (For large plug)
q Tool R4 (For small plug)
a Although tools R3 and R4 have differ-
ent shapes, use them similarly to
drive in the plugs.
1] Insert plug (3) in the plug insertion
window of the guide of tool R3/R4.
a Apply oil (GO90) to the outside of the
plugs and install it with the small
diameter end on the pin side.
2] Push the bar of tool R3/R4 with the
hand until the plug stops.
3] Push the plug with the bar to press
the guide against pin (4).
When recycling for grease-filled track 4] Drive in the bar with a hammer.
a Driving distance (a) from pin end:
1. Preparation work
Large plug: 2.5 ± 1 mm
1) Cleaning seal assembly
Small plug: 6 ± 2 mm
Remove the seal assembly from the link
a If the plugs were not pulled out when
and divide it into seal ring (1) and load ring
the shoe was disassembled, reuse
(2), then clean them.
them as they are.
a Since the seal ring and load ring are
deteriorated easily by the cleaning liq-
4) If the outside of the pin, surfaces of the
uid, clean them quickly. After cleaning
spacer, and ends and inside of the bush-
them, wipe off the cleaning agent
ing are dirty, clean them.
from them.
5) Apply grease to the outside of the pin and
surfaces of the spacer.
2) When reusing the pin, chamfer its end cor-

ners carefully with a grinder so that it will
be press fitted smoothly.
50-400 44 D65EX, PX, WX-16

6) Installation of seal assembly a Set the link receiving face of jaw [4]
Clean and degrease parts (b) indicated vertically.
with thick lines (the counterbore portion of a Wear plate [5] should be a replace-
the link and seal assembly) carefully. able one, if possible.
Then, using tool R6, push in the seal
assembly to the bottom.
a If oil or grease is sticking to the coun-
terbore portion of the link or seal
assembly, the seal will turn and its
s e a l i n g p e r f o r m a n c e w i l l l o w e r.
Accordingly, do not apply any oil or
grease to that portion.
2. Assembly of link
1) Apply lithium grease (G2-LI) to the mating
surfaces of the pin and bushing and
assemble them, then set them before the
jaw of the link press.
a When reusing (reversing) the bush-
ing, set the worn outside surface of
the bushing on the shoe fitting side of
7) Adjust the dimensions of the press fitting the link (set the bushing with the worn
jig of the link press to keep the projection outside surface up on the link press).
of the pin and bushing constant and keep
the installed dimensions of the seal within
the standard range.
q Dimension c: 3 mm
d: 3 mm
e: 49.7 mm
a If the pin end (part f) or link sides
(parts g and h) are worn, add the
dimensions of the worn parts when
adjusting the standard dimensions so
that the projections of the pins and
bushings on both sides will be even.
D65EX, PX, WX-16 50-400 45

2) Press fit the master links on both bushing 5) Measure the projections of the bushing on
sides to the bushing with the shoe fitting both sides with a depth gauge.
faces up. a Adjust the press fitting jig of the link
a At this time, use the master links on press so that the projections on both
the pin side as supports. sides will be even.
a Press fitting force for bushing:
98 – 147 kN {10 – 15 tons}
6) Send the master links and set the next pin

and bushing.
3) Using the shoe bolt hole pitch gauge, a When reusing a pin, install it so that
press fit the master links until the distance its side hole will be the link tread side
between the shoe bolt holes of both links similarly to a new one.
is the standard value. a If it is not installed so, its strength may
a Remove the all steel chips caused by be lowered. Accordingly, indicate the
press fitting of the bushing with com- direction of the side hole on the end
pressed air. face to prevent a mistake.
4) Turn over the master links and check that a If the outside of the pin is worn, install
they are press fitted in parallel. it so that the un-worn surface will be
on the traction side. In this case,
install the pin so that its side hole will
be the link tread side, too.
50-400 46 D65EX, PX, WX-16

7) Set both links and operate both pushing 3. Installation of shoe

jigs to press fit the pin and bushing simul- 1) Set the link assembly on the bed and
taneously. install the shoe with a shoe bolt impact
a If the pin and bushing have play when wrench and a torque wrench.
they are press fitted, the seal may 2 Shoe bolt:
come off the link. To prevent this, Lubricant containing molybde-
press fit smoothly. If the seal comes num disulfide (LM-P)
off the link, stop press fitting and set 3 Shoe bolt (Regular link)
the seal to the link correctly, then start Initial torque:
press fitting again. 539 ± 49 Nm {55 ± 5 kgm}
a Pushing force of pin and bushing: Retightening angle: 120º ± 10º
539 kN {55 tons}
Pushing force 1.8 x Average pres-
sure
(Adjust the relief pressure of the link
press to set the press cutting force.)
2) When a 2-piece track is used, place the

assembled 2 shoes on a level place in 1
line with the shoe side up.
3) Pull pin-side master link (5) and bushing-
side master link (6) together and set them
8) Using a shoe bolt hole pitch gauge, mea- to each other by the mating faces.
sure the distance between the shoe bolt 4) Place shoe (7) on the links and fit the mat-
holes. When the distance is in the stan- ing faces of the links.
dard range, stop press fitting. 5) Check that shoe bolts (8) can be tightened
easily, then connect the links with the
master bolts.
2 Shoe bolt:
Lubricant containing molybde-
num disulfide (LM-P)
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
–0º
Retightening angle: 180º –20º
9) Assemble the master link on the pin side

at last.
a Check that the master links on both
sides are press fitted in parallel.
D65EX, PX, WX-16 50-400 47

a Tighten the bolts in the order of [1] –

[4].
50-400 48 D65EX, PX, WX-16

Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe) SEN05113-02
Whole disassembly and whole Whole disassembly

assembly of track shoe assembly a For details of general disassembly of the track
(PLUS type track shoe) 1
shoe assembly, see “Whole disassembly and
whole assembly of track shoe assembly (Con-
a In this section, the points different from the ventional type track shoe)” which is also appli-
conventional type track shoe are described. cable to the track shoe assembly of the PLUS
Special tools type track shoe.
a When disassembling, decide that each part
New/Remodel
should be reused or replaced, referring to the
Necessity
Symbol
Sketch
following material.
Q’ty
Part No. Part name
q Guidance for reusable parts, undercar-
riage, and oil lubricated track
q Guidance for reusable parts, undercar-
791-932-1110 Push tool t 1
riage, and pin bushing reversal manual
4 791-646-7523 Bar t 1 k Use a track press having protective cover
791-646-7590 Guide t 1 [1].
5 790-701-3000 Checker t 1
7 791-601-1000 Oil pump t 1
791T-532-1100 Push tool assembly t 1 Q
791T-532-1110 • Adapter 1 Q
791T-532-1130 • Ring 1 Q
791T-532-1140 • Plate 1 Q
791T-532-1150 • Ring 1 Q
791T-532-1160 • Push tool 1 Q
18 791T-532-1170 • Adapter 1 Q
791T-532-1180 • Spring 1 Q
791T-532-1190 • Spring 1 Q
791T-532-1210 • Bolt 1 Q k When removing the pin, totally cover pin
791T-632-5730 • Bar 1 Q end push tool [2] and wedge ring (1) with
01580-11210 • Nut 1 thick cloth [3] so that the broken pieces of
wedge ring (1) will not be scattered.
01252-60610 • Bolt 4
R
791T-532-1120 • Adapter 1 Q
791T-532-1130 • Ring 1 Q
791T-532-1140 • Plate 1 Q
791T-532-1150 • Ring 1 Q
791T-532-1160 • Push tool 1 Q
19 791T-532-1170 • Adapter 1 Q
791T-532-1180 • Spring 1 Q
791T-532-1190 • Spring 1 Q
791T-532-1220 • Bolt 1 Q
791T-632-5730 • Bar 1 Q
01580-11210 • Nut 1
01252-60610 • Bolt 4
791T-532-1310 • Push tool 2 Q
20
791T-632-5730 • Bar 2 Q
01580-11210 • Nut 2
21 791T-432-1130 Push tool t 1 Q
D65EX, PX, WX-16 50-400 49

SEN05113-02 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe)
Whole assembly
1. Preparation work
1) Installation of seal assembly
1] Install the seal assemblies to the
counterbores of the master link, inner
link, outer link and offset link.
2] Thoroughly clean and degrease bold-
line portions (a) (counterbore of the
link and the seal assembly), and then
push in the seal assembly to the bot-
tom with tool R21.
a If any oil sticks to the counter-
bore of the link or the seal
assembly, the seal will rotate and
k Ensure that thick cloth [3] and protective the sealing performance will be
cover [1] are installed, and then start the reduced. Accordingly, do not
work. apply oil or grease.
a Use 1 set of offset link only when
an odd number of link assem-
blies are set.
k The track press operator and other workers

must put on helmets, safety glasses and
earplugs.
k When the wedge ring is cut, it makes a
cracking sound. This phenomenon is nor-
mal, however.
k Since the cut wedge ring has sharp edges,
which are dangerous, be sure to put on
leather gloves when working.
50-400 50 D65EX, PX, WX-16

2) Adjust the dimensions of the press fitting 3) Adjust the relief pressure of the link press
jig of the link press. so that the pressing force of the press will
a Adjust the dimensions to keep the not exceed the following specified value.
projection dimensions of the pin and Specified pressing force: 353 kN {36 ton}
b u s h i n g c o n s ta n t a n d k e e p t h e a Too strong pressing force can cause
installed dimension of the seal within the following troubles.
the specified range. q The spacer will be pressed forc-
a Press fitting jigs and their Installed ibly against the bushing to break-
dimensions age.
Dimension (b): 4.7 mm q The spacer and bushing end
Dimension (c): 87 mm face will be worn abnormally.
Dimension (d): 100 mm
2. Assembly of links (When odd number of
link assemblies are set)
1) Assemble pin (1), bushing (2) and 2 spac-
ers (3) temporarily and prepare 3 pin sub-
assemblies (4).
2) Set pin sub-assemblies (4a) and (4b) to

the jaw and set (4c) on this side of the jaw.
a Set the link receiving face of jaw [4]

vertically.
a Wear plate [5] should be a replace-
able one, if possible.
D65EX, PX, WX-16 50-400 51

3) Install inner links (5), to which the seals a Using depth gauge [6], measure pro-
have been installed, to the right and left of jection dimension (g) and adjust it to
pin sub-assemblies (4b) and (4c) with the the following dimension while press
shoe mounting faces (e) up. fitting the pin.
a Adjust the positions of the inner links Projection dimension (g):
so that the spacers and seals will not 4.7 ± 0.2 mm
be caught.
4) Set spacers (7) to the right and left of pin

sub-assembly (4b) at the center.
5) Set offset links (6), to which the seals
have been installed, to the positions
shown below with shoe mounting faces (f)
up.
6) Press fit offset link sub-assemblies (6) to
pin sub-assembly (4b) at the center.
a Before press fitting, align the pin hole
of the link with the pin.
a When installing, take care that the
right and left seals will not come off
and the seal and spacer (7) will not be
caught. 7) Set spacers (8) to the right and left sides
a Press fit the right and left sides of pin of front pin sub-assembly (4a).
sub-assembly (4b) simultaneously. 8) Set shoe mounting-side master links (9),
a The press fitting force of the pin sub- to which the seals have been installed, to
assembly must not exceed the follow- the positions shown below with shoe
ing force. mounting faces (h) up.
Press fitting force: 353 kN {36 ton} 9) Press fit shoe mounting-side master links
(9) to pin sub-assembly (4a) at the front.
caught.
a Press fit the right and left sides of pin
sub-assembly (4a) simultaneously.
a Ensure that the right and left master
links are press fitted in parallel.
50-400 52 D65EX, PX, WX-16

a The press fitting force of the pin sub- 12) Align tool R18 (large plug side) with the
assembly must not exceed the follow- pin and push in until wedge ring (10) is fit-
ing force ted to the pin groove.
Press fitting force: 353 kN {36 ton} a Install wedge ring (10) with opening
(j) toward the shoe mounting face of
the ring.
a When wedge ring (10) is fitted to the
pin groove, it clicks.
13) Using tool R19 (small plug side), similarly
install the wedge ring on the opposite
side. (See the special tool table.)
10) Using shoe bolt hole pitch gauge [7],

check that the shoe bolt pitch is in the
specified range.
If longer than specified range:
Disassemble and check for abnormality
and then reassemble.
If shorter than specified range:
The wear of the spacer or bushing end
face may have exceeded the allowable
limit. Disassemble and replace the worn
parts.
14) Using too R20, press fit the wedge ring.

a The wedge ring press fitting force
must not exceed the following force.
Press fitting force:
11) Set wedge ring (10) to tool R18. 147 – 275 kN {15 – 28 ton}
D65EX, PX, WX-16 50-400 53

15) Each time 1 link is assembled, bleed air a Charge oil (GO90) so that space
from the pin with tool R5 and check the depth (L) of the pin hole will be in the
sealing performance. following specified range.
a Keep the space in the pin at a vac- Space depth (L): 30 – 50 mm
uum degree of 91 – 95 kPa {680 –
710 mmHg} for 5 seconds and ensure
that the pressure does not change.
If the pressure changes, disassem-
ble and check the seal. If no abnor-
mality is detected, reassemble.
17) After charging the oil, drive the small plug

into the specified position with tool R4.
a Before driving the small plug, apply oil
(GO90) to its outside.
a Driving depth of small plug from pin
end face: 1 ± 1 mm
16) Using too R7, charge oil (GO90) until the
charge pressure becomes 196 – 294 kPa
{2 – 3 kg/cm2}.
a Increasing the oil pressure too high
has bad effects on the seal.

assemblies (4).
a Set the link assembly with the small

plug side up and leave it as it is for 30
minutes and then check the oil level.
50-400 54 D65EX, PX, WX-16

19) Move assembled link assembly (11) a The press fitting force of the pin sub-
toward the front of the ring press bed. assembly must not exceed the follow-
20) Set pin sub-assembly (4d) to the center of ing force.
the jaw and set (4e) on this side of the jaw. Press fitting force: 353 kN {36 ton}
21) Install inner links (5), to which the seals a Using depth gauge [6], measure pro-
have been installed, to the right and left of jection dimension (g) and adjust it to
pin sub-assemblies (4d) and (4e) with the the following dimension while press
shoe mounting faces (e) up. fitting the pin.
a Adjust the positions of the inner links Projection dimension (g):
so that the spacers and seals will not 4.7 ± 0.2 mm
be caught.

sub-assembly (4c) at the front and pin
sub-assembly (4d) at the center.
23) Set outer links (12), to which the seals
shown below with shoe mounting faces (k)
up.
24) Press fit outer links (12) to pin sub-assem-
bly (4c) at the front and pin sub-assembly
(4d) at the center.
caught.
sub-assemblies (4c) and (4d) simulta-
neously.
D65EX, PX, WX-16 50-400 55

25) Perform steps 10) – 17) above.

27) Assemble the master link on the roller
tread side finally.
3. Assembly of link (When even number of

link assemblies are set)
assemblies (4).

sub-assembly (4a) at the front.
5) Set roller tread-side master links (13), to
which the seals have been installed, to the
positions shown below with master link
engaging faces (m) up.
6) Press fit roller tread-side master links (13)
to pin sub-assembly (4a) at the front.
2) Set pin sub-assemblies (4a) and (4b) to and the seal and spacer (7) will not be
the jaw. caught.
sub-assembly (4a) simultaneously.
a The press fitting force of the pin sub-
assembly must not exceed the follow-
ing force.
Press fitting force: 353 kN {36 ton}
3) Install inner links (5), to which the seals

have been installed, to the right and left of
pin sub-assemblies (4a) and (4b) with the
shoe mounting faces (e) up.
a Adjust the positions of the inner links
so that the spacers and seals will not
be caught.
50-400 56 D65EX, PX, WX-16

a Using depth gauge [6], measure pro- 8) Set wedge ring (10) to tool R18.
jection dimension (g) and adjust it to
the following dimension while press
fitting the pin.
Projection dimension (g):
4.7 ± 0.2 mm
9) Align tool R18 (large plug side) with the

pin and push in until wedge ring (10) is fit-
ted to the pin groove.
a Install wedge ring (10) with opening
(j) toward the shoe mounting face of
the ring.
a When wedge ring (10) is fitted to the
pin groove, it clicks.
10) Using tool R19 (small plug side), similarly
install the wedge ring on the opposite
side. (See the special tool table.)
7) Using shoe bolt hole pitch gauge [7],

check that the shoe bolt pitch is in the
specified range.
If longer than specified range:
Disassemble and check for abnormality
and then reassemble.
If shorter than specified range:
The wear of the spacer or bushing end
face may have exceeded the allowable
limit. Disassemble and replace the worn
parts.
D65EX, PX, WX-16 50-400 57

11) Using too R20, press fit the right and left
wedge rings simultaneously.
a The wedge ring press fitting force
must not exceed the following force.
Press fitting force:
147 – 275 kN {15 – 28 ton}
a Set the link assembly with the small

plug side up and leave it as it is for 30
minutes and then check the oil level.
a Charge oil (GO90) so that space
depth (L) of the pin hole will be in the
following specified range.
12) Each time 1 link is assembled, bleed air Space depth (L): 30 – 50 mm
from the pin with tool R5 and check the
sealing performance.
a Keep the space in the pin at a vac-
uum degree of 91 – 95 kPa {680 –
710 mmHg} for 5 seconds and ensure
that the pressure does not change.
If the pressure changes, disassem-
ble and check the seal. If no abnor-
mality is detected, reassemble.
14) After charging the oil, drive the small plug

into the specified position with tool R4.
a Before driving the small plug, apply oil
(GO90) to its outside.
a Driving depth of small plug from pin
end face: 1 ± 1 mm
13) Using too R7, charge oil (GO90) until the

charge pressure becomes 196 – 294 kPa
{2 – 3 kg/cm2}.
a Increasing the oil pressure too high
has bad effects on the seal.
50-400 58 D65EX, PX, WX-16

15) Assemble pin (1), bushing (2) and 2 spac- 19) Set spacers (7) to the right and left of pin
ers (3) temporarily and prepare 3 pin sub- sub-assembly (4c) at the front and pin
assemblies (4). sub-assembly (4d) at the center.
20) Set outer links (12), to which the seals
shown below with shoe mounting faces (k)
up.
21) Press fit outer links (12) to pin sub-assem-
bly (4c) at the front and pin sub-assembly
(4d) at the center.
caught.
16) Move assembled link assembly (11) sub-assemblies (4c) and (4d) simulta-
toward the front of the ring press bed. neously.
17) Set pin sub-assembly (4d) to the center of a The press fitting force of the pin sub-
the jaw and set (4e) on this side of the jaw. assembly must not exceed the follow-
ing force.
Press fitting force: 353 kN {36 ton}
18) Install inner links (5), to which the seals

have been installed, to the right and left of
pin sub-assemblies (4d) and (4e) with the
shoe mounting faces (e) up.
a Adjust the positions of the inner links
so that the spacers and seals will not
be caught.
D65EX, PX, WX-16 50-400 59

a Using depth gauge [6], measure pro- 4. Installation of shoe

jection dimension (g) and adjust it to a Set and install the shoe so that master link
the following dimension while press (1) and shoe grouser (2) on the shoe side
fitting the pin. will be positioned as shown below.
Projection dimension (g):
4.7 ± 0.2 mm
a Set the link assembly on the link press

bed and install the shoe with the shoe bolt
impact wrench and torque wrench.
a Tighten the shoe bolts in the following
order.
2 Shoe bolt (Regular link):
Molybdenum disulfide lubricant (LM-P)
Initial torque:
539 ± 49 Nm {55 ± 5 kgm}
Retightening angle: 120 ± 10°

24) Assemble the master link on the roller
tread side finally.
50-400 60 D65EX, PX, WX-16

Field disassembly and assembly of one link (Conventional type track shoe) SEN05113-02
Field disassembly and assembly
New/remodel
Symbol
of one link (Conventional type
Necessity
Part No. Part name
Sketch
track shoe) 1
Q’ty
a In this section, how to use the special tools is
explained mainly. 791-635-3110 Frame t 1
a For details of disassembly and assembly, see 791-635-3160 Extension t 1
“Whole disassembly and whole assembly of
791-635-3170 Nut t 4
track shoe assembly”.
791-635-3180 Screw t 2
Special tools 14
791-635-3190 Screw t 1
New/remodel
791-645-3520 Adapter t 1
Symbol
Necessity
Part No. Part name 791-645-3540 Guide t 1
Sketch
t 1
Q’ty
R 791-645-3550 Pusher
791-432-1110 Push tool t 1 15 791-646-3270 Guide t 1
3 791-646-7550 Bar t 1 791-635-3110 Frame t 1
791-646-7560 Guide t 1 791-635-3160 Extension t 1
791-932-1110 Push tool t 1 791-635-3170 Nut t 4

16
4 791-646-7523 Bar t 1 791-635-3180 Screw t 2
791-646-7590 Guide t 1 791-635-3190 Screw t 1
6 791-432-1120 Installer t 1 791-645-3510 Adapter t 1
7 791-601-1000 Oil pump t 1

791-635-3110 Frame t 1 Disassembly
791-635-3160 Extension t 1 1. Pins
791-635-3170 Nut t 4 1) Set track shoe assembly on block.
8 791-635-3180 Screw t 2 2) Using tool R8 (frame, extension, nut,
screw, adapter, pusher), and tool R9
791-635-3190 Screw t 1
(pump, cylinder), remove pins (1) and (2).
791-645-3510 Adapter t 1 a If the tip of the pin or the side of the
791-646-3260 Pusher t 1 link are unevenly worn, correct with a
790-101-1102 Pump t 1 hand grinder to ensure that the part is
9 at a right angle to tool R8.
R 790-101-1300 Cylinder t 1
Jack
790-105-2300 t 1
10 (196 kN {20 ton})
790-101-1102 Pump t 1
791-645-3520 Adapter t 1
11
791-432-1210 Spacer t 1
12 791-645-3540 Guide t 1
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
791-635-3190 Screw t 1
13
791-645-3510 Adapter t 1
791-645-3520 Adapter t 1
791-645-3530 Pusher t 1
791-432-1210 Spacer t 1
791-432-1220 Spacer t 1
D65EX, PX, WX-16 50-400 61

SEN05113-02 Field disassembly and assembly of one link (Conventional type track shoe)
2. Links Assembly
1) Put tool R10 and spacer [1] (Outside 1. Bushing
diameter: 55 mm, Thickness: 47 mm) to Put tool R11 in contact with the end face of link
the tread side of links (3) and (4). (4), and press fit bushing (7).
a Set tool R10 as close to the tip of the a Bushing press fitting force:
link as possible. 98 – 147 kN {10 – 15 tons}
2) Apply hydraulic pressure slowly to the a Always use a new bushing.
puller until the tip of the link opens 6 – 8
mm, then disconnect the link.
a There is danger that the bushing will
come out, so do not apply more
hydraulic pressure than necessary.
a If an electric pump is used, there is
danger that more hydraulic pressure
will be applied than necessary, so
always use a hand pump.
2. Pins
1) Using tool R3, knock a large plug into the
oil hole of pin (1).
a Always use a new pin.
3) Disconnect links (5) and (6) in the same

way.
50-400 62 D65EX, PX, WX-16

2) To determine the pushing pressure when

carrying out the final assembly, measure
the outside diameter of the pin with a
micrometer and note down the measure-
ment.
3. Seal
Install seal (8) with tool R6.
a Check that there is no oil on the contact
surface of the link and seal.
3) Coat the press-fitting hole (a) for the pin in

link (4) with gasket sealant (198-32-
19890).
a If the link is used again, finish the
press fitting hole for the pin smoothly
with sandpaper.
a Remove all oil and grease from portions

(b).
4) Put tool R11 in contact with the end face

of link (4), and press fit pin (1).
a Press fit so that the side hole (b) in
the pin is on the same side as the link
tread.
a Pin press fitting force:
147 – 196 kN {15 – 20 tons}
D65EX, PX, WX-16 50-400 63

4. Link sub-assembly 2) Coat the press-fitting hole (a) for the pin in
1) Install link sub-assembly (10). link (3) with gasket sealant (198-32-19890).
a Check that there is no dirt or dust a If the link is used again, finish the
stuck to the surface of the seal or the press-fitting hole for the pin smoothly
end face on the bushing, then coat with sandpaper.
with oil (GO90) using a clean cloth or
small brush.
3) Install seal (8) with tool R6.

a Check that there is no oil on the con-
2) Install tool R12 (guide used when press tact surface of the link and seal.
fitting link) to bushing (7).
5. Link
the dimensions of the press-fitting hole for
the pin in link (3) with a cylinder gauge,
and note down the measurement.
4) Check that there is no dirt or dust stuck to

the surface of the seal or the end face of
the bushing, then coat with oil (GO90)
using a clean cloth or small brush.
50-400 64 D65EX, PX, WX-16

5) Using tool R13, press fit pin portion of link 2) Lower the track shoe assembly to the
(3) to link sub-assembly (10). ground.
a Pin press fitting force: 3) Set lever block [2] to the left and right link
294 – 392 kN {30 – 40 tons} assemblies as shown in the fig, then put
tool R10 and spacer [1] (outside diameter
55 mm, thickness 47 mm) in contact with
the tread on links (5) and (6).
a Set tool R10 as close to the tip of the
link as possible.
6) Using tool R14, press fit bushing portion of

link (3) to link sub-assembly (10).
a To prevent the use of any excessive
force, press fit the pin portion and
bushing portion gradually in turn.
a Pin and bushing press fitting force: 4) Using tool R6, install seals (13) and (14) to
245 – 343 kN {25 – 35 tons} links (5) and (6).
a Always use new seals.
a Check that there is no oil on the con-
tact surface of the link and seal.
6. Connecting link
1) Finish the inside surface of the press-fit-
ting hole for the pin in links (5) and (6)
smoothly with sandpaper. 5) Check that there is no dirt or dust stuck to
the surface of the seal or the end face of
bushing (7), then coat with oil (GO90)
using a clean cloth or small brush.
6) Apply hydraulic pressure slowly to the
puller until the tips of links (5) and (6) open
6 – 8 mm.
a There is danger that the bushing will
come out, so do not apply more
hydraulic pressure than necessary.
a If an electric pump is used, there is
danger that more hydraulic pressure
will be applied than necessary, so
always use a hand pump.
D65EX, PX, WX-16 50-400 65

7) Operate lever block [2], align the centers 5) Temporarily stop press fitting when there
of the link hole and bushing hole, and con- is 15 – 20 mm left for press fitting pin (2).
nect the links with tool R15 (guide pin).
a Operate lever block [2] slowly and be
careful not to damage the seal or get
sand stuck to the seal surface.
6) Coat the remaining press-fitting portion of

pin (2) with gasket sealant (198-32-
19890).
7. Pin
1) Using tool R3, knock a large plug into the
oil hole of pin (2).
7) Coat the press-fitting hole for the pin in

link (6) with gasket sealant (198-32-
19890), then continue to press fit pin (2).

the outside diameter of pin (2) with a
micrometer, and note down the measure-
ment.
3) Set the track shoe assembly on block
again.
4) Using tool R16, press fit pin (2) to links (5)
and (6).
a Press fit so that the side hole in the
pin is on the same side as the link
tread.
a Pin press fitting force:
98 – 147 kN {10 – 15 tons}
50-400 66 D65EX, PX, WX-16

8) Using tool R13, apply the specified pres- 9. Charging with oil
sure to links (3) and (4) and links (5) and 1) Using tool R7, charge with oil (GO90)
(6). through the small plug hole in the pin.
a Set pushing force of pin and bushing: a Be careful not to raise the pressure
539 kN {55 tons} too high when charging with oil. This
Set pushing force 1.8 x average will have an adverse effect on the
pushing force seal.
(Adjusting the relief pressure of link a Take into consideration the expansion
press to fix the set pushing force) of the oil under heat, and be careful
not to charge with too much oil.
8. Vacuum test
Using hand vacuum pump [3], remove the air 2) Using tool R4, drive in the small plug to
from the small plug hole at the end face of pins the following depth quickly.
(1) and (2) and check the sealing performance. a Coat the outside circumference of the
a Check that the airtightness is maintained small plug with oil (GO90).
for 5 seconds at a negative pressure of q Depth to drive from end face:
92.7 ± 1.9 kPa {695 ± 15 mmHg}. 2.5 ± 1 mm
D65EX, PX, WX-16 50-400 67

SEN05113-02 Field disassembly and assembly of one link (PLUS type track shoe)
Field disassembly and assembly q Sketch of tool (See the special tool list)
of one link
(PLUS type track shoe) 1
a In this section, how to use the special tools is

described.
a For details of disassembly and assembly, see
“General disassembly and assembly of track
shoe assembly (PLUS type track shoe)”.
Special tools
New/remodel
Symbol
Necessity
Part No. Part name
Sketch
Q’ty
Pump
1 790-101-1102 t 1
assembly
Jack (196 kN
2 790-105-2300 t 1
{20 t})
Remover &
1 791-532-2201 installer t 1
assembly
Cylinder (980
2 790-101-1300 1
kN {100 t})
3 791-532-2210 • Plate 1
4 791-532-2220 • Plate 1
5 791-532-2230 • Block 1
R 17 6 791-532-2240 • Stud bolt 2 Disassembly
7 791-532-2390 • Rod 2 1. Shoe
3 8 791-532-2260 • Plate 1) Set the track so that the link to be discon-
1
nected will be on the upper side.
9 791-532-2270 • Boss 2 2) Referring to “General disassembly and
10 791-532-2280 • Boss 2 assembly of track shoe assembly (PLUS
11 791-532-2290 • Plate 1 type track shoe)”, remove 4 shoe mount-
ing bolts (1) and shoe (2). [*1]
12 01582-12722 • Nut 4
a Remove shoes (2a) and (2b) similarly
13 791-532-2380 • Washer 2 so that the pins can be removed eas-
14 01252-61645 • Bolt 4 ily.
15 02205-12437 • Nut 4
16 791-532-2370 • Plate 1
17 791-532-2340 • Push tool 2
50-400 68 D65EX, PX, WX-16

Field disassembly and assembly of one link (PLUS type track shoe) SEN05113-02
2. Wedge ring 6) Using snap ring pliers [1] and a flat-head

q If the wedge ring is stuck, release it screwdriver, remove wedge ring (4).
according to the following procedure. a When removing the wedge ring, do
1) Sling tool R17-3 and set it to the link not damage the wedge ring contact
assembly. surfaces of the outer link and pin.
a Do not reuse the removed wedge
ring.
2) While slinging tool R17-3, align it with the

pin.
3) Apply tool R17-3-11 to outer link (3) of the 3. Master link
wedge ring to be removed. 1) Remove the shoe of the master link. For
4) Operate tool R17-1 (See the special tool details, see “Expansion and installation of
list) to press tool R17-3-11 in the direction track shoe assembly”.
of t h e a rr o w a n d m a k e a c l e a r a nc e 2) Disconnect 2 master links (5) and expand
between wedge ring (4) and outer link (3). the link assembly. [*2]
a The pressing force of tool R17-3-11
must not exceed 353 kN {36 ton}.
5) Remove tool R17-3.
4. Regular link
1) Set the link assembly on a flat place.
2) Sling tool R17-3 and set it to the link
assembly.
3) While lifting tool R17-3, hold outer link (3)
between tool R17-3-11 and R17-3-8 and
align the tools with the pin.
a Hold and fix outer link (3) securely. If
it is not fixed securely, the right and
left pins may not come out simulta-
neously.
a Tool R17-3-8 is set diagonally since it
is applied to the rusted surface of
outer link (3). Using shims, adjust tool
R17-3-8 in parallel with tool R17-3-11.
D65EX, PX, WX-16 50-400 69

4) Operate tool R17-1 (See the special tool 5. Pins and bushing
list) to press tool R17-3-8 in the direction 1) Remove outer link (6) and 2 pins (7).
of the arrow and remove outer link (3).
2) Using tool R17-3, increase dimension (j)

of inner link (8) a little.
q Condition when disassembled (See the special a Increase dimension (j) of inner link (8)
tool list) to a degree that bushing (9) can be
a. Thickness of tool R17-3-3: 36 mm pulled out lightly. If dimension (j) is
b. Thickness of tool R17-3-12: 22 mm increased too much, the oil seal on
c. Thickness of tool R17-3-11: 32 mm the opposite side to the disassembled
d. Thickness of tool R17-3-8: 32 + 6 mm side may be broken.
e. Thickness of tool R17-3-12: 22 mm 3) Remove bushing (9).
f. Dimension: 90 mm
g. Dimension: 35 mm
h. Pulling distance: 25 mm
Arrow: Moving direction of tool R17-3-2 cylin-
der
(3) Outer link
(6) Outer link
6. Oil seal and ring

Remove the oil seal and spacer from the
removed link and clean them thoroughly.
50-400 70 D65EX, PX, WX-16

Field disassembly and assembly of one link (PLUS type track shoe) SEN05113-02
Assembly 4) Operate tool R17-1 (See the special tool

q Carry out assembly in the reverse order to dis- list) to press tool R17-3-11 in the direction
assembly. of the arrow and press fit outer links (3)
1. Install the oil seal and spacer to the link. and (6).
2. Bushing
1) Using tool R17-2, increase dimension (j)
of inner link (8) a little.
a Increase dimension (j) of inner link (8)
to a degree that bushing (9) can be
pulled out lightly. If dimension (j) is
increased too much, the oil seal on
the opposite side to the disassembled
side may be broken.
2) Install bushing (9) to inner link (8).
q Condition when assembled (See the special

tool list)
a. Thickness of tool R17-3-3: 36 mm
b. Thickness of tool R17-3-12: 22 mm
c. Thickness of tool R17-3-11: 32 mm
d. Thickness of tool R17-3-8: 32 + 6 mm
e. Thickness of tool R17-3-12: 22 mm
f. Dimension: 90 mm
g. Dimension: 35 mm
h. Pressing distance: 25 mm
Arrow: Moving direction of tool R17-3-2 cylin-
3. Pins and outer link der
1) Install outer link (6) and 2 pins (7). (3) Outer link
(6) Outer link
2) Sling tool R17-3 and set it to the link.

3) While lifting tool R17-3, align it with the
pin.
a Hold and fix outer link (3) securely. If
it is not fixed securely, the right and
left pin may not be inserted simulta-
neously.
a Tool R17-3-8 is set diagonally since it
is applied to the rusted surface of
outer link (3). Using shims, adjust tool
R17-3-8 in parallel with tool R17-3-11.
D65EX, PX, WX-16 50-400 71

6) Using depth gauge [2], measure projec- 8) Sling tool R17-3 and set it to the link.
tion dimension (k) of the pin (7) end from 9) While lifting tool R17-3, align it with the
outer link (3). pin.
Standard projection dimension (k): 10) Operate tool R17-1 (See the special tool
4.7 ± 0.2 mm list) to press tool R17-3-17 in the direction
of the arrow with the following specified
force and fit the pin to the wedge ring.
Specified force:
147 – 275 kN {15 – 28 ton}
q Carry out the following assembly in the reverse

order to disassembly.
[*1]
2 Shoe bolt (Regular link):
Lubricant containing molybdenum disul-
fide (LM-P)
Initial torque: 539 ± 49 Nm {55 ± 5 kgm}
7) Using snap ring pliers [1], install wedge Retightening angle: 120 ± 10°
ring (4).
a Install wedge ring (4) with its opening [*2]
2 Shoe bolt (Master link):
toward the shoe mounting face of the
link. Lubricant containing molybdenum disul-
a Install the wedge ring so that its fide (LM-P)
height above the side of the link will
be even. Initial torque: 343 ± 39 Nm {35 ± 4 kgm}
0°
Retightening angle: 180° –20°
q Charging with oil

Charge the track with oil similarly to the ordi-
nary oil lubricated track. For details, see
“Whole disassembly and whole assembly of
track shoe assembly (PLUS type track shoe)”.
5 Track shoe pin: Gear oil (GO90)
50-400 72 D65EX, PX, WX-16

Removal and installation of pivot shaft assembly SEN05113-02
Removal and installation of pivot Installation

shaft assembly 1 q Carry out installation in the reverse order to
removal.
Special tool
[*1]
3
New/Remodel
Pivot shaft mounting bolt:
Necessity
Symbol
Sketch
455 – 565 Nm {46.5 – 58.0 kgm}
Q’ty
Part No. Part name
[*2]
791-430-1200 Installer assembly t 1 a Assemble the seal (2) as follows.
1) Turn over the seal so that the embossed
P 790-101-2102 Puller t 1
letter (a) on the seal is on the inside.
790-101-1102 Pump t 1 2) With the seal turned over, insert the seal
on the pivot shaft (1).
a When inserting the seal, be careful not to dam-
Removal age the surface.
1. Remove track frame assembly. For details, see
“Removal and installation of track frame
assembly”.
2. Sling pivot shaft assembly (1).
3. Remove mounting bolts, then using forcing
screw [1], raise pivot shaft assembly and pull
out. [*1]
4 Pivot shaft assembly:
90 kg (D65EX-16)
100 kg (D65EX-16 PAT,
D65PX, WX-16)
[*3]
a Press fit ring (3) using tool P.
a Press fitting force: 18.6 kN {1.9 ton}
4. Remove seal (2). [*2]

5. Remove ring (3). [*3]
D65EX, PX, WX-16 50-400 73

SEN05113-02 Removal and installation of equalizer bar assembly
Removal and installation of 4. Sling equalizer bar (5) temporarily.

equalizer bar assembly 1
Special tool
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
Remover assem-
791-450-1100 t 1
bly
N
790-101-2102 Puller t 1
790-101-1102 Pump t 1
5. Remove lock plate (6). Using tool N, pull out

Removal center pin (7). [*2]
1. Remove side pin cover (1). k Do not operate the hydraulic equip-
ment of tool N in front of or under the
puller, but operate it away as much as
possible.
6. Lower and remove equalizer bar (5).

4 Equalizer bar assembly: 130 kg
2. Using jack, raise the chassis and set a stand

under front frame.
k Set the stands securely.
3. Remove lock (3) and pull out pin (4). [*1]
50-400 74 D65EX, PX, WX-16

Removal and installation of equalizer bar assembly SEN05113-02
Installation
removal.
[*1]
k When aligning the pin holes, never insert
your fingers in them.
[*2]
kWhen aligning the pin holes, never insert
2 Frame boss:
Lubricant containing molybdenum disul-
fide (LM-P)
D65EX, PX, WX-16 50-400 75

SEN05113-02 Disassembly and assembly of equalizer bar side bushing
Disassembly and assembly of Assembly

equalizer bar side bushing 1 1. Install ring (2) to one side.
Disassembly 2. Using push tool [1] and a press, press fit

1. Remove seals (1). spherical bushing (3).
a Press fitting force: 15.7 kN {1.6 ton}
2. Remove rings (2).
3. Install ring (2) to opposite side.
3. Remove spherical bushing (3).
4. Install seals (1).
2 Between bushing and seal:
Grease (G2-LI)
50-400 76 D65EX, PX, WX-16

Disassembly and assembly of equalizer bar side bushing SEN05113-02
D65EX, PX, WX-16 50-400 77

SEN05113-02

©2011 KOMATSU
All Rights Reserved
50-400 78
SEN05114-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
500 Hydraulic system

Removal and installation of hydraulic tank assembly...................................................................................... 2
Removal and installation of control valve assembly ....................................................................................... 5
Disassembly and assembly of control valve assembly ................................................................................... 8
Disassembly and assembly of blade lift and tilt PPC valve assembly .......................................................... 10
Disassembly and assembly of ripper PPC valve assembly ...........................................................................11
Removal and installation of HSS and cooling fan pump assembly ............................................................... 12
Removal and installation of power train and lubrication pump assembly ..................................................... 14
Removal and installation of scavenging pump assembly ............................................................................. 16
Removal and installation of HSS motor assembly ........................................................................................ 17
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 20
D65EX, PX, WX-16 50-500 1

SEN05114-00 Removal and installation of hydraulic tank assembly
Removal and installation of 5. Remove the fuel tank assembly. For details,
hydraulic tank assembly 1
assembly”.
Removal
k Stop the machine on a level place and 6. Remove the ROPS cab assembly. For details,
apply the parking brake. see “Removal and installation of ROPS cab
tank cap gradually to release the pressure 7. Disconnect HSS case oil feed pipe (2). [*2]
the atmosphere.
Therefore, make sure to wear protec- 8. Remove 2 clamps (3) and disconnect 2
tive glasses when collecting or filling hydraulic hoses (4).
work must be conducted by a qualified 9. Remove 2 clamps (5) and disconnect 2
person. hydraulic hoses (6) and 2 hydraulic hoses (7).
1. Collect the refrigerant (air conditioner gas: the oil from flowing out.
q Quantity of refrigerant: 900 ± 50 g 10. Disconnect suction hose (8). [*3]

tank bottom.
6 Fuel tank: 415 l

50-500 2 D65EX, PX, WX-16

Removal and installation of hydraulic tank assembly SEN05114-00
11. Remove wiring harness clamp (9) and discon- Installation

nect wiring harness connector CN-HDT (10). q Carry out installation in the reverse order to
removal.
a Plug the hose and adapter to prevent the [*1]
oil from flowing out. a When installing the air conditioner hoses, take
them.
deterioration.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
13. Sling the hydraulic tank assembly. 27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
14. Remove 4 hydraulic tank mounting bolts (12) (M6 x 1.0) (Width across flats: 10 mm):
from the lower part. [*4] 3.9 – 6.9 Nm {0.4 – 0.7 kgm}
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
15. Lift off hydraulic tank assembly (13).

4 Hydraulic tank assembly (13): 90 kg
[*2]
3
HSS case oil feed pipe (2) hose mounting
assembly.
clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
3 Suction hose (11) mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
3 Hydraulic tank mounting bolt (16):
230 – 289 Nm {23.5 – 29.5 kgm}
D65EX, PX, WX-16 50-500 3

SEN05114-00 Removal and installation of hydraulic tank assembly

ant (R134a).

compressor oil”.

5 Radiator (Engine coolant): Addition
only (For details, see “Table of fuel,
coolant and lubricants”.)

and lubricants”.)

again.
and lubricants”.)
q Bleeding air (Work equipment system)

Bleed air from the piping. For details, see Test-
ing and adjusting, “Bleeding air from work
equipment cylinders”.

tem for leakage”.

circuit”.
50-500 4 D65EX, PX, WX-16

Removal and installation of control valve assembly SEN05114-00
Removal and installation of 7. Disconnect hydraulic hoses (8) and (9).

control valve assembly 1
Removal
q Precautions for handling refrigerant 8. Remove the hose clamps and disconnect 12
k Collect refrigerant (R134a) beforehand. hydraulic hoses (10) and 2 hydraulic hoses
a Ask professional traders for collecting and (11).
filling the refrigerant (R134a). a Plug the hoses and adapters to prevent
a Never release the refrigerant (R134a) to the oil from flowing out.
the atmosphere.
k If the refrigerant (R134a) gets inside 9. Remove the clamp and disconnect HSS case
ones eyes, it may cause blindness. oil feed pipe (12). [*2]
person.


tank bottom.
6 Fuel tank: 415 l
10. Sling the control valve assembly.

11. Remove 4 control valve mounting bolts (13).
assembly”.
4. Remove the ROPS cab assembly. For details,

see “Removal and installation of ROPS cab
assembly”.
5. Remove 2 wiring harness clamps (1) and 1 wir-

ing harness clamp (2).

nectors.
(3): CN-HSL
(4): CN-WLK
(5): CN-PTP
(6): CN-HDT
(7): CN-HSR
D65EX, PX, WX-16 50-500 5

SEN05114-00 Removal and installation of control valve assembly
12. Lift off control valve assembly (14). Installation

4 Control valve assembly (14): 90 kg q Carry out installation in the reverse order to
a Ensure that all the wiring and piping are removal.
disconnected before lifting off the control
valve assembly. [*1]
them.
deterioration.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
[*2]
3 HSS case oil feed pipe (2) hose mounting
clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
50-500 6 D65EX, PX, WX-16

Removal and installation of control valve assembly SEN05114-00

ant (R134a).

compressor oil”.


and lubricants”.)

again.
5 Hydraulic tank (Hydraulic oil): Addition

Bleed air from the piping. For details, see Test-
ing and adjusting, “Bleeding air from work
equipment cylinders”.

tem for leakage”.

circuit”.
D65EX, PX, WX-16 50-500 7

SEN05114-00 Disassembly and assembly of control valve assembly
Disassembly and assembly of

control valve assembly 1
q In this section, only the precautions for assem-

bling the control valve assembly are described.
q For details and tightening torque of each part,
see Structure, function and maintenance stan-
dard, “Control valve”.
Assembly
1. Tighten the upper cover (1) mounting bolts
1) Tighten the bolts in the order of [1] – [4]
shown below.
2) Tighten to the following torque.
3 Mounting bolt
1st time:
19.6 – 29.4 Nm {2 – 3 kgm}
2nd time:
39.2 – 49.0 Nm {4 – 5 kgm}
3rd time:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2. Tighten the lower cover (2) mounting bolts

1) Tighten the bolts in the order of [1] – [4]
shown below.
2) Tighten to the following torque.
3 Mounting bolt
1st time:
58.8 – 68.6Nm {6 – 7 kgm}
2nd time:
78.5 – 88.3 Nm {8 – 9 kgm}
3rd time:
98.1 – 113 Nm {10.0 – 11.5 kgm}
50-500 8 D65EX, PX, WX-16

Disassembly and assembly of control valve assembly SEN05114-00
3. When installing steering spool (3), direct the 4. Install lift spool plug (4) and tilt spool plug (5)
identification groove toward port (A1) shown according to the following procedure
above. 1) Thoroughly degrease and dry the
threaded portions of the plug and spool
hole.
2) Apply LOCTITE (No. 638) of 1 drop (0.02
g) to position (c) at dimension (b) from
plug end (a).
Dimension (b): 2 – 3 mm
3) Install lift spool plug (4) and tilt spool plug
(5).
3 Lift spool plug (4) and tilt spool plug
(5):
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
a After installing the plugs, leave them
for at least 2 hours.
D65EX, PX, WX-16 50-500 9

SEN05114-00 Disassembly and assembly of blade lift and tilt PPC valve assembly

blade lift and tilt PPC valve a Tighten mounting bolts (38) of plates (17) and
assembly 1
(18) (to be tightened together) to the following
torque.
q In this section, only the precautions for assem- 3 Mounting bolt (38):
bling the blade lift and tilt PPC valve assembly 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
are described. a Apply grease to the rocking parts of joint (19)
and contact parts of disc (20) and pistons (23),
(24) and (25).
2 Rocking parts of joint (19) (7 – 10 ml/
periphery): Grease (G2-LI)
2 Contact parts of disc (20) and pistons
(23), (24) and (25) (0.3 – 0.8 ml/place):
Grease (G2-LI)
a Install joint (19) to the valve body (1) according
1) Thoroughly degrease and dry the
threaded portions of the joint and body
hole.
2) Apply LOCTITE to 2 places at dimension
(a) from the body threaded hole end.
2 2 places at dimension (a) from end
(1 drop, 0.02 mg each):
LOCTITE (No. 648)
q Dimension (a): 5 – 7 mm
3) Tighten joint (19) to the following torque.
3 Joint (19): 39 – 49 Nm {4 – 5 kgm}
q The parts are not available excluding below:

(15), (16), (19), (22), (36) and (38).
a Tighten nut (22) to the following torque.

3 Nut (22):
93.1 – 112.7 Nm {9.5 – 11.5 kgm}
a Adjust the play of the lever. For details, see
Testing and adjusting, “Adjusting play of work
equipment PPC valve”.
50-500 10 D65EX, PX, WX-16

Disassembly and assembly of ripper PPC valve assembly SEN05114-00

ripper PPC valve assembly 1 a When installing spring (6), see the following.
a The position of each port is stamped on the
q In this section, only the precautions for assem- underside of valve body (1).
bling the ripper PPC valve assembly are
described. Free length
Port position Spring
(mm)
P1, P2 (6) 33.88
a When installing piston (7), apply grease to its

outside and inside of the valve body hole.
2 Outside of piston and inside of valve
body hole: Grease (G2-LI)
a Tighten mounting bolts (15) of plates (17) and
(12) (to be tightened together) to the following
torque.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
a Apply grease to the rocking parts of lever (11)
and contact parts of piston (7).
2 Rocking parts of lever (11) and contact
parts of piston (7): Grease (G2-LI)
q The parts are not available excluding below:

(3) – (10) and (14) – (17).
D65EX, PX, WX-16 50-500 11

SEN05114-00 Removal and installation of HSS and cooling fan pump assembly
Removal and installation of HSS 5. Remove the fuel tank assembly. For details,
and cooling fan pump assembly 1
assembly”.
Removal
k Stop the machine on a level place and 6. Remove the ROPS cab assembly. For details,
apply the parking brake. see “Removal and installation of ROPS cab
tank cap gradually to release the pressure 7. Remove the power train unit assembly. For
inside the hydraulic tank. details, see “Removal and installation of power
k Disconnect the cable from the negative (–) train unit assembly”.
k If the radiator coolant temperature is high, 8. Set the power train unit assembly horizontally
wait until it decreases to avoid getting with blocks etc.
q Precautions for handling refrigerant 9. Remove the mounting bolts and HSS and cool-
k Collect refrigerant (R134a) beforehand. ing fan pump assembly (1).
4 HSS and cooling fan pump assembly
(1): 130 kg
a HSS and cooling fan pump assembly (1)
the atmosphere.
cannot be removed while it is mounted on
the machine. (The suction tube interferes
with the ROPS cab mounting frame)
person.


tank bottom.
6 Fuel tank: 415 l

50-500 12 D65EX, PX, WX-16

Removal and installation of HSS and cooling fan pump assembly SEN05114-00

5
a When installing the air conditioner hoses, take Radiator (Engine coolant): Addition
care that dirt, dust, water, etc. will not enter only (For details, see “Table of fuel,
them. coolant and lubricants”.)
a Check that O-ring (70) is free from flaw and q Refilling with fuel (Fuel tank)
5
deterioration. Fuel tank (Diesel fuel): 415 l (For
a When connecting the refrigerant piping, apply details, see “Table of fuel, coolant
compressor oil for new refrigerant (R134a) and lubricants”.)
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm} q Refilling with oil (Hydraulic tank)
3 Thread size (M22 x 1.5) (Width across flats: Add oil through the oil filler to the specified
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm} level. Run the engine to circulate the oil
3 Thread size (M24 x 1.5) (Width across flats: through the system. Then, check the oil level
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm} again.
(M6 x 1.0) (Width across flats: 10 mm): details, see “Table of fuel, coolant
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
and lubricants”.)
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm} q Checking for fuel leakage (Fuel system)
tem for leakage”.

circuit”.

ant (R134a).

compressor oil”.
D65EX, PX, WX-16 50-500 13

SEN05114-00 Removal and installation of power train and lubrication pump assembly
Removal and installation of power 2) Remove inspection cover (3) of the floor
train and lubrication pump plate.
assembly 1
Removal

1. Open right and left doors (1) of the ROPS cab

and lock them.
a Lock the doors securely.
3) Disconnect wiring harness connector CN-
PAC (4) from the underside of the floor
plate.
2. Remove the floor plate assembly according to

1) Remove floor mat (2).
4) Disconnect the turnbuckle of brake rod
“Adjusting brake pedal”. [*1]
5) Lift off floor plate assembly (6).
50-500 14 D65EX, PX, WX-16

Removal and installation of power train and lubrication pump assembly SEN05114-00
3. Remove undercover (7) under the power train. Installation

removal.
[*1]
brake pedal”.
[*2]
3 Hydraulic tube (8) hose mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
3 Power train and lubrication pump assembly
4. Disconnect hydraulic tube (8) under the power (11) mounting bolt:
train and lubrication pump assembly. [*2] 98 – 123 Nm {10.0 – 12.5 kgm}
5. Disconnect upper hydraulic hoses (9) and (10).

q Refilling with oil (Power train case)
again.
6. Sling power train and lubrication pump assem-

bly (11).
7. Remove the mounting bolts and lift off power

train and lubrication pump assembly (11). [*3]
4 Power train and lubrication pump
a Since a crane cannot be used inside the
ROPS cab, use a bar etc. to lift off power
train and lubrication pump assembly (11).
D65EX, PX, WX-16 50-500 15

SEN05114-00 Removal and installation of scavenging pump assembly
Removal and installation of Installation

scavenging pump assembly 1 q Carry out installation in the reverse order to
removal.
Removal
apply the parking brake. q Refilling with oil (Power train case)
k Lower the work equipment to the ground Add oil through the oil filler to the specified
and stop the engine. level. Run the engine to circulate the oil
k Disconnect the cable from the negative (–) through the system. Then, check the oil level
terminal of the battery. again.
5 Power train case (Power train oil): 53 l
1. Remove undercover (1) under the power train.
(For details, see “Table of fuel, cool-
ant and lubricants”.)
2. Drain the oil from the power train case.

6 Power train case: 53 l
4. Remove the mounting bolts and scavenging

pump assembly (3).
50-500 16 D65EX, PX, WX-16

Removal and installation of HSS motor assembly SEN05114-00
Removal and installation of HSS

motor assembly 1
Removal
scalded and then drain the coolant. 6. Remove the ROPS cab assembly. For details,
q Precautions for handling refrigerant see “Removal and installation of ROPS cab
k Collect refrigerant (R134a) beforehand. assembly”.
a Ask professional traders for collecting and a Remove the ROPS cab assembly to dis-
filling the refrigerant (R134a). connect hydraulic hoses (3) and (4).
the atmosphere. 7. Disconnect hydraulic hoses (1), (2), (3) and
k If the refrigerant (R134a) gets inside (4).
ones eyes, it may cause blindness. a Plug the hoses and adapters to prevent
Therefore, make sure to wear protec- the oil from flowing out.
person.


tank bottom.
6 Fuel tank: 415 l

8. Remove hose clamp (5) and bracket (6) and
mo v e 2 hy d r au li c ho s es ( 7 ) t ow ar d th e
assembly”.
machine.
a Secure a space for pulling out the HSS
motor assembly.
D65EX, PX, WX-16 50-500 17

SEN05114-00 Removal and installation of HSS motor assembly
9. Sling the HSS motor assembly (8). Installation

10. Remove the mounting bolts and lift off HSS removal.
motor assembly (8).
4 HSS motor assembly (8): 45 kg [*1]
them.
deterioration.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
50-500 18 D65EX, PX, WX-16

Removal and installation of HSS motor assembly SEN05114-00

ant (R134a).

compressor oil”.

again.
and lubricants”.)

and lubricants”.)

tem for leakage”.

circuit”.
D65EX, PX, WX-16 50-500 19

SEN05114-00 Disassembly and assembly of hydraulic cylinder assembly

hydraulic cylinder assembly 1 a Names of work equipment and cylinders
Work equipment
Special tools Symbol Cylinder name
name
ST-T Straight tiltdozer
New/Remodel
Blade lift, Blade tilt
Necessity
SGM Sigma dozer
Symbol
Sketch
Q’ty
Part No. Part name Sigma power pitch
SGM-PP
dozer Blade lift, blade
Straight tilt power tilt, blade pitch
ST-TPP
790-502-1003 Repair stand t 1 pitch dozer
1 Power angle power Blade lift, blade
790-101-1102 Pump t 1 PAT
tilt dozer angle, blade tilt
2 790-330-1100 Wrench assembly t 1 A Angledozer Blade lift
Socket (Width
790-302-1270 t 1 – Ripper Ripper lift
across flats: 50 mm)
Socket (Width
3 790-102-1330 t 1
across flats: 75 mm)
1. Piston rod assembly
Socket (Width 1) Set cylinder assembly (1) to tool U1.
790-302-1340 t 1
across flats: 80 mm) 2) Using a hydraulic pump or a power
4 790-720-1000 Expander t 1 wrench, remove cylinder head assembly
796-720-1650 Ring t 1 (2) with tool U2.
07281-01029 Clamp t 1
796-720-1660 Ring t 1
5
07281-01159 Clamp t 1
U 796-720-1670 Ring t 1
07281-01279 Clamp t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6
790-201-1781 • Push tool 1
790-201-1811 • Push tool 1
790-201-1791 • Push tool 1
790-201-1500 Push tool kit t 1 a (A) indicates a blade lift cylinder other
790-101-5021 • Grip 1 than PAT.
01010-50816 • Bolt 1
q Excluding blade tilt cylinder and blade
7 pitch cylinder for ST-TPP and SGM-PP.
790-201-1590 • Plate 1
790-201-1620 • Plate 1
790-201-1610 • Plate 1
50-500 20 D65EX, PX, WX-16

Disassembly and assembly of hydraulic cylinder assembly SEN05114-00
q Blade tilt cylinder and blade pitch cylinder

for ST-TPP and SGM-PP.
3. Disassembly of piston assembly

1) Remove wear ring (7).
3) With cylinder assembly (1) set to tool U1, 2) Remove piston ring (8).
sling piston rod assembly (3) and pull it q Blade tilt cylinder, blade pitch cylinder, rip-
out of cylinder (1). per lift cylinder
2. Piston assembly and cylinder head assem- q Blade lift cylinder, blade angle cylinder
bly
1) Set piston rod assembly (3) to tool U1.
2) Using tool U3, remove nut (5).
3) Remove piston assembly (6) and cylinder
head assembly (2).
Width across flats of nut
Cylinder name
(mm)
Blade lift 50
Blade angle (PAT) 75
Blade tilt, blade pitch 80
Blade tilt (PAT) 80
Ripper lift 80
D65EX, PX, WX-16 50-500 21

a Perform steps 3) and 4) for only the blade 4. Disassembly of cylinder head assembly
lift cylinder. 1) Remove the O-ring and backup ring (15).
3) Remove 2 covers (9) and 2 pins (10). 2) Remove snap ring (16) and dust seal (17).
4) Remove 4 shafts (11) and 8 seats (12). 3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
a Remove O-ring (21) in step 6) from
only the blade lift cylinder, blade
angle cylinder, blade tilt cylinder,
blade pitch cylinder and ripper lift cyl-
inder.
6) Remove O-ring (21).
a Perform steps 5), 6) and 7) for only the

blade angle cylinder.
5) Remove 1 cover (9) and 1 pin (10).
6) Remove 4 shafts (11) and 4 seats (12).
7) Remove 4 valves (13) and 4 springs (14).
50-500 22 D65EX, PX, WX-16

Assembly 2. Assembly of piston assembly

a Apply hydraulic oil (For details, see “Table of 1) Set piston ring (8) to tool U4 and rotate the
fuel, coolant and lubricants”) to the sliding sur- handle 8 – 11 turns to expand the piston
faces of each part. ring.
a When assembling the piston rod, packing, dust 2) Remove piston ring (8) from tool U4 and
seal and O-ring, take care not to damage install it to piston (6).
them. 3) Using tool U5, compress piston ring (8).
a Before inserting the backup ring, warm it in hot
water at about 50 – 60°C.
1. Assembly of cylinder head assembly

1) Using tool U6, press fit bushing (20).
2) Install buffer ring (19).
3) Install rod packing (18).
4) Using tool U7, install dust seal (17) and fix
it with snap ring (16).
5) Install the backup ring and O-ring (15).
a Install O-ring (21) in step 6) to only the
blade lift cylinder, blade angle cylinder,
blade tilt cylinder and ripper lift cylinder.
6) Install O-ring (21).
4) Install wear ring (7).
q Blade tilt cylinder, blade pitch cylinder, rip-
per lift cylinder
q Blade lift cylinder, blade angle cylinder
D65EX, PX, WX-16 50-500 23

a Perform steps 5) and 6) for only the blade 3. Piston rod assembly
lift cylinder. 1) Thoroughly clean, degrease and dry the
5) Install 8 seats (12) and 4 shafts (11). threaded portion of piston rod (3).
6) Install 2 pins (10) and 2 covers (9). 2 Threaded portion of piston rod (3):
Adhesive (LOCTITE No. 262 or
equivalent)
2) Set piston rod (3) to tool U1 and install cyl-
inder head assembly (2) and piston
assembly (6).
3) Using tool U3, tighten nut (5).
a When installing nut (5), direct its
machined side toward the piston.
a Perform steps 7), 8) and 9) for only the

blade angle cylinder.
7) Install 4 springs (14) and 4 valves (13).
8) Install 4 seats (12) and 4 shafts (11).
9) Install 1 pin (10) and 1 cover (9).
3 Nut (5):
Nut tightening
Cylinder Width across
torque
name flats (mm)
(kNm {kgm})
1.08 ± 0.11
Blade lift 50
{110 ± 11.0}
Blade angle 3.14 ± 0.31
75
(PAT) {320 ± 32}
Blade tilt, 3.97 ± 0.41
80
blade pitch {405 ± 40.5}
Blade tilt 3.97 ± 0.41
80
(PAT) {405 ± 40.5}
3.97 ± 0.41
Ripper lift 80
{405 ± 40.5}
50-500 24 D65EX, PX, WX-16

4) Set cylinder assembly (1) to tool U1 and a (A) indicates a blade lift cylinder other
sling piston rod assembly (3) and install to than PAT.
cylinder (1). q Excluding blade tilt cylinder and blade
pitch cylinder for ST-TPP and SGM-PP.
5)Using a hydraulic pump or a power

wrench, tighten cylinder head assembly q Blade tilt cylinder and blade pitch cylinder
(2) with tool U2. for ST-TPP and SGM-PP.
3 Cylinder head assembly (2):
Cylinder head
Cylinder name
tightening torque
677 ± 67.5 Nm
PAT
{69 ± 6.90 kgm}
Blade lift
Other 637 ± 63.5 Nm
than PAT {65 ± 6.50 kgm}
1.37 ± 0.14 kNm
Blade angle (PAT)
{140 ± 14 kgm}
1.01 ± 0.10 kNm
Blade tilt, blade pitch
{103 ± 10.3 kgm}
1.03 ± 0.10 kNm
Blade tilt (PAT)
{105 ± 10.5 kgm}
1.01 ± 0.10 kNm
Ripper lift
{103 ± 10.3 kgm}
D65EX, PX, WX-16 50-500 25

SEN05114-00

©2009 KOMATSU
All Rights Reserved
50-500 26
SEN05115-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
600 Work equipment

Removal and installation of blade assembly (ST-TPP dozer) ......................................................................... 2
Removal and installation of blade assembly (PAT dozer) ............................................................................... 5
Removal and installation of ripper assembly .................................................................................................. 7
D65EX, PX, WX-16 50-600 1

600 Work equipment
SEN05115-00 Removal and installation of blade assembly (ST-TPP dozer)
Removal and installation of blade 2) Sling blade lift cylinder assembly (3), start
assembly (ST-TPP dozer) 1
the engine, and retract blade lift cylinder
rod (1) to the stroke end.
q ST-TPP: Straight tilt power pitch dozer 3) Using stay [2], fix blade lift cylinder assem-
Removal bly (3) to the machine.
k Stop the machine on a level place and a Fix blade lift cylinder rod (1) with a
apply the parking brake. wire etc. so that it will not come out.
stop the engine, and loosen the hydraulic 3. Similarly, disconnect the right blade lift cylinder
tank cap gradually to release the pressure from the blade.
1. Set blocks [1] under the right and left straight

frames.
4. Remove right and left steps (4) and trunnion

covers (5).
2. Disconnect the left blade lift cylinder assembly

from the blade according to the following pro-
cedure.
1) Remove cap (2) from blade lift cylinder rod
(1). [*1]
a Check and record the thickness and quan-
tity of the shim.
50-600 2 D65EX, PX, WX-16

600 Work equipment
Removal and installation of blade assembly (ST-TPP dozer) SEN05115-00
5. Disconnect 2 hydraulic hoses (6) each from Installation

the right and left sides. q Carry out installation in the reverse order to
a Plug the hoses and adapters to prevent removal.
[*1]
6. Remove 2 mounting bolts (7) each from the a Adjust clearance (a) in the mating face of cap
right and left sides and remove trunnion cap (2) to the following dimension with shims.
(8) and shim (9). [*2] q Standard clearance (a): 0.2 – 0.5 mm
a Check and record the thickness and quan- q Standard shim thickness: 4 mm
tity of the shim. a Ensure that cap (2) rotates smoothly.
7. Start the engine and move the machine in [*2]

reverse slowly to disconnect straight frame a Adjust the shim of trunnion cap (8). For details,
(11) from trunnion (10). [*3] see Testing and adjusting, “Adjusting blade”.
D65EX, PX, WX-16 50-600 3

600 Work equipment
SEN05115-00 Removal and installation of blade assembly (ST-TPP dozer)
[*3]
a Using block [3], adjust height (b) and width (c)
of the right and left straight frames to the fol-
lowing dimensions.
q Height (b): 494 mm (D65EX-16)
494 mm (D65PX-16)
494 mm (D65WX-16)
q Width (c): 2,600 mm (D65EX-16)
3,136 mm (D65PX-16)
3,136 mm (D65WX-16)

again.

Bleed air from the work equipment cylinders.
For details, see Testing and adjusting, “Bleed-
ing air from work equipment cylinders”.
50-600 4 D65EX, PX, WX-16

600 Work equipment
Removal and installation of blade assembly (PAT dozer) SEN05115-00
Removal and installation of blade 3. Similarly, disconnect the right blade lift cylinder
assembly (PAT dozer) 1
from the blade.
q PAT: Power angle power tilt dozer

Removal
1. Set blocks [1] under the right and left work

equipment frames.
4. Remove right hose cover (4) and left hose

cover (5).
2. Disconnect the left blade lift cylinder assembly

from the blade according to the following pro-
cedure.
1) Remove pin (2) from blade lift cylinder rod
(1). 5. Disconnect 3 hydraulic hoses (6) from the right
side of the machine and disconnect 3 hydraulic
hoses (7) from the left side.
2) Sling blade lift cylinder assembly (3), start

the engine, and retract blade lift cylinder
rod (1) to the stroke end.
3) Using stay [2], fix blade lift cylinder assem-
bly (3) to the machine.
a Fix blade lift cylinder rod (1) with a
wire etc. so that it will not come out.
D65EX, PX, WX-16 50-600 5

600 Work equipment
SEN05115-00 Removal and installation of blade assembly (PAT dozer)
6. Remove 2 mounting bolts (8) each from the Installation

right and left sides and remove trunnion cap q Carry out installation in the reverse order to
(9) and shim (10). [*1] removal.
a Check and record the thickness and quan-
tity of the shim. [*1]
a Adjust the shim of trunnion cap (9). For details,
see Testing and adjusting, “Adjusting blade”.
[*2]
a Using blocks [1], adjust height (a) of the right
and left work equipment frames to the follow-
ing dimension.
q Height (a): 857 mm (D65EX-16)

857 mm (D65PX-16)
857 mm (D65WX-16)
7. Start the engine and move the machine in

reverse slowly to disconnect work equipment
frame (11) from the trunnion. [*2]

again.

50-600 6 D65EX, PX, WX-16

600 Work equipment
Removal and installation of ripper assembly SEN05115-00
Removal and installation of k Release the residual pressure in the piping

ripper assembly 1
and then loosen the hydraulic tank oil filler
cap to release the pressure inside the
Removal hydraulic tank. For details, see Testing and
a In this section, both disassembly and assembly adjusting, “Releasing residual pressure in
of the ripper assembly are explained. the hydraulic tank”.
apply the parking brake. 7. Disconnect 2 ripper hoses (3).
k Lower the work equipment to the ground, a Plug the disconnected hoses to prevent
stop the engine, and loosen the hydraulic the oil from flowing out.
1. Set block [1] under the arm of the ripper

assembly.
2. Set hydraulic jack [2] under the beam center of

the ripper assembly.
8. Sling the ripper lift cylinder (4).
9. Remove the pin mounting bolts and remove 2

pins (5). [*2]
10. Lift off ripper lift cylinder (4).

4 Ripper lift cylinder (4): 80 kg
3. Sling the left link (1).
4. Remove the pin mounting bolts and remove 2

pins (2). [*1]
5. Lift off link (1).

4 Link (1): 50 kg
6. Similarly, remove the right link.
D65EX, PX, WX-16 50-600 7

600 Work equipment
SEN05115-00 Removal and installation of ripper assembly
11. Sling the beam (6). 17. Sling support bracket (10).
12. Remove the pin mounting bolts and remove 2 18. Remove 10 mounting bolts (11) and 6 bolts
pins (7) on the right and left sides. [*3] (12) and lift off support bracket (10). [*5]
4 Support bracket (10): 310 kg
13. Lift off beam (6).
4 Beam (6) (with 3 shanks): 500 kg
19. Remove the shank according to the following

procedure.
14. Sling arm (8). 1) Start the engine and raise the ripper
assembly to the stroke end.
15. Remove the pin mounting bolts and remove 2 k After operating, apply the work
pins (9) on the right and left sides. [*4] equipment lock lever to lock the
ripper control lever securely.
16. Lift off arm (8). 2) Sling the shank.
4
3) Remove lock pin (13) and pin (14). [*6]
Arm (8): 260 kg
50-600 8 D65EX, PX, WX-16

600 Work equipment
Removal and installation of ripper assembly SEN05115-00
4) Sling and lift off shank (15) gradually. Installation

4 Shank (15): 90 kg q Carry out installation in the reverse order to
removal.
[*1], [*2], [*3], [*4]

k When aligning the pin holes, never insert
2 Pin: Grease (G2-LI)
[*5]
785 – 980 Nm {80 – 100 kgm}
1,960 – 2,450 Nm {200 – 250 kgm}
[*6]
a Install lock pin (13) securely.

again.

D65EX, PX, WX-16 50-600 9

SEN05115-00

©2009 KOMATSU
All Rights Reserved
50-600 10
SEN05116-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Removal and installation of ROPS cab assembly........................................................................................... 2
Removal and installation of FRP canopy (FRP canopy specification) ............................................................ 9
Removal and installation of floor frame assembly (FRP canopy specification)............................................. 10
Removal and installation of operator’s cab glass (Stuck glass) .................................................................... 14
Removal and installation of air conditioner unit assembly ............................................................................ 20
Removal and installation of air conditioner compressor assembly ............................................................... 24
D65EX, PX, WX-16 50-700 1

SEN05116-01 Removal and installation of ROPS cab assembly
Removal and installation of ROPS 5. Lift off operator seat assembly (2).
cab assembly 1 4 Operator seat assembly (2): 50 kg
Removal
k
ROPS cab, use a bar etc. to lift off opera-
Stop the machine on a level place and
tor seat assembly (2).
the atmosphere.
ones eyes, it may cause blindness. 6. Remove the floor plate assembly according to
Therefore, make sure to wear protec- the following procedure.
tive glasses when collecting or filling 1) Remove floor mat (3).
person.


tank bottom.
6 Fuel tank: 415 l

2) Remove inspection cover (4) of the floor
assembly”.
plate.
and lock them.
50-700 2 D65EX, PX, WX-16

Removal and installation of ROPS cab assembly SEN05116-01
3) Disconnect wiring harness connector CN- 8. Open battery cover (9) on the left side of the
PAC (5) from the underside of the floor machine and lock it.
plate. a Lock the doors securely.
4) Disconnect the turnbuckle of brake rod 9. Disconnect the parking brake cable (10). For
(6). For details, see Testing and adjusting, details, see Testing and adjusting, “Adjusting
“Adjusting brake pedal”. [*2] parking brake lever”. [*3]
5) Lift off floor plate assembly (7).
10. Disconnect wiring harness connectors CN-PL1

(11) and CN-FD1 (12).
a To disconnect wiring harness connectors
CN-PL1 (11) and CN-FD1 (12), loosen the
hexagon socket head bolt (4 mm) at their
7. Remove inspection cover (8) under the opera- centers. [*4]
tor seat. a How to disconnect harness connectors
CN-PL1 (11) and CN-FD1 (12)
Disconnect the connector straight slowly
and check the seal for breakage, peeling
and sticking foreign matter.
a If the seal is damaged, replace it.
D65EX, PX, WX-16 50-700 3

11. Disconnect external air duct (13). [*5] 14. Disconnect 2 heater hoses (17) and remove
bracket (17a).
12. Remove hose clamp (14) and disconnect 4

wiper water hoses (15). 15. Remove hose clamp (18).

AC05 (18a).
17. Disconnect air conditioner tubes (18b) and

(18c).
a Disconnect air conditioner tube (18c) at air
conditioner compressor side.
13. Disconnect ground cable (16) from the rear of

the machine.
18. Remove 2 pins (19). [*6]

a Remove all the wiring harness clamps
under the floor.
50-700 4 D65EX, PX, WX-16

19. Remove covers (20), (22) and (23) from the 22. Remove right armrest (27) and cover (28).
inside of the ROPS cab.
20. Reverse cover (23) and disconnect CN-

CBACC (25) and CN-CBCIG (24).
23. Remove right step plate (29).

a If step plate (29) is not removed, the
mounting bolts of control valve cover (30)
cannot be removed.
24. Remove control valve cover (30).
21. Remove cover (26) from the right rear.
D65EX, PX, WX-16 50-700 5

25. Disconnect the quick couplers of ripper PPC 29. Sling the ROPS cab assembly.
hoses (31) and (32).
30. Remove 4 ROPS cab front mounting bolts (44)
26. Disconnect the quick couplers of blade PPC each on the right and left sides. [*7]
hoses (33), (34), (35), (36), (37) and (38).
27. Disconnect blade PPC hoses (39) and (40)

and ripper PPC hose (41).
28. Disconnect hydraulic hoses (42) and (43).

a Hydraulic hoses (42) and (43) interfere
with the ROPS cab.
31. Remove 4 ROPS cab rear mounting bolts (45)

each on the right and left sides. [*8]
32. Lift off ROPS cab assembly (46).

4 ROPS cab assembly (46): 1,000 kg
disconnected before lifting off the ROPS
cab assembly.
50-700 6 D65EX, PX, WX-16

Installation [*4]
q Carry out installation in the reverse order to a How to connect harness connectors CN-PL1
removal. (11) and CN-FD1 (12)
1) Check that the seal is correctly installed to
[*1] the plug.
a When installing the air conditioner hoses, take 2) Check that the key is positioned to be
care that dirt, dust, water, etc. will not enter matched to the groove of the receptacle
them. (key is not positioned oppositely).
a When installing each joint of the air conditioner 3) Set the plug connector to the receptacle
hose, check that O-ring (70) is fitted to it. straight (since the seal is projected) and fit
a Check that O-ring (70) is free from flaw and it a little, while check that the seal is not
deterioration. rolled up.
a When connecting the refrigerant piping, apply 4) Tighten the hexagon bolt at the center of
compressor oil for new refrigerant (R134a) the connector by 2 – 3 turns.
(DENSO: ND-OIL8) to O-ring (70). 5) Fit the plug connector to the end and
3 Thread size (M16 x 1.5) (Width across flats: adjust it so that the clearance between it
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm} and the fitted receptacle will be even when
3 Thread size (M22 x 1.5) (Width across flats: seen from each direction.
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm} 6) Tighten the lock bolt to the specified
3 Thread size (M24 x 1.5) (Width across flats: torque.
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm} 3 Hexagon lock bolt (4 mm):
3 Receiver tank refrigerant tube mounting bolt 2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
(M6 x 1.0) (Width across flats: 10 mm): a If the lock bolt is tightened too
3.9 – 6.9 Nm {0.4 – 0.7 kgm} strongly, it will be broken and cannot
3 Air conditioner compressor refrigerant tube lock.
mounting bolt (M6 x 1.0) (Width across flats: Take care
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
[*2]
brake pedal”.
[*3]
a Install parking brake cable (10). For details,
see Testing and adjusting, “Adjusting parking
brake lever”.
D65EX, PX, WX-16 50-700 7

[*5]
a Direct down the mounting clamp bolt of heater
air duct (13) so that it can be tightened from
the rear of the machine.
[*6]
3 Pin (19) mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
[*7]
3 ROPS cab front mounting bolt (43):
235 – 285 Nm {23.5 – 29.5 kgm}
[*8]
3 ROPS cab rear mounting bolt (44):
245 – 309 Nm {25.0 – 31.5 kgm}

ant (R134a).

compressor oil”.


and lubricants”.)

tem for leakage”.

circuit”.
50-700 8 D65EX, PX, WX-16

Removal and installation of FRP canopy (FRP canopy specification) SEN05116-01
Removal and installation of FRP canopy (FRP canopy specification) 1
Removal
1. Remove the mounting bolts of roof (1) on can-

opy bracket (2) and remove the roof.
2. Sling canopy bracket (2), remove the mounting
bolts of poles (3), and remove canopy bracket
(2) and poles (3) together.
a The canopy pole mounting bolts are also
used to mount the rear portion of the floor
frame.
4 Canopy bracket and pole assembly:
90 kg
Installation
removal.
a The canopy pole mounting bolts are also used
to mount the rear portion of the floor frame.
3 Canopy pole mounting bolt:
2.7 ± 0.3 Nm {26 ± 3 kgm}
D65EX, PX, WX-16 50-700 9

SEN05116-01 Removal and installation of floor frame assembly (FRP canopy specification)
Removal and installation of floor frame assembly (FRP canopy

specification) 1
Removal 5. Remove the floor plate assembly according to

k Place the machine on a level ground and the following procedure.
apply the parking brake. 1) Remove floor mat (3).
1. Drain the fuel through the fuel valve at the bot-

tom of the fuel tank.
6 Fuel tank:
415 liters
see REMOVAL AND INSTALLATION OF
FUEL TANK ASSEMBLY.
3. Remove the canopy assembly. For details, see
REMOVAL AND INSTALLATION OF CANOPY
ASSEMBLY. 2) Remove inspection cover (4) of the floor
4. Sling and remove operator's seat assembly plate.
(2).
4 Operator's seat assembly (2):
35 kg
3) Disconnect harness connector CN-PAC

(5) under the floor plate.
50-700 10 D65EX, PX, WX-16

Removal and installation of floor frame assembly (FRP canopy specification) SEN05116-01
4) Disconnect the turnbuckle of brake rod 8. Disconnect harness connectors CN-PL1 (11)
(6). For detail, see Testing and adjusting, and CN-FD1 (12).
ADJUSTING BRAKE PEDAL. [*2] a To disconnect harness connectors CN-
5) Sling and remove floor plate assembly (7). PL1 (11) and CN-FD1 (12), loosen the
4
hexagon socket head cap screw (4 mm) at
Floor plate assembly:
their centers. [*3]
30 kg
a How to disconnect harness connectors
CN-PL1 (11) and CNFD1 (12): Disconnect
the connector straight and check for
breakage and peeling of the seal and
sticking of foreign matter.
a If the seal is defective, replace it.
6. Open battery cover (9) on the left side of the

machine and secure it with the lock.
a Apply the lock securely.
9. Disconnect ground cable (16) from the rear of

the chassis.
7. Disconnect the parking brake cable (10). For

detail, see Testing adjusting, ADJUSTING
PARKING BRAKE LEVER. [*2]
10. Remove right armrest (27) and cover (28).
D65EX, PX, WX-16 50-700 11

SEN05116-01 Removal and installation of floor frame assembly (FRP canopy specification)
11. Remove right step plate (29).

a If you do not remove step plate (29), you
cannot remove the mounting bolts of con-
trol valve cover (30).
12. Remove control valve cover (30).
16. Sling the floor frame assembly.

17. Remove front floor frame mounting bolts (44),
4 pieces each from the right and left sides. [*4]
18. Sling and remove floor frame assembly (45).

4 Floor frame assembly:
13. Disconnect the quick couplers of blade PPC 560 kg
hoses (33), (34), (35), (36), (37), and (38). a Check that all the wiring and piping are
14. Disconnect blade PPC hoses (39) and (40). disconnected before removing the floor
15. Disconnect hydraulic hoses (42) and (43). frame assembly.
a If hydraulic hoses (42) and (43) are not
disconnected, they interfere with the floor
frame.
50-700 12 D65EX, PX, WX-16

Removal and installation of floor frame assembly (FRP canopy specification) SEN05116-01
Installation [*4]
q Perform installation in the reverse order to 3 Front floor frame mounting bolt (44):
removal. 235 to 285 Nm {23.5 to 7.5 kgm}
[*1] q Refilling with fuel (Fuel tank)

5
a Install the turnbuckle of brake rod (6). For Fuel tank (diesel fuel):
detail, see Testing and adjusting, ADJUSTING
BRAKE PEDAL. 415 liters
[*2] (For details, see LIST OF LUBRICANT AND
a Install parking brake cable (10). For detail, see WATER)
Testing and adjusting, ADJUSTING PARKING
BRAKE LEVER. q Checking for fuel leakage (fuel system)
[*3] Check the fuel system for leakage. For details,
a How to install harness connectors CN-PL1 (11) see Testing and adjusting, CHECKING FUEL
and CN-FD1 (12) SYSTEM FOR LEAKAGE.
1) Check that the seal is installed to the plug
correctly. q Bleeding air (fuel system)
2) Check that the key is matched to the Bleed air from the fuel circuit. For details, see
groove on the receptacle side. Testing and adjusting, BLEEDING AIR FROM
3) Match the connector on the plug side FUEL CIRCUIT.
straight with the receptacle (since the seal
is projected), and fit the connector a little
while checking that the seal does not roll
up.
4) Tighten the hexagonal socket head cap
screw at the center of the connector by 2
to 3 turns.
5) Fit the connector on the plug side fully and
adjust it so that the clearance between it
and receptacle will be even when viewed
from each direction.
6) Tighten the lock bolt to the specified
torque.
3 Hexagonal socket head cap screw
(4 mm):
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
a Tightening too strongly can break the
lock bolt. So be careful.
D65EX, PX, WX-16 50-700 13

SEN05116-01 Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of operator’s cab glass (Stuck glass) 1
a Among the panes of window glass of the oper- (1): Trim seal
ator’s cab, the 3 panes of (3), (4), (5) and (6) (2): Both-sided adhesive tape
on both sides are stuck. (3): Front window glass
In this section, the procedure for replacing the (4): Rear window glass
stuck glass is explained. (5): Right door window glass
(6): Left door window glass
50-700 14 D65EX, PX, WX-16

Removal and installation of operator’s cab glass (Stuck glass) SEN05116-01
Special tools a If the window glass is broken finely, it may be

removed with knife [4] and a screwdriver.
New/remodel
a Widening the cut with a screwdriver, cut the
Necessity
Symbol
Sketch
adhesive and both-sided adhesive tape with
Q’ty
Part No. Part name
knife [4].
(The following figure shows the operator’s cab
of a wheel loader.)
X 1 793-498-1210 Lifter (Suction cup) t 2
Removal
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (6) and operator’s cab
(metal sheet) (7).
2. Remove the window glass.
a If a seal cutter is not available, make holes on

the adhesive and both-sided adhesive tape
with a drill and pass a fine wire (piano wire,
etc.) [2] through the holes. Grip the both ends
of the wire with pliers [3], etc. (or hold them by
winding them onto something) and move the
wire to the right and left to cut the adhesive
and both-sided adhesive tape.
Since the wire may be broken by the frictional
heat, apply lubricant to it.
(The following figure shows the operator’s cab
of a wheel loader.)
D65EX, PX, WX-16 50-700 15

Installation a Do not remove the release tape of the

1. Using a knife and scraper [5], remove the both-sided adhesive tape on the glass
remaining adhesive and both-sided adhesive sticking side before sticking the glass.
tape from the metal sheets (glass sticking sur- a When sticking the both-sided adhesive
faces) of the operator’s cab. tape, do not touch the cleaned surface as
a Remove the adhesive and both-sided long as possible.
adhesive tape to a degree that they will a Take care that the both-sided adhesive
not affect adhesion of the new adhesive. tape will not float at each corner of the
Take care not to scratch the painted sur- window frame.
faces. a Do not lap the finishing end of both-sided
(If the painted surfaces are scratched, adhesive tape (3) over the starting end.
adhesion will be lowered.) Connect the finishing end (a).
(The following figure shows the operator’s
cab of a wheel loader.)
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (7) and window glass (8) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
3. Stick both-sided adhesive tape (3) along the

inside edges of the front window glass sticking
section and both door window glass sticking
sections.
50-700 16 D65EX, PX, WX-16

4. Position the new window glass. 5. Apply adhesive.

1) Using tool X1, set the window glass to the 2 Adhesive:
sticking position. Check the clearance Sikaflex 256HV manufactured by Sika
between the window glass and the opera- Japan
tor’s cab on the right, left, upper, and lower a Do not use primer.
sides, and then adjust it evenly. a The using limit of the adhesive is 6 months
a Position front window glass (1) from after the date of manufacture. Do not use
inside of operator’s cab (7). Adjust it the adhesive after this limit.
so that the difference between black a Keep the adhesive in a dark place where
coated part and the metal sheet of the temperature is below 25ºC.
operator’s cab (7) will be even on the a Never heat the adhesive higher than 30ºC.
right, left, upper, and lower sides. a When reusing the adhesive, remove the
a When positioning each door window all hardened part from the nozzle tip.
glass (2), adjust the door window
glass so that the positional relation- 1) Break aluminum seal (11) of the outlet of
ship between it and door metal sheet adhesive cartridge (10) and install the
will be even all around the window. nozzle.
2) After positioning the glasses, stick tapes
[6] between front window glass (1) and
operator’s cab (7) and the right, left, and
lower parts of each door window glass (2)
and each door (9), and then draw position-
ing line (e).
3) Cut the tapes between window glasses (1)
and (2) and operator’s cab (7) with a knife,
and then remove the window glasses.
a Do not remove the tapes left on the
window glasses and operator’s cab
before installing the window glasses.
2) Cut the tip of the adhesive nozzle (12) so

that dimensions (f) and (g) will be as fol-
lows.
q Dimension (f): 10 mm
q Dimension (g): 15 mm
D65EX, PX, WX-16 50-700 17

3) Set adhesive cartridge (10) to caulking

gun [7].
a An electric caulking gun is more effi-
cient.
a Apply adhesive (13) to dimensions (h) and (j)

of both-sided adhesive tape (3) of operator’s
cab (7).
q Dimension (h): 10 mm
4) Remove release tape of the both-sided q Dimension (j): 15 mm
adhesive tape (3a) on the glass side. a Apply adhesive (13) higher than both-sided
adhesive tape (3).
a Apply the adhesive evenly.
5) Apply adhesive (13) to the outside of both-

sided adhesive tape (3) of the operator’s
cab.
50-700 18 D65EX, PX, WX-16

6. Install the front window glass. 8. Fix the window glasses.

1) Using tool X1, match front window glass 1) Using styrene foam blocks [10] and rubber
(1) to line (e) on positioning tapes [6] bands [11], fix the front window glass to fit
drawn in step 5 and install it to operator’s it completely.
cab (7). a You may use sealing tapes to fix the
a Since the window glass cannot be front window glass.
removed and stuck again, stick it very (The figure shows the operator’s cab of a
carefully. hydraulic excavator.)
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking the window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
9. After installing the window glasses, remove the

primer and adhesive from them and the opera-
tor’s cab.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glasses, do not give an
impact to them.
7. Install both door window glasses.
1) Using tool X1, match both door window 10. Protect the stuck window glasses.
glasses (2) to lines (e) on positioning 1) Keep the stopper rubbers, styrene foam
tapes [6] drawn in step 5 and install them blocks, and rubber bands installed for 10
to both doors (9). hours (at temperature of 20ºC and humid-
a Since the window glass cannot be
ity of 65%).
removed and stuck again, stick it very
2) After applying the adhesive, wait for at
carefully.
least 24 hours, before operating the
a Stick the glass within 5 minutes after
applying the adhesive. machine actually.
2) After sticking each window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of each window
glass firmly.
D65EX, PX, WX-16 50-700 19

SEN05116-01 Removal and installation of air conditioner unit assembly
Removal and installation of air 4. Open right and left doors (1) of the ROPS cab
conditioner unit assembly 1
and lock them.
Removal
a Never release the refrigerant (R134a) to 5. Lift off operator seat assembly (2).
the atmosphere.
k If the refrigerant (R134a) gets inside 4 Operator seat assembly (2): 50 kg
ones eyes, it may cause blindness. a Since a crane cannot be used inside the
Therefore, make sure to wear protec- ROPS cab, use a bar etc. to lift off opera-
tive glasses when collecting or filling tor seat assembly (2).
person.


undercover.

6 Radiator: 36 l
6. Remove covers (3), (4), and (5) from the inside
of the ROPS cab.
7. Reverse cover (5) and disconnect CN-CBACC

(7) and CN-CBCIG (6).
50-700 20 D65EX, PX, WX-16

Removal and installation of air conditioner unit assembly SEN05116-01
10. Remove right armrest (10).
11. Remove internal air filter (11).

a Remove this filter to prevent damage to it
when cover (13) is removed.
12. Remove covers (12) and (13).
8. Remove cover (8) and air duct (9).
13. Remove air ducts (14) and (15).
9. Remove air duct (9a).
14. Disconnect 2 air conditioner heater hoses (16)

and 2 refrigerant tubes (17).
D65EX, PX, WX-16 50-700 21

SEN05116-01 Removal and installation of air conditioner unit assembly
15. Open battery cover (18) on the left side of the 20. Remove 4 mounting bolts (25).
machine and lock it.
a Lock the doors securely. 21. Remove air conditioner unit assembly (26).
16. Remove the 2 mounting bolts and external air

duct adapter (19).
17. Disconnect wiring harness connectors CN-

AC01 (20) and CN-AC02 (21).
18. Remove air conditioner controller (22) and

bracket (23) together.
a Place air conditioner controller (22) and
bracket on the air conditioner unit.
50-700 22 D65EX, PX, WX-16

Removal and installation of air conditioner unit assembly SEN05116-01

5
a When installing the air conditioner hoses, take Radiator (Engine coolant): 36 l (For
care that dirt, dust, water, etc. will not enter details, see “Table of fuel, coolant
them. and lubricants”.)
deterioration.
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm}
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}

ant (R134a).

compressor oil”.
D65EX, PX, WX-16 50-700 23

SEN05116-01 Removal and installation of air conditioner compressor assembly
Removal and installation of air

conditioner compressor
assembly 1
a In this section, only the precautions for install-

i n g t h e a i r c o n d i t io n e r c o m p r e s s o r a r e
described.
Installation
1. Install air conditioner compressor assembly (1)
with 4 mounting bolts (2).
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
k If mounting bolts (2) are tightened too
strongly, the inside of the air condi-
tioner compressor may be broken.
Accordingly, observe the tightening
torque strictly.
50-700 24 D65EX, PX, WX-16

Removal and installation of air conditioner compressor assembly SEN05116-01
D65EX, PX, WX-16 50-700 25

SEN05116-01

©2011 KOMATSU
All Rights Reserved
50-700 26
SEN05117-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up

Removal and installation of monitor panel assembly ...................................................................................... 2
Removal and installation of engine controller assembly ................................................................................. 4
Removal and installation of power train controller assembly .......................................................................... 6
Removal and installation of KOMTRAX terminal assembly ............................................................................ 8
D65EX, PX, WX-16 50-800 1

SEN05117-00 Removal and installation of monitor panel assembly
Removal and installation of

monitor panel assembly 1
Removal

and lock them.
5. Remove 2 mounting bolts (5) each on the right
and left sides.
6. Take out monitor panel assembly (6) and

reverse it.
2. Remove dashboard upper cover (2) and

reverse it.
3. Disconnect wiring harness connector CN-SLS

(3) from upper cover (2).
4. Remove cover (4). nectors from monitor panel assembly (6).
(7): CN-GPS
(8): CN-KEY
(9): CN-CM02
(10): CN-CM01
(11): CN-LMD
(12): CN-CM03
50-800 2 D65EX, PX, WX-16

Removal and installation of monitor panel assembly SEN05117-00
8. Remove 4 mounting bolts (13) and separate q Monitor assembly (15)

bracket (14) and monitor panel assembly (15).

RLSW (16) and CN-FLSW (17).
a If bracket (14) and monitor panel assem-
bly (15) are not separated, wiring harness
connectors RLSW (16) and CN-FLSW
(17) cannot be disconnected.
10. Remove bracket (14) and monitor assembly

(15).
Installation
removal.
a Before installing the monitor panel assembly,
remove dirt etc. sticking to the wiring harness
connectors.
q Bracket (14)
D65EX, PX, WX-16 50-800 3

SEN05117-00 Removal and installation of engine controller assembly

engine controller assembly 1
Removal CE03 (5), CN-CE01 (6) and CN-CE02 (7).
k Stop the machine on a level place and a To disconnect wiring harness connectors
apply the parking brake. CN-CE01 (6) and CN-CE02 (7), loosen
k Lower the work equipment to the ground the hexagon socket head bolts (4 mm) at
and stop the engine. their centers. [*1]
1. Open left engine side cover (1) and lock it.

6. Remove 5 mounting bolts (8) and engine con-

troller assembly (9).
3. Remove air conditioner hose clamp (3).
50-800 4 D65EX, PX, WX-16

Removal and installation of engine controller assembly SEN05117-00
Installation
removal.
a Before installing the engine controller assem-
bly, remove dirt etc. sticking to the wiring har-
ness connectors.
[*1]
3 Hexagon socket head bolts (4 mm) at cen-
ters of wiring harness connectors CN-CE01
(6) and CN-CE02 (7):
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
D65EX, PX, WX-16 50-800 5

SEN05117-00 Removal and installation of power train controller assembly
Removal and installation of power 3. Remove cover (3) at the left inside the ROPS
train controller assembly 1
cab.
Removal

and lock them.

STC3 (4), CN-STC2 (5) and CN-STC1 (6).
a To disconnect wiring harness connectors
CN-STC3 (4), CN-STC2 (5) or CN-STC1
(6), loosen the hexagon socket head bolts
(4 mm) at their centers. [*1]
5. Remove the 4 mounting bolts and power train

controller assembly (7).
2. Lift off operator seat assembly (2).

4 Operator seat assembly (2): 50 kg
50-800 6 D65EX, PX, WX-16

Removal and installation of power train controller assembly SEN05117-00
Installation
removal.
a Before installing the power train controller
assembly, remove dirt etc. sticking to its wiring
harness connectors.
[*1]
3 Hexagon socket head bolts (4 mm) at cen-
ters of wiring harness connectors CN-STC3
(4), CN-STC2 (5) and CN-STC1 (6):
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
D65EX, PX, WX-16 50-800 7

SEN05117-00 Removal and installation of KOMTRAX terminal assembly
Removal and installation of 3. Remove covers (3), (4), and (5) from the inside
KOMTRAX terminal assembly 1
of the ROPS cab.
Removal 4. Reverse cover (5) and disconnect CN-CBACC

k Stop the machine on a level place and (7) and CN-CBCIG (6).

and lock them.
2. Lift off operator seat assembly (2).

4 Operator seat assembly (2): 50 kg
5. Remove covers (8), (9), (10) and (11).
50-800 8 D65EX, PX, WX-16

Removal and installation of KOMTRAX terminal assembly SEN05117-00
6. Remove 4 mounting bolts (12) and remove Installation

and reverse KOMTRAX terminal assembly q Carry out installation in the reverse order to
(13). removal.
a Before installing the KOMTRAX terminal
assembly, remove dirt etc. sticking to its wiring
harness connectors.

CK02 (14), CN-CK01 (15) and CN-AT21 (16).
8. Remove KOMTRAX terminal assembly (13).
D65EX, PX, WX-16 50-800 9

SEN05117-00

©2009 KOMATSU
All Rights Reserved
50-800 10
SEN05041-00
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
80 Appendix 80
100 Air conditioner

Structure and function ..................................................................................................................................... 4
Air conditioner component ....................................................................................................................... 4
Configuration and function of refrigerating cycle ..................................................................................... 6
Outline of refrigerating cycle .................................................................................................................... 7
Air conditioner unit ................................................................................................................................. 10
Control plate .......................................................................................................................................... 14
Compressor ........................................................................................................................................... 15
Condenser ............................................................................................................................................. 16
Receiver drier ........................................................................................................................................ 17
Testing, adjusting and troubleshooting.......................................................................................................... 18
Caution about refrigerant ....................................................................................................................... 18
Troubleshooting procedure .................................................................................................................... 19
Block diagram ........................................................................................................................................ 20
Circuit diagram and arrangement of connector pins.............................................................................. 22
Detail of air conditioner unit ................................................................................................................... 24
Parts and connectors arrangement ....................................................................................................... 26
Testing air leakage (duct)....................................................................................................................... 32
Testing with self-diagnosis function ....................................................................................................... 34
Testing temperature control ................................................................................................................... 37
Testing vent (mode) changeover ........................................................................................................... 39
Testing Recirc/Fresh changeover .......................................................................................................... 42
Testing inner sensor............................................................................................................................... 43
Testing evaporator temperature sensor ................................................................................................. 44
D65EX, PX, WX-16 80-100 1

100 Air conditioner
SEN05041-00
Testing sunlight sensor .......................................................................................................................... 47

Testing (dual) pressure switch for refrigerant......................................................................................... 48
Testing relays and diodes ...................................................................................................................... 50
Troubleshooting chart 1 ......................................................................................................................... 52
Troubleshooting chart 2 ......................................................................................................................... 53
Troubleshooting for electrical system (E mode)..................................................................................... 56
E-1 Power supply system (Air conditioner does not operate)......................................................... 57
E-2 Compressor and refrigerant system (Air is not cooled)............................................................ 60
E-3 Blower motor system (No air comes out or air flow is abnormal)............................................. 63
E-4 Temperature cannot be controlled............................................................................................ 66
E-5 Vent (mode) cannot be changed over ...................................................................................... 68
E-6 Recirc/Fresh air cannot be changed over ................................................................................ 70
Troubleshooting with gauge pressure .................................................................................................... 72
Connection of service tool...................................................................................................................... 75
Precautions for connecting air conditioner piping .................................................................................. 76
Handling of compressor oil .................................................................................................................... 77
1. Control of compressor oil (Denso: ND-OIL8: For R134a) ......................................................... 77
2. Adding of compressor oil .......................................................................................................... 77
3. Compressor replacement.......................................................................................................... 78
4. Applying compressor oil for O-ring............................................................................................ 78
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100 Air conditioner
SEN05041-00
D65EX, PX, WX-16 80-100 3

100 Air conditioner
Structure and function
SEN05041-00 Air conditioner component
Structure and function 1
Air conditioner component
1. Condenser Specifications
2. Hot water return piping Refrigerant R134a
3. Hot water piping
4. Air conditioner compressor Refrigerant refilling level (g) 900 ± 50
5. Refrigerant piping
6. Receiver drier
7. (Dual) pressure switch
8. Air conditioner unit
9. Control amplifier (CNTAMP)
10. Recirculated air filter
11. Fresh air filter
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100 Air conditioner
Air conditioner component SEN05041-00
A. Front window and door window defroster

B. Air outlet for face
C. Air outlet for center
D. Air outlet for rear
E. Air outlet for foot
D65EX, PX, WX-16 80-100 5

100 Air conditioner
SEN05041-00 Configuration and function of refrigerating cycle
Configuration and function of refrigerating cycle

Component
Compressor Condenser Expansion valve Evaporator
Item
In operator’s cab In operator’s cab
Location Engine compartment Front of radiator
(In air conditioner unit) (In air conditioner unit)
Circulates refrigerant Condenses refrigerant Lowers temperature and Evaporates refrigerant
gas and increases its to discharge heat pressure of refrigerant to absorb heat from (or
temperature and absorbed in evaporator. liquid and gas for easy cool) air around
pressure so that it can evaporation with throttle. evaporator.
Function be liquefied easily in Controls flow rate, too.
condenser.
(Compression of (condensation of (Throttle of refrigerant) (Evaporation of

refrigerant) refrigerant) refrigerant)
Gas o Liquid Liquid and gas o Gas
State of Gas o Gas Liquid o Liquid and gas
Constant pressure Constant pressure
refrigerant Adiabatic compression Adiabatic expansion
change change
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100 Air conditioner
Outline of refrigerating cycle SEN05041-00
Outline of refrigerating cycle

The refrigerating cycle performs the following four 3. Expansion (Expansion valve)
actions. The refrigerant is liquefied and gasified The pressure of the refrigerant liquid is low-
repeatedly while it is circulated in the cycle. ered by the restricting action [*1] of the expan-
sion valve to a level at which the refrigerant is
1. Compression (Compressor) evaporated easily.
The refrigerant gas is compressed by the com- The action to lower the pressure of the refriger-
pressor to the state where it can be liquefied ant to a level at which the refrigerant is evapo-
easily at the normal temperature (ambient tem- rated easily before the refrigerant is sent to the
perature). evaporator is called expansion.
The refrigerant evaporated in the evaporator is The expansion valve which performs this
sucked into the compressor. action also controls the flow rate of the refriger-
This action is performed to keep the refrigerant ant.
pressure in the evaporator low so that the In other words, the quantity of the refrigerant
refrigerant liquid can continue evaporation liquid evaporated in the evaporator is decided
actively even if the ambient temperature is by the quantity of heat to be removed (refriger-
close to 0°C. ation load) at the specified evaporation tem-
The refrigerant gas sucked into the compres- perature (evaporation pressure), and the
sor is compressed in the cylinder and its pres- expansion valve senses it and controls the
sure and temperature are so changed that is refrigerant flow rate properly.
can be liquefied easily when it is cooled with
the external air at the normal temperature. [*1] Restricting action
If there is a suddenly narrowed part in a pipe in
2. Condensation (Condenser) which a liquid is flowing, there is resistance to
The refrigerant gas in the condenser is cooled the flow. Since the sectional area is increased
to be liquefied with the external air. suddenly through this part, the liquid expands
The refrigerant gas of high temperature and suddenly and its pressure and temperature
high pressure discharged from the compressor lower. No heat is exchanged between the
is cooled to be liquefied with the external air inside and outside of the pipe during this
and then stored in the receiver drier. action.
The heat discharged from the refrigerant of
high temperature and high pressure dis-
charged from the compressor is called the con-
densation heat, which is the total of the heat
that the refrigerant absorbed from the opera-
tor’s cab through the evaporator (vaporization
heat) and the work performed to compress the
refrigerant (the value converted into heat).
During condensation, the refrigerant gas and
refrigerant liquid are mixed together in the con-
denser. While the refrigerant gas changes to
the refrigerant liquid, the relationship between
the pressure (condensation pressure) and
temperature (condensation temperature) is
kept constant.
Reference: The pressure varies with the

type of refrigerant and the con-
densation temperature.
D65EX, PX, WX-16 80-100 7

100 Air conditioner
SEN05041-00 Outline of refrigerating cycle
4. Evaporation (Evaporator) q Receiver drier

The refrigerant changes from liquid to gas The refrigerant liquefied in the condenser is
(superheated vapor) in the evaporator. reserved in the receiver drier temporarily so
The refrigerant mist in the evaporator evapo- that it can be supplied to the evaporator
rates actively. according to the cooling load. A strainer and a
At this time, the refrigerant evaporates quickly, drying agent are sealed in the receiver drier to
absorbing heat necessary for evaporation remove “dirt” and “water” in the refrigerating
(latent heat of vaporization) from the air around cycle.
the cooling fins (air in the operator’s cab). The If any water is in the refrigerating cycle, it is fro-
cooled air is spread in the operator’s cab by zen in the small hole of the expansion valve
the fan to lower the temperature in the opera- and retards the flow of the refrigerant.
tor’s cab. It can cause a cooling trouble.
The refrigerant mist sent through the expan-
sion valve and the evaporated refrigerant are
mixed together in the evaporator. While the
refrigerant liquid changes to the refrigerant
gas, the relationship between the pressure
(evaporation pressure) and temperature (evap-
oration temperature) is kept constant. If the
pressure is set, the temperature is decided
automatically.
That is, the relationship between the above
pressure and temperature is equal to the rela-
tionship between saturation pressure and satu-
ration temperature.
To evaporate the refrigerant at lower tempera-
ture, the pressure in the evaporator must be
kept lower.
Accordingly, the evaporated refrigerant is
sucked into the compressor.
The refrigerant circulates in the refrigerating
cycle, repeating the above four actions, to
move the heat from the operator’s cab where
the temperature is low to the outside where the
temperature is high.
If the amount of the refrigerant is insufficient,
all of the refrigerant is evaporated while it is
passing through the evaporator and the evapo-
rator capacity decreases. It can cause a cool-
ing trouble.
To the contrary, if the amount of the refrigerant
is too much, a part of it is not evaporated in the
evaporator and is absorbed in the compressor.
As a result, the compressor compresses the
liquid and may be broken.
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100 Air conditioner
Outline of refrigerating cycle SEN05041-00
D65EX, PX, WX-16 80-100 9

100 Air conditioner
SEN05041-00 Air conditioner unit
Air conditioner unit

a This air conditioner unit is auto temperature control type.
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100 Air conditioner
Air conditioner unit SEN05041-00
1. Evaporator q Air flow adjustment

2. Heater core The machine monitor sends air flow data to the
3. Fan (Blower) control amplifier according to the air flow
4. Cool door adjustment switch.
5. Hot door The control amplifier controls fan (blower) (3)
6. Sub hot door speed and adjust the air flow with the power
7. Foot door transistor (PTR).
8. Defroster door
9. Front face door q Vent (mode) changeover
10. Rear face door The machine monitor sends mode data to the
11. Box control amplifier according to the vent selector
12. Inside air temperature (inner) sensor (mode) switch.
13. Evaporator temperature sensor The control amplifier controls the blowing out
(mode) servomotor (MODES) to adjust the
Fu5A: Fuse (5A) angles of the foot door (7), defroster door (8),
PTR: Power transistor front door (9) and rear door (10) for vent
A/MS: Air mix servomotor changeover.
MODES: Air outlet (mode) servomotor
R/FS: FRESH/RECIRC changeover servomotor q Changeover of FRESH/RECIRC air
EXPV: Expansion valve FRESH/RECIRC air data are sent to the con-
trol amplifier by operating the FRESH/RECIRC
selector switch. The control amplifier opens
Outline and closes the door in box (11) by controlling
q The air conditioner unit consists of the evapo- FRESH/RECIRC changeover servomotor (R/
rator (1), heater core (2) and fan (blower) (3) FS).
and generates cool air and hot air.
q Automatic air conditioner
q Temperature control The inner temperature sensor (12) senses the
The machine monitor sends temperature set- room temperature by the change of resistance.
ting data to the control amplifier (See “Control The control amplifier converts the change of
plate”) according to the temperature control resistance of the inner temperature sensor (12)
switch operation. into a change of voltage and detects the room
The control amplifier controls the air mix servo- temperature by the change of voltage.
motor (A/MS) to adjust the angle of the cool The control amplifier checks the inner air tem-
door (4), hot door (5) and sub hot door (6) for perature sensor (12) voltage so that the room
temperature control. temperature will be kept at the temperature set
with the machine monitor.
q Over-cooling (Freezing) prevention
The evaporator temperature sensor (13) a The 5 A fuse (Fu5A) for the air conditioner unit
senses temperature of evaporator (1) by the is installed to the wiring harness.
change of resistance. The control amplifier a The door is the same as the damper.
converts the change of resistance of the evap-
orator temperature sensor (13) into a change
of voltage and detects the temperature of Functions of major components
evaporator (1) by the change of voltage. q Evaporator (1)
The control amplifier turns OFF the compres- Fins of evaporator (1) are cooled by low-pres-
sor clutch relay so that the evaporator (1) will sure, low-temperature refrigerant gas being
not be frozen. sent from the expansion valve (EXPV). Air
from the fan (blower) (3) is cooled and dehu-
midified when passing through the fins.
q Heater core (2)

Fins of the heater core (2) are heated by the
hot water (cooling water) being sent from the
engine. Air from the fan (blower) (3) is heated
as it passes through the fins.
D65EX, PX, WX-16 80-100 11

100 Air conditioner
SEN05041-00 Air conditioner unit
q Expansion valve (EXPV)
1. Evaporator 1) Structure
2. Diaphragm The box-type expansion valve (EXPV) consists
3. Thermosensing rod of the diaphragm (2), thermosensing rod (3),
4. Needle valve (ball) needle valve (ball) (4), spring (5), etc. The out-
5. Spring side of diaphragm (2) (hatched part) is pre-
6. Refrigerant gas enclosed with refrigerant gas (6).
The spring (5) is installed on the needle valve
EXPV: Expansion valve (ball) (4) side of the thermosensing rod (3).
C: Refrigerant (from receiver) (high pressure) The needle valve (4) opening ratio is decided
D: Refrigerant (to compressor) (low pressure) when the constant force of the spring (5) to
push the ball (4) to the right is balanced with
This valve converts high-pressure, high-tempera- the force (Fg) of the refrigerant gas (6) to push
ture liquid refrigerant coming from the receiver to the thermosensing rod (3) to the left through
low-pressure, low-temperature misty refrigerant the diaphragm (2). As a result, the refrigerant
through the throttling function. flow rate to the evaporator (1) is decided and
It controls the flow rate of the refrigerant by chang- the temperature is controlled.
ing the level of throttling depending on the thermal
load (heat) in the operator's cab. As a result, tem-
perature of the air blown out of the grill is adjusted
depending on the volume of refrigerant circulated in
evaporator (1).
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100 Air conditioner
Air conditioner unit SEN05041-00
2) Operation q Servomotor
The thermosensing rod (3) senses the temper-
ature of the refrigerant which passed the evap-
orator (1). The temperature at this time is
conducted through the thermosensing rod (3)
to the refrigerant gas (6) in the diaphragm
chamber (hatched part).
As the temperature of pre-enclosed refrigerant
gas (6) changes, the gas pressure changes
and pressing force (Fg) also changes. The
thermosensing rod (3) attached directly to the
diaphragm (2) so moves that the constant
force of the spring (5) to push the ball (4) will
be balanced with variable force (Fg) to adjust
the needle valve (4) opening ratio.
a This servomotor is used for temperature con-
A When the evaporator (1) outlet temperature is trol (AIR MIX) and blowing out (MODE).
high (at start of cooling (air is not cooled yet))
The gas (6) pressure in the diaphragm cham- 1. If the switch on the control panel is operated,
ber increases and the gas volume increases. the control amplifier supplies 24 V power
Pushing force (Fg) of the refrigerant gas (6) across (6) and (7). (The rotation direction
increases and the thermosensing rod (ball) (3) changes according to the polarities of the sup-
moves to the left and the needle valve (4) plied power.)
opens wide. Much refrigerant is supplied to the
evaporator (1) and the cooling capacity 2. There is a variable resistor in the servomotor
increases. and its resistance varies with the angle of the
motor shaft. The control amplifier applies 5 V
B When the evaporator (1) outlet temperature is voltage to both ends of this variable resistor
low (during cooling (air is cooled already)) and judges the rotation angle of the motor by
The gas (6) pressure in the diaphragm cham- the potential difference (PT).
ber decreases and the gas volume decreases. When the door (damper) comes to the position
Since pushing force (Fg) of the refrigerant gas set with each switch, the control amplifier stops
(6) is small, the thermosensing rod (ball) (3) supplying the power to the servomotor.
moves to the right and the needle valve (4) is a Do not apply the power directly to the
narrowed. Accordingly, refrigerant supply and motor terminal to drive the motor because
the cooling capacity decrease. the motor output shaft is damaged or the
motor coil is broken.
3. If the potential difference (PT) does not reach

the voltage set for the servomotor control, the
control amplifier notifies the error to the
machine monitor.
Then, the letters of “A/C Controller Error” are
displayed red on the air conditioner operation
screen of the machine monitor.
a The Recirc/Fresh changeover servomotor
does not have this potential difference
(PT). Accordingly, it does not have the
self-diagnosis function.
D65EX, PX, WX-16 80-100 13

100 Air conditioner
SEN05041-00 Control plate
Control plate Functions of main component parts

q Control amplifier (CNTAMP) (1)
1) Communicates with the machine monitor
through CAN communication system and
controls the air conditioner unit with the
switch inputs related to the air conditioner.
2) Controls the three servomotors in the air
conditioner unit to adjust the temperature,
changeover the vent (mode), and
changeover the recirculated air or fresh
air.
3) Turns ON and OFF blower main relay
(switch to blow air) and compressor clutch
relay (switch to operate the compressor).
See item 8 in “Part and connector loca-
tions”.
a Control amplifier (CNTAMP) (1) con-
trols compressor clutch relay on the
basis of following three (input) data.
1] “A/C” switch or “AUTO” switch on the
machine monitor
2] Evaporator temperature sensor
3] (Dual) pressure switch
4) Has the self-diagnosis function. If any
abnormality is detected, the control ampli-
fier notifies it to the machine monitor by
the CAN communication.
Then, the letters of “A/C Controller Error”
are displayed red on the air conditioner
operation screen of the machine monitor.
1. Control amplifier (CNTAMP) 5) Adjusts the room temperature to the set
temperature on the basis of the data of the
A/C U: Air conditioner unit sunlight sensor and inner air sensor in the
AC01: Intermediate connector to air conditioner automatic air conditioner mode.
control amplifier (CNTAMP)
(GND, sunlight sensor, pressure switch,
connectors for relay)
AC02: Intermediate connector to air conditioner
control amplifier (CNTAMP)
(24 V, CAN communication with machine
monitor)
Fu5A: Fuse for control amplifier (CNTAMP) and
air conditioner unit (A/C U)
80-100 14 D65EX, PX, WX-16

100 Air conditioner
Compressor SEN05041-00
Compressor
A: Refrigerant inlet port from air conditioner unit Function

B: Refrigerant outlet port to condenser q Other than circulating the refrigerant, compres-
C: Pulley sor compresses the refrigerant gas from the
D: Relief valve evaporator to a high-pressure, high-tempera-
ture misty refrigerant so that it may be easily
regenerated (liquefied) at normal temperature.
q The magnetic clutch in the compressor is
engaged depending on the evaporator temper-
ature and refrigerant pressure.
If the magnetic clutch is engaged, the shaft in
the compressor rotates to operate the com-
pressor.
Specifications
Piston capacity (cc/rev) 157.3
Allowable maximum speed

6,000
(rpm)
Denso: ND-OIL8
Refrigerant oil used
(For R134a)
Refrigerant oil refilling volume
180
(cc)
D65EX, PX, WX-16 80-100 15

100 Air conditioner
SEN05041-00 Condenser
Condenser
1. Condenser Function
Condenser (1)
A: Refrigerant inlet from compressor q Condenser cools and liquefies the high-pres-
B: Refrigerant outlet to receiver drier sure, high-temperature misty refrigerant from
the compressor.
a If the fins are crushed or clogged with dirt, heat

exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As a result, pressure in the refrigerant cir-
culation circuit will be increased, applying extra
load to the engine or degrading the cooling
effect. Thus, care must be used in its handling
and daily inspection.
Specifications
Fin pitch (mm) 4.0
Height × Width × Thickness 350 × 570 × 16
Max. pressure used

3.6 {36}
(MPa {kg/cm2})
80-100 16 D65EX, PX, WX-16

100 Air conditioner
Receiver drier SEN05041-00
Receiver drier
1. Receiver drier (Dual) pressure switch (2)

2. (Dual) pressure switch a Connector is AC05
3. Sight glass q If abnormally low or high pressure is generated
in the refrigerant circulation circuit, the (dual)
A: Refrigerant inlet from condenser pressure switch is turned “OFF”. (it is normally
B: Refrigerant outlet to air conditioner unit turned “ON”.) When the (dual) pressure switch
become “OFF”, the control amplifier turns the
Function compressor clutch relay “OFF”. So the mag-
Receiver drier (1) netic clutch of the compressor is disengaged
q It is used to store liquefied high-pressure, high- and the devices related to the air conditioner
temperature misty refrigerant from the con- are protected.
denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspection of the refriger-
ant flow.
Even if 5 minutes elapsed after engine start up
and turning ON of A/C switch, when bubbles
are seen through sight glass (1), the amount of
the refrigerant is insufficient.
LA: 0.20 MPa {2 kg/cm2}
If the amount of the refrigerant is proper, no
LB: 0.02 MPa {0.2 kg/cm2}
bubbles are seen there.
HA: 3.14 MPa {32 kg/cm2}
a If there is no (or excessive) refrigerant in the
HB: 0.59 MPa {6 kg/cm2}
refrigerating cycle, no bubbles are seen
through sight glass (1), too.
Specifications
Capacity (cc) 370
D65EX, PX, WX-16 80-100 17

100 Air conditioner
Testing, adjusting and troubleshooting
SEN05041-00 Caution about refrigerant
Testing, adjusting and troubleshooting 1
Caution about refrigerant

k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit before
disconnecting air conditioner hose to
replace air conditioner unit, air conditioner
compressor or receiver drier and so on.
a Ask a qualified shop for collecting, adding
and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. And if it touches
your skins, you may suffer from frostbite.
Accordingly, put on protective goggles,
gloves and working suits with long sleeves
while you are collecting the refrigerant
(R134a) or filling the air conditioner circuit
with the refrigerant (R134a). Collecting and
filling work must be conducted by a quali-
fied person.
q Refrigerant (R134a) filling up quantity:
900 g ± 50 g
80-100 18 D65EX, PX, WX-16

100 Air conditioner
Troubleshooting procedure SEN05041-00
Troubleshooting procedure
The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function,
you can inspect the operation of sensors and servomotors in the system.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Find the troubled section with the self-diagnosis function (See “Inspection with self-diagnosis”).
If the air conditioner unit does not operate at all, check that the power supplied to the control amplifier is
normal and that CAN communication between machine monitor and the control amplifier is normal.
If any part of the air conditioner unit operates, the power supply and CAN communication do not need to
be checked.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic flow of troubleshooting
Occurrence of trouble:
Examination,
confirmation of failure
1. Battery voltage (24 V)
2. Tension of compressor belt
Basic check 3. Oil stain at air conditioner hose joints (*2)
4. Abnormal sound check (*3)
Compressor, blower motor and air conditioner
hose (clamp)
E-1 Power supply system (Air

operate? conditioner does not operate)
Inspection with self-diagnosis

function (*1) and with each switch
Troubleshooting with
Troubleshooting with E mode
troubleshooting chart 1
Troubleshooting with gauge

pressure
Inspection with
troubleshooting chart 2
*1: By error display or abnormal display on “Abnormality Record” screen on machine monitor.
*2: If refrigerant leaks, recirculating compressor oil in the air conditioner circuit always leaks, too.
*3: Start engine and then air conditioner switch ON.
D65EX, PX, WX-16 80-100 19

100 Air conditioner
SEN05041-00 Block diagram
Block diagram
a This air conditioner unit is auto temperature control type.
80-100 20 D65EX, PX, WX-16

100 Air conditioner
Block diagram SEN05041-00
q Input and output signals of control amplifier (CNTAMP)

Connector on controller side: AMP 040-36PM
Connector on wiring harness side: [1], [2]
[1] AMP 040-16PF [2] AMP 040-20PF
Input Input
Pin Symbol Signal name and Pin Symbol Signal name and
No. output No. output
Input/
1 — — — 17 CAN H CAN communication + Output
2 A/M PA/M servo potentiometer Input 18 CAN L CAN communication – Input/
voltage Output
Servo potentiometer 5V power Recirculated air and fresh air
3 POT 5V supply Output 19 R/F A servo terminal A Output
(Dual) pressure switch Recirculated air and fresh air
4 PRESS SW (Refrigerant pressure) Input 20 R/F B servo terminal B Output
5 — — — 21 A/M A A/M servo terminal A Output
6 +24 V Power supply Input 22 A/M B A/M servo terminal B Output

Blowing out (mode) servo
7 BLOW F/B Blower feedback signal Input 23 MODE A terminal A Output
8 PTR B Power transistor control signal Output 24 MODE B Blowing out (mode) servo Output
terminal B
Blowing out (mode) servo
9 MODE P potentiometer voltage Input 25 — — —
10 — — — 26 — — —
11 THI Inner air temperature sensor Input 27 GND S Sensor GND Input
12 THEVA Evaporator temperature sensor Input 28 — — —
13 — — — 29 — — —
14 — — — 30 — — —
15 SS Sunlight sensor Input 31 — — —
16 GND GND Input 32 — — —
33 — — —
34 — — —
35 CCRL Compressor clutch relay Output
36 BLOW RL Blower main relay Output
q A/M: Air mix

q F/B: Feedback
q R/F: Recirculation/Fresh
D65EX, PX, WX-16 80-100 21

100 Air conditioner
SEN05041-00 Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins
80-100 22 D65EX, PX, WX-16

100 Air conditioner
Circuit diagram and arrangement of connector pins SEN05041-00
a INSIDE TEMP. SENSOR means “Inner sensor” on “Abnormality Record” screen: “03 Air-conditioning
System”.
a BLOWING OUT (MODE) SERVOMOTOR means BLOWING OUT (MODE) CHANGEOVER SERVO-
MOTOR.
D65EX, PX, WX-16 80-100 23

100 Air conditioner
SEN05041-00 Detail of air conditioner unit
Detail of air conditioner unit
1. Foot door [8]: Inside air temperature (inner) sensor connector

2. Defroster door [9]: Evaporator temperature sensor connector
3. Front face door
4. Rear face door A: Recirculation air opening
5. FRESH/RECIRC selector door B: Fresh air opening
6. Inside air temperature (inner) sensor
EXPV: Expansion valve
[1], [2]: Control amplifier connector Fu5A: Fuse (5A)
[3]: Blower (fan) motor connector PTR: Power transistor
[4]: Power transistor (PTR) connector A/MS: Air mix servomotor
[5]: Air outlet (mode) servomotor connector MODES: Air outlet (mode) servomotor
[6]: Temperature control (air mix) servomotor R/FS: FRESH/RECIRC changeover servomotor
connector
[7]: FRESH/RECIRC changeover servomotor
connector
80-100 24 D65EX, PX, WX-16

100 Air conditioner
Detail of air conditioner unit SEN05041-00
q Evaporator
Installation location of evaporator temperature sensor
D65EX, PX, WX-16 80-100 25

100 Air conditioner
SEN05041-00 Parts and connectors arrangement
Parts and connectors 3. Move operator seat (3) forward.

arrangement
4. Remove recirculation air filter (4).
a There are 2 fuses. One is in the fuse box and
the other is twisted around the wiring harness
between the air conditioner unit and control
amplifier.
a An air conditioner unit is set up at the lower
rear of the operator seat.
1. Remove cover (1) at the lower left of the oper-

ator seat.
6. Disconnect connectors CBCIG and CBACC

from the back of cover (5).
2. Remove fuse box cover (2).

q FS12-13 (13th fuse from top) (20A): For
power supply to blower (fan) and air con-
ditioner compressor
80-100 26 D65EX, PX, WX-16

100 Air conditioner
Parts and connectors arrangement SEN05041-00
7. Remove covers (6). a Condition with the covers (10) are removed
q A/C U: Air conditioner unit
q CNTAMP: Control amplifier
q [1], [2]: Control amplifier connector
q AC01: Connector to air conditioner unit,
and for connect ground, compres-
sor relay, pressure switch, blower
motor relay and sunlight sensor
q AC02: Connector to air conditioner unit,
and for connect 24V power supply
and CAN communication connec-
tor with machine monitor (com-
mon communication line with
engine controller and power train
controller)
8. Remove cover (7). a CN-N10 connector label is stuck on the air
conditioner unit side.
9. Remove duct (8). q Fu5A: Fuse 5A is installed at the lower
bracket (13).
For power supply to air condi-
tioner unit (including primary side
of relays for blower (fan) and air
conditioner compressor)
q [5]: Air outlet (mode) servomotor
(MODES) connector
q [6]: Temperature control (air mix) ser-
vomotor (A/MS) connector
12. Remove duct (11).
13. Remove rear duct (12).
10. Remove armrest (9). 14. Remove connectors AC01 and AC02.
11. Remove covers (10). 15. Remove bracket (13).
D65EX, PX, WX-16 80-100 27

100 Air conditioner
a Fu5A is installed in the holder. 16. Relay and diode

Fuse part number The relay and diode are installed at the left rear
Fu5A: ND93950-05003 of the operator seat.
q AC03: Blower main relay connector • • •
turning fan motor ON/OFF
q AC04: Compressor clutch relay connector
• • • turning air compressor (clutch)
ON/OFF
q Diode array ACD:
Cutting counter electromotive forces
caused by primary coils of blower
main relay and compressor clutch
relay. Protecting control amplifier
(CNTAMP).
q FD1: Intermediate connector (inside) [*1]
IF: Inside air filter

[3]: Blower (fan) motor connector
[9]: Evaporator temperature sensor connector
17. Pressure switch

a Air conditioner unit bottom Open the engine left cover.
[4]: Power transistor (PTR) connector
[7]: FRESH/RECIRC changeover servomotor From back of P portion
connector q AC05: Pressure switch connector
[8]: Inside air temperature (inner) sensor q RD: Receiver driver
connector q SG: Sight glass
H: Air conditioner unit wiring harness
PTR: Power transistor
80-100 28 D65EX, PX, WX-16

100 Air conditioner
18. Air conditioner compressor 19. Sunlight sensor connector SLS and machine
q ACC: Air conditioner compressor monitor connector CM02 (CAN communication
q A/C: Air conditioner compressor connec- connector)
tor a If machine monitor connector CM02 is dis-
q ACG: Diode connector of air conditioner connected, both engine controller and
compressor power train controller cannot perform the
q GND4: Diode ground CAN communication, and accordingly fail-
ure code: [DAFRMC] is displayed. If the
screen is switched to air conditioner oper-
ation screen, an error message "AIR
CONDITIONER ERROR" will appear on
the screen in red. If the above error is not
displayed, check is not required.
Note:
The message "AIR CONDITIONER
ERROR" displayed on the air conditioner
operation screen is also displayed when
the air outlet cannot be changed, when
temperature control is abnormal or when
the refrigerant pressure switch is turned
OFF.
Open the engine right cover. 1) Remove dashboard cover (14).
q EG2: Intermediate connector of air condi- 2) Disconnect connector (SLS) of sunlight
tioner compressor sensor (S) from the back of cover (14).
q ST: Starting motor

4) Remove bolts (16) and pull the machine
monitor assembly (17) toward near side.
a Since the wiring harness is con-
nected, pull the machine monitor
assembly slowly.
D65EX, PX, WX-16 80-100 29

100 Air conditioner
5) Disconnect connector (LMD) from the clip 2) Open the engine hood.
on the back of machine monitor assembly q DSH: Machine monitor intermediate
(17). connector (outside)
6) Check connectors CM01, CM02, CM03 a Connector DHS is DRC-40, which
and GPS. must be handled with care. [*1]
a CM02 and CM03 can be inserted
inversely. Take care. CM03 is the
green connector.
3) Open cover (19).
20. Intermediate connector

a For up to removal of cover (15), see step
19-1) - 3).
q DSH: Machine monitor intermediate con-
nector (inside)
a Connector DHS is DRC-40, which must be
handled with care. [*1]
4) Disconnect the battery ground cable.

5) Check connector FD1. [*1]
80-100 30 D65EX, PX, WX-16

100 Air conditioner
[*1]
q How to disconnect connectors DSH and FD1
Disconnect the connector straight slowly and
check the seal for breakage, peeling and stick-
ing foreign matter.
a If the seal is damaged, replace it.
q How to connect connectors DSH and FD1

1) Check that the seal is correctly installed to
the plug.
2) Check that the key is positioned to be
matched to the groove of the receptacle
(key is not positioned oppositely).
3) Set the plug connector to the receptacle
straight (since the seal is projected) and fit
it a little, while check that the seal is not
rolled up.
4) Tighten the hexagon bolt at the center of
the connector by 2 – 3 turns.
5) Fit the plug connector to the end and
adjust it so that the clearance between it
and the fitted receptacle will be even when
seen from each direction.
6) Tighten the lock bolt to the specified
torque.
3 Hexagon lock bolt:
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
a If the lock bolt is tightened too
strongly, it will be broken and cannot
lock.
Take care
D65EX, PX, WX-16 80-100 31

100 Air conditioner
SEN05041-00 Testing air leakage (duct)
Testing air leakage (duct) 2) Front left ducts (9)

1. Move operator seat (1) forward. 7. Remove ducts (9).
2. Remove recirculation air filter (2). 8. Remove cover (7).
3. Remove covers (3).
9. Check if the followings are half removed.

1) Front left duct (FLD)
4. Remove armrest (4). 2) Front duct (FD)
3) Rear duct (RFD)
5. Remove covers (5) and (6). 4) Defroster duct (DD)
a Cover (7) will be removed in step 8. q A/C U: Air conditioner unit
10. When air does not come out of ceiling lou-

ver in defroster mode
1) Remove ducts (FLD) and (FD).
6. Check if the followings are half removed.

1) Front right duct (8)
80-100 32 D65EX, PX, WX-16

100 Air conditioner
Testing air leakage (duct) SEN05041-00
2) Check if defroster duct (DD1) (portion P in 4) Remove mirror stay (13).

particular) is half removed. 5) Remove louver (14).
3) Remove defroster duct (DD1) and check if 6) Remove room lamp (15).
air comes out. 7) Remove radio (16).
8) Remove switch panel (17).
9) Remove speaker cover (18).
10) Remove the clip bolts and covers (19) and
(20).
a If air does not come out from

defroster duct (DD1) in the defroster
mode, see "Testing air outlet (mode)
selection".
11. Open the left fender and check fresh air duct
a Since the ceiling duct will not come off, the pro- (21).
cedure for removing the ceiling duct is shown
below for reference.
Reference: Procedure for removing ceiling

1) Remove garnish (10).
2) Remove handle (11).

3) Remove the clip bolt and garnish (12).
D65EX, PX, WX-16 80-100 33

100 Air conditioner
SEN05041-00 Testing with self-diagnosis function
Testing with self-diagnosis Explanation of machine monitor operating pro-

function cedure
1. While pressing numeral key [4] on the normal
Outline screen, press [1], [2] and [3] in order.
On the air conditioner operation screen of the
machine monitor, the system performs self-diagno-
sis for the communication with the air conditioner
unit, temperature control, vent (mode) changeover
and refrigerant pressure with the pressure switch. If
any of these items has trouble, “A/C Controller
error” is displayed red to notify the trouble.
a Once a problem is detected, its indication is

not reset even if it becomes normal. The indi-
cation can be reset after the starting switch is
turned OFF.
On the air conditioner “Abnormality Record”
screen in the service mode of the machine
monitor, the system performs self-diagnosis for
various sensors, in addition to the above items, 2. On the service menu screen, press [F3] (s)
and displays “Error” red if any problem is once to select “02 Abnormality Record”.
detected.
a The system does not have self-diagnosis 3. Press [F6] (✔) to confirm.
function for the Recirc/Fresh changeover
servomotor.
q How to enter air conditioner “Abnormality

Record” screen in service mode of machine
monitor.
Outline of machine monitor operation

Normal screen
O While pressing [4], press [1], [2] and [3]
in order.
Service menu (Mode)
O Press [F3] once. Press [F6].
02 Abnormality Record
O Press [F3] twice. Press [F6].
03 Air-conditioning system “Abnormality
Record” screen
80-100 34 D65EX, PX, WX-16

100 Air conditioner
Testing with self-diagnosis function SEN05041-00
4. On the “Abnormality Record” screen, press q Clearing “Abnormality Record” by machine

[F3] (R) twice to select “03 Air-conditioning monitor
System”. While the “Abnormality Record” screen is dis-
played, press [F2], and the number of occur-
5. Press [F6] (✔) to confirm. rence time of abnormality is reset. If it is
confirmed at this time that the abnormality has
been reset, the display changes to Normal.
Caution
Inner Sensor means inside temperature sensor on
“block diagram” or “circuit diagram”.
“Ventilating Sensor is abnormal” means that evapo-
rator temperature sensor is short circuit or discon-
nected.
“Sunlight Sensor is abnormal” means that Sunlight
Sensor is short circuit only.
“Ventilation is abnormal” means servomotor for
blowing out changeover (mode) damper does not
rotate judging from the servomotor potentiometer
q Information displayed on Abnormality Record voltage.
screen: “03 Air-conditioning System” screen a Damper is the same as door.
(a): System/Component name “Air Mix is abnormal” means servomotor
(b): Number of occurrence time for Air Mix (temperature adjustment)
(c): Condition (Normal or abnormal) damper does not rotate judging from the
(d): If CAN status is abnormal in condition, servomotor potentiometer voltage.
CAN communication cannot be carried out “Refrigerant” means refrigerant pressure
normally but air conditioner unit is discon- from (dual) pressure switch. Namely,
nected. Accordingly, the conditions (d) of “refrigerant is abnormal” means that (dual)
other items are not displayed. pressure switch of refrigerant is OFF.
(e): If [E] is displayed on the left of a condition,
the abnormality is still occurring or clear- 1. CAN Status (communication) is abnormal
ing of it has not been confirmed. The CAN communication between the
q [F2]: Clear “Abnormality Record” machine monitor and air conditioner control
q [F5]: Return to “Abnormality Record” screen amplifier (CNTAMP) is not carried out normally.
a If failure code [DAFRMC] (Error of CAN
communication with engine controller) is
displayed, all the communication circuit is
abnormal. In this case, see failure code
[DAFRMC] in Chapter 40. If [DAFRMC] is
not displayed, only the communication
between control amplifier (CNTAMP) and
machine monitor is abnormal.
(Check connectors CN-AC01, CN-AC02
(CN-N10), [1] and [2] for disconnection.
See “Part and connector locations” 3. –
11. or see E-1.)
2. Setting abnormal
The software of the air conditioner amplifier
does not match that of the monitor. Check the
part numbers of those components.
D65EX, PX, WX-16 80-100 35

100 Air conditioner
SEN05041-00 Testing with self-diagnosis function
3. Inner Sensor abnormal 6. Ventilating Sensor is abnormal

Inner Sensor is the same as inside tempera- Servomotor for blowing out changeover
ture sensor on “block diagram” or “circuit dia- (mode) damper does not rotate judging from
gram”. the servomotor potentiometer voltage.
There is a Disconnection or a short circuit in a Damper is the same as door.
the line between the control amplifier and a Trouble: Blowing out is not changed.
Inside temperature sensor. a Action of control amplifier:
a Action of air conditioner amplifier: The control amplifier stops outputting to
The air conditioner amplifier controls with the servomotor for blowing out
only the set temperature since the data of changeover (mode).
the Inside temperature sensor are not a Even if the link is disconnected and the
available. damper does not rotate, the self-diagnosis
a Trouble: The air conditioner does not func- system judges the damper normal since
tion automatically but functions when the servomotor potentiometer voltage
operated manually. changes normally.
a See “Testing inner sensor”. (For mechanical troubles, see “Testing
vent (mode) changeover”.
4. Ventilating Sensor abnormal
a Ventilating Sensor is the same as evapo- 7. Air Mix is abnormal
rator temperature sensor. Servomotor for Air Mix (temperature adjust-
There is a disconnection or a short circuit ment) damper does not rotate judging from the
in the line between the control amplifier servomotor potentiometer voltage.
and evaporator temperature sensor. a Damper is the same as door.
a Action of control amplifier: a Trouble: The temperature control system
The control amplifier stops outputting does not work.
to the compressor. a Action of control amplifier:
a Trouble: The air conditioner does not The control amplifier stops outputting to
work. the air mix servomotor.
(See “Testing evaporator temperature a Even if the link is disconnected and the
sensor”.) damper does not rotate, the self-diagnosis
system judges the damper normal since
5. Sunlight Sensor abnormal the servomotor potentiometer voltage
There is a short circuit between the control changes normally.
amplifier and Sunlight Sensor. (For mechanical troubles, see “Testing
a Action of control amplifier: temperature control”.
The control amplifier controls without the
Sunlight Sensor. 8. Refrigerant is abnormal
a Trouble: The automatic air conditioner (Dual) pressure switch signal for refrigerant is
does not work when the machine i s abnormal. Namely pressure switch for refriger-
exposed to the direct sunlight in the auto- ant is OFF.
matic air conditioner mode. a Trouble: The air conditioner does not
a See “Testing sunlight sensor”. work.
a Action of control amplifier:
The control amplifier stops outputting to
the compressor.
k When replacing the pressure switch,
be sure to collect the refrigerant. See
“Cautions about refrigerant”.
a See “Testing (dual) pressure switch for
refrigerant”.
80-100 36 D65EX, PX, WX-16

100 Air conditioner
Testing temperature control SEN05041-00
Testing temperature control 3. Check the rod (RODAM) for disconnection.

q Temperature is controlled by mixing ratio of the 4. Start the engine and turn the air conditioner
hot air from the heater and cooled air from the power ON.
evaporator by changing the angles of the four
doors (dampers) in the air mix section. The 5. Set the temperature to 18°C and 32°C on the
angle of each door (damper) is set changed by air conditioner screen of the monitor and check
the air mix servomotor through plate (P1), visually that lever 5 (L5) and lever 6 (L6) move
lever 1 (L1) – lever 6 (L6) and rod (RODAM). smoothly between COOL MAX and HOT MAX.
Only rod (RODAM), lever 5 (L5) and lever 6 a Since the control amplifier controls the
(L6) are seen from outside. (For the figure, see temperature automatically, lever 5 (L5)
item 5.) and lever 6 (L6) are not set to HOT MAX
when the room temperature is high, and
a If lever 5 (L5) and lever 6 (L6) move smoothly are not set to COOL MAX when the room
between COOL MAX and HOT MAX, plate temperature is low.
(P1) and lever 1 (L1) – lever 4 (L4) operate If lever 5 (L5) and lever 6 (L6) are not set
normally, too. to COOL MAX while the room temperature
a Control amplifier (CNTAMP) control tempera- is high, and if lever 5 (L5) and lever 6 (L6)
ture is automatically based on inside tempera- are not set to HOT MAX while the room
ture sensor. So levers cannot be changed temperature is low, the air conditioner sys-
freely between COOL MAX and HOT MAX tem has a trouble.
with the temperature setting, depending on the a For COOL MAX and HOT MAX, see the
room temperature. next page.
a To reset the self-diagnosis system (To clear the
air conditioner error displayed on the air condi- q When lever 5 (L5) and lever 6 (L6) do not
tioner screen of the machine monitor), the move smoothly through the range shown in the
starting switch must be turned OFF (While the figure
self-diagnosis system is indicating a problem, 1. Disconnect connectors [5] and [6] of the servo-
no signals are output to the servomotor). motor.
1. Referring to “Part and connector locations” 3. – 2. Make match marks on servomotors (MODES)
11., and remove cover from the rear of the and (A/MS) to show which connector has been
operator seat. connected to which servomotor. (The servo-
motor will be exchanged with each other later.)
a State with cover removed
q A/C U: Air conditioner unit 3. Remove servomotors (MODES) and (A/MS).
q CNTAMP: Control amplifier
2. Check contacts of connector [6] of the air mix
servomotor (A/MS) (for disconnection).
D65EX, PX, WX-16 80-100 37

100 Air conditioner
SEN05041-00 Testing temperature control
5. Rotate plate (P1) with the hand between

COOL MAX and HOT MAX to see where lever
1 (L1) – lever 6 (L6) are hitched and then
repair.
a If the levers do not move smoothly, clean
them and apply grease to the links.
2 Link: Molykote ®MH-62 Grease
(Dow Corning Toray Co. Ltd.)
6. When plate (P1) is rotated with the hand

between COOL MAX and HOT MAX, if lever 1
(L1) – lever 6 (L6) move smoothly, the servo-
motor may have trouble. In this case,
exchange servomotors (5) and (6) and operate
them.
a For electrical problems, see “E-4 Temper-
ature cannot be controlled”.
a Plate (P1), lever 1 (L1) – lever 4 (L4) are not

seen from outside.
80-100 38 D65EX, PX, WX-16

100 Air conditioner
Testing vent (mode) changeover SEN05041-00
Testing vent (mode) changeover

The vent (modes) are selected by changing the
angles of the 4 internal doors (dampers). The
angles of the doors (dampers) are changed by the
servomotor through plate, defroster rod (RODD),
front face rod (RODF) and lever 7 (LEVER 7) –
lever 12 (LEVER 12). Only defroster rod (RODD),
front face rod (RODF), lever 7 (L7) and lever 8 (L8)
are seen from outside. (For the figure, see item 5.)
Visually check the positions of the levers and open-
ing and closing operations of the doors (dampers)
of the front face and rear face.
The rear face door (damper) angle is changed by
the servomotor through lever (L13) and rod
(RODR). Since lever (L11) of the front face and
lever (L13) and rod (RODR) of the rear face are not
seen from outside, remove the duct and check the
revolution of the door (damper) directly.
a To reset the self-diagnosis system (To delete
the air conditioner error displayed on the air
conditioner screen of the machine monitor),
the starting switch must be turned OFF (While
the self-diagnosis system is indicating a trou-
ble, no signals are output to the servomotor).
1. Referring to “Part and connector locations” 3. –

11., and remove cover from the rear of the
operator seat.
2. Check contacts of connector [5] of the servo-

motor (for disconnection).
3. Check the defroster rod (RODD) and foot rod

(RODF) for disconnection.
4. Start the engine and turn the air conditioner

power ON.
5. Press the vent selector switch on the air condi-

tioner screen of the monitor and check visually
that lever 7 (L7) and lever 8 ( L8) move
smoothly between the foot mode and defroster
mode shown in the figure.
6. Stop the engine.
7. Remove front left duct (FLD).
8. Remove rear face duct (RFD).
9. Remove front face duct (FD).
D65EX, PX, WX-16 80-100 39

100 Air conditioner
SEN05041-00 Testing vent (mode) changeover

power ON.
11. Press the vent selector switch on the air condi-

tioner screen of the monitor and check the
opening and closing operations of the front
face door (1) and rear face door (damper) (2).
q When lever 7 (L7) and lever 8 (L8) do not

move smoothly through the range shown in the
figure or the front face door and rear face door
(damper) do not open or close
1. Disconnect connectors [5] and [6] of the servo-
motor.
2. Make match marks on servomotors (MODES)

and (A/MS) to show which servomotor has
been installed. ( The servomotor will be
exchanged with each other later.)
3. Remove servomotors (MODES) and (A/MS).
80-100 40 D65EX, PX, WX-16

100 Air conditioner
Testing vent (mode) changeover SEN05041-00
5. Rotate plate (P2) with the hand to see where

lever 7 (L7) – lever 12 (L12) are hitched and
then repair.
a If the levers do not move smoothly, clean
them and apply grease to the links.
2 Link: Molykote ®MH-62 Grease
(Dow Corning Toray Co. Ltd.)
6. When plate (P2) is rotated with the hand, if

lever 7 (L7) – lever 12 (L12) move smoothly,
the servomotor may have trouble. In this case,
exchange servomotors (5) and (6) and operate
them.
a The figures of the foot mode and defroster

mode are shown before.
a For electrical problem, see “E-5 Vent (mode)

cannot be changed over”.
a F. Face door position will change from “OPEN”

to “Half” gradually when raising the setting
temperature from 18°C to 32°C gradually.
D65EX, PX, WX-16 80-100 41

100 Air conditioner
SEN05041-00 Testing Recirc/Fresh changeover
Testing Recirc/Fresh changeover Reference

q [8]: Inside air temperature (inner) sensor con-
Recirculated air or fresh air is selected by changing nector
the door (damper) angle in the air conditioner unit q [4]: Power transistor (PTR) connector
with the servomotor. Check the opening and clos- a FRESH/RECIRC changeover servomotor (R/
ing operations of the door (damper) visually. FS) cannot be replaced unless the air condi-
a The system does not have self-diagnosis func- tioner unit is removed.
tion for the Recirc/Fresh changeover servomo-
tor.
1. Remove recirculation air filter from behind the

operator seat.

power ON.
3. Press the RECIRC/FRESH selector switch on

the air conditioner screen of the monitor and
check visually that door (damper) (F/R D)
opens and closes.
4. When door (damper) (1) does not open and

close, trace wiring harness (H) and check con-
nection of connector [7] of FRESH/RECIRC
changeover servomotor (R/FS) by touch
through A portion.
a For electric problems, see “E-6 Recirc/Fresh

air cannot be changed over”.
80-100 42 D65EX, PX, WX-16

100 Air conditioner
Testing inner sensor SEN05041-00
Testing inner sensor 2. Disconnect connectors [1] and [2] from control
amplifier (CNTAMP).
a Inner sensor is the same as inside temperature
sensor on “block diagram” or “circuit diagram”. 3. Check that the resistance between connector
q If “Inner Sensor abnormal” is displayed by the [1] (11) (PB) (on the wiring harness side) and
self-diagnosis (“Abnormality Record” screen connector [2] (27) (BrR) (on the wiring harness
on machine monitor: “03 Air-conditioning Sys- side) (same as resistance between sensor ter-
tem”), test the inner sensor. minals).
q To reset the self-diagnosis system (detection of Normal value: 0°C ----- 1.6 kz
abnormality), the starting switch must be 25°C ----- 5 kz
turned OFF. (If not, the inner sensor or wiring harness is
defective.)
1. Referring to “Testing Fresh/Recirc changeover”, a Inner sensor (inside temperature sensor)
check contacts of inner sensor connector [8] by cannot be replaced unless the air condi-
touch (for disconnection). tioner unit is removed.
Reference
Resistance between terminals on sensor side of
connector [8]:
Normal value: 0°C ----- 1.6 kz
25°C ----- 5 kz
4. Connect all the connectors.
5. Turn the starting switch ON and perform self-

diagnosis (“Abnormality Record” screen on the
machine monitor: “03 Air-conditioning Sys-
tem”). If “Inner Sensor abnormal” is still dis-
played, replace the control amplifier.
D65EX, PX, WX-16 80-100 43

100 Air conditioner
SEN05041-00 Testing evaporator temperature sensor
Testing evaporator temperature 5. Ensure contact of connector [9]. (Check for

sensor disconnection.)
q If “Ventilating Sensor abnormal” is displayed by 6. Disconnect connector [9].

the self-diagnosis (“Abnormality Record”
screen on machine monitor: “03 Air-condition- 7. Measure the resistance between the mate
ing System”), test the evaporator temperature (female) of connector [9] and the terminal on
sensor. the evaporator temperature sensor side.
q To reset the self-diagnosis system (detection of Normal value: 0°C ----- 4.8 kz
abnormality), the starting switch must be 15°C ----- 2.3 kz
turned OFF.
1. Referring to “Part and connector locations” 3. –

operator seat.
2. Remove duct (FLD) and (RFD) from air condi-

tioner unit (A/C U).
a If an error is detected by the self-diagnosis

and evaporator temperature sensor is nor-
mal, control amplifier (CNTAMP) or the
wiring harness is defective.
8. Disconnect connectors [1] and [2] from control

amplifier (CNTAMP). (Connect connector [9].)
Resistance between terminal (11) (PB) of con-
3. Disconnect connectors AC01 and AC02. nector [1] and (27) (BrR) of [2]:
Normal value: 0°C ----- 4.8 kz
4. Remove control amplifier (CNTAMP) and its 15°C ----- 2.3 kz
bracket (1) together. a If the result of 8. above is normal, control
amplifier (CNTAMP) is defective. If the
result of 8. above is abnormal, and the
result of 7. is normal, the wiring harness is
defective.
80-100 44 D65EX, PX, WX-16

100 Air conditioner
Testing evaporator temperature sensor SEN05041-00
a If the evaporator temperature sensor is defec-

tive, replace it according to the following proce-
dure.
q Replacing evaporator temperature sensor.

1. Remove air conditioner unit assembly (A/C U).
For details, see Shop Manual, Chapter 50,
“Removal and installation of air conditioner unit
assembly”.
2. Remove wiring harness. (For each connector,

see the “Part and connector locations”.)
3. Remove servomotors (2) and (3).
5. Remove the link section. For details, see “Air

conditioner unit”.
6. Separate cases (5) and (6).
D65EX, PX, WX-16 80-100 45

100 Air conditioner
SEN05041-00 Testing evaporator temperature sensor
7. Remove the evaporator.
8. Remove the holder from part (P) and remove

the evaporator temperature sensor.
Installation
1. Install the evaporator temperature sensor to
the position shown in the previous figure with
the holder.
2. Perform the following installation in the reverse

order to removal.
80-100 46 D65EX, PX, WX-16

100 Air conditioner
Testing sunlight sensor SEN05041-00
Testing sunlight sensor 3. Referring to “Part and connector locations” 3. –

q If “Sunlight Sensor abnormal” is displayed by operator seat.
the self-diagnosis (“Abnormality Record”
screen on machine monitor: “03 Air-condition- 4. Remove duct (FLD).
ing System”), test sunlight sensor connector
(SLS). 5. Disconnect connector [1] from control amplifier
q To reset the self-diagnosis system (detection of (CNTAMP).
abnormality), the starting switch must be
turned OFF. 6. Ensure that the female terminals of connector
a A short circuit between the terminals of (SLS) (on the wiring harness side) are not
the sunlight sensor unit is a defect. shorted to each other. (If they are shorted, the
Whether the sunlight sensor is normal wiring harness is defective.)
cannot be checked by measuring resis-
tance, etc., however. Accordingly, if the 7. Check that the resistance between female con-
wiring is normal, presume the sunlight nector SLS (2) (Gr) (on the wiring harness
sensor to be abnormal and replace it. If side) and connector [1] (3) (YW) (on the wiring
“Sunlight Sensor abnormal” is still dis- harness side) is 1 z or below. (If not, the wiring
played, replace the control amplifier. harness is defective.)
a If the result of item 7 or item 8 is abnormal,
1. Remove cover (1) and check connector (SLS) check the contact of connector CN-AC01.
of sunlight sensor (S) on the rear side of the (See “Part and connector locations.”)
cover (for disconnection).
8. Check that the resistance between female con-
2. Disconnect connector (SLS), and measure nector SLS (1) (YG) (on the wiring harness
voltage between male terminals on sunlight side) and connector [1] (15) (RB) (on the wiring
sensor (S) at voltage range of tester because harness side) is 1 z or below. (If not, the wiring
the sensor (S) may be broken by measure- harness is defective.)
ment of resistance at resistance range of
tester.
q Approximate voltage of sunlight sensor
unit
0.55 (V): direct sunlight
0.45 (V): cloudy
0.4 (V): in room

diagnosis (on the air conditioner fault history
screen of the machine monitor). If “Sunlight
Sensor abnormal” is still displayed, replace the
control amplifier.
D65EX, PX, WX-16 80-100 47

100 Air conditioner
SEN05041-00 Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for 3. Ensure that the terminals on the switch side of
refrigerant connector AC05 are shorted to each other
(ON). (When they are not shorted "OFF", the
q If “Refrigerant abnormal” is displayed by the pressure switch detects abnormal refrigerant
self-diagnosis (“Abnormality Record” screen pressure.)
on machine monitor: “03 Air-conditioning Sys- a When the pressure switch is "OFF", con-
tem”), test pressure switch connector AC05. nect a pressure gauge to the high pres-
q To reset the self-diagnosis system (detection of sure side of the air conditioner
abnormality), the starting switch must be compressor and check the refrigerant
turned OFF. pressure.
q The pressure switch unit is "ON" when the See “Connection of service tool” and
refrigerant pressure is normal and "OFF" when “Troubleshooting with gauge pressure.”
the refrigerant pressure is abnormal. a If refrigerant pressure is normal, the pres-
a The pressure switch unit may be "OFF" sure switch is defective.
when ambient temperature below 0°C
because the refrigerant pressure becomes q (Dual) pressure switch
down. The pressure switch unit is not
defective but normal.
1. Open engine left cover.
2. Disconnect pressure switch connector AC05

from back of (P) portion.
q RD: Receiver drier
q SG: Sight glass
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
k When replacing the pressure switch, be
sure to collect the refrigerant.
80-100 48 D65EX, PX, WX-16

100 Air conditioner
Testing (dual) pressure switch for refrigerant SEN05041-00
q When the terminals on the switch side of con-

nector AC05 are shorted (ON) (See E-2 for cir-
cuit)
1. Referring to “Part and connector locations" 3. –
operator seat.
2. Disconnect connector [1] from control amplifier

(CNTAMP).

nector AC05 (2) (B) (on the wiring harness
side) and the ground is 1 z or below. (If not,
the wiring harness is defective.)

nector AC05 (1) (YR) (on the wiring harness
side) and connector [1] (4) (GB) (on the wiring
harness side) is 1 z or below. (If not, the wiring
harness is defective.)
a If the result of item 4. is abnormal, check
the contact of connector CN-AC01 with
removed duct (FLD).

diagnosis (“Abnormality Record” screen on
machine monitor: “03 Air-conditioning Sys-
tem”). If “Refrigerant abnormal” is still dis-
played, replace the control amplifier.
D65EX, PX, WX-16 80-100 49

100 Air conditioner
SEN05041-00 Testing relays and diodes
Testing relays and diodes q Checking relay unit

a Since no T-adapter is available, it is
a If the air conditioner compressor is normal (air impossible to check whether the relay is
is cooled) and air comes out, the relays are "ON" while the voltage is applied to the
normal. Accordingly, skip these relay tests. coil actually.
a Bring your ear to each relay to check its opera-
tion by sound. q Blower main relay (AC03)
1) The resistance of the coil between termi-
There are two relays. nals (1) and (2) is 140 – 340 z.
q Blower main relay (connector AC03): Used to 2) While the voltage (DC20 – 30 V) is not
turn the fan motor ON/OFF. applied between terminals (1) (+) and (2),
q Compressor clutch relay (connector AC04): terminals (3) and (4) are disconnected
Used to turn the air conditioner compressor from each other and terminals (3) and (5)
(clutch) ON/OFF are connected to each other.
3) While the voltage (DC20 – 30 V) is applied
1. Check contacts of connectors AC03 and AC04 between terminals (1) (+) and (2), termi-
(for disconnection) from left behind of operator nals (3) and (4) are connected to each
seat. other and terminals (3) and (5) are discon-
nected from each other.
2. Turn the starting switch ON (do not start the
engine) and turn the main power of the air con-
ditioner ON. If the blower-off relay is normal, it
is turned ON. Check its click.
3. If the air conditioner switch is turned ON at this

time, the compressor relay is turned ON if it is
normal. Check its click.
a Control amplifier (CNTAMP) does not turn
the compressor relay ON in the following
cases.
1) When the evaporator temperature is
below 3°C (depending on the input voltage
from the evaporator temperature sensor).
2) When the pressure switch detects abnor-
mality (it is turned OFF). q Compressor clutch relay (AC04)
a If the fan sound is too loud to hear the com- 1) The resistance of the coil between termi-
pressor relay sound, disconnect connector nals (1) and (3) is 140 – 340 z.
AC03 with the starting switch in the OFF posi- 2) Without voltage (DC20 – 30 V) applied
tion, and then check. between terminals (1) (+) and (3), termi-
nals (2) and (4) are disconnected from
IF: Recirculated air filter each other.
3) With the voltage (DC20 – 30 V) applied
between terminals (1) (+) and (3), termi-
nals (2) and (4) are connected to each
other.
80-100 50 D65EX, PX, WX-16

100 Air conditioner
Testing relays and diodes SEN05041-00
q Testing diode array units (ACD) (male)

a Measure with a circuit tester in the diode
range.
a Between ACD (2) (+) and (6) (–): No continuity
Between ACD (2) (–) and (6) (+): Continuity
Between ACD (3) (+) and (7) (–): No continuity
Between ACD (3) (–) and (7) (+): Continuity
D65EX, PX, WX-16 80-100 51

100 Air conditioner
SEN05041-00 Troubleshooting chart 1
Troubleshooting chart 1
a The numbers in the boxes are the item numbers in the troubleshooting table.
a E-2, E-3 means Troubleshooting for electrical system (E mode).
1. Cooling trouble
2. Heating trouble
80-100 52 D65EX, PX, WX-16

100 Air conditioner
Troubleshooting chart 2 SEN05041-00
Troubleshooting chart 2
1. Blower fan motor does not revolve or its speed is different from set value.
a See troubleshooting "E-3 Blower motor system (No air comes out or air flow is abnormal)" for trou-
bleshooting for the electrical system.
Possible cause Check method Remedy

Defective BLOWER MAIN RELAY See “Testing relays and diodes” Replace
Disconnection of wire or defective Check connector of blower fan motor for disconnec- Repair broken parts and con-
connection tion. See E-3 and “Part and connector locations” nect correctly
Check two lead wires of motor with circuit tester. If
Defective blower motor there is not continuity, motor is defective. See E-3 Replace
and “Part and connector locations”
Defective POWER TRANSISTOR
Move fan switches in sequence and check fan speed. Replace
(PTR)
Check diode (ACD1).
Defective diode (ACD1) Replace
See E-3 and “Testing relays and diodes”.
2. Blower fan motor is normal but air flow is insufficient.

Large duct resistance Check duct for crushing and filter for clogging Repair
Air leakage See “Testing air leakage (duct)” Repair or replace
Obstruction on suction side of
Check evaporator for stain and obstruction Remove obstruction and clean
evaporator
Defective evaporator tempera- Evaporator is frozen. Check sensor clip. Check sen- Repair or replace
ture sensor, defective contact of sor for dirt. (Evaporator temperature sen-
evaporator temperature sensor or Check the frost on the hose near pressure switch sor and expansion valve are in
defective expansion valve (when freezing advances furthermore) air conditioner unit)
3. Low/high pressure

Collect refrigerant, then
Excessive or insufficient refriger-
charge with proper quantity of
ant
refrigerant again
If R-134a is used as refrigerant, its quantity cannot
Repair leaking part, then
be checked through sight glass.
Insufficient refrigerant charge with proper quantity of
Accordingly, check by connecting gauge manifold.
refrigerant again
Purpose of sight glass is to check refrigerant flow.
Collect refrigerant, then
Overcharge with refrigerant charge with proper quantity of
refrigerant again
Normal pressure range
Low pressure:
Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Judgment by pressure at inlet/ High pressure: See Troubleshooting with
outlet of compressor Appox. 1.5 – 1.7 MPa {15 – 17 kg/cm2} gauge pressure
These values are for following condition, however.
Temperature in cab: 30 – 35°C
Engine speed: Appox. 1500 rpm
D65EX, PX, WX-16 80-100 53

100 Air conditioner
SEN05041-00 Troubleshooting chart 2
4. Compressor does not revolve at all or its speed is low.

a See "E-2 compressor system (Air is not cooled)" for troubleshooting for the electrical system.
Troubled part Possible cause Check method Remedy

Compressor belt Loosened compressor belt Vibration amplitude of belt is large Adjust tension
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil or seizure
Heating of compressor See "Handling compressor oil"
in the compressor
Low battery voltage Slip of clutch Charge battery
Inspect with circuit tester (10 –
Disconnection or short circuit in coil Replace
Magnet clutch 20 z)
Disconnection in wiring or defective Check ground wire and connec-
Repair
connection of ground wire tions
Relay Defective compressor clutch relay See “Testing relays and diodes.” Replace
Refrigerant Low/high pressure Troubleshooting with gauge Troubleshooting with gauge
pressure (Operation of pressure switch) pressure pressure
See “Testing (dual) pressure
Pressure switch Defective pressure switch Replace
switch for refrigerant” and E-2
Check diode (ACD).
Diode Defective diode (ACD) See E-2 and “Testing relays and Replace
diodes.”
5. Blower fan motor is normal but air flow is insufficient.

Large duct resistance Check duct for crushing and filter for clogging Repair
Check duct joints for defective duct seal and dis-
Air leakage through duct joints Repair
connection of duct
Clogging of heater core fins Check heater core fins for clogging Repair
6. Check of hot water

Warm up engine, and then check engine coolant
Low engine coolant temperature Find out cause
temperature
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of engine Check engine coolant piping for clogging (Hose,
Bleed air and repair
coolant pipe, and core)
Contrary connection of IN and OUT
Check the destination of heater hoses Repair
heater hoses
7. Fan rotation speed

See "Measuring fan motor speed" and "Measuring
Fan rotation speed is low fan pump circuit pressure" in chapter 30 "Testing Repair
and adjusting" of shop manual.
80-100 54 D65EX, PX, WX-16

100 Air conditioner
Troubleshooting chart 2 SEN05041-00
8. Other items
Possible cause Check method Remark

See "Testing temperature control" and "Trouble-
Temperature cannot be adjusted
shooting for electrical system, E-4"
Vent (mode) cannot be changed See "Testing vent (mode) changeover" and "Trou- Common to cooling and heat-
over bleshooting for electrical system, E-5" ing
Recirc/Fresh cannot be changed See "Testing Recirc/Fresh changeover" and "Trou-
over bleshooting for electrical system, E-6"
Excessive compressor oil See "Handling compressor oil"
Cooling only
Water leakage into the cab Clogging of drain hole
D65EX, PX, WX-16 80-100 55

100 Air conditioner
SEN05041-00 Troubleshooting for electrical system (E mode)
Troubleshooting for electrical system (E mode)

diagram. Before troubleshooting, understand the information fully.
Trouble Problem that appears on machine
Related
information
Causes Procedure, measuring location, standard (value) and remarks

• Procedure
1 • Measuring location
a“Between A – B” means “Measure voltage or resistance and so on between
Assumed causes for trouble A and B”
(Perform troubleshooting • Standard value in normal condition to evaluate assumed cause if it is good
according to these numbers, condition or not.
however.) • Remarks required to evaluate the cause is correct
2
<Notes on troubleshooting>
(1) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as shown below
unless otherwise specified.
• Connect the plus (+) lead to pin or harness indicated in the front.
3 – defective (2) Example of troubleshooting by inspection of multiple items
aNormal in 1 but abnormal in 2
At this time "– defective" shown at left is applied
a If a wiring harness is burnt, replace it.
<Phenomenon of defective harness>

q Disconnection in wiring
The connector connection is defective or wiring harness is disconnected.
q Ground fault
A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit
or machine accidentally.
q Hot short circuit
A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)
This is the excerpted circuit diagram related to troubleshooting

q Connector No.: Indicates (Model – No. of pins) (Color).
q See “Arrangement of connector pins” and “Arrangement of parts and connectors”
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown,
Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are 2 colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally turned ON)
q [1], [2],··· are connector numbers.
q Arrow (↔): Roughly indicates mounting place on machine.
80-100 56 D65EX, PX, WX-16

100 Air conditioner
Troubleshooting for electrical system (E mode) SEN05041-00
E-1 Power supply system (Air conditioner does not operate)

Problem Air conditioner does not operate due to power supply system failure.
Indication of
• “A/C Controller Error” is displayed red on air conditioner screen of machine monitor.
problem on
• No air blows out (Blower motor does not rotate).
machine
• If failure code [DAFRMC] is displayed on machine monitor, see Chapter 40 Troubleshooting first
and repair so that [DAFRMC] will not be displayed.
a CAN communication is connected to machine monitor, engine controller, power train controller and
air conditioner control amplifier.
• “A/C Controller Error” is displayed on air conditioner operation screen of machine monitor in
following cases. In E-1, 1), 2) and 3) of following cases are explained.
• Power is not supplied to control amplifier.
• Control amplifier is broken.
• Control amplifier (CNTAMP) cannot communicate with machine monitor.
• Blowing out door (damper) servomotor does not rotate.
• Temperature control (AIRMIX) door (damper) servomotor does not rotate.
• Refrigerant pressure is abnormal.
Related
• Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine
information
monitor: “03 Air-conditioning System” and check to see if “CAN Status” is abnormal. Abnormality of
“CAN Status” indicates that control amplifier at rear of air conditioner unit cannot communicate with
machine monitor.
“CAN Status” is indicated as abnormal in any case of 1), 2) and 3) above.
• Fuse Fu5A is twisted around the air conditioner wiring harness with tape. (Referring to “Part and
connector locations”)
• Ground cable of air conditioner is grounded together with that of machine wiring harness for
electrical equipment of machine.
• For each connector and relay, see “Part and connector locations”.
• If fuse is broken when A/C switch is pressed, see E-2.
• T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for AC01 and AC02 connectors.

1) Turn starting switch OFF.
2) Disconnect battery ground cable.
Defective wiring harness 3) Disconnect connector [1] from control amplifier.
1
(ground cable)
Between (16) (black) on wiring harness side of con-
Resistance Max. 1 z
nector [1] and ground
2 Broken fuse
2) Referring to “Part and connector locations”, check fuse Fu5A.
a If fuse is broken, replace it.
3) Disconnect connectors [1] and [2] from control amplifier.
4) Turn starting switch ON.
Between (6) (red) and (16) (B) on wiring
Voltage 20 – 30 V A
harness side of connector [1]
a If fuse is broken again in test A above, perform following procedure. (Replace
broken fuse.)
3 Defective wiring harness
3) Disconnect control amplifier connector [1].
a If fuse is broken again in test A above and results B and C below are normal,
blower motor circuit may be cause of trouble. See E-3.
Between (6) (red) and (16) (black) on
Resistance Min. 1 Mz B
wiring harness side of connector [1]
Between (6) (red) on wiring harness side
Resistance Min. 1 Mz C
of connector [1] and ground
D65EX, PX, WX-16 80-100 57

100 Air conditioner

a If fuse is broken again in test A for cause 3 and result of B or C is abnormal,
identify wiring harness having ground fault.
3) Disconnect connectors AC01, AC02 and [1].
4) Connect T-adapter to wiring harness side of connector [1].
a If result D or E below is abnormal: Short circuit in air conditioner wiring harness
(on plate)
a If result F or G below is abnormal: Short circuit in machine wiring harness
Ground fault in wiring harness
4 Between (6) (red) and (16) (black) on
(Contact with GND circuit) Resistance Min. 1 Mz D
wiring harness side of connector [1]
Between (6) (red) on wiring harness side
Resistance Min. 1 Mz E
of connector [1] and ground
Between connector AC02 (female) (4)
Resistance Min. 1 Mz F
and AC01 (female) (5) (black)
Resistance Min. 1 Mz G
(red) and (5) (black)
Disconnection in wiring a If fuse is not broken and test result A for cause 3 is abnormal, check with circuit
5
harness diagram.
a If CAN communication circuit has short circuit or ground fault, [DAFRMC] error
is displayed.
a Terminal resistors of about 120 z are in machine monitor and on engine. Since
they are connected in parallel, combined resistance is about 60 z.
3) Disconnect control amplifier connectors [1] and [2] and connect T-adapter to
wiring harness side.
Between connector [2] (17) and (18) Resistance Approx. 60 z H
Disconnection in CAN
communication circuit a If result H above is abnormal, perform following procedure.
6 (Communication between a If result H above and J below are abnormal, operator cab wiring harness is
control panel and control abnormal.
amplifier is defective) a If result H above is abnormal and J below is normal, air conditioner wiring
harness (on plate) is abnormal.
a Terminal resistors of about 120 z are in machine monitor and on engine. Since
they are connected in parallel, combined resistance is about 60 z.
3) Disconnect control amplifier connectors [1] and [2] and connect T-adapter to
wiring harness side.
Resistance Approx. 60 z J
and (2)
When test results for causes 1, 2, result A for cause 3 and result H for cause 6 are
7 Defective control amplifier
normal, replace control amplifier.
8 Defective machine monitor When no abnormality is found by the above checks, machine monitor is defective.
80-100 58 D65EX, PX, WX-16

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D65EX, PX, WX-16 80-100 59

100 Air conditioner
E-2 Compressor and refrigerant system (Air is not cooled)

Problem Air is not cooled due to compressor system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air
Indication of is not cooled as displayed on screen.
problem on • Air conditioner compressor does not operate.
machine • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. Causes
of this phenomenon are 1) – 6). For 1) – 5), see “Related information” in E-1.
In E-2, “6) Refrigerant pressure is abnormal” of “Related information” in E-1 is explained.
• Referring to “Testing with self-diagnosis function”, display air conditioner fault history screen on
machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is
abnormal, compressor is not turned ON and air is not cooled consequently.
Related a Abnormal refrigerant pressure indicates that “Signal (connector [1] (4)) from pressure switch is not
information grounded”.
• Air conditioner may not be turned ON if ambient temperature is below 5°C (Normal).
• For each connector, see “Part and connector locations”.
a T-adapter is not prepared for AC01 – AC05 connectors.

a If “A/C Controller Error” is displayed red on air conditioner operation screen of
machine monitor, perform following procedure.
2) Disconnect battery ground terminal.
3) Disconnect pressure switch connector AC05.
a Pressure switch may operate normally and turn off itself. Accordingly, if
1 Defective pressure switch following is abnormal (if switch is turned OFF), install pressure gauge to low
pressure side of air conditioner compressor and check refrigerant pressure.
Between (1) and (2) on pressure switch side of
Resistance Max. 1 z
connector AC05
k Before replacing pressure switch, collect refrigerant.
2) Disconnect connector A/C from air conditioner compressor.
a Ensure connection of air conditioner compressor ground cable and GND04.
Defective air conditioner (See “Part and connector locations”.)
2
compressor
Between (1) on air conditioner compressor side of
connector A/C and ground (Air conditioner compressor Resistance Approx. 15 z
coil resistance)
2) Disconnect connectors ACG, ACD.
a Test at diode range.
Between ACG (male) (1) (+) and (2) (–) No continuity
3 Defective Diode
Between ACG (male) (1) (–) and (2) (+) Continuity
Between ACD (male) (3) (+) and (7) (–) No continuity
Between ACD (male) (3) (–) and (7) (+) Continuity
2) Disconnect connectors [1], AC04 and ACG.
a Ensure that test result for cause 1 is normal (pressure switch is ON) and that for
cause 2 is normal (air conditioner compressor is normal) and that cause 3 is
normal.
4 Between connector [1] (4) and ground
harness Resistance Max. 1 z
(Pressure switch is turned ON)
Between connector AC04 (female) (2) and ground
Resistance Approx. 15 z
(Air conditioner compressor coil resistance)
Between connector ACG (male) (2) and ground Resistance Max. 1 z
80-100 60 D65EX, PX, WX-16

100 Air conditioner

• Referring to “Testing relays”, check sound made
when compressor clutch relay is turned ON.
Click is
a If blower sound is too large to hear operating sound A
heard.
of compressor clutch relay, turn starting switch OFF
temporarily and disconnect connector R30.
a If A above and B below are abnormal and C is normal (relay is normal), go to
causes 7 and 8.
Defective compressor clutch 2) Disconnect connector AC04.
5
relay (Does not turn ON) 3) Short (2) (blue) and (4) (green Iine on red
background) on wiring harness side of connector Air is cooled. B
AC04 with wire.
(Turn compressor ON forcibly without using relay.)
2) Disconnect connector AC04.
Between AC04 (relay side) (1) and (3) Approx.
Resistance C
(coil resistance) 140 – 340 z
a If fuse is not broken, skip troubleshooting.
6
Ground fault in wiring harness a Ensure that test result for cause 2 is normal.
(Contact with GND circuit)
Between (2) on machine wiring harness side of
connector AC04 and ground Resistance Approx. 15 z
(Air conditioner compressor coil resistance)
2) Disconnect connector AC04, ACD and [2].
7
Short circuit in wiring harness a Ensure that test result for cause 2 is normal.
(with another wiring harness)
Between (3) and (1) on machine wiring harness side of
connector AC04
8 Check with circuit diagram.
harness
2) Disconnect connectors [1] and [2] and insert T-adapter in wiring harness side.
9 Defective control amplifier 4) Display air conditioner operation screen on machine monitor and press A/C
switch.
Between connector [2] (35) and [1] (16) Voltage Max. 1 V
Defective machine monitor 2) Display air conditioner operation screen on machine monitor.
10
(Defective switch)
Press A/C switch. “A/C ON” is displayed.
D65EX, PX, WX-16 80-100 61

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80-100 62 D65EX, PX, WX-16

100 Air conditioner
E-3 Blower motor system (No air comes out or air flow is abnormal)
Problem No air comes out or air flow is abnormal due to blower motor system failure.
Indication of • LCD of machine monitor on air conditioner operation screen lights normally but air does not come
problem on out.
machine • Air flow does not match fan switch setting on air conditioner operation screen.
• This trouble is not checked with self-diagnosis function.
• If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. Possible
causes for this trouble are as follows.
• Compressor clutch relay is defective (Stuck closed). (See E-2, 5, A.)
• Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air
Related conditioner unit.)
information • Expansion valve is adjusted improperly. (Remove air conditioner unit and replace expansion valve.)
• If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
• If air comes out but its flow is abnormal in heating mode, replace power transistor first.
• For each connector, relay, and power transistor, see “Part and connector locations”.
a T-adapter is not prepared for AC01 – AC03, [3] and [4] connectors.

2) Disconnect connector [3].
1 Defective blower (fan) motor
Between wiring harness terminals on blower motor
Continuity
side of connector [3]
a If power transistor is normal, all of following are normal. Reverse is not always
true, however (Transistor itself cannot be checked if transistor unit is removed).
Between (2) (+) and (1) of connector [4] (male) (power
transistor) (Internal fuse and resistor must not be
broken) Approx. 11 kz
a If test result is abnormal, overcurrent has flowed. In
2 Defective power transistor this case, replace blower motor, too.
Between (3) and (4) of connector [4] (male) (power
Approx. 2.2 kz
transistor) (Internal resistor must not be broken)
Between (1) (+) and (3) (–) of connector [4] (male) Continuity
(power transistor) * Diode range
Between (3) (+) and (1) (–) of connector [4] (male) No continuity
(power transistor) * Diode range
• Referring to “Testing relay”, check turn-on sound of Click is
A
blower main relay. heard.
a If test results A above and B below are abnormal and C is normal (relay is
normal), go to causes 8-J and 10.
3) Short (4) (green line on red background) and (5) (yellow) of connector AC03
(wiring harness side) with wire. (Turn blower ON forcibly without using relay.)
Defective blower main relay 4) Turn starting switch ON.
3
(Does not turn ON)
Air comes
Operate fan on air conditioner operation screen. B
out.
a If air does not come out even when blower is turned ON forcibly without using
relay, cause is part other than relay.
Between (1) and (3) of AC03 (relay side) Approx.
Resistance C
(coil resistance) 140 – 340 z
2) Disconnect connector ACD.
a Test at diode range.
4 Defective Diode
Between ACD (male) (2) (+) and (6) (–) No continuity
Between ACD (male) (2) (–) and (6) (+) Continuity
D65EX, PX, WX-16 80-100 63

100 Air conditioner

Defective wiring harness 2) Disconnect connector [4].
5
(ground) Between (1) (black) on wiring harness side of
Resistance Max. 1 z
connector [4] and ground
• Blower motor input voltage
1)Turn starting switch OFF.
2)Disconnect connector [3].
3)Turn starting switch ON.
4)Press fan switch on air conditioner operation screen. (Air flow may be set to any
position.)
a If result is abnormal, go to causes 8-J and 10.
Between (1) (red/yellow) on wiring harness side of
Voltage Approx. 24 V
connector [3] and ground
• Power transistor input voltage
(Since no current flows to blower motor, blower motor does not rotate.)
4) Press fan switch on air conditioner operation screen. (Air flow may be set to any
position.)
a If D below is abnormal, go to G below.
6
Check of input and output a If E below is abnormal, go to causes (9) and (10).
voltages
Between (2) (brown/black) and (1)
(black) on wiring harness side of Voltage Max. 2 V D
connector [4]
Between (3) (black/blue) and (1) (black) Approx. 24 V
Voltage E
on wiring harness side of connector [4] *1
• Control amplifier
2)Disconnect connectors [1] and [2] and insert T-adapter.
4)Press fan switch on air conditioner operation screen.
(Air flow may be set to any position.)
a If F below is abnormal, go to causes 7-J and 9.
a If G below is abnormal, go to causes (9) and (10).
Between (36) of connector [2] and (16)
Voltage Max. 1 V F
of connector [1]
Between (8) and (16) of connector [1] Voltage Max. 2 V G
7 Defective blower (fan) motor 2) Disconnect connector [3].
Between (1) and (2) of connector [3] (male) Continuity
2) Disconnect connectors AC03, ACD and [1].
Short circuit in wiring harness Between (3) and (1) on wiring harness
8 Resistance Min. 1 Mz J
(with another wiring harness) side of connector AC03
Between (6) and (7) on wiring harness
Ground fault in wiring harness 2) Disconnect connectors [1] and [4].
9
(Contact with GND circuit) Between (2) and (1) on wiring harness
10 Check with circuit diagram.
harness
Control amplifier is defective in following cases.
11 Defective control amplifier 1) F for cause 6 is abnormal, J for cause 8 is normal, and cause 10 is normal.
2) G for cause 6 is abnormal and causes 9 and 10 are normal.
80-100 64 D65EX, PX, WX-16

100 Air conditioner

12
(Defective switch) LCD display of air flow changes from
Press fan switches from MIN to MAX.
MIN to MAX.
*1: At blower main relay ON
D65EX, PX, WX-16 80-100 65

100 Air conditioner
E-4 Temperature cannot be controlled

Problem Temperature cannot be controlled.
• “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-
Indication of
1.)
problem on
• While air conditioner operation screen of machine monitor is displayed, temperature does not
machine
change even if temperature control switch is operated.
a Temperature control means “Air Mix” of cooled air and hot air.
monitor: “03 Air-conditioning System” and check to see if “Air Mix is abnormal” and “Inner sensor is
abnormal”.
See “Testing inner sensor” when “Inner sensor is abnormal”.
• Even if rod etc. is disconnected (See “Testing temperature control”), if current is supplied to air mix
servomotor by operating switches and potentiometer in servomotor reaches normal voltage, self-
diagnosis function judges system normal.
• Referring to “Testing temperature control”, check that there is not contact of connector [6] or
Related mechanical trouble (removal or interference of link, etc.)
information • Air mix servomotor and air blowing out (mode) servomotor are same part number. Operating angle
of temperature control (air mix) is less, however. Accordingly, do not test servomotor to see if it
rotates by connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix
servomotor and blowing out (mode) servomotor to see if they are normal.
• Air mix servomotor can be checked for trouble by connecting new servomotor to connector [6] and
see if it operates normally.
a Since T-adapter is not prepared for [5] and [6] connectors, check signals with control amplifier
during operation.

Between (6) and (7) of connector [6] (on servomotor 400 –
Resistance
Defective air mix servomotor side) (There must not be disconnection or short circuit) 3000 z
1
(Unit test) Between (1) and (3) of connector [6] (on servomotor
Resistance 4 k – 8 kz
side) (There must not be disconnection or short circuit)
Between (1) and (5) of connector [6] (on servomotor
2) Disconnect connectors [1] and [2] and insert T-adapter.
Between connector [1] (3) and [2] (27) Voltage 5V
1)
Turn starting switch OFF.
2)
Disconnect connectors [1] and [2] and insert T-adapter.
3)
Turn starting switch ON.
4)
Set temperature control switch on air conditioner operation screen to COOL
MAX.
Defective air mix servomotor or
5) Set temperature control switch on air conditioner operation screen to HOT
2 defective air conditioner wiring
MAX.
harness
a Voltage appears across (21) and (22) of connector [2] for about 3 seconds (only
while door moves).
a Voltage across connectors [1] (2) and [2] (27) changes for about 3 seconds
(only while door moves) (It is stabilized after door stops).
Between (21) (+) and (22) (–) of connector [2]
a If temperature is changed from HOT MAX to COOL Voltage Approx. 24 V
MAX, voltage polarities are reversed.
Change
Between connector [1] (2) (+) and [2] (27) (–) Voltage
below 5 V
a When test result for cause 1 is normal and that for cause 2 is abnormal, perform
Defective air conditioner wiring following procedure.
3
harness
Check with circuit diagram.
a When test result for cause 1 is normal and that for cause 2 is abnormal and that
for cause 3 is normal, control amplifier is defective.
80-100 66 D65EX, PX, WX-16

100 Air conditioner

5
(Defective switch) LCD display changes from
Press temperature control switch.
18 to 32°C.
a Each servomotor is the same.
D65EX, PX, WX-16 80-100 67

100 Air conditioner
E-5 Vent (mode) cannot be changed over

Problem Vent (mode) cannot be changed over.
• “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-
Indication of
1.)
problem on
• When vent selector switch on air conditioner operation screen of machine monitor is operated, vent
machine
does not change.
monitor: “03 Air-conditioning System” and check to see if “Ventilating sensor is abnormal”.
• Even if rod etc. is disconnected (See “Testing vent (mode) changeover”), if current is supplied to
blowing out (mode) servomotor by operating switches and potentiometer in servomotor reaches
normal voltage, self-diagnosis function judges system normal.
• Referring to “Testing vent (mode) changeover”, check that there is not contact of connector [5] or
mechanical trouble (removal or interference of link, etc.)
Related • Air mix servomotor and blowing out (mode) servomotor are same. Operating angle of temperature
information control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by
connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor
and blowing out (mode) servomotor to see if they are normal.
• Blowing out servomotor can be checked for trouble by connecting new servomotor to connector [5]
and see if it operates normally.
a Since T-adapter is not prepared for [5] and [6] connectors, check signals with control amplifier
during operation.

Between (6) and (7) of connector [5] (on servomotor 400 –
Resistance
Defective blowing out (mode) side) (There must not be disconnection or short circuit) 3000 z
1
servomotor (Unit test) Between (1) and (3) of connector [5] (on servomotor
Between (3) and (5) of connector [5] (on servomotor
Between connector [1] (3) and [2] (27) Voltage 5V
2)Disconnect connectors [1] and [2] and insert T-adapter.
4)Set vent selector switch on air conditioner operation screen to FACE.
Defective blowing out (mode)
5)Set vent selector switch on air conditioner operation screen to DEFROST.
2 servomotor or defective air
a Voltage appears across (24) and (23) of connector [2] for about 3 seconds (only
conditioner wiring harness
while door moves).
a Voltage across connectors [1] (9) and [2] (27) changes for about 3 seconds
(only while door moves) (It is stabilized after door stops).
Between (24) (+) and (23) (–) of connector [2]
a If vent is changed from DEFROST to FACE, Voltage Approx. 24 V
voltage polarities are reversed.
Changes
Between connector [1] (9) (+) and [2] (27) (–) Voltage
below 5 V
a When test result for cause 1 is normal and that for cause 2 is abnormal, perform
Defective air conditioner following procedure.
3
wiring harness
Check with circuit diagram.
a When test result for cause 1 is normal and that for cause 2 is abnormal and that
for cause 3 is normal, control amplifier is defective.
2) Display air conditioner operation screen on machine monitor.
Defective machine monitor
5 Operate air outlet switch and change LCD display to
(Defective switch) LCD display changes to
FACE, FACE and REAR, FOOT, FACE and REAR,
each mode
FOOT, FOOT and DEFRSOT, and DEFROST.
80-100 68 D65EX, PX, WX-16

100 Air conditioner
a Each servomotor is the same.
D65EX, PX, WX-16 80-100 69

100 Air conditioner
E-6 Recirc/Fresh air cannot be changed over

Problem Recirc/Fresh air cannot be changed over.
Indication of
• When Recirc/Fresh selector switch of machine monitor is operated, recirculated or fresh air does
problem on
not changeover (Recirc/Fresh changeover door (damper) does not rotate).
machine
• Recirc/Fresh changeover is not checked with self-diagnosis function.
• Referring to “Testing Recirc/Fresh changeover”, operate Recirc/Fresh selector switch and check
that there is not mechanical trouble (removal or interference of link, etc.) in Recirc/Fresh
changeover door.
Related
• Operating angle of Recirc/Fresh changeover servomotor is 90°.
information
a Since T-adapter is not prepared for AC02 and [7] connectors, check signals with control amplifier
during operation.

a Since connector [7] cannot be disconnected easily, test on control amplifier
side.
2) Disconnect connectors [1] and [2] and connect T-adapter to wiring harness
Defective Recirc/Fresh side.
changeover servomotor
1 Between connector [1] (wiring harness side) (6) and
(Unit test) or defective air 400 –
connector [2] (wiring harness side) (19) Resistance
conditioner wiring harness 3000 z
(There must not be disconnection or short circuit)
Between connector [1] (wiring harness side) (6) and
400 –
connector [2] (wiring harness side) (20) Resistance
3000 z
(There must not be disconnection or short circuit)
Defective air conditioner wiring a When test result for cause 1 is abnormal, perform following procedure.
2
harness Check with circuit diagram.
4) Set Recirc/Fresh selector switch on air conditioner operation screen to Recirc.
5) Set Recirc/Fresh selector switch on air conditioner operation screen to Fresh.
a Voltage appears across connector [1] (6) and connector [2] (20) for about 3
seconds (only while door moves to Fresh position).
Defective control amplifier or Between connector [1] (6) (+) and connector [2] (20)
3 defective Recirc/Fresh Voltage Approx. 24 V
(–)
changeover servomotor
See 1) – 3) above.
4) Set Recirc/Fresh selector switch on air conditioner operation screen to Fresh.
5) Set Recirc/Fresh selector switch on air conditioner operation screen to Recirc.
a Voltage appears across connector [1] (6) and connector [2] (19) for about 3
seconds (only while door moves to Recirc position).
Between connector [1] (6) (+) and connector [2] (19)
Voltage Approx. 24 V
(–)
a When test result for cause 1 is abnormal and that for cause 2 is normal, Recirc/
Defective Recirc/Fresh Fresh changeover servomotor is defective.
4
changeover servomotor (If all test results for causes 1, 2 and 3 are normal, cause may be mechanical
trouble such as hitch.)
a When test results for causes 1 and 2 are normal and that for cause 3 is
abnormal, control amplifier is defective.
6
(Defective switch) Display of Recirc/Fresh
Press Recirc/Fresh selector switch.
changes.
80-100 70 D65EX, PX, WX-16

100 Air conditioner
D65EX, PX, WX-16 80-100 71

100 Air conditioner
SEN05041-00 Troubleshooting with gauge pressure
Troubleshooting with gauge pressure

Referring to “Connection of service tool”, perform <Measurement condition for pressure>
troubleshooting by reading the high and low gauge Item Condition value
pressures of the cooling cycle.
Atmospheric temperature 20 – 50°C
a The gauge pressure varies largely with the Engine speed Low idle
weather condition and operating condition of Air conditioner switch ON
the machine. Take care. Fan switch Hl
q High pressure is too high: Set temperature Full cool

Above approx. 2.5 MPa {25 kg/cm2}
q High pressure is too low: q Dual pressure switch
Below approx. 1 MPa {10 kg/cm2} a Normally "ON", abnormal pressure "OFF" for
q Low pressure is too high: compressor.
Above approx. 0.3 MPa {3 kg/cm2}
q Low pressure is too low:
Below approx. 0.05 MPa {0.5 kg/cm2}
a (Dual) pressure switch on high pressure side

protects air conditioner circuit with "OFF":
See right
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-100 72 D65EX, PX, WX-16

100 Air conditioner
Troubleshooting with gauge pressure SEN05041-00
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another
Pressure is normal cause.
High pressure: Approx. 1.5 – 1.7 MPa {15 – 17 kg/cm2}
Low pressure: Approx. 0.13 – 0.2 MPa {1.3 – 2.0 kg/cm2}
Collect refrigerant, then fill
Bubble can be seen in the
Insufficient refrigerant up with proper quantity of
sight glass (*1)
refrigerant again (*2)
There is a temperature dif-
ference between inlet and Replace
Clogging of receiver drier
outlet pipes of receiver drier. (*2)
Tank is frosty
Clean or replace
Clogging of expansion valve Expansion valve is frosty
(*2)
Both high pressure and low
pressure are too low Gas leakage at heat sens- Low pressure gauge Replace
ing tube of expansion valve becomes vacuum (*2)
Low pressure becomes vac- Evaporator is frozen Repair or replace
uum Defective evaporator sensor
Air flow is down by freezing Replace receiver drier
or defective contact of sen-
(At cool max. and HI speed Collect refrigerant, then fill
sor (removal of mounting
of fan, later it becomes not to up with proper quantity of
clip)
cold.) refrigerant again (*2)
Piping between receiver
drier and compressor is
Clogging or flattening or pip- clogged or flattened. If Clean or replace
ing clogged completely, low (*2)
gauge pressure becomes
vacuum
Collect refrigerant, then fill
Filling too much with refriger-
Connect gauge manifold up with proper quantity of
ant
refrigerant again (*2)
Stain of condenser, clogging Clean, repair fins, or repair
Defective cooling of con-
or crushing of fins, or defec- or replace condenser
denser
Both high pressure and low tive revolution of cooling fan (*2)
pressure are too high Defective adjustment of
Bubble can be seen in the Replace
expansion valve (Valve is
sight glass (*2)
opened too wide)
Evacuate and then fill up
Bubble can be seen in the
Air in cycle with proper quantity of refrig-
sight glass
erant again (*2)
Clogging or flattening of pip- There is a remarkable tem- Clean inside of cycle or
High pressure is too high
ing between compressor and perature difference between replace
and low pressure is too low
condenser before and after clogged part (*2)
Both high pressure and low
Defective compressor (Com- pressure are balanced while
High pressure is too low and Replace
pression trouble of compres- compressor is in operation.
low pressure is too high (*2)
sor) Compressor has seized and
is extremely hot.
*1 If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are
stained with oil. Increase tightening of the joints or replace parts.
*2. k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
D65EX, PX, WX-16 80-100 73

100 Air conditioner
SEN05041-00 Troubleshooting with gauge pressure
a Sight glass (2) is on the receiver drier (1).
80-100 74 D65EX, PX, WX-16

100 Air conditioner
Connection of service tool SEN05041-00
Connection of service tool

a Use the service tool kit for R134a.
Connect the gauge manifold, hoses and other ser-
X 799-703-1200 Service tool kit vice tools according to the following procedure.
1. Close the high-pressure valve (HI) and low-
pressure valve (LO) of gauge manifold (1).
Service tool kit
1. Gauge manifold 2. Connect red charging hose (2) to the (HI) side
2. High pressure charging hose (red) and blue charging hose (3) to the (LO) side.
3. Low pressure charging hose (blue)
4. Quick joint (Hi) (Large diameter) 3. Connect quick joints (4) and (5) to each hose.
5. Quick joint (Lo) (Small diameter)
4. Connect the quick joints to the service valves
a. The thread is rough. So be careful not to loosen. of the high and low-pressure pipings.
D65EX, PX, WX-16 80-100 75

100 Air conditioner
SEN05041-00 Precautions for connecting air conditioner piping
Precautions for connecting air conditioner piping

q When connecting the piping, apply compressor
oil NDOIL-8 for R134a to the O-rings. (See
item 4. in “Handling of compressor oil”)
Do not apply oil to the threads of a bolt, nut or
union, however.
q Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
When removing it, use a soft tool (such as a
toothpick) so that the piping will not be dam-
aged.
q Push in each pipe to the stopper (until it clicks)
and tighten the bolt or nut fully with your fin-
gers.
q Be sure to use two wrenches to tighten each
nut (Apply a torque wrench to the tightening
side). Place one wrench and tighten the nut
with the other wrench to the specified torque.
Refrigerant piping diagram
Table of tightening torque for refrigerant piping adapter and installation

Unit: Nm {kgm}
Screw size Tightening torque
3.9 – 6.9 {0.4 – 0.7} (Receiver drier)
M6 × 1.0
8 – 12 {0.8 – 1.2} (A/C unit and compressor)
M16 × 1.5 12 – 15 {1.2 – 1.5}
M22 × 1.5 20 – 25 {2.0 – 2.5}
M24 × 1.5 30 – 35 {3.1 – 3.6}
80-100 76 D65EX, PX, WX-16

100 Air conditioner
Handling of compressor oil SEN05041-00
Handling of compressor oil 2. Adding of compressor oil

k Since refrigerant is dangerous and bad for
1. Control of compressor oil environment, collect the refrigerant before
(Denso: ND-OIL8: For R134a) disconnecting the air conditioner hose. See
Compressor oil does not need to be checked “Caution about refrigerant”.
or added so frequently as engine oil. Insuffi- k If refrigerant gets in your eyes, you may
ciency or excess of compressor oil can cause lose your sight. (Put on protective gog-
the following troubles. gles.)
Condition Contents a If oil for CFC-12 (R-12) is used, lubrication
trouble will occur and the compressor may be
Lubrication trouble and seizure
Insufficiency of oil
of compressor
broken or seized.
Be sure to use the specified oil for R134a
Cooling trouble (Excessive oil (Denso: ND-OIL8)
Excess of oil stick to parts and lower heat
exchange performance) a Oil for R134a absorbs moisture very easily.
Accordingly, fit the cap immediately after using
Accordingly, compressor oil must be filled to oil to stop the atmosphere.
the specified level, similarly to refrigerant. Store the oil can in a dry and ventilated place.
a Precautions for using oil
Oil for R134a (Denso: ND-OIL8 in particular)
may dissolve acrylic resin and polystyrene
(excluding baked polystyrene paint film).
Accordingly, do not stick oil to those plastics.
Check compressor oil in the following cases, and

then add new oil if necessary.
q When much refrigerant is discharged because
of leakage.
q When the compressor is troubled and replaced.
q When a cycle parts such as the air conditioner
unit, condenser, receiver drier, evaporator unit,
etc. is replaced.
q Quantity of oil to be added when cycle part is

replaced
Quantity to be added
Air conditioner part (cm3)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (Compressor – M24 joint) Approx. 10
Hose
(Condenser – Receiver driver) Approx. 10
Hose (M24 joint – Cab) Approx. 10
Hose (Cab – Receiver driver) Approx. 10
D65EX, PX, WX-16 80-100 77

100 Air conditioner
SEN05041-00 Handling of compressor oil
3. Compressor replacement 4. Applying compressor oil for O-ring

q In case of compressor seizure or breakage. When connecting a pipe or hose, apply oil (Denso:
Metal chips will circulate through the air condi- ND-OIL8) to its O-ring to prevent refrigerant leak-
tioner circuit and contaminate the compressor age.
oil extremely. k When discarding a can which still has some
In this case, flush the air conditioner circuit and oil in it, make a hole on it to discharge gas
replace the compressor and receiver drier. and oil.
The compressor oil is removed from the air
conditioner circuit by flushing.
Accordingly, install a new compressor with the
oil of the specified quantity (180 cc) filled in it.
q Other cases
a New compressor has 180 cc compressor oil in
it. So drain excessive compressor oil before
installing new compressor in the following.
1) Prepare an oil pan and drain oil from old
compressor.
2) Measure the quantity of the drained oil
with a graduated cylinder, and note the
quantity or mark the level.
3) Drain below-mentioned quantity of oil from

new compressor.
180 cc – “the noted quantity”.
EX. If drained oil quantity from removed
compressor is 30cc, drain oil of
180 – 30 cc = 150 cc from new one.
80-100 78 D65EX, PX, WX-16

100 Air conditioner
Handling of compressor oil SEN05041-00
D65EX, PX, WX-16 80-100 79

SEN05041-00

©2009 KOMATSU
All Rights Reserved
80-100 80
SEN04934-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
90 Diagrams and drawings 90
100 Hydraulic diagrams and drawings

Power train hydraulic circuit diagram .............................................................................................................. 3
Work equipment hydraulic circuit diagram ...................................................................................................... 7
D65EX, PX, WX-16 90-100 1

SEN04934-01
90-100 2 D65EX, PX, WX-16

Power train hydraulic circuit diagram SEN04934-01
Power train hydraulic circuit diagram 1
D65EX-16, D65PX-16, D65WX-16
D65EX, PX, WX-16 90-100 3

Power train hydraulic circuit diagram (subextremely cold weather spec.) SEN04934-01
Power train hydraulic circuit diagram (subextremely cold weather spec.) 1
D65EX-16
a See STD spec. for items not described in this circuit diagram.
D65EX, PX, WX-16 90-100 5

Work equipment hydraulic circuit diagram
Work equipment hydraulic circuit diagram D65EX-16, D65PX-16, D65WX-16 1
D65EX-16, D65PX-16, D65WX-16 Straight tilt dozer (ST-T)

Straight tilt dozer (ST-T) Sigma dozer (SGM)
Sigma dozer (SGM)
SEN04934-01
D65EX, PX, WX-16
90-100 7
D65EX-16, D65PX-16, D65WX-16 Power angle power tilt dozer (PAT)

SEN04934-01
D65EX, PX, WX-16
90-100 9
D65EX-16, D65PX-16, D65WX-16 Straight tilt power pitch dozer (ST-TPP)

Straight tilt power pitch dozer (ST-TPP) Sigma power pitch dozer (SGM-PP)
SEN04934-01
D65EX, PX, WX-16
90-100 11
SEN04934-01
D65EX, PX, WX-16 90-100 13

SEN04934-01

© 2012 KOMATSU
All Rights Reserved
90-100 14
SEN04935-03
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
90 Diagrams and drawings 1
200 Electrical diagrams and drawings

Electrical circuit diagram ................................................................................................................................. 3
Electrical circuit diagram (Sand terrain specification) ................................................................................... 41
Electrical circuit diagram (FRP canopy specification) ................................................................................... 47
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Electrical circuit diagram (1/10)
Electrical circuit diagram (1/10) D65EX-16, D65PX-16, D65WX-16
1
D65EX-16, D65PX-16, D65WX-16 (cab specification) (cab specification)

a This figure covers the equipment and devices that are unavailable as optional items in some areas.
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Electrical circuit diagram subex-
Electrical circuit diagram subextremely cold weather spec. (1/9) tremely cold weather spec. (1/9)
1
D65EX-16 (cab specification) D65EX-16 (cab specification)

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Electrical circuit diagramsubex-
Electrical circuit diagramsubextremely cold weather spec. (2/9) tremely cold weather spec. (2/9)
1

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Electrical circuit diagram subextremely cold weather spec.(3/9) tremely cold weather spec.(3/9)
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Electrical circuit diagram (Sand ter-
Electrical circuit diagram (Sand terrain specification) (1/3) rain specification) (1/3)
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Electrical circuit diagram (FRP can-
Electrical circuit diagram (FRP canopy specification) (1/6) opy specification) (1/6)
1
D65EX-16 D65EX-16
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All Rights Reserved
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SEN04887-09

BULLDOZER D65EX -16

Machine model Serial number

00 Index and foreword 00

D65EX, PX, WX-16 00-100 1

Composition of shop manual 1

Section Title Form Number

00 Index and foreword .................................................................................................................... SEN04923-09

01 General ...................................................................................................................................... SEN04924-02

10 Structure, function and maintenance standard........................................................................... SEN04925-04

20 Standard value table................................................................................................................... SEN04926-01

30 Testing and adjusting ................................................................................................................. SEN04927-04

00-100 2 D65EX, PX, WX-16

305 Troubleshooting by failure code (Display of code), Part 5..................................................SEN05035-01

50 Disassembly and assembly ........................................................................................................SEN04929-04

90 Diagrams and drawings ..............................................................................................................SEN04930-03

D65EX, PX, WX-16 00-100 3

00 Index and foreword

10 Structure, function and maintenance standard

00-100 4 D65EX, PX, WX-16

Idler (Without idler support automatic thrust adjustment) .............................................................................. 20

20 Standard value table

30 Testing and adjusting

D65EX, PX, WX-16 00-100 5

Testing engine speed .................................................................................................................................... 5

00-100 6 D65EX, PX, WX-16

200General information on troubleshootingSEN05030-01

D65EX, PX, WX-16 00-100 7

Failure code [CA323] Inj #5(L#5) Open/Short Error...................................................................................... 38

00-100 8 D65EX, PX, WX-16

Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection.................................................................... 4

D65EX, PX, WX-16 00-100 9

Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................................................. 36

00-100 10 D65EX, PX, WX-16

H-12 Work equipment does not move ........................................................................................................... 14

50 Disassembly and assembly

D65EX, PX, WX-16 00-100 11

Disassembly and assembly of HSS assembly .............................................................................................. 54

00-100 12 D65EX, PX, WX-16

Air conditioner component............................................................................................................................. 4

90 Diagrams and drawings

D65EX, PX, WX-16 00-100 13

D65EX-16, D65PX-16, D65WX-16 Bulldozer

Machine model Serial number

00 Index and foreword 00

200 Foreword and general information

D65EX, PX, WX-16 00-200 1

Safety notice (Rev. 2008/08-a)1

1. General precautions 7) If welding repairs are needed, always

00-200 2 D65EX, PX, WX-16

2. Preparations for work 6) When removing a cover which is under

D65EX, PX, WX-16 00-200 3

4. Precautions for sling work and making

00-200 4 D65EX, PX, WX-16

D65EX, PX, WX-16 00-200 5

00-200 6 D65EX, PX, WX-16

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly