17355274-Komatsu D65ex-17 D65px-17 D65wx-17 Dozer Bulldozer Service Repair Workshop Manual Download SN 1001 and Up

SEN05536-01
BULLDOZER D65EX -17

D65PX -17
D65WX -17
D65EX- 1001
SERIAL NUMBERS D65PX- 1001 and up
D65WX-1001
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number
D65EX-17 1001 and up

D65PX-17
D65WX-17
00 Index and foreword

1 00 Index and foreword
D65EX,PX,WX-17 00-1
Index
Index
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-15
Important safety notice ....................................................................................................... 00-15
How to read the shop manual.............................................................................................. 00-20
Explanation of terms for maintenance standard .................................................................... 00-22
Handling of fuel system devices .......................................................................................... 00-24
Handling of intake system parts........................................................................................... 00-25
Handling of hydraulic equipment.......................................................................................... 00-26
Method of disconnecting and connecting push-pull type coupler............................................. 00-28
Handling of electrical equipment.......................................................................................... 00-31
How to read electric wire code............................................................................................. 00-39
Precautions when performing operation ............................................................................... 00-42
Standard tightening torque table.......................................................................................... 00-45
List of abbreviation ............................................................................................................. 00-49
Conversion table ................................................................................................................ 00-53
01 Specification................................................................................................................................. 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-6
Weight table ...................................................................................................................... 01-30
Table of fuel, coolant and lubricants ..................................................................................... 01-38
10 Structure and function ................................................................................................................... 10-3
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
Damper ............................................................................................................................... 10-6
Cooling system .................................................................................................................... 10-8
Cooling fan pump ............................................................................................................... 10-10
Cooling fan motor............................................................................................................... 10-24
Power train............................................................................................................................... 10-32
Power train ........................................................................................................................ 10-32
HSS system ...................................................................................................................... 10-35
Overall drawing of power train unit ....................................................................................... 10-37
Power train mount .............................................................................................................. 10-39
Power train hydraulic piping drawing.................................................................................... 10-40
Transmission, steering, and brake control ............................................................................ 10-42
Universal joint .................................................................................................................... 10-44
Torque converter and PTO .................................................................................................. 10-45
Transmission ..................................................................................................................... 10-51
Transmission control valve.................................................................................................. 10-64
Forward and reverse clutch ECMV and gear shift clutch ECMV .............................................. 10-66
Lockup clutch ECMV .......................................................................................................... 10-73
Main relief valve and torque converter relief valve ................................................................. 10-77
Transmission lubricating oil relief valve ................................................................................ 10-80
Bevel gear shaft, HSS, and brake ........................................................................................ 10-81
Brake valve ..................................................................................................................... 10-102
Final drive ....................................................................................................................... 10-106
Undercarriage and frame......................................................................................................... 10-110
Main frame ...................................................................................................................... 10-110
Suspension ..................................................................................................................... 10-112
Track frame and idler cushion ........................................................................................... 10-114
Hydraulic system .................................................................................................................... 10-116
Hydraulic piping drawing................................................................................................... 10-116
Work equipment control .................................................................................................... 10-120
Hydraulic tank.................................................................................................................. 10-122
CLSS .............................................................................................................................. 10-124
Scavenging pump ............................................................................................................ 10-127
00-2 D65EX,PX,WX-17
Index
Steering lubricating oil pump and power train pump............................................................. 10-128

HSS pump....................................................................................................................... 10-129
HSS motor ...................................................................................................................... 10-150
Control valve ................................................................................................................... 10-159
Blade PPC valve .............................................................................................................. 10-186
Ripper PPC valve............................................................................................................. 10-194
Quick drop valve .............................................................................................................. 10-198
Work equipment lock solenoid valve .................................................................................. 10-201
Pitch selector solenoid valve ............................................................................................. 10-206
Angle control EPC valve ................................................................................................... 10-207
Hydraulic oil cooler bypass valve ....................................................................................... 10-212
PPC accumulator ............................................................................................................. 10-213
Work equipment ..................................................................................................................... 10-214
Work equipment............................................................................................................... 10-214
Ripper ............................................................................................................................. 10-217
Piston valve..................................................................................................................... 10-218
Cab and its attachments .......................................................................................................... 10-220
ROPS cab ....................................................................................................................... 10-220
Cab mount ...................................................................................................................... 10-222
Electrical system .................................................................................................................... 10-223
Engine control system ...................................................................................................... 10-223
Cooling system control system .......................................................................................... 10-226
Palm command control system.......................................................................................... 10-228
Machine monitor system ................................................................................................... 10-232
KOMTRAX system ........................................................................................................... 10-252
System component part.................................................................................................... 10-255
Sensors .......................................................................................................................... 10-270
20 Standard value table ..................................................................................................................... 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
30 Testing and adjusting .................................................................................................................... 30-3
General information on testing and adjusting................................................................................. 30-4
Tools for testing, adjusting, and troubleshooting ...................................................................... 30-4
Testing engine speed ........................................................................................................... 30-8
Measuring boost pressure................................................................................................... 30-10
Measuring exhaust gas temperature .................................................................................... 30-11
Measuring exhaust gas color............................................................................................... 30-13
Measuring and adjusting valve clearance ............................................................................. 30-15
Measuring compression pressure ........................................................................................ 30-17
Measuring blowby pressure ................................................................................................ 30-19
Measuring engine oil pressure............................................................................................. 30-21
Measuring EGR valve and KVGT oil pressure....................................................................... 30-22
Releasing remaining pressure from fuel system .................................................................... 30-23
Measuring fuel pressure ..................................................................................................... 30-24
Measuring fuel delivery, return rate and leakage ................................................................... 30-31
Handling cylinder cutout mode operation.............................................................................. 30-35
Handling no injection cranking operation .............................................................................. 30-36
Bleeding air from fuel system .............................................................................................. 30-37
Checking fuel circuit for leakage .......................................................................................... 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Replacing alternator belt ..................................................................................................... 30-40
Adjusting fuel dial and decelerator pedal .............................................................................. 30-41
Power train system ................................................................................................................... 30-43
Measuring power train oil pressure ...................................................................................... 30-43
Adjusting transmission output shaft speed sensor (replacement procedure) ............................ 30-48
Simple test procedure for brake performance ....................................................................... 30-49
Adjusting brake pedal ......................................................................................................... 30-50
D65EX,PX,WX-17 00-3
Index
Adjusting parking brake lever .............................................................................................. 30-52

Retrieval of disabled machine using brake release device ..................................................... 30-54
Undercarriage and frame........................................................................................................... 30-57
Adjusting idler clearance..................................................................................................... 30-57
Checking sprocket wear ..................................................................................................... 30-58
Checking and adjusting track shoe tension........................................................................... 30-59
Hydraulic system ...................................................................................................................... 30-60
Releasing remaining pressure in work equipment cylinder ..................................................... 30-60
Measuring and adjusting work equipment and HSS oil pressure............................................. 30-61
Measuring source pressure of control circuit ......................................................................... 30-64
Measuring PPC valve output pressure ................................................................................. 30-65
Adjusting play of work equipment PPC valve ........................................................................ 30-68
Isolating the parts causing hydraulic drift in blade and ripper .................................................. 30-70
Measure internal oil leakage of work equipment cylinder........................................................ 30-71
Checking fan speed ........................................................................................................... 30-72
Measuring fan circuit oil pressure ........................................................................................ 30-73
Bleeding air from hydraulic circuit ........................................................................................ 30-74
Work equipment ....................................................................................................................... 30-76
Adjusting work equipment lock lever .................................................................................... 30-76
Adjustment of straight tilt dozer............................................................................................ 30-77
Cab and its attachments ............................................................................................................ 30-79
Adjusting operator's cab ..................................................................................................... 30-79
Adjusting play of blade center ball........................................................................................ 30-82
Electrical system ...................................................................................................................... 30-83
Special functions of machine monitor ................................................................................... 30-83
Handling voltage circuit of engine controller........................................................................ 30-143
Adjustment method when controller has been replaced ....................................................... 30-144
Testing diodes ................................................................................................................. 30-146
Pm clinic ................................................................................................................................ 30-147
Pm Clinic service ............................................................................................................. 30-147
Pm Clinic check sheet ...................................................................................................... 30-153
40 Troubleshooting............................................................................................................................ 40-8
General information on troubleshooting ........................................................................................ 40-9
Instruction on troubleshooting ............................................................................................... 40-9
How to proceed troubleshooting .......................................................................................... 40-11
Check before troubleshooting.............................................................................................. 40-12
Testing procedure before troubleshooting............................................................................. 40-14
Classification and procedure for troubleshooting ................................................................... 40-23
Classification and procedures for troubleshooting numbers.................................................... 40-25
Information mentioned in troubleshooting table ..................................................................... 40-28
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 40-30
Connector list and layout .................................................................................................... 40-32
Connector contact identification........................................................................................... 40-45
T-branch box and T-branch adapter table ............................................................................. 40-82
Fuse locations table ........................................................................................................... 40-88
Precautions for cleaning and replacing KDPF (KCSF, KDOC) ................................................ 40-91
Troubleshooting by failure code (Display of code) ........................................................................ 40-93
Failure codes table............................................................................................................. 40-93
Failure code [1500L0] Transmission clutch:Abnormal.......................................................... 40-104
Failure code [15SAL1] Forward clutch:Fill High................................................................... 40-105
Failure code [15SALH] Forward clutch:Fill Low ................................................................... 40-107
Failure code [15SBL1] Reverse clutch:Fill High................................................................... 40-109
Failure code [15SBLH] Reverse clutch:Fill Low....................................................................40-111
Failure code [15SEL1] Speed 1st clutch:Fill High ................................................................ 40-113
Failure code [15SELH] Speed 1st clutch:Fill Low ................................................................ 40-115
Failure code [15SFL1] Speed 2nd clutch:Fill High ............................................................... 40-117
Failure code [15SFLH] Speed 2nd clutch:Fill Low ............................................................... 40-119
Failure code [15SGL1] Speed 3rd clutch:Fill High ............................................................... 40-121
Failure code [15SGLH] Speed 3rd clutch:Fill Low................................................................ 40-123
00-4 D65EX,PX,WX-17
Index
Failure code [15SJL1] L/U :Fill Hihg ................................................................................... 40-125

Failure code [15SJLH] L/U :Fill low .................................................................................... 40-127
Failure code [1800MW] P/L clutch:Slip ............................................................................... 40-129
Failure code [879AKA] Air Conditioner Inner Sensor Disconnection...................................... 40-130
Failure code [879AKB] Air Conditioner Inner Sensor Disconnection...................................... 40-131
Failure code [879BKA] Air Conditioner Outside Air Sensor Disconnection ............................. 40-132
Failure code [879BKB] Air Conditioner Outside Air Sensor Disconnection ............................. 40-133
Failure code [879CKA] Ventilating Sensor Disconnection .................................................... 40-134
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-135
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-136
Failure code [879EMC] Ventilation Abnormal ...................................................................... 40-137
Failure code [879FMC] A/M Damper Abnormal ................................................................... 40-138
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-139
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-140
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-141
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-142
Failure code [A1U0N3]: KDPF Dry Request (HC Release)................................................... 40-143
Failure code [A1U0N4] KDPF Dry Request (HC Release).................................................... 40-145
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-147
Failure code [AB00KE] Battery Charge Voltage Low ........................................................... 40-148
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-150
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-151
Failure code [B@CENS] P/L Oil Overheat .......................................................................... 40-152
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-153
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-154
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-155
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-157
Failure code [CA131] Throttle Sensor High Error................................................................. 40-159
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-161
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-163
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-165
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-167
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-169
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-171
Failure code [CA234] Eng Overspeed ................................................................................ 40-173
Failure code [CA221] Ambient Press Sens High Error ......................................................... 40-174
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-176
Failure code [CA227] Sens Supply 2 Volt High Error ........................................................... 40-178
Failure code [CA238] Ne Speed Sens Supply Volt Error ...................................................... 40-179
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-180
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-182
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-184
Failure code [CA281] Pump Press Balance Error ................................................................ 40-186
Failure code [CA295] Ambient Pressure Sensor In Range Error ........................................... 40-187
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-188
Failure code [CA323] Inj #5 (L#5) Open/Short Error ............................................................ 40-190
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-200
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-201
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-204
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-206
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-209
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-211
Failure code [CA435] Eng Oil Press SW Error .................................................................... 40-213
D65EX,PX,WX-17 00-5
Index
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-214

Failure code [CA442] Battery Voltage High Error................................................................. 40-216
Failure code [CA449] Rail Press Very High Error................................................................. 40-217
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-219
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-221
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-223
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-224
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-226
Failure code [CA553] Rail Press High Error ........................................................................ 40-228
Failure code [CA555] Crankcase Press High Error 2 ........................................................... 40-229
Failure code [CA556] Crankcase Pressure High Error 3 ...................................................... 40-230
Failure code [CA559] Rail Pump Press Low Error ............................................................... 40-231
Failure code [CA595] Turbocharger Speed High Error 2 ...................................................... 40-235
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-236
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-238
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-242
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-244
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-246
Failure code [CA698] ECM Internal Temp Sensor Low Error ................................................ 40-247
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-248
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-250
Failure code [CA1117] Engine Controller Partial Data Lost Error........................................... 40-255
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-256
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-258
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-261
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-262
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-264
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-266
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-268
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-270
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-272
Failure code [CA1921] KDPF Soot Level High Error 1 ......................................................... 40-275
Failure code [CA1942] Crankcase Press Sensor In Range Error .......................................... 40-281
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-282
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-283
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-285
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-287
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-288
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-290
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-292
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-294
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-297
Failure code [CA2311] lMV Solenoid Error.......................................................................... 40-298
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-299
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-301
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-303
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-304
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-306
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-308
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-310
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-312
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-314
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-316
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-318
Failure code [CA2387] KVGT Valve Servo Error ................................................................. 40-320
Failure code [CA2554] Exh Manifold Press Sens In Range error .......................................... 40-321
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-322
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-324
00-6 D65EX,PX,WX-17
Index
Failure code [CA2637] KDOC Blocked............................................................................... 40-326

Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-328
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-331
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-332
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-333
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-335
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-337
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-340
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-343
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-344
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-347
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-348
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-349
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-353
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-356
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-360
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-364
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-367
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-371
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-375
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-379
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-382
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-386
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-388
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-390
Failure code [D130KA] Neutral relay:Open ......................................................................... 40-391
Failure code [D130KB] Neutral relay:Short circuit................................................................ 40-393
Failure code [D19DKA] Amber light relay:Open .................................................................. 40-395
Failure code [D19DKB] Amber light relay:Short circuit ......................................................... 40-397
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-399
Failure code [D811MC] KOMTRAX Error............................................................................ 40-402
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-403
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX) ....................................... 40-404
Failure code [D8ALKB] Operating Lamp Short Circuit(KOMTRAX) ....................................... 40-406
Failure code [D8AQKR] CAN2 Discon(KOMTRAX) ............................................................. 40-407
Failure code [DAF0MB] Monitor Memory Error.................................................................... 40-408
Failure code [DAF0MC] Monitor Malfunction....................................................................... 40-409
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-410
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-412
Failure code [DAFGMC] GPS Module Error........................................................................ 40-413
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-414
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) ............................................ 40-416
Failure code [DAFQKR] CAN2 Discon ............................................................................... 40-417
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-418
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-419
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-423
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-428
Failure code [DBE0KT] PT controller:Abnormality in controller.............................................. 40-433
Failure code [DBE1KK] PT controller:Source voltage low..................................................... 40-434
Failure code [DBE2KK] PT controller:Output voltage low ..................................................... 40-436
Failure code [DBE5KK] PT:Sensor volt 5V (0) Out of normal range ....................................... 40-438
Failure code [DBE6KK] PT:Sensor volt 24V Out of normal range .......................................... 40-440
Failure code [DBE9KQ] PT controller:Type select signal ...................................................... 40-444
Failure code [DBELKA] Operating Lamp Open Circuit(PT Con)............................................ 40-445
Failure code [DBELKB] Operating Lamp Short Circuit(PT Con) ............................................ 40-447
Failure code [DBEQKR] CAN2 Discon (PT Con) ................................................................. 40-448
Failure code [DBERKR] CAN1 Discon (PT Con) ................................................................. 40-449
D65EX,PX,WX-17 00-7
Index
Failure code [DD12KA] Shift up Sw:Open .......................................................................... 40-450

Failure code [DD12KB] Shift up Sw:Short circuit ................................................................. 40-452
Failure code [DD13KA] Shift down Sw:Open ...................................................................... 40-454
Failure code [DD13KB] Shift down Sw:Short circuit ............................................................. 40-456
Failure code [DD14KA] Parking lever Sw:Open .................................................................. 40-458
Failure code [DD14KB] Parking lever Sw:Short circuit ......................................................... 40-460
Failure code [DDKFL4] Left Angle Sw:Signal mismatch ....................................................... 40-462
Failure code [DDKGL4] Right Angle Sw:Signal mismatch .................................................... 40-464
Failure code [DDKHKA] iB Sw:Open.................................................................................. 40-466
Failure code [DDKHKB] iB Sw:Short circuit ........................................................................ 40-468
Failure code [DDN7KA] Weq pitch SW: Open ..................................................................... 40-470
Failure code [DDN7KB] Pitch select solenoid:Short circuit ................................................... 40-472
Failure code [DDNLKA] Weq lock Sw:Open ....................................................................... 40-474
Failure code [DDNLKB] Weq lock Sw:Short circuit .............................................................. 40-476
Failure code [DGS1KA] Hyd oil temp sensor:Open ............................................................. 40-478
Failure code [DGS1KX] Hyd oil temp: signal abnormal ........................................................ 40-479
Failure code [DGT1KA] T/C oil temp sensor:Open .............................................................. 40-481
Failure code [DGT1KX] T/C oil temp sensor:Out of normal range ......................................... 40-482
Failure code [DH21KA] Weq pressure sensor:Open............................................................ 40-484
Failure code [DH21KB] Work equipment pressure sensor:Hot Short..................................... 40-486
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ....................................... 40-488
Failure code [DHTDKA] T/C pressure sensor:Open............................................................. 40-489
Failure code [DHTDKB] T/C pressure sensor:Hot Short....................................................... 40-491
Failure code [DK10KA] Fuel control Dial:Open ................................................................... 40-493
Failure code [DK10KB] Fuel control Dial:Short circuit .......................................................... 40-495
Failure code [DK30KA] ST lever1:Open ............................................................................. 40-497
Failure code [DK30KB] ST lever:Hot Short ......................................................................... 40-499
Failure code [DK30KX] ST lever:Main and Sub Error........................................................... 40-501
Failure code [DK30KZ] ST lever:Main and Sub Error ........................................................... 40-502
Failure code [DK30L8] ST lever:Signal mismatch................................................................ 40-503
Failure code [DK31KB] ST lever2:Hot Short ....................................................................... 40-506
Failure code [DK40KA] Brake potentiometer:Open.............................................................. 40-508
Failure code [DK40KB] Brake potentiometer:Hot Short........................................................ 40-510
Failure code [DK55KX] FR lever:Main and Sub Error .......................................................... 40-512
Failure code [DK55KZ] FR lever:Main and Sub Error........................................................... 40-513
Failure code [DK55L8] FR lever:Signal mismatch ............................................................... 40-514
Failure code [DK56KA] FR lever1:Open ............................................................................. 40-515
Failure code [DK56KB] FR lever1:Hot Short ....................................................................... 40-517
Failure code [DKH1KA] Pitch angle sensor:Open................................................................ 40-523
Failure code [DKH1KB] Pitch angle sensor:Hot Short.......................................................... 40-525
Failure code [DLM3KA] Fan rev. sensor:Open .................................................................... 40-527
Failure code [DLM3MB] Fan control:Mismatch.................................................................... 40-529
Failure code [DLT3KA] T/M out-speed sensor:Open............................................................ 40-530
Failure code [DLT3KB] T/M out-speed sensor:Short circuit .................................................. 40-532
Failure code [DV20KB] Back-up alarm :Short Circuit ........................................................... 40-533
Failure code [DW5AKA] Pitch select solenoid:Disconnection ............................................... 40-535
Failure code [DW5AKB] Pitch select solenoid:Short circuit................................................... 40-536
Failure code [DW5AKY] Pitch select solenoid:Hot short....................................................... 40-537
Failure code [DW7BKA] Fan reverse solenoid:Open ........................................................... 40-539
Failure code [DW7BKB] Fan reverse solenoid:Short circuit .................................................. 40-541
Failure code [DWN1KA] Hss EPC RH:Open....................................................................... 40-542
Failure code [DWN1KB] Hss EPC RH:Short circuit ............................................................. 40-543
Failure code [DWN1KY] Hss EPC RH:Hot short ................................................................. 40-544
Failure code [DWN2KA] Hss EPC LH:Open ....................................................................... 40-546
Failure code [DWN2KB] Hss EPC LH:Short circuit .............................................................. 40-547
Failure code [DWN2KY] Hss EPC LH:Hot short .................................................................. 40-548
00-8 D65EX,PX,WX-17
Index
Failure code [DWN5KA] Fan pump solenoid 1 :Open .......................................................... 40-550

Failure code [DWN5KB] Fan pump solenoid 1 :Short circuit ................................................. 40-551
Failure code [DWN5KY] Fan pump solenoid 1: Hot short ..................................................... 40-552
Failure code [DXA2KA] TVC solenoid 1: Open ................................................................... 40-554
Failure code [DXA2KB] TVC solenoid 1: Short circuit .......................................................... 40-555
Failure code [DXA2KY] TVC solenoid 1: Hot short .............................................................. 40-556
Failure code [DXH1KA] Lock-up ECMV:Open..................................................................... 40-558
Failure code [DXH1KB] Lock-up ECMV: Short circuit .......................................................... 40-560
Failure code [DXH1KY] Lock-up ECMV: Hot short .............................................................. 40-561
Failure code [DXH4KA] 1st clutch ECMV:Open .................................................................. 40-563
Failure code [DXH4KB] 1st clutch ECMV:Short circuit ......................................................... 40-564
Failure code [DXH4KY] 1st clutch ECMV:Hot short ............................................................. 40-565
Failure code [DXH5KA] 2nd clutch ECMV:Open ................................................................. 40-567
Failure code [DXH5KB] 2nd clutch ECMV:Short circuit ........................................................ 40-568
Failure code [DXH5KY] 2nd clutch ECMV:Hot short ............................................................ 40-569
Failure code [DXH6KA] 3rd clutch ECMV:Open .................................................................. 40-571
Failure code [DXH6KB] 3rd clutch ECMV:Short circuit......................................................... 40-572
Failure code [DXH6KY] 3rd clutch ECMV:Hot short ............................................................. 40-573
Failure code [DXH7KA] R clutch ECMV:Open .................................................................... 40-575
Failure code [DXH7KB] R clutch ECMV:Short circuit ........................................................... 40-576
Failure code [DXH7KY] R clutch ECMV:Hot short ............................................................... 40-577
Failure code [DXH8KA] F clutch ECMV:Open..................................................................... 40-579
Failure code [DXH8KB] F clutch ECMV:Short circuit............................................................ 40-580
Failure code [DXH8KY] F clutch ECMV:Hot short................................................................ 40-581
Failure code [DXJ4KA] Weq lock Sol.:Open ....................................................................... 40-583
Failure code [DXJ4KB] Weq lock Sol.:Short circuit .............................................................. 40-585
Failure code [DXJCKA] Blade angle left EPC:Open............................................................. 40-586
Failure code [DXJCKB] Blade angle left EPC:Short circuit ................................................... 40-587
Failure code [DXJCKY] Blade angle left EPC:Hot short ....................................................... 40-588
Failure code [DXJDKA] Blade angle right EPC:Open .......................................................... 40-590
Failure code [DXJDKB] Blade angle right EPC:Short circuit ................................................. 40-591
Failure code [DXJDKY] Blade angle right EPC:Hot short ..................................................... 40-592
Troubleshooting of electrical system (E-mode) .......................................................................... 40-594
E-1 Engine does not start (Engine does not crank) .............................................................. 40-594
E-2 Manual preheating does not work ................................................................................ 40-600
E-3 Automatic preheating does not work ............................................................................ 40-603
E-4 While preheating is working, preheating monitor does not light up .................................. 40-605
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-607
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor
lights up ............................................................................................................. 40-610
E-7 Air cleaner clogging monitor lights up in yellow while engine is running ........................... 40-611
E-8 Charge level monitor lights up while engine is running ................................................... 40-612
E-9 Engine coolant temperature monitor lights up while engine is running ............................. 40-614
E-10 Engine oil pressure monitor lights up while engine is running ....................................... 40-615
E-11 Power train oil temperature monitor lights up while engine is running ............................ 40-616
E-12 Hydraulic oil temperature monitor lights up while engine is running ............................... 40-617
E-13 Engine coolant temperature gauge does not indicate correct temparature ..................... 40-618
E-14 Fuel level gauge does not indicate correct level .......................................................... 40-619
E-15 Power train oil temperature gauge (multi-gauge) does not indicate correct
temperature ....................................................................................................... 40-621
E-16 Hydraulic oil temperature gauge (multi-gauge) does not indicate correct
temperature ....................................................................................................... 40-622
E-17 Operation mode does not change .............................................................................. 40-623
E-18 Gearshift mode does not change ............................................................................... 40-624
E-19 Operating customize switch does not display customize screen ................................... 40-625
E-20 Modifying setting on customize screen does not change setting of machine .................. 40-626
E-21 Reverse slow mode does not function properly ........................................................... 40-627
E-22 Alarm buzzer does not sound or does not stop sounding ............................................. 40-628
E-23 While starting switch is in OFF position, service meter is not displayed ......................... 40-629
D65EX,PX,WX-17 00-9
Index
E-24 Service mode cannot be selected .............................................................................. 40-630

E-25 Horn does not sound ................................................................................................ 40-631
E-26 Horn does not stop sounding..................................................................................... 40-632
E-27 Backup alarm does not sound ................................................................................... 40-633
E-28 Backup alarm does not stop sounding........................................................................ 40-635
E-29 Headlamp does not light up....................................................................................... 40-636
E-30 Rear lamp does not light up....................................................................................... 40-639
E-31 No wiper operates continuously or intermittently.......................................................... 40-641
E-32 Front wiper does not operate (Failure in both continuous and intermittent
operations)......................................................................................................... 40-644
E-33 Rear wiper does not operate (Failure in both continuous and intermittent
operations)......................................................................................................... 40-647
E-34 Left door wiper does not operate (Failure of both continuous and intermittent
operations)......................................................................................................... 40-650
E-35 Right door wiper does not operate (Failure of both continuous and intermittent
operations)......................................................................................................... 40-653
E-36 KOMTRAX system does not operate properly............................................................. 40-656
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-658
Information mentioned in troubleshooting table (H mode) .................................................... 40-658
System diagram of hydraulic and mechanical system.......................................................... 40-659
List of Failure Mode and Cause ......................................................................................... 40-661
H-1 Machine lacks power (insufficient drawbar pull) ............................................................ 40-664
H-2 Machine cannot travel (at 2nd or 3rd speed) ................................................................. 40-666
H-3 Machine does not start at all gear speeds..................................................................... 40-667
H-4 Machine travels only in one direction, either forward or in reverse .................................. 40-668
H-5 Large time lag at gear shifting or directional selection.................................................... 40-669
H-6 Machine cannot be steered (machine does not turn left or right) ..................................... 40-670
H-7 Steering speed or power is insufficient ......................................................................... 40-671
H-8 Brake does not operate .............................................................................................. 40-672
H-9 Torque converter does not lock up ............................................................................... 40-673
H-10 Power train oil overheats .......................................................................................... 40-674
H-11 Unusual noise is heard from around HSS and work equipment pump or HSS
motor ................................................................................................................. 40-675
H-12 All work equipment operates slowly ........................................................................... 40-676
H-13 All work equipment does not operate ......................................................................... 40-677
H-14 Blade lift speed or power is low ................................................................................. 40-678
H-15 Blade tilt speed or power is low ................................................................................. 40-679
H-16 Blade angle speed or power is low............................................................................. 40-680
H-17 Ripper lift speed or power is low ................................................................................ 40-681
H-18 Hydraulic drift of lifted blade is large........................................................................... 40-682
H-19 Hydraulic drift of tilted blade is large........................................................................... 40-683
H-20 Hydraulic drift of lifted ripper is large .......................................................................... 40-684
H-21 Fans speed is abnormal (high, low, or no rotation)....................................................... 40-685
H-22 Unusual noise is heard from around fan ..................................................................... 40-687
Troubleshooting of engine (S-mode)......................................................................................... 40-688
Information contained in troubleshooting table (S mode)...................................................... 40-688
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-689
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-690
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
does not start) .................................................................................................... 40-691
S-4 Startability is poor....................................................................................................... 40-692
S-5 Engine does not pick up smoothly ............................................................................... 40-694
S-6 Engine stops during operation ..................................................................................... 40-696
S-7 Engine runs rough or is unstable ................................................................................. 40-698
S-8 Engine lacks power .................................................................................................... 40-699
S-9 Exhaust gas is black (KDPF gets clogged in a short time) .............................................. 40-701
S-10 Engine oil consumption is excessive .......................................................................... 40-703
S-11 Engine oil becomes contaminated early...................................................................... 40-704
S-12 Fuel consumption is excessive .................................................................................. 40-705
00-10 D65EX,PX,WX-17
Index
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-706
S-14 Oil pressure drops .................................................................................................... 40-707
S-15 Fuel mixes into engine oil.......................................................................................... 40-708
S-16 Water mixes into engine oil (milky) ............................................................................. 40-709
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-710
S-18 Unusual noise is made ............................................................................................. 40-711
S-19 Vibration is excessive ............................................................................................... 40-712
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-713
S-21 Frequent active regeneration..................................................................................... 40-714
S-22 Active regeneration is long ........................................................................................ 40-715
S-23 White smoke is exhausted during active regeneration ................................................. 40-716
50 Disassembly and assembly ........................................................................................................... 50-3
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tool list................................................................................................................... 50-10
Sketches of special tools .................................................................................................... 50-20
Engine and cooling system ........................................................................................................ 50-35
Removal and installation of supply pump assembly............................................................... 50-35
Removal and installation of fuel injector assembly................................................................. 50-40
Removal and installation of cylinder head assembly.............................................................. 50-54
Removal and installation of radiator assembly ...................................................................... 50-72
Removal and installation of aftercooler and assembly ........................................................... 50-77
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-80
Removal and installation of power train oil cooler assembly ................................................... 50-82
Removal and installation of cooling fan drive assembly ......................................................... 50-84
Removal and installation of cooling fan motor assembly ........................................................ 50-86
Removal and installation of engine assembly ....................................................................... 50-88
Removal and installation of damper assembly ...................................................................... 50-95
Removal and installation of engine front seal ........................................................................ 50-98
Removal and installation of engine rear seal....................................................................... 50-101
Removal and installation of engine hood assembly ............................................................. 50-109
Removal and installation of fuel tank assembly ....................................................................50-111
Removal and installation of KDPF assembly....................................................................... 50-113
Disassembly and assembly of KDPF ................................................................................. 50-117
Removal and installation of KCCV assembly ...................................................................... 50-125
Removal and installation of air cleaner assembly ................................................................ 50-129
Power train............................................................................................................................. 50-130
Removal and installation of power train unit assembly ......................................................... 50-130
Disconnecting and connecting of power train unit assembly ................................................. 50-135
Disassembly and assembly of PTO ................................................................................... 50-140
Disassembly and assembly of torque converter .................................................................. 50-144
Disassembly and assembly of TORQFLOW transmission.................................................... 50-153
Disassembly and assembly of HSS ................................................................................... 50-177
Removal and installation of final drive assembly ................................................................. 50-196
Disassembly and assembly of final drive ............................................................................ 50-198
Removal and installation of track frame assembly ............................................................... 50-211
Removal and installation of idler assembly ......................................................................... 50-213
Disassembly and assembly of idler .................................................................................... 50-215
Removal and installation of recoil spring assembly.............................................................. 50-219
Disassembly and assembly of recoil spring ........................................................................ 50-220
Removal and installation of track roller assembly ................................................................ 50-224
Disassembly and assembly of track roller ........................................................................... 50-225
Removal and installation of carrier roller assembly .............................................................. 50-228
Disassembly and assembly of carrier roller......................................................................... 50-229
Separation and connection of track shoe assembly (Standard type track shoe) ..................... 50-232
Separation and connection of track shoe assembly (PLUS type track shoe) .......................... 50-235
Overall disassembly and assembly of track shoe (standard type track shoe) ......................... 50-236
D65EX,PX,WX-17 00-11
Index
Overall disassembly and assembly of track shoe (PLUS type track shoe) ............................. 50-249
Disassembly and assembly of one link in field (standard type track shoe).............................. 50-261
Disassembly and assembly of one link in field (PLUS type track shoe).................................. 50-268
Removal and installation of pivot shaft assembly ................................................................ 50-273
Removal and installation of equalizer bar assembly ............................................................ 50-274
Disassembly and assembly of equalizer bar side bushing.................................................... 50-276
Removal and installation of hydraulic tank assembly ........................................................... 50-277
Removal and installation of control valve assembly ............................................................. 50-280
Disassembly and assembly of control valve........................................................................ 50-284
Disassembly and assembly of blade PPC valve.................................................................. 50-285
Disassembly and assembly of ripper PPC valve ................................................................. 50-286
Removal and installation of HSS pump and cooling fan pump assembly ............................... 50-287
Removal and installation of steering lubrication pump and power train pump
assembly ........................................................................................................... 50-289
Removal and installation of cooling scavenging pump assembly .......................................... 50-291
Removal and installation of HSS motor assembly ............................................................... 50-292
Disassembly and assembly of hydraulic cylinder................................................................. 50-294
Work equipment ..................................................................................................................... 50-300
Removal and installation of blade assembly (ST-TPP dozer)................................................ 50-300
Removal and installation of blade assembly (PAT dozer) ..................................................... 50-302
Removal and installation of ripper assembly ....................................................................... 50-304
Removal and installation of ROPS cab assembly................................................................ 50-307
Removal and installation of operator's cab glass (adhesion glass) ........................................ 50-313
Removal and installation of operator's sea.......................................................................... 50-318
Removal and installation of seat belt .................................................................................. 50-319
Removal and installation of air conditioner unit assembly..................................................... 50-320
Removal and installation of air conditioner compressor assembly......................................... 50-324
Electric system ....................................................................................................................... 50-325
Removal and installation of machine monitor assembly ....................................................... 50-325
Removal and installation of engine controller assembly ....................................................... 50-326
Removal and installation of power train controller assembly................................................. 50-327
Removal and installation of mass air flow and temperature sensor ....................................... 50-329
Removal and installation of KOMTRAX terminal ................................................................. 50-330
60 Maintenance standard................................................................................................................... 60-2
Engine mount ...................................................................................................................... 60-3
Damper ............................................................................................................................... 60-4
Cooling system .................................................................................................................... 60-6
Cooling fan pump ................................................................................................................. 60-7
Power train............................................................................................................................... 60-12
Universal joint .................................................................................................................... 60-14
Transmission ..................................................................................................................... 60-18
Forward-reverse clutch ECMV and gear shift clutch ECMV .................................................... 60-23
Brake valve ....................................................................................................................... 60-32
Final drive ......................................................................................................................... 60-33
Sprocket............................................................................................................................ 60-36
Main frame ........................................................................................................................ 60-41
Suspension ....................................................................................................................... 60-43
00-12 D65EX,PX,WX-17
Index
Track frame and idler cushion ............................................................................................. 60-45

Idler .................................................................................................................................. 60-47
Track roller ........................................................................................................................ 60-49
Carrier roller ...................................................................................................................... 60-53
Track shoe ........................................................................................................................ 60-55
Hydraulic tank.................................................................................................................... 60-60
Scavenging pump .............................................................................................................. 60-61
Steering lubricating pump and power train pump................................................................... 60-62
HSS pump......................................................................................................................... 60-63
HSS motor ........................................................................................................................ 60-65
Control valve ..................................................................................................................... 60-67
Blade PPC valve ................................................................................................................ 60-74
Ripper PPC valve............................................................................................................... 60-76
Quick drop valve ................................................................................................................ 60-78
Work equipment lock solenoid valve .................................................................................... 60-80
Angle control EPC valve ..................................................................................................... 60-83
Work equipment ....................................................................................................................... 60-84
Work equipment................................................................................................................. 60-84
Cutting edge and end bit ..................................................................................................... 60-92
Ripper ............................................................................................................................... 60-94
Lift cylinder ........................................................................................................................ 60-95
Tilt cylinder ........................................................................................................................ 60-96
Pitch cylinder ..................................................................................................................... 60-97
Angle cylinder .................................................................................................................... 60-98
Ripper cylinder................................................................................................................... 60-99
Cab mount ...................................................................................................................... 60-100
80 Appendix...................................................................................................................................... 80-2
Air conditioner ............................................................................................................................ 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-16
Air conditioner controller ..................................................................................................... 80-17
Air conditioner compressor ................................................................................................. 80-18
Condenser ........................................................................................................................ 80-19
Receiver drier .................................................................................................................... 80-20
Sunlight sensor .................................................................................................................. 80-21
Outside air temperature sensor ........................................................................................... 80-22
Procedure for testing and troubleshooting ............................................................................ 80-23
Circuit diagram and arrangement of connector pins............................................................... 80-25
System diagram................................................................................................................. 80-27
Input and output signals of the air conditioner controller ......................................................... 80-28
Layout of air conditioner related parts and connectors ........................................................... 80-30
Testing air leakage (duct) .................................................................................................... 80-39
Testing with self-diagnosis function ...................................................................................... 80-42
How to enter the electrical system abnormality record screen in service mode of machine
monitor ................................................................................................................ 80-43
Testing vent (mode) changeover.......................................................................................... 80-45
Testing FRESH/RECIRC air changeover.............................................................................. 80-46
Testing sunlight sensor ....................................................................................................... 80-47
Testing (dual) pressure switch for refrigerant......................................................................... 80-48
Testing relays .................................................................................................................... 80-49
Troubleshooting chart 1 ...................................................................................................... 80-50
D65EX,PX,WX-17 00-13
Index
Failure code list related to air conditioner.............................................................................. 80-55

Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-56
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-57
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-58
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-60
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-62
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-63
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-64
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-66
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-67
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-68
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-69
A-2 Troubleshooting for compressor system (Air is not cooled)............................................... 80-71
A-3 Troubleshooting for blower motor system (Air does not come out or air flow is
abnormal) ............................................................................................................ 80-74
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-76
Troubleshooting with gauge pressure................................................................................... 80-78
Connection of service tool................................................................................................... 80-81
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-82
Handling of compressor oil.................................................................................................. 80-84
90 Diagrams and drawings................................................................................................................. 90-2
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Power train hydraulic circuit diagram...................................................................................... 90-7
Hydraulic circuit diagram....................................................................................................... 90-9
Electric circuit diagram .............................................................................................................. 90-21
Symbols in electric circuit diagram ....................................................................................... 90-21
Electric circuit diagram........................................................................................................ 90-25
Electric circuit diagram for air conditioner unit ....................................................................... 90-51
Index.................................................................................................................................................................... 1
00-14 D65EX,PX,WX-17
Foreword, safety and general information

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

cap and other clothes suited for welding work.
k Inappropriate handling creates an extreme • Before starting work, warm up your body
danger. Read and understand what is thoroughly to start work under good condition.
described in the Operation and Maintenance • Avoid continuing work for long hours and take
Manual before operating the machine. In rests at proper intervals to keep your body in
addition read this manual carefully and good condition. Take rests in specified safe
understand its contents before starting work. places.
• Before performing any greasing or repairs, read Safety points
all the safety labels stuck to the machine. For 1 Good arrangement
the locations of the safety labels and detailed 2 Correct work clothes
explanation of precautions, see the Operation Following work standard
3
and Maintenance Manual.
4 Making and checking signals
• Locate a place in the repair workshop to keep
Prohibition of operation and handling by
tools and removed parts. Always keep the tools 5
unlicensed workers
and parts in their correct places. Always keep
6 Safety check before starting work
the work area clean and make sure that there is
Wearing protective goggles (for cleaning or
no dirt, water, or oil on the floor. Smoke only in 7 grinding work)
the areas provided for smoking. Never smoke
Wearing shielding goggles and protectors (for
while working. 8 welding work)
• When performing any work, always wear safety
shoes and helmet. Do not wear loose work 9 Good physical condition and preparation
clothes, or clothes with buttons missing. Precautions against work which you are not
10 used to or you are used to too much
1. Always wear the protective eyeglasses when
hitting parts with a hammer. Preparation work
2. Always wear the protective eyeglasses when • Before adding oil or making any repairs, park the
grinding parts with a grinder, etc. machine on a hard and level ground, and apply
• When performing any work with two or more the parking brake and chock the wheels or
workers, always agree on the operating tracks to prevent the machine from moving.
procedure before starting. Always inform your • Before starting work, lower the work equipment
fellow workers before starting any step of the (blade, ripper, bucket, etc.) to the ground. If this
work. During the work, hang UNDER REPAIR is not possible, insert the lock pin or use blocks
warning tag in the operator's compartment. to prevent the work equipment from falling. In
• Only qualified workers must perform the work addition, be sure to lock all the control levers
and operation which require license or and hang warning tag on them.
qualification. • When disassembling or assembling, support the
• Keep all tools in good condition. Learn the machine with blocks, jacks, or stands before
correct way to use them, and use the proper starting the work.
ones of them. Before starting work, thoroughly • Remove all mud and oil from the steps or other
check the tools, machine, forklift truck, service places used to get on and off the machine.
car, etc. Always use the handrails, ladders or steps when
• If welding repairs are needed, always have a getting on or off the machine. Never jump on or
trained and experienced welder perform the off the machine. When a scaffolding is not
work. When performing welding work, always
D65EX,PX,WX-17 00-15
provided, use steps or a step ladder to secure When installing hoses and wires, be sure that
your footing. they will not be damaged by contact with other
parts when the machine is operated.
Precautions during work • When installing high pressure hoses and tubes,
• For the machine equipped with a battery make sure that they are not twisted. Damaged
disconnect switch, before starting the work, hoses and tubes are dangerous, so be
check that the system operating lamp is turned extremely careful when installing hoses and
OFF, and then turn the battery disconnect switch tubes for high-pressure circuits. In addition,
to the OFF (Q) position and pull the switch key check that connections of them are correct.
out. For machines without a battery disconnect • When assembling or installing parts, always
switch, before starting the work, remove the tighten them to the specified torques. When
cables from the battery. Always remove the installing protective parts such as guards, or
cable from the negative (–) terminal first. parts which vibrate violently or rotate at high
• Before disconnecting or removing components speeds, be particularly careful to check that they
of the oil, water, or air circuits, first release the are installed correctly.
remaining pressure completely from the circuit. • When aligning two holes, never insert your
When removing the oil filter cap, a drain plug, or fingers or hand. Be careful not to get your
an oil pressure pickup plug, loosen it slowly to fingers caught in a hole.
prevent the oil from spurting out. • When measuring hydraulic pressure, check that
• The coolant and oil in the circuits are hot when the measuring tools are correctly installed.
the engine is shut down. Be careful not to get • Take care when removing or installing the tracks
scalded. Wait for the oil and coolant to cool of track-type machines. When removing the
before performing any work on the oil or water track, the track separates suddenly, so never let
circuits. anyone stand at either end of the track.
• Before starting work, shut down the engine. • If the engine is operated for a long time in a
When working on or around a rotating part, in place which is not ventilated well, you may suffer
particular, shut down the engine. When checking from gas poisoning. Accordingly, open the
the machine without stopping the engine windows and doors to ventilate well.
(measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to get Precautions for slinging work and making
rolled or caught in rotating parts or moving parts. signals
• When raising a heavy component (heavier than • Only one appointed worker must make signals
25 kg), use a hoist or crane. Before starting work, and co-workers must communicate with each
check that the slings (wire ropes, chains, and other frequently. The appointed signaler must
hooks) are free from damage. Always use slings make specified signals clearly at a place where
which have ample capacity and install them to he (she) is well seen from the operator's seat
proper places. Operate the hoist or crane slowly and where he (she) can see the working
to prevent the component from hitting any other condition easily. The signaler must always stand
part. Do not work with any part still raised by the in front of the load and guide the operator safely.
hoist or crane. 1. Do not stand under the load.
• When removing a cover which is under internal 2. Do not step on the load.
pressure or under reaction force of a spring, • Check the slings before starting sling work.
always leave two bolts in diagonal positions. • Keep putting on gloves during sling work. (Put
Loosen those two bolts gradually and alternately on leather gloves, if available.)
to release the pressure, and then remove the • Measure the weight of the load by the eye and
cover. check its center of gravity.
• When removing components, be careful not to • Use proper sling according to the weight of the
break or damage the electrical wiring. Damaged load and method of slinging. If too thick wire
wiring may cause electrical fires. ropes are used to sling a light load, the load may
• When removing piping, stop the fuel or oil from slip and fall.
spilling out. If any fuel or oil drips onto the floor, • Do not sling a load with one wire rope alone. If it
wipe it off immediately. Fuel or oil on the floor is slung by one wire rope, It may rotate and slip
can cause you to slip and can even cause fires. out of the rope. Install two or more wire ropes
• As a general rule, do not use gasoline to wash symmetrically.
parts. Do not use it to clean electrical parts, in
particular. k Slinging with one rope may cause turning of
• Be sure to assemble all parts again in their the load during hoisting, untwisting of the
original places. Replace any damaged parts and rope, or slipping of the rope from its original
parts which must not be reused with new parts.
00-16 D65EX,PX,WX-17
winding position on the load, which can result

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

brake, clutch, controller, rails, over wind stop
device, ground fault circuit interrupter, crane
collision prevention device, and power
application warning lamp, and check safety.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Check the direction indicator plates (north, south,
east, and west) and the directions of the control
buttons without fail.
D65EX,PX,WX-17 00-17
• Do not sling a load at an angle. Do not move the Precautions for disconnecting and connecting
crane while the slung load is swinging. hoses and tubes in air conditioner circuit
• Do not raise or lower a load while the crane is
Disconnection
moving longitudinally or laterally.
• Do not drag a sling. k Disconnection although the refrigerant
• When lifting up a load, stop it just after it leaves (refrigerant gas: R134a) used on the
the ground and check safety, and then lift it up. machine's air conditioner is less destructive
• Consider the travel route in advance and lift up a to the ozone layer for environmentally
load to a safe height. friendliness, it is not allowed to be released
• Place the control switch in a position where it will into the atmosphere as is. Whenever
not be an obstacle to work and passage. disconnecting the air conditioner gas circuit,
• After operating the hoist, do not swing the be sure to recover the refrigerant gas to
control switch. reuse it.
• Remember the position of the main switch so
that you can turn off the power immediately in an a Ask a qualified person for collection, and charge
emergency. of the refrigerant (R134a).
• If the hoist stops because of a power failure, turn a Never release the refrigerant (R134a) to the
the power switch OFF. When turning on a switch atmosphere.
which was turned OFF by the ground fault circuit
interrupter, check that the devices related to that k If refrigerant gas (R134a) gets in your eyes,
switch are not in operating condition. you may lose your sight. And if it touches
• If you find an obstacle around the hoist, stop the your skins, you may suffer from frostbite.
operation. Accordingly, put on protective eyeglasses,
• After finishing the work, stop the hoist at the gloves and working suits with long sleeves
specified position and raise the hook to at least while you are collecting or filling the
two meters above the floor. Do not leave the refrigerant (R134a).
sling attached to the hook.
• When loosening the nuts fixing air conditioner
Selecting wire ropes hoses and tubes, be sure to use two wrenches;
• Select adequate ropes depending on the weight use one wrench to fix and use the other one to
of parts to be hoisted, referring to the table loosen the nut.
below
Connection
Wire ropes (standard "Z" twist ropes without
• When installing the air conditioner hoses and
galvanizing) (JIS G3525, No. 6, Type 6x37-A)
tubes, take care to prevent any dirt, dust or
Nominal water from entering.
diameter of rope Allowable load
• When installing the air conditioner hoses and
mm kN ton tubes, check that O-rings are fitted to their joints.
10 8.8 0.9 • Once an O-ring is used, it is deformed and
12 12.7 1.3 deteriorated. Accordingly, do not reuse it.
14 17.3 1.7 • When removing O-rings, use a soft tool so that
16 22.6 2.3 the piping will not be damaged.
18 28.6 2.9 • Check that there is no defect or deterioration on
20 35.3 3.6 the O-ring.
• Apply compressor oil for refrigerant (R134a) to
25 55.3 5.6
the O-ring.
30 79.6 8.1
40 141.6 14.4 a However, do not apply oil to the threads
50 221.6 22.6 portion of a bolt, nut or union.
60 318.3 32.4 Manufacturer Part name
DENSO ND–OIL8
a The allowable load is one-sixth of the breaking
VALEO
strength of the rope to be used (Safety THERMAL ZXL100PG (equivalent to PAG46)
coefficient: 6). SYSTEMS
SANDEN SP–10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with
00-18 D65EX,PX,WX-17
the other wrench to the specified torque (Use a

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

"Precautions for disconnection and connection
of air conditioner piping".
D65EX,PX,WX-17 00-19
How to read the shop manual

(Rev. 2011/02)
• 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.
• Materials and specifications are subject to change without notice.
• 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.
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 contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of each component. It serves not only to give an
understanding for the structure of each component, but also serves as reference material for
troubleshooting.
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 tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are
explained in "Standard value table".
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.
60. Maintenance standard
• This section gives maintenance standard values of each component. The maintenance standard sub-
section explains the criteria and remedies for disassembly and service.
80. Appendix
• The section contains the equipment which can not be class, field in the other sections.
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment.
90 Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
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.
Filing method
• File pages in the correct order of the page numbers printed in the LIST OF REVISED PAGES.
• Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)
• Revisions
The revised pages are shown in the LIST OF REVISED PAGES.
00-20 D65EX,PX,WX-17
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol Item Description
Safety Special safety precautions which are necessary when performing work are
k described.
Special technical precautions or other precautions for preserving
a Caution standards which are necessary when performing work are described.
Weight of parts of component or parts are indicated. Caution necessary
4 Weight when selecting hoisting wire, or when working posture is important, etc.
are described.
Tightening
3 Tightening torque of the places that requires special attention.
torque
2 Coat Places to be coated with adhesives, etc. during assembly are indicated.
5 Oil, coolant Places where oil, etc. must be added, and capacity are indicated.
Places where oil, etc. must be drained, and quantity to be drained are
6 Drain
indicated.
Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
D65EX,PX,WX-17 00-21
Explanation of terms for maintenance standard

(Rev. 2011/02)
• The maintenance standard chapter describes the criteria for replacing or reusing products or parts in the
machine disassembly and maintenance work. The following terms are used to describe the criteria.
Standard dimension and tolerance

• To be accurate, the finished dimension of parts
is slightly different from one to another.
• To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
• The above dimension set is called the "standard
dimension" and the range of difference from the
standard dimension is called the "tolerance".
• The tolerance with the symbols of + or is
indicated on the right side of the standard
dimension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example) 120 (–0.022/–0.126)
• Usually, the dimension of a hole and the
dimension of the shaft to be inserted into that
hole are indicated by the same standard
dimension and different tolerances of the hole
and shaft. The tightness of fit is decided by the
tolerance. Standard interference
• Indication of dimension of rotating shaft and hole • When the diameter of a hole of a part shown in
and their related drawing. the given standard dimension and tolerance
Example: table is smaller than that of the shaft to be
Standard Tolerance inserted, the difference between those
dimension Shaft Hole diameters is called the "interference".
-0.030 +0.046 • Subtract the maximum dimension of the hole
60 from the minimum dimension of the shaft and
-0.076 0
call it (A). Subtract the minimum dimension of
Standard clearance and standard value the hole from the maximum dimension of the
• The clearance made when new parts are shaft and call it (B). The range between (A) and
assembled is called the standard clearance, (B) is the "standard interference".
which is indicated by the range from the • After repairing or replacing some parts, measure
minimum clearance to the maximum clearance. the dimension of their hole and shaft and check
• When some parts are repaired, the clearance is that the interference is in the standard range.
generally adjusted to the standard clearance.
Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimension of parts changes due to the wear
"standard value", which is indicated by a range or deformation while they are used. When the
or a target value. dimension charges exceeding certain valve,
• When some parts are repaired, the value of parts can not be used any longer. This value is
performance/function is set to the standard called the "repair limit".
value. • If a part is worn to the repair limit, it must be
replaced or repaired.
00-22 D65EX,PX,WX-17
• The performance and function of products

lowers while they are used. When alternative
charactaristic value of the performance and
function towers exceeding certain limit, it fluence
operation etc. This value is called the allowable
value or allowable dimension
• If a product deviates from the allowable value, it
must be checked or repaired. However, since
the allowable values are generally estimated
from various tests or experiences in most cases,
it must be judged after considering the operating
condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• If the interference between the parts exceeds
the allowable interference, they must be
replaced or repaired.
D65EX,PX,WX-17 00-23
Handling of fuel system devices

(Rev. 2011/02)
• The common rail fuel injection system (CRI)
consists of more precise parts than the
conventional fuel injection pump and nozzles. If
foreign matter enters this system, it can cause a
problem. Use special care to prevent entry of
foreign matter when performing inspection and
maintenance of the fuel system.
Be careful of the work environment

• Avoid replacing filters or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
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.
Cleaning off dusts

• Wash the system carefully with clean fuel if
dusts enter the system.
Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzles, it
employs a high-efficiency special filter to prevent
foreign matter from entering it. If a filter other
than the genuine one is used, the fuel system
may have a trouble. Accordingly, never use such
a filter.
00-24 D65EX,PX,WX-17
Handling of intake system parts

(Rev. 2011/02)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the conventional turbocharger.
If foreign matter enters this system, it can cause
a problem. Use special care to prevent entry of
foreign matter when servicing the air intake
system.

• Avoid repairing the machine in rain or high winds,
or at places where there is a lot of dust.
Sealing openings
• Install a cap, tape, plastic bag, etc. to the open
ends of disconnected piping to prevent entry of
foreign matter. Never leave the openings
uncovered nor plug the openings with rags.
Foreign matter will enter the system.
D65EX,PX,WX-17 00-25
Handling of hydraulic equipment

(Rev. 2011/02)
• With the increase in pressure and precision of hydraulic components, the most common cause of failure is
dirt (foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding
hydraulic oil, or when disassembling or assembling hydraulic components.

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

• When disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the Preventing intrusion of foreign materials during
performance should be checked with special refilling operations.
test equipment. • Be careful not to let any foreign materials 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
cleaning device is used, it is possible to filter out
the dirt that has been collected during storage,
so this is an even more effective method.
Sealing openings
• After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any foreign materials from
entering. If the opening is exposed or is blocked
with a rag, there is a danger of foreign materials
entering or of the surrounding area being Replacing hydraulic oil while its temperature is
contaminated by leaking oil, so never do this. Do high
not simply drain oil out onto the ground, but • When hydraulic oil or other oil is warm, it flows
collect it and ask the customer to dispose of it, or easily. In addition, the sludge can also be
take it back with you for disposal. drained out easily from the circuit together with
the oil, so it is better to change the oil when it is
still warm. When changing the oil, the old
hydraulic oil must be drained out as much as
possible. (Drain the oil not only from the
hydraulic tank, but also from the filter and the
drain plug hole 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.
00-26 D65EX,PX,WX-17
Flushing operations
• After disassembling and assembling the
equipment, or changing the oil with new one,
use flushing oil to remove the contaminants,
sludge, and old oil from the hydraulic circuit.
Normally, flushing is performed twice. Primary
flushing is performed by use of flushing oil and
secondary flushing is performed by use of the
specified hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
D65EX,PX,WX-17 00-27
Method of disconnecting and connecting push-pull type coupler

(Rev. 2011/02)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank slowly to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3), aligning them with each
other. (Fig. 4)
a The adapter can be pushed in approximately
3.5 mm. a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
a Do not hold rubber cap portion (4).
the other side perfectly, pull it back to check the
2. While hose joint (2) is pushed into adapter (3),
connecting condition (Fig. 5)
press rubber cap portion (4) against adapter (3)
until it "clicks". (Fig.2) a When the hose is pulled back, the rubber cap
3. Hold hose adapter (1) or hose (5) and pull it out. portion moves toward the hose
(Fig. 3) approximately 3.5 mm. This does not
indicate abnormality, however.
a Since some hydraulic oil flows out, prepare
an oil container.
00-28 D65EX,PX,WX-17
Type 2
Disconnection
1. Hold the tightening adapter portion and push
body (7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
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 disconnect it. (Fig. 8)
Connection
• Hold the tightening adapter portion and push
contacts contact surface (a) of the hexagonal
D65EX,PX,WX-17 00-29
Type 3
Disconnection
1. Hold the tightening adapter portion and push
contacts contact surface (b) of the hexagonal
2. While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the male
end. (Fig. 11)
3. While holding the condition of Steps 1) and 2),
pull out whole body (9) to disconnect it. (Fig. 12)
Connection
• Hold the tightening adapter portion and push
contacts contact surface (b) of the hexagonal
00-30 D65EX,PX,WX-17
Handling of electrical equipment

(Rev. 2011/02)
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
performed. 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".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted 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 Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For • The pins of the male and female connectors are
this reason, it is necessary to be extremely attached to wires by crimping or soldering. If
careful when handling wiring harnesses. excessive force is applied to the wire, the joint
area may become loose, which may result in a
defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective contact
between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the harness is pulled to disconnect the
occur because the male connector is not connector, or components are lifted with a crane
properly inserted into the female connector, or while the harness is still connected, or a heavy
because one or both of the connectors is object hits the harness, the crimping of the
deformed or the position is not correctly aligned, connector may separate, or the soldering may
or because there is corrosion or oxidization of be damaged, or the harness may be broken.
the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connector appoximately ten
times.
D65EX,PX,WX-17 00-31
dry cloth or blow it with compressed air and

spray it with electrical contact cleaner.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier, so
remove the oil and water from the
compressed air completely before cleaning
with compressed air.
High-pressure water entering connector

• The connector is designed to make it difficult for
water to enter (drip-proof structure), 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 spray 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 to drain it. Therefore, if water
should get into the connector, the pins will be
short-circuited by the water, so if any water gets Removing, installing, and drying connectors
and wiring harnesses
in, immediately dry the connector or take other
Disconnecting connectors
appropriate action before passing electricity
through it. 1. Hold the connectors when disconnecting.
• 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
them apart. For connectors which have a
lock stopper, press down the stopper with
your thumb and pull the connectors apart.
a Never pull with one hand.
Entry of water or mud or dirt when disconnecting a

connector
• If any water or mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting a connector, wipe off any
stuck water or dirt using a piece of dry cloth or
blow it with compressed air.
Oil or mud or dirt stuck to connector 2. When removing from clips
• If any oil or grease are stuck to the connector • Both of the connector and clip have stoppers,
and an oil film is formed on the mating surface of which are engaged with each other when the
the male and female pins, the oil will prevent connector is installed.
electricity from passing through, resulting in
defective contact. If any oil or grease or mud or
dirt is stuck to the connector, wipe it off with a
00-32 D65EX,PX,WX-17
• Check that connector pins are free from

deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water, or dirt are stuck to the
connector, wipe it off with a dry cloth. If any
water is 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.
• When removing a connector from a clip, pull
a If there is any damage or breakage, replace
the connector in a parallel direction to the clip
the connector.
for removing stoppers.
2. Fix the connector securely.
a If the connector is pried up and down or • Align the position of the connectors correctly
to the right or left, the housing may break. and then fit them securely. For connectors
with the lock stopper, push in the connector
until the stopper "clicks" into position.
3. Action to take after removing connectors

• After removing a connector, cover it with a
vinyl bag to prevent entry of dust, dirt, oil, or 3. Correcting protrusion of the boot and
water to the contact portion. misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness is misaligned or the clamp is
cover the connector. out of position, adjust it to its correct position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
Connecting connectors
1. Check the connector visually.
• Check that there is no oil, dirt, or water stuck
to connector pins (joint portion).
D65EX,PX,WX-17 00-33
• If the connector clamp is removed, be sure to • If there is any oil or dirt on the wiring harness,
return it to its original position. Also check wipe it off with a dry cloth. Avoid washing it in
that there are no loose clamps. 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 follows.
1. Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is the risk that oil in
the air may cause defective contact,
remove oil and water in the air before
starting air blow.
Deutsch connector (DT8-pin, DT12-pin)

Disconnection
1. While pressing locks (a) and (b), pull out female
connector (2).
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 hot air is used in
order to prevent the connector or related
Connection parts from becoming too hot, as this will
cause deformation or damage to the
1. Push in female connector (2) horizontally until
connector.
the lock clicks. (Arrow: x)
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: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins
caused by water.
Drying wiring harness
00-34 D65EX,PX,WX-17
a After completely drying the connector,

blow it with contact restorer and
reassemble.
Connection
1. Insert the connector straight until it "clicks".
Slide, lock type (Type 2) (FRAMATOME-24)

Handling of connectors used on engine • 107/114/125 series
• Intermediate connector between machine wiring
a Mainly, following engines are object for following
harness and engine wiring harness
connectors.
Examples)
• 95E-5 Intermediate connector (engine wiring harness):
• 107E-1, 107E-2 OEM CONNECTION (107/114/125 series)
• 114E-3, 114E-5 Disconnection
• 125E-5, 125E-6
1. Slide down lock (red) (L1).
• 140E-5, 140E-6
• 170E-5
• 12V140E-3
Slide, lock type (Type 1) (FRAMATOME-3,
FRAMATOME-2)
• 95/107/114/125/140/170/12V140 Series
• Various pressure sensors and Ne speed sensor
Examples)
Charge (boost) pressure sensor in the air intake
manifold: PIM (125/170/12V140 series)
Oil pressure sensor: POIL (125/170/12V140
series)
Oil pressure switch (95/107/114 series)
Ne speed sensor on flywheel housing: Ne (95/ 2. While pressing lock (L2), pull out connector (1).
107/114/125/140/170/12V140 series)
Ambient pressure sensor: PAMB (125/170/
12V140 series)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a Even if lock (L2) is pressed, connector (1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A with a
small flat-head screwdriver while press lock
(L2), and then pull out connector (1) toward
you.
a Lock (L2) is located in the back of connector
(1).
D65EX,PX,WX-17 00-35
Connection • 107 series

1. Insert the connector straight until it "clicks".
Pull lock type (PACKARD-2)

• 95/107/114/125/140/170/12V140 Series
• Various temperature sensors
Examples)
Charge (boost) temperature sensor in the air
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR and other.
Disconnection
1. Disconnect the connector by pulling lock (B) (on
the wiring harness side) of connector (2) a If the lock is located on the underside, use
outward. flat-head screwdriver [1] since you cannot
insert your fingers.
While pressing up lock (C) of the connector
with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
Connection
1. Insert the connector straight in until it "clicks".
Push lock type (1)

• 95/107/114 series
Connection
Examples)
Fuel pressure sensor in common rail (BOSCH-3) 1. Insert the connector straight until it "clicks".
Disconnection
Push lock type (2)
1. While pressing lock (C), pull out connector (3) in • 107/114 series
the direction of the arrow. Examples)
• 114 series Charge (boost) pressure sensor in the air intake
manifold (SUMITOMO-4)
Disconnection
1. While pressing lock (D), pull out connector (4) in
the direction of the arrow.
00-36 D65EX,PX,WX-17
Connection Connection
1. Insert the connector straight in until it "clicks". 1. Insert the connector straight in until it "clicks".
Push lock type (3) Turn-housing type (Round green connector)

• 95/125/140/170/12V140 series • 140 series
Disconnection Example) Charge (boost) pressure sensor in the
1. While pressing lock (E) of the connector, pull out air intake manifold: PIM (CANNON-4), etc.
connector (5) in the direction of the arrow. Disconnection
Example) Fuel pressure sensor in common rail 1. Turn housing (H1) in the direction of the arrow.
PFUEL etc (AMP-3)
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 harness
side.
Example) Injection pressure control valve of

supply pump: PCV (SUMITOMO-2)
Connection
1. Insert the connector to the end, while aligning its
groove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".
Example) Speed sensor of supply pump: G

(SUMITOMO-3)
a Pull the connector straight up.
D65EX,PX,WX-17 00-37
connected to the controller.Fit an arc welding

ground close to the welding point.
Precautions for troubleshooting electrical

circuits
• Be sure to turn the power "OFF" before
disconnecting or connecting connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check by disconnecting and connecting the
related connectors several times.
• Be sure to connect any disconnected
connectors before going on to the next step.
Handling controller
a If the power is turned ON with the connectors
• Electronic circuits for control including
still disconnected, unnecessary warning not
microcomputers are assembled in the controller.
related to the part where an abnormality
These electronic circuits inside must be handled
occurs will be displayed.
with care since they control the machine.
• When performing troubleshooting of circuits
• Do not place objects on top of the controller.
(measuring the voltage, resistance, continuity, or
current), wag the related wiring harnesses and
connectors several times and check that the
tester reading does not change.
a If there is any value change on the tester,
there may be a defective contact in the
circuit.
• Cover the control connectors with tape or a vinyl

bag. Never touch the connector contacts with
your hand.
• During rainy weather, do not leave the controller
in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
temperature even for a short period of time.
(Place it on a suitable dry stand.)
• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all wiring harness connectors
00-38 D65EX,PX,WX-17
How to read electric wire code

(Rev. 2011/02)
• In the electric circuit diagram, material, thickness, and color of each electric wire are indicated by symbols.
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 nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

• AV and AVS are different only in thickness and outside diameter of the coating. CAVS has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Operating
Type Sym- temperature Example of use
Material
bol range (˚C)
Low-voltage Conduc- Annealed copper wire for General wiring
wire for AV tor electric appliance
automobiles (nominal No. 5 and above)
Insulator Soft polyvinyl chloride
Thin low- Conduc- Annealed copper wire for
voltage wire for tor electric appliance General wiring
automobile AVS
(nominal No. 3 and below)
Insulator Soft polyvinyl chloride -30 to +60
(type 1)
Thin low- Conduc- Annealed copper wire for
tor electric appliance For mid- to small-size
voltage wire for
automobile CAVS excavators
Insulator Soft polyvinyl chloride (nominal No. 1.25 and below)
(type 2)
Heat resistant Conduc- Annealed copper wire for General wiring in extremely cold
low-voltage tor electric appliance weather district. For wiring in a
AEX -50 to +110 place of high atmospheric
wire for Heat-resistant crosslinked
automobiles Insulator polyethylene temperature
D65EX,PX,WX-17 00-39
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/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
Conduc- strand
tor Cross-
section 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 –
Coating D
AV Standard – – – – – – – 4.6
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/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
Conduc- strand
tor Cross-
section 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 – – – – – – – – –
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/Circular 11/Circular 16/Circular
– – –
Diameter of compressed compressed compressed
Conduc- strand
tor Cross-
section – 0.56 – 0.88 – 1.29
area (mm2)
d (approx.) – 0.9 – 1.1 – 1.4
Coating D
CAV- – – –
Standard 1.6 1.8 2.1
S
a "f" of nominal No. denotes "flexible".
00-40 D65EX,PX,WX-17
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
a 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.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes

Type of wire AVS, AV, CAVS 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-17 00-41
Precautions when performing operation

(Rev. 2011/02)
• When performing "removal or installation", "disassembly or assembly" of units, be sure to follow the
general precautions given below.
Precautions for removal work

• If the coolant contains antifreeze, dispose of it correctly as chemicals.
• After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
• When draining oil, prepare an adequate-size container to catch the oil.
• Check the match marks showing the installation position, and put match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installation position to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When slinging component, be sure to use lifting tool strong enough.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• 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
Put the following plugs into the piping after disconnecting it during disassembly works.
Face seal type hoses and tubes
Nominal Plug (nut end) Nut (elbow end)
No.
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
Split flange type hoses and tubes
Nominal Flange (hose end) Sleeve head (tube end) Split flange
No.
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part 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
00-42 D65EX,PX,WX-17
Precautions for installation work

• Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
• Install the hoses without twisting or interference and fix them with intermediate clamps, if equipped.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean and degrease the part, and coat the threaded portion with two to three
drops of adhesive.
• When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making sure
that the surface is free from dirt or damage.
• Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
• After installing the snap rings, check that the snap ring is settled in the ring groove completely.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
them securely.
• When using eyebolts, check that there is no deterioration or deformation, screw them in fully, and align the
direction of the hook.
• When installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on one
side.
a When the cylinders, hydraulic pumps and other hydraulic component are removed for repair, and then
reassembled again, be sure to bleed the air as follows before operating the hydraulic cylinders for the first
time.
1. Start and run the engine at low idle.
2. Operate the work equipment control lever to operate the hydraulic cylinder and stop at 100 mm off the
end of its stroke. Repeat this four to five times.
3. Next, operate the hydraulic cylinder three to four times to the end of its stroke.
a When using the machine for the first time after it has been repaired or after a long period of storage, follow
the same procedure.
Precautions for completing work

Refilling of coolant, oil and grease
• If the coolant is drained, close the drain valve securely, and add coolant to the specified level. Run the
engine to circulate the coolant through the system. Then add the coolant to the specified level again if
necessary.
• If the hydraulic component is removed and installed again, add engine oil to the specified level. Run the
engine to circulate the oil through the system. Then add the oil to the specified level again if necessary.
• If the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system after
reassembling the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
Check of installed condition of cylinder head and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any part is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
D65EX,PX,WX-17 00-43
Check of engine piping for damage and looseness

Intake and exhaust Check the piping for damage, the mounting bolts and nuts for looseness, and the
system joints for air suction and exhaust gas leakage.
If any part is loose or damaged, retighten or repair it.
Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the
joints for water leakage.
Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the
joints for fuel leakage.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounts for a crack and damage. If any part is
damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loose, retighten it.
Check of KDPF or muffler function
• Check KDPF or muffler for unusual noise and sound different from that of a new one.
If any abnormal noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly
and assembly".
00-44 D65EX,PX,WX-17
Standard tightening torque table

(Rev. 2011/02)
Table of tightening torque for bolt and nuts

a Unless otherwise specified, tighten metric bolt and nut to the torque shown in the following table.
1. The following table applies to the bolt in Fig. A.
Thread Width Tightening torque
diameter across flats
(Nm) (kgm)
(mm) (mm)
6 10 (10) 11.8 to 14.7 1.2 to 1.5
8 13 (12) 27 to 34 2.8 to 3.5
10 17 (14) 59 to 74 6.0 to 7.5
12 19 (17) 98 to 123 10.0 to 12.5
14 22 157 to 196 16 to 20
16 24 245 to 309 25 to 31.5
18 27 343 to 427 35 to 43.5
20 30 490 to 608 50 to 62
22 32 662 to 829 67.5 to 84.5
24 36 824 to 1,030 84 to 105
27 41 1,180 to 1,470 120 to 150
30 46 1,520 to 1,910 155 to 195
33 50 1,960 to 2,450 200 to 250
36 55 2,450 to 3,040 250 to 310
39 60 2,890 to 3,630 295 to 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
(Nm) (kgm)
(mm) (mm)
6 10 5.9 to 9.8 0.6 to 1.0
8 12 13.7 to 23.5 1.4 to 2.4
10 14 34.3 to 46.1 3.5 to 4.7
12 17 74.5 to 90.2 7.6 to 9.2
Fig. A Fig. B
a Values with ( ) are applied to * marked bolt (flange bolt) as the width across flats.
D65EX,PX,WX-17 00-45
Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten split flanged bolt to the torque shown in the following table.
(Nm) (kgm)
(mm) (mm)
10 14 59 to 74 6.0 to 7.5
12 17 98 to 123 10.0 to 12.5
16 22 235 to 285 23.5 to 29.5
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten O-ring boss piping joint to the torque shown in the following table.
Thread Width Tightening torque (Nm {kgm})
Nominal diameter across flats
number Range Target
(mm) (mm)
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
– 18 Varies 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 depending 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 on type of 128 to 186 {13.0 to 19.0} 157 {16.0}
10, 12 33 connector. 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten O-ring boss plug to the torque shown in the following table.
Thread Width Tightening torque (Nm {kgm})
Nominal diameter across flats
number Range Target
(mm) (mm)
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 – 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 – 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 – 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
00-46 D65EX,PX,WX-17
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque to when the thread is coated with engine oil (wetted).
Tightening torque (Nm {kgm}) Taper seal Face seal
Width
Nominal across Nominal No. Thread root
number Thread size – Number of diameter
flats Range Target
of hose (mm) (mm) threads, type (mm)
of thread (Reference)
34 to 54 {3.5 to 5.5} 44 {4.5} – 9/16-18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 – –
22 54 to 93 {5.5 to 9.5} 74 {7.5} – 11/16-16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 – –
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 – –
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 – –
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 – –
Table of tightening torque for face seal joints

a Tighten the face seal joint (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 when the thread is coated with engine oil (wetted).
Outer Tightening torque (Nm {kgm}) Face seal

Width Nominal No. –
diameter of Thread root
across flats Number of
pipe Range Target diameter (mm)
(mm) threads, type of
(mm) (Reference)
thread
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1-14UNS 25.4
22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
Table of tightening torque for 102, 107 and 114 engine series (bolt and nut)
a Unless otherwise specified, tighten the metric bolt and nut used for the 102, 107 and 114 engine series to
the torque shown in the following table.
Thread diameter Tightening torque
(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 – –
D65EX,PX,WX-17 00-47
Table of tightening torque for 102, 107 and 114 engine series (eye joint)
a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series to the
torque shown in the following table.
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
Table of tightening torque for 102, 107 and 114 engine series (tapered screw)
a Unless otherwise specified, tighten the tapered screw with pipe thread for the 102, 107 and 114 series
engines to the torque shown in the following table.
Material In cast iron or steel In aluminum
Tightening torque Tightening torque
Thread diameter (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
00-48 D65EX,PX,WX-17
List of abbreviation
(Rev. 2011/02)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations that appear infrequently are marked in the text with an *.
• This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the
manual, and the second part is a list of abbreviations used in circuit diagrams.
List of abbreviations used in the shop manual

Purpose of use (major
Abbre- Full Spelling applicable machine (*), Explanation
viation or component/system)
Travel and brake With this function, when the tires skid (wheels stop
Anti-skid Brake
ABS rotating), the brakes are released, and when the
System (HD, HM) wheels start to rotate, the brakes are applied again.
Automatic Idling
AISS Engine This function automatically sets the idle speed.
Setting System
Advanced Steering Instead of a steering wheel, a lever is used to perform
AJSS Joystick Steering the steering operations as well as to shift gear and
System (WA) change direction (FORWARD or REVERSE).
Automatic If the accelerator pedal is released, when the machine
Retarder Travel and brake
ARAC is travelling downhill, this function automatically applies
Accelerator (HD, HM) the retardar with a constant braking force.
Control
If the accelerator pedal is released, when the machine
Automatic Travel and brake is travelling downhill, this function automatically applies
ARSC Retarder Speed the retardar to ensure that the machine speed does not
Control (HD, HM)
accelerate above the speed set by the operator.
Automatic Spin Travel and brake When the rear wheels spin on soft ground surfaces,
ASR Regulator this function automatically uses the optimum braking
(HD, HM) force to drive both wheels.
A device that can be fixed onto a machine in order to
ATT Attachment Work equipment
enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil Brake bypasses part of the brake cooling oil to reduce the
BCV
control Valve (HD) load on the hydraulic pump.
Controller Area Communication and Communications standard that is standardized as
CAN
Network electronic control ISO11898.
Crankcase Indicates regulator valve which is installed to KCCV
CDR Depression Engine ventilator.It is written as CDR valve and it is not used
Regulator independently.
Closed-center System that can simultaneously actuate multiple
CLSS Load Sensing Hydraulic actuators regardless of the load (provides better ease
System of combined operation than OLSS).
Uses engine controller to perform electronic control of
Common Rail supply pump, common rail, and injector. Functions to
CRI Engine
Injection maintain optimum fuel injection amount and fuel
injection timing.
Electronic control device that uses the signals from the
Electronic Electronic control
ECM sensors on the machine to indicate to the actuators the
Control Module system
optimum actuation. (same as ECU)
Electronic Transmission Proportional electromagnetic valve that gradually
ECMV Control increases oil pressure to engage clutch and reduces
(D, HD, WA, etc.)
Modulation Valve transmission shock.
Electronically
Travel System that ensures smooth high-speed travel by
Controlled
ECSS Suspension using hydraulic spring effect of accumulator to absorb
(WA) vibration of machine during travel
System
D65EX,PX,WX-17 00-49

Electronic control device that uses the signals from the
Electronic Electronic control
ECU sensors on the machine to indicate to the actuators the
Control Unit system
optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to
Exhaust Gas Engine combustion chamber in order to reduce combustion
EGR
Recirculation temperature, controls emission of Nox.
Equipment System that allows data (filter, oil replacement interval,
Management malfunctions on machine, failure code, and failure
EMMS Monitoring Machine monitor
history) from each sensor on the machine to be
System checked on monitor.
Electromagnetic Used for electromagnetic proportional control. Actuator
EPC Proportional Hydraulic in this system operate in proportion to the current
Control supplied.
Falling Object This structure protects the operator's head from falling
FOPS Protective Cab and canopy objects. (Falling Object Protective Structure)
Structure This performance is standardized as ISO 3449.
FORWARD-
F-N-R NEUTRAL- Operation FORWARD-NEUTRAL-REVERSE
REVERSE
Global Communication Global Positioning System. A satellite positioning
GPS Positioning (KOMTRAX, system that is used to determine the current location
System KOMTRAX Plus) on the earth.
Steering function that uses a combination of hydraulic
Hydrostatic Steering motor and bevel shaft to control difference in travel
HSS Steering System (D) speed of right and left tracks to turn machine without
using steering clutch.
Transmission Hydraulic transmission system that uses a combination
Hydro Static of hydraulic pump and hydraulic motor to shift gear
HST
Transmission (D, WA) steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel intake
Inlet Metering Engine
IMA amount in order to control fuel delivery of supply pump.
Actuator
Same as IMV.
Inlet Metering Engine amount in order to control fuel delivery of supply pump.
IMV
Valve Referred to as IMV (IMA).
KOMATSU This mechanism separates oil in blowby gas and
Closed Engine returns it to the intake side to afterburn it there. It
KCCV
Crankcase primarily consists of filters.
Ventilation
KOMATSU This filter is used to capture soot in exhaust gas.
KCSF Catalyzed Soot Engine
Filter It is built in to KDPF.
KOMATSU
The catalyst used for purifying exhaust gas.
KDOC Diesel Oxidation Engine
Catalyst It is built in to KDPF.
KOMATSU This component with built-in KDOC (catalyst) and
KDPF Diesel Particulate Engine KCSF (soot-capturing filter) purifies exhaust gas.
Filter It is installed in place of the currently used muffler.
KOMATSU
Variable The turbocharger on which the cross-section area of
KVGT Geometry Engine
the exhaust passage is made variable.
Turbocharger
Image display device made up of a large number of
Liquid Crystal pixels filled with liquid crystal. Liquid crystal display
LCD Display Machine monitor image display device such as monitor, mcorporatal with
liquid crystal pixels.
00-50 D65EX,PX,WX-17

Light emitting diode. It refers to semiconductor element
Light Emitting Electronic parts
LED that emits light when the voltage is applied in forward
Diode
direction.
Function that senses differential pressure of pump and
LS Load Sensing Hydraulic
controls discharge amount according to load.
This indicates engine intake air flow.It is not used
MAF Mass Air Flow Engine independently but it is used as combined with sensor.
Mass air flow sensor can be called as MAF sensor.
Multimedia Service that allows transmission and reception of short
MMS Messaging Communication messages consisting of characters or voice or images
Service between cell phones.
Device actuated to open electric or hydraulic circuits
NC Normally Closed Electric and hydraulic
that are normally closed if not actuated.
Device actuated to close electric or hydraulic circuits
NO Normally Open Electric and hydraulic
that are normally open if not actuated.
Open-center
Hydraulic system that can operate multiple actuators at
OLSS Load Sensing Hydraulic
the same time, regardless of the load.
System
Pressure
PC Hydraulic A function used to correct oil pressure.
Compensation
Steering System in which a controller instantly analyses data
Palm Command
PCCS Control System from each lever, pedal, and dial, and performs optimum
(D) electronic control of the engine and transmission.
Pump Control Engine amount in order to control fuel discharge amount of
PCV
Valve supply pump.
Proportional Used for controlling proportional pressure. This system
PPC Hydraulic
Pressure Control moves actuators in proportion to the oil pressure.
Piston Pump and Hydraulic Piston pump and motor.
PPM
Motor (D, PC, etc.)
A device to take off the power of the engine and supply
PTO Power Take Off Power transmission
it to other units.
Power Tilt and Work equipment Function that performs hydraulic control of the tilt and
PTP power Pitch pitch of the bulldozer blade.
dozer (D)
If a machine tips over, this structure protects the
Roll-Over operator with the seat belt fastened from being
ROPS Protective Cab and canopy crushed. (Operator Protective Structure When Tipping)
Structure
This performance is standardized as ISO 3471.
Le System Abbreviation for the "International System of Units". It
SI International d’ Unit is universal unit system and a single unit for single
Unites quantity" is the basic principle applied.
Solenoid is a loop of wire. However, as a matter of fact
in engineering, it refers to an actuator consists of a
SOL Solenoid Electric solenoid and an iron core that is moved by the
magnetic force when the solenoid is energized. The
word solenoid also often refers to a solenoid valve.
TWV Two Way Valve Hydraulic and electric Solenoid valve that switches over direction of flow.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
D65EX,PX,WX-17 00-51
Abbreviation Full Spelling

A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
00-52 D65EX,PX,WX-17
Conversion table
(Rev. 2011/02)
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 examples given below.
Example: Method of using the conversion table to convert from millimeters to inches
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 horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore 55 mm = 2.165 in.
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. Then convert 55 mm to 2.165 in by the same procedure as above.
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 in.
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 2.017 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 2.847 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
D65EX,PX,WX-17 00-53
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 2.847 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
Kilograms to pounds
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
l to U.S.Gallons
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
00-54 D65EX,PX,WX-17
l 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
D65EX,PX,WX-17 00-55
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
00-56 D65EX,PX,WX-17
Temperature
Fahrenheit-Centigrade conversion
• A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice
versa is to refer the number in the center column of the following table.
• When converting from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
• When converting from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 deg.F
°C deg.F °C deg.F °C deg.F °C deg.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
D65EX,PX,WX-17 00-57
00-58 D65EX,PX,WX-17
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
01 Specification
D65EX,PX,WX-17 01-1
01 Specification
Table Of Contents
01 Specification................................................................................................................................. 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-6
Weight table ...................................................................................................................... 01-30
Table of fuel, coolant and lubricants ..................................................................................... 01-38
1 01 Specification
01-2 D65EX,PX,WX-17
01 Specification
Specification drawing
Specifications
D65EX-17
ROPS cab with air conditioner
D65EX-17
Item Unit Power angle power tilt
Sigma dozer
dozer
Machine weight kg 19,600 [19,920] 21,080 [21,400]
Engine name - Komatsu SAA6D114E-5 diesel engine
Engine rated output
• Net [ISO 9249/SAE J1349] (*1) kW {HP}/ 153 {205}/1,950
• Gross [SAE J1995](*2) rpm 155 {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
For-
Travel speed km/h 3.6/5.6/7.3/11.3
ward
[1st/2nd/3nd (Low)/3rd] Re-
km/h 4.5/6.7/8.7/13.6
verse
Track shoe
• Type - Single grouser Single grouser
• Width mm 510 560
Rear work equipment - Hitch Counterweight
Values in [ ] are for machines equipped with PLUS type track shoes.
*1: Indicates the value at the lowest cooling fan speed.
*2: Indicates the value of the engine alone (without cooling fan).
a The engine rated output is indicated 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 output (net) at the maximum cooling fan speed.
139 kW {186 HP}/1,950 rpm
a The maximum engine gross output is:
163.7 kW {219 HP}/1,950 rpm
D65EX,PX,WX-17 01-3
01 Specification
D65PX-17
D65PX-17
Straight tilt dozer
dozer
Engine rated output
• Net [ISO 9249/SAE J1349] (*1) kW {HP}/ 153 {205}/1,950
• Gross [SAE J1995] (*2) rpm 155 {207}/1,950
For-
ward
km/h 4.5/6.7/8.7/13.6
verse
Track shoe
• Width mm 915 760
Rear work equipment - Hitch Hitch
139 kW {186 HP}/1,950 rpm
163.7 kW {219 HP}/1,950 rpm
01-4 D65EX,PX,WX-17
01 Specification
D65WX-17
D65WX-17
Sigma dozer
dozer
Engine rated output
• Net [ISO 9249/SAE J1349] (*1) kW {HP}/ 153 {205}/1,950
• Gross [SAE J1995](*2) rpm 155 {207}/1,950
For-
ward
km/h 4.5/6.7/8.7/13.6
verse
Track shoe
• Width mm 760 760
Rear work equipment - Hitch Counterweight
139 kW {186 HP}/1,950 rpm
163.7 kW {219 HP}/1,950 rpm
D65EX,PX,WX-17 01-5
01 Specification
Specifications
Specifications
D65EX-17
Weight
D65EX-17
Machine model Power angle power tilt
Sigma dozer
dozer
Serial number 1001 and up 1001 and up
Machine weight
• Bare tractor and ROPS cab kg 17,210 [17,530] 18,120 [18,440]
• With work equipment kg 19,600 [19,920] 21,080 [21,400]
• With work equipment and ripper kg (21,370) [(21,690)] (22,850) [(23,170)]
Values in ( ) are shown for reference.
Performance
D65EX-17
Sigma dozer
dozer
Min. turning radius m - [Counter-rotation turn] - [Counter-rotation turn]
Gradeability deg. 30 30
Stability (front/rear/left/right) deg. 35 35
Forward 1st km/h 3.6 3.6
Forward 2nd km/h 5.6 5.6
Travel speed
Forward 3rd (Low) km/h 7.3 7.3

Forward 3rd km/h 11.3 11.3
Reverse 1st km/h 4.5 4.5
Reverse 2nd km/h 6.7 6.7
Reverse 3rd km/h 13.6 13.6
kPa 55.5 {0.57} 53.2 {0.54}
Ground pressure
Bare tractor and ROPS cab

{kg/cm2} [56.7 {0.58}] [54.3 {0.55}]
kPa 63.2 {0.64} 61.9 {0.63}
With work equipment
{kg/cm2} [64.5 {0.66}] [63.1 {0.64}]
With work equipment and kPa (68.9 {0.70}) (67.1 {0.68})
ripper {kg/cm2} [(70.2 {0.72})] [(68.3 {0.70})]
01-6 D65EX,PX,WX-17
01 Specification
Specifications
Dimensions
D65EX-17
Sigma dozer
dozer
Bare tractor mm 4,250 4,250
Overall length
With work equipment mm 5,490 5,790

Overall width
To tip of exhaust pipe mm 3,080 [3,085] 3,080 [3,085]

Overall height
With ROPS cab

mm 3,155 [3,160] 3,155 [3,160]
(excluding antenna)
With ROPS canopy mm 3,155 [3,160] 3,155 [3,160]
Track gauge mm 1,880 2,050

Length of track on ground mm 2,980 [2,970] 2,980 [2,970]
Shoe width (Standard track shoe) mm 510 560
Min. ground clearance mm 410 [415] 410 [415]
D65EX,PX,WX-17 01-7
01 Specification
Specifications
Engine
D65EX-17
Sigma dozer
dozer
Type SAA6D114E-5
4-cycle, water-cooled, in-line, vertical, direct injection,
Type
with turbocharger and air-cooled aftercooler
No. of cylinders - bore x stroke mm 6 - 114 x 144.5
Piston displacement l {cc} 8.85 {8,850}
Rated horsepower
• Net (*1)
153 {205}/1,950
[ISO 9249/SAE J1349]
kW {HP}/rpm
• Gross (*2)
Performance
155 {207}/1,950
[SAE J1995]
Nm {kgm}/
Max. torque (*2) 1,012 {103}/1,450
rpm
Max. speed with no load rpm 2,100 ± 50
Min. speed with no load rpm 825 ± 25
Fuel concumption rate at rated g/kWh
227 {169}
horsepower {g/HPh}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 60 A
Battery (*3) 12 V, 110 Ah x 2
Radiator core type Corrugated aluminum
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
139 kW {186 HP}/1,950 rpm
163.7 kW {219 HP}/1,950 rpm
01-8 D65EX,PX,WX-17
01 Specification
Specifications
Power train
D65EX-17
Sigma dozer
dozer
Torque converter 3-element, 1-stage, 2-phase
Planetary gear, multiple disc clutch, hydraulic, gear
Transmission pump pressure fed oil lubrication, 3 forward/reverse
gear speeds, manual electronic type
Spiral bevel gear, gear pump pressure fed oil lubrication
Bevel gear shaft
type
Differential planetary gear type, hydraulic motor drive
HSS unit
HSS type, manually and electronically controlled type,

hydrorically driven type
Wet multiple disc, spring-boosted, foot-operated,
Brake hydraulic type
Single reduction spur gear single reduction , planetary
Final drive gear , lubricating oil splash lubrication type
Undercarriage
D65EX-17
Sigma dozer
dozer
Suspension Semirigid, balancing beam type
Carrier roller 2 each side
Track roller seven on one side
Track shoe
Width: 510 mm Width: 560 mm
• Assembled single grouser shoe
(PLUS type) 42 on each side 42 on each side
Pitch: 203.2 mm Pitch: 203.2 mm
D65EX,PX,WX-17 01-9
01 Specification
Specifications
Hydraulic system
D65EX-17
Sigma dozer
dozer
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

Steering lubricating pump and
power train pump
Type Gear type (tandem)
Theoretical delivery cm3/rev 43.7 x 2
Scavenging pump
Type Gear type
Theoretical delivery cm3/rev 61.2
HSS motor
Hydraulic motor
Type Fixed displacement swash plate type piston motor, with

brake valve
Motor capacity cm3/rev 90
Cooling fan motor
Type Fixed displacement swash plate type piston motor
3-spool type, 1 piece
4-spool type: 1
Control valve
(machine with ripper)

Type and numbers
5-spool type x 1
(Straight tilt power pitch dozer)
(Power angle power tilt dozer)
Operating method Hydraulic assist type
Hydraulic tank Box type (external control valve type)
Hydraulic oil filter Tank return side
Oil cooler Corrugated aluminum
01-10 D65EX,PX,WX-17
01 Specification
Specifications
Work equipment hydraulic system

• For other than power angle power tilt dozer
D65EX-17
Machine model
Sigma dozer Power angle power tilt dozer
Type Double-acting piston -
Cylinder bore mm 85 -
Lift cylinder
Piston rod diameter mm 60 -

Stroke mm 1,145 -
Max. distance between
mm 1,695 -
pins
Min. distance between pins mm 550 -
Cylinder bore mm -
Tilt and pitch cylinder
125
Stroke mm 145 -
mm 1,222 -
pins
Min. distance between pins mm 1,077 -
• Power angle power tilt dozer

D65EX-17
Machine model
Type - Double-acting piston
Cylinder bore mm - 90
Lift cylinder
Piston rod diameter mm - 60

Stroke mm - 1,016
mm - 1,400
pins
Min. distance between pins mm - 384
Tilt cylinder

Stroke mm - 160
mm - 1,200
pins
Min. distance between pins mm - 1,040
Angle cylinder

Stroke mm - 550
mm - 1,547
pins
D65EX,PX,WX-17 01-11
01 Specification
Specifications
• Ripper cylinder
D65EX-17
Machine model
Ripper cylinder
Type Double-acting piston
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
Work equipment
• Straight tilt dozer
D65EX-17
Sigma dozer
dozer
Blade supporting method Left: brace type, right: tilt cylinder type
Max. lift above ground mm 1,100 [1,105] -
Dimensions Performance
Max. drop below ground mm 435 [430] -

Max. adjustment tilt mm 870 -
Blade cutting angle adjustment deg. ±7 -
Blade width mm 3,415 -

Blade height mm 1,225 -
Blade cutting angle deg. 55 -
• Sigma dozer
D65EX-17
Sigma dozer
dozer


01-12 D65EX,PX,WX-17
01 Specification
Specifications
• Straight tilt power pitch dozer

D65EX-17
Sigma dozer
dozer
Blade supporting method Left: tilt cylinder, Right: pitch cylinder


• Sigma power pitch dozer
D65EX-17
Sigma dozer
dozer


D65EX-17
Sigma dozer
dozer
Blade supporting method Right/left: angle cylinder type
Max. lift above ground mm - 1,165 [1,170]
Max. drop below ground mm - 700 [695]

Max. adjustment tilt mm - 500
Maximum angle deg. - 25
Blade cutting angle deg. - ±3
Blade width mm - 3,870
Blade height mm - 1,235
Blade cutting angle deg. - 55
D65EX,PX,WX-17 01-13
01 Specification
Specifications
• Angle dozer
D65EX-17
Sigma dozer
dozer
Blade supporting method Right/left: brace type

Maximum angle deg. 25 -

Ripper
D65EX-17
Sigma dozer
dozer
Type Parallelogram type
Beam length mm 2,170
Number of shanks piece 3
Digging angle deg. 55
Performance
Digging depth adjustment 3-stage variable

Max. digging depth mm 590 [585]
Max. lift above ground mm 640 [645]
Shank position (left/right) mm 950/950
D65PX-17
Weight
D65PX-17
Straight tilt dozer
dozer
Machine weight
• With work equipment and ripper kg - -
Performance
D65PX-17
Straight tilt dozer
dozer
01-14 D65EX,PX,WX-17
01 Specification
Specifications
D65PX-17
Straight tilt dozer
dozer
Travel speed

kPa 31.0 {0.32} 37.2 {0.38}
Ground pressure

{kg/cm2} [31.6 {0.32}] [38.0 {0.39}]
kPa 34.4 {0.35} 43.1 {0.44}
With work equipment
{kg/cm2} [35.0 {0.36}] [43.9 {0.45}]
With work equipment and kPa
- -
ripper {kg/cm2}
D65EX,PX,WX-17 01-15
01 Specification
Specifications
Dimensions
D65PX-17
Straight tilt dozer
dozer
Bare tractor mm 4,360 [4,370] 4,360 [4,370]
Overall length

Overall width

Overall height
With ROPS cab

mm 3,155 [3,160] 3,155 [3,160]
(excluding antenna)

01-16 D65EX,PX,WX-17
01 Specification
Specifications
Engine
D65PX-17
Straight tilt dozer
dozer
Type SAA6D114E-5
Type
No. of cylinders – bore x stroke mm 6 - 114 x 144.5
Rated horsepower
• Net (*1)
153 {205}/1,950
[ISO 9249/SAE J1349]
kW {HP}/rpm
• Gross (*2)
Performance
155 {207}/1,950
[SAE J1995]
Nm {kgm}/
Max. torque (*2) 1,012 {103}/1,450
rpm
fuel concumption rate at rated g/kWh
227 {169}
horsepower {g/HPh}
Battery (*3) 12 V, 110 Ah x 2
139 kW {186 HP}/1,950 rpm
163.7 kW {219 HP}/1,950 rpm
D65EX,PX,WX-17 01-17
01 Specification
Specifications
Power train
D65PX-17
Straight tilt dozer
dozer
Bevel gear shaft
type
HSS unit

hydraulically driven type
Single reduction spur gear single reduction , planetary
Final drive gear , lubricating oil splash lubrication type
Undercarriage
D65PX-17
Straight tilt dozer
dozer
Track roller 8 (each side)
Track shoe
01-18 D65EX,PX,WX-17
01 Specification
Specifications
Hydraulic system
D65PX-17
Straight tilt dozer
dozer
HSS pump
Type
load sensing type
Cooling fan pump
Hydraulic pump

power train pump
Scavenging pump
Type Gear type
HSS motor
Hydraulic motor

brake valve
Cooling fan motor
4-spool type: 1
Control valve

Type and numbers
5-spool type x 1
D65EX,PX,WX-17 01-19
01 Specification
Specifications

D65PX-17
Machine model
Straight tilt dozer Power angle power tilt dozer
Lift cylinder

Stroke mm 1,075 -
mm 1,975 -
pins
Cylinder bore mm -
125
Stroke mm 145 -
mm 1,222 -
pins

D65PX-17
Machine model
Straight tilt dozer Power angle power tilt dozer
Lift cylinder

Stroke mm - 1,016
mm - 1,400
pins
Tilt cylinder

Stroke mm - 160
mm - 1,200
pins
Angle cylinder

Stroke mm - 550
mm - 1,547
pins
01-20 D65EX,PX,WX-17
01 Specification
Specifications
Work equipment
• Straight tilt dozer
D65PX-17
Straight tilt dozer
dozer


• Straight tilt power pitch dozer
D65PX-17
Straight tilt dozer
dozer


D65PX-17
Straight tilt dozer
dozer

D65EX,PX,WX-17 01-21
01 Specification
Specifications
D65WX-17
Weight
D65WX-17
Sigma dozer
dozer
Machine weight
• With work equipment and ripper kg (22,220) [(22,540)] (23,750) [(24,070)]
Performance
D65WX-17
Sigma dozer
dozer
Travel speed

kPa 38.9 {0.40} 41.1 {0.42}
Ground pressure

{kg/cm2} [39.7 {0.40}] [41.9 {0.43}]
kPa 44.3 {0.45} 47.6 {0.49}
With work equipment
{kg/cm2} [45.1 {0.46}] [48.4 {0.49}]
With work equipment and kPa (48.1 {0.49}) (51.4 {0.52})
ripper {kg/cm2} [(48.9 {0.50})] [(52.3 {0.53})]
01-22 D65EX,PX,WX-17
01 Specification
Specifications
Dimensions
D65WX-17
Sigma dozer
dozer
Overall length

Overall width

Overall height
With ROPS cab

mm 3,155 [3,160] 3,155 [3,160]
(excluding antenna)

D65EX,PX,WX-17 01-23
01 Specification
Specifications
Engine
D65WX-17
Sigma dozer
dozer
Type SAA6D114E-5
Type
No. of cylinders – bore x stroke mm 6 - 114 x 144.5
Rated horsepower
• Net (*1)
153 {205}/1,950
[ISO 9249/SAE J1349]
kW {HP}/rpm
• Gross (*2)
Performance
155 {207}/1,950
[SAE J1995]
Nm {kgm}/
Max. torque (*2) 1,012 {103}/1,450
rpm
Fuel concumption rate at rated g/kWh
227 {169}
horsepower {g/HPh}
Battery (*3) 12 V, 110 Ah x 2
139 kW {186 HP}/1,950 rpm
163.7 kW {219 HP}/1,950 rpm
01-24 D65EX,PX,WX-17
01 Specification
Specifications
Power train
D65WX-17
Sigma dozer
dozer
Bevel gear shaft
type
HSS unit

hydraulically driven type
Single reduction spur gear single reduction, planetary
Final drive gear, lubricating oil splash lubrication type
Undercarriage
D65WX-17
Sigma dozer
dozer
Track roller seven on one side
Track shoe
D65EX,PX,WX-17 01-25
01 Specification
Specifications
Hydraulic system
D65WX-17
Sigma dozer
dozer
HSS pump
Type
load sensing type
Cooling fan pump
Hydraulic pump

power train pump
Scavenging pump
Type Gear type
HSS motor
Hydraulic motor

brake valve
Cooling fan motor
4-spool type: 1
Control valve

Type and numbers
5-spool type x 1
01-26 D65EX,PX,WX-17
01 Specification
Specifications

D65WX-17
Machine model
Lift cylinder

Stroke mm 1,145 -
mm 1,695 -
pins
Cylinder bore mm -
125
Stroke mm 145 -
mm 1,222 -
pins

D65WX-17
Machine model
Lift cylinder

Stroke mm - 1,016
mm - 1,400
pins
Tilt cylinder

Stroke mm - 160
mm - 1,200
pins
Angle cylinder

Stroke mm - 550
mm - 1,547
pins
D65EX,PX,WX-17 01-27
01 Specification
Specifications
• Ripper cylinder
D65WX-17
Machine model
Type Double-acting piston
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
Work equipment
• Sigma dozer
D65WX-17
Sigma dozer
dozer


• Sigma power pitch dozer
D65WX-17
Sigma dozer
dozer


01-28 D65EX,PX,WX-17
01 Specification
Specifications

D65WX-17
Sigma dozer
dozer

Ripper
• Parallelogram type
D65WX-17
Sigma dozer
dozer
Beam length mm 2,170
Number of shanks piece 3
Digging angle deg. 55
Performance
Digging depth adjustment 3-stage variable

Max. digging depth mm 590 [585]
Max. lift above ground mm 640 [645]
Shank position (left/right) mm 950/950
D65EX,PX,WX-17 01-29
01 Specification
Weight table
Weight table
D65EX-17
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model D65EX-17
Serial number 1001 and up
Engine and damper assembly (excluding coolant and oil) 1,100
• Engine assembly 996
• Damper assembly 32
• Engine related parts (wiring, mounts) 69
Universal joint 23
Cooling assembly (excluding coolant) 126
• Radiator assembly 26 + 13
• Aftercooler assembly 22
Hydraulic oil cooler (excluding oil) 4
Power train oil cooler (excluding oil) 9
Cooling fan pump 30
Cooling fan motor 13
Fuel tank (excluding fuel) 290
Power train unit assembly (excluding oil) 1,460
• Torque converter and PTO assembly 340
• Transmission assembly 370
• Transmission control valve assembly 26
• Main relief valve and torque converter relief valve assembly 5
• HSS unit assembly 680
• Brake valve assembly 5
HSS motor 41
HSS pump 75
Power train and steering lubrication pump 14
Scavenging pump 5
Quick drop valve 7
Hydraulic tank (excluding oil) 85
Control valve
<3-spool valve> 45
<4-spool valve>
(Straight tilt dozer + ripper) 50
(Sigmal dozer + ripper)
<5-spool valve>
55
(Sigma power pitch dozer)
Blade PPC valve 3
Ripper PPC valve 1
Electric steering lever 4
Main frame assembly
<Other than power angle power tilt dozer> 2,710
<Power angle power tilt dozer> 2,870
Engine underguard 125
Transmission underguard 22
Final drive assembly (each side)
<Other than power angle power tilt dozer + conventional type track shoe> 765
<Other than power angle power tilt dozer + PLUS type track shoe> 775
01-30 D65EX,PX,WX-17
01 Specification
Weight table
Unit: kg
<Power angle power tilt dozer + conventional type track shoe> 785
<Power angle power tilt dozer + PLUS type track shoe> 795
Sprocket teeth (each side)
<Conventional type track shoe> 8x9
<PLUS type track shoe> 9x9
Track frame assembly (each side)
<Other than power angle power tilt dozer + conventional type track shoe> 1,580
<Other than power angle power tilt dozer + PLUS type track shoe> 1,640
<Power angle power tilt dozer + conventional type track shoe> 1,560
<Power angle power tilt dozer + PLUS type track shoe> 1,620
• Track frame (each side)
<Other than power angle power tilt dozer> 685
<Power angle power tilt dozer> 660
• Idler assembly (each side) 200
• Idler cushion assembly (each side) 245
• Single flange track roller assembly (each side)
<Conventional type track shoe> 53 x 5
<PLUS type track shoe> 56 x 5
• Double flange track roller assembly (each side)
• Carrier roller assembly (each side)
• Center roller guard (each side)
<Conventional type track shoe> 29
<PLUS type track shoe> 29
• Full roller guard (each side)
Track shoe assembly (each side)
<Single grouser shoe (510 mm)> 1,430
<Triple grouser shoe (510 mm)> 1,535
<PLUS type single grouser shoe (510 mm)> 1,525
Pivot shaft (one side)
Equalizer bar
ROPS cab assembly
1,130
(including floor, operator's seat, and air conditioner)
Operator's seat 50
Air conditioner unit 10
Compressor 7
Condenser 2
D65EX,PX,WX-17 01-31
01 Specification
Weight table
Unit: kg
Receiver 1
Straight tilt dozer assembly 2,060
• Blade 1,200
• Straight frame (each side) 300
• Tilt cylinder assembly 62
Sigma dozer assembly 2,390
• Blade 1,525
Straight tilt power pitch dozer assembly 2,110
• Blade 1,200
• Pitch cylinder assembly 62
Sigma power pitch dozer assembly 2,440
• Blade 1,525
Power angle power tilt dozer assembly 2,960
• Blade 1,510
• U-frame 1,110
• Angle cylinder assembly 80x2
Angle dozer assembly 2,200
• Blade 1,030
• C-frame 850
Lift cylinder assembly 85 x 2
Ripper assembly 1,770
Ripper cylinder assembly 70
D65PX-17
Unit: kg
Machine model D65PX-17
Universal joint 23
Cooling fan pump 30
01-32 D65EX,PX,WX-17
01 Specification
Weight table
Unit: kg
HSS motor 41
HSS pump 75
Scavenging pump 5
Quick drop valve 7
Control valve
<3-spool valve> 45
<4-spool valve>
<5-spool valve>
55
Blade PPC valve 3
Main frame assembly
• Double flange track roller assembly (each side) 61 x 2
D65EX,PX,WX-17 01-33
01 Specification
Weight table
Unit: kg
<PLUS type track shoe>
29
<Conventional type track shoe>
73
<Conventional type track shoe>
<Swamp shoe (940 mm)> 2,120
Equalizer bar
ROPS cab assembly
1,130
Operator's seat 50
Compressor 7
Condenser 2
Receiver 1
Straight tilt dozer assembly 2,100
• Blade 1,250
Straight tilt power pitch dozer assembly 2,160
• Blade 1,250
• Blade 1,540
• U-frame 1,110
• Angle cylinder assembly 80 x 2
D65WX-17
Unit: kg
Machine model D65WX-17
01-34 D65EX,PX,WX-17
01 Specification
Weight table
Unit: kg
Universal joint 23
Cooling fan pump 30
HSS motor 41
HSS pump 75
Scavenging pump 5
Quick drop valve 7
Control valve
<3-spool valve> 45
<4-spool valve>
<5-spool valve>
55
Blade PPC valve 3
Ripper PPC valve 1
Main frame assembly
D65EX,PX,WX-17 01-35
01 Specification
Weight table
Unit: kg
• Double flange track roller assembly (each side)
Equalizer bar
ROPS cab assembly
1,130
Operator's seat 50
Compressor 7
Condenser 2
Receiver 1
Sigma dozer assembly 2,500
• Blade 1,585
Sigma power pitch dozer assembly 2,550
• Blade 1,585
• Blade 1,540
01-36 D65EX,PX,WX-17
01 Specification
Weight table
Unit: kg
• U-frame 1,110
• Angle cylinder assembly 80 x 2
Ripper assembly 1,770
Ripper cylinder assembly 70
D65EX,PX,WX-17 01-37
01 Specification
Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2 ...) in the table, see Operation and Maintenance Manual.
Unit: l
Grease point Specified capacity Refill capacity
Engine oil pan 30 25
Damper case 1.7 1.7
Idler (each side) 0.25 0.25
Power train case 53 48
Final drive case 25 25
(both sides) 21(*1) 21(*1)
Hydraulic oil system 82 55
Cooling system (including sub-tank) 36 -
Fuel tank 415 -
*1: Value for other than power angle power tilt dozer.
01-38 D65EX,PX,WX-17
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
10 Structure and function
D65EX,PX,WX-17 10-1
Table Of Contents
10 Structure and function ................................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-4
Damper ............................................................................................................................... 10-6
Cooling system .................................................................................................................... 10-8
Cooling fan pump ............................................................................................................... 10-10
Power train............................................................................................................................... 10-32
Power train ........................................................................................................................ 10-32
HSS system ...................................................................................................................... 10-35
Overall drawing of power train unit ....................................................................................... 10-37
Power train hydraulic piping drawing.................................................................................... 10-40
Transmission, steering, and brake control ............................................................................ 10-42
Universal joint .................................................................................................................... 10-44
Transmission ..................................................................................................................... 10-51
Forward and reverse clutch ECMV and gear shift clutch ECMV .............................................. 10-66
Brake valve ..................................................................................................................... 10-102
Final drive ....................................................................................................................... 10-106
Main frame ...................................................................................................................... 10-110
Suspension ..................................................................................................................... 10-112
Track frame and idler cushion ........................................................................................... 10-114
Hydraulic piping drawing................................................................................................... 10-116
Work equipment control .................................................................................................... 10-120
Hydraulic tank.................................................................................................................. 10-122
CLSS .............................................................................................................................. 10-124
Scavenging pump ............................................................................................................ 10-127
Steering lubricating oil pump and power train pump............................................................. 10-128
HSS pump....................................................................................................................... 10-129
HSS motor ...................................................................................................................... 10-150
Control valve ................................................................................................................... 10-159
Blade PPC valve .............................................................................................................. 10-186
Ripper PPC valve............................................................................................................. 10-194
Quick drop valve .............................................................................................................. 10-198
Work equipment lock solenoid valve .................................................................................. 10-201
Pitch selector solenoid valve ............................................................................................. 10-206
Angle control EPC valve ................................................................................................... 10-207
Hydraulic oil cooler bypass valve ....................................................................................... 10-212
PPC accumulator ............................................................................................................. 10-213
Work equipment ..................................................................................................................... 10-214
Work equipment............................................................................................................... 10-214
Ripper ............................................................................................................................. 10-217
Piston valve..................................................................................................................... 10-218
ROPS cab ....................................................................................................................... 10-220
Cab mount ...................................................................................................................... 10-222
Electrical system .................................................................................................................... 10-223
Engine control system ...................................................................................................... 10-223
Cooling system control system .......................................................................................... 10-226
10-2 D65EX,PX,WX-17
Palm command control system.......................................................................................... 10-228

Machine monitor system ................................................................................................... 10-232
KOMTRAX system ........................................................................................................... 10-252
System component part.................................................................................................... 10-255
Sensors .......................................................................................................................... 10-270
1 10 Structure and function
D65EX,PX,WX-17 10-3
Engine related parts
Engine and cooling system

1. Auto-tentioner
10-4 D65EX,PX,WX-17
2. KDPF(*1)
3. Dust indicator
4. Air cleaner (*1)
5. KCCV ventilator (*1)
6. Rear engine mount
7. Fuel filter
8. Front engine mount
9. Drain plug
10. Vibration damper (*1)
11. KVGT(*1)
12. Engine oil filter
13. EGR cooler (*1)
*1: For the details, see Engine Shop Manual.
Function
• KVGT (11) is a turbocharger which can vary the cross-sectional area in the exhaust circuit.
• EGR cooler (13) is a device which cools the exhaust gas with the coolant.
• KGPF (2) is a device which has KDOC (catalyzer) and KCSF (filter to catch soot) for purification of the
exhaust gas.
• KCCV ventilator (5) is a mechanism which mainly consists of filters and separates oil from blowby gas to
return the gas to the air intake side for afterburning.
D65EX,PX,WX-17 10-5
Damper
Damper
1. Breather
2. Oil filler plug
3. Inspection plug
10-6 D65EX,PX,WX-17
Damper
4. Drain plug
5. Damper case
6. Coupling
7. Shaft
8. Bearing
9. Drive plate
10. Friction plate
11. Friction spring
12. Stopper pin
13. Hub
14. Cover
Specifications
Type Wet, friction spring type
Stopper angle (deg.) 4
Stopper torque (Nm {kgm}) 2,685 {274}
Function
• The damper protects the power train (such as the torque converter and transmission) by buffering
torsional vibrations resulting from fluctuations in engine torque or impact torque resulting from sudden
acceleration or heavy duty operation.
D65EX,PX,WX-17 10-7
Cooling system
Cooling system
1. Cooling fan motor

2. Radiator cap
3. Cooling fan
10-8 D65EX,PX,WX-17
Cooling system
4. After cooler
5. Aftercooler inlet hose
6. Hydraulic oil cooler inlet
7. Hydraulic oil cooler outlet
8. Power train oil cooler inlet
9. Power train oil cooler outlet
10. Aftercooler outlet hose
11. Hydraulic oil cooler
12. Radiator inlet hose
13. Reservoir tank
14. Radiator 2
15. Radiator 1
16. Radiator outlet hose
17. Power train oil cooler outlet hose
18. Drain plug
19. Power train oil cooler
20. Hydraulic oil cooler bypass valve
Specifications
Power train oil Hydraulic oil
Radiator 1 Radiator 2 Aftercooler
cooler cooler
Core type Corrugated Corrugated Corrugated Corrugated
PTO-OL
aluminum aluminum aluminum aluminum
Fin pitch (mm) 8.0/2 8.0/2 – 8.0/2 8.0/2
Total heat
dissipation area 61.88 27.20 1.722 2.98 15.89
(m2)
Pressure valve
cracking 88.3 ± 14.7 88.3 ± 14.7
– – –
pressure (kPa {0.9 ± 0.15} {0.9 ± 0.15}
{kg/cm2})
Vacuum valve
cracking 0 to 4.9 0 to 4.9
– – –
pressure (kPa {0 to 0.05} {0 to 0.05}
{kg/cm2})
D65EX,PX,WX-17 10-9
Cooling fan pump
Cooling fan pump
P1: Pump delivery port

PCEPC: EPC output pressure pickup port
PEPC: EPC valve source pressure pickup port
PR1: Self-pressure reducing valve output port
PS: Pump suction port
T0: Drain port
T1: Drain plug
1. Servo valve
10-10 D65EX,PX,WX-17
Cooling fan pump
2. Self-pressure reducing valve
1. Shaft
2. Oil seal
3. Spring
4. Servo piston
5. Case
6. Rocker cam
7. Shoe
8. Piston
9. Cylinder block
10. Valve plate
11. Ball retainer
12. Valve
13. Spring
D65EX,PX,WX-17 10-11
Cooling fan pump
Structure
• Cylinder block (7) is supported to shaft (1) by spline (a). Shaft (1) is supported by each bearings at the
front and rear.
• The tip of piston (6) is shaped as a concave sphere and is crimped with shoe (5). Piston (6) and shoe (5)
constitute a spherical bearing.
• Rocker cam (4) has flat surface (A) and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) pivot on ball retainer (11).
• Piston (6) performs reciprocal motion in the axial direction inside each cylinder chamber of cylinder block
(7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation. The oil
pressure balance on the valve plate is maintained properly.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Specifications
Model LPV30
Variable displacement swash plate type
Type
Piston pump
Theoretical delivery (cm3/rev) 30
Rated delivery pressure (MPa {kg/cm2) 24.5 {250}
Rated speed (rpm) 2,280
10-12 D65EX,PX,WX-17
Cooling fan pump
Function
• The pump converts the engine speed and torque transmitted to its shaft into oil pressure and delivers
pressurized oil corresponding to the load.
• It is possible to change the delivery by changing the swash plate angle.
Operation
Operation of pump
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) tilts around ball retainer (11), and as a result angle (a) between center line (X) of rocker
cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• If swash plate angle (a) is made between center line (x) of rocker cam (4) and the axis of cylinder block (7),
plane (A) functions as a cam against shoe (5).
• Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7). Each piston (6) sucks and discharges oil by (F) - (E)
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases. The volume of
chamber (F) grows larger and, in this process, the oil is sucked. [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-17 10-13
Cooling fan pump
• As center line (X) of rocker cam (4) matches the axis of cylinder block (7) (swash plate angle = 0), the
difference between volumes (E) and (F) inside cylinder block (7) equals 0. The pump does not carry out
any suction or discharge of oil. (Actually, however, the swash plate angle is not set to 0 deg.)
• Pump delivery is in proportion to the swash plate angle (a).
Control of delivery
10-14 D65EX,PX,WX-17
Cooling fan pump
• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and delivery (Q)
increases. Swash plate angle (a) is changed by servo piston (10).
• Servo piston (10) moves in a linear reciprocating movement according to the signal pressure of the servo
valve. This linear movement is transmitted to rocker cam (4), which is supported by and pivots on ball
retainer (11).
Servo valve
P: EPC valve source pressure port

PE: Control piston pressure
PH: Pump delivery pressure
PCEPC: EPC output pressure pickup plug
PEPC: EPC valve source pressure pickup plug
T: Drain
1. Plug
2. Lever
3. Retainer
D65EX,PX,WX-17 10-15
Cooling fan pump
4. Seat
5. Spool
6. Piston
7. Sleeve
8. EPC valve
9. Air bleeder
A: Drain side
B: Pump delivery pressure input side
C: EPC output pressure receiving pressure
D: EPC output pressure
Function
• The servo valve controls the servo piston so thatthe delivery (swash plate angle) is related to thecurrent
input to the EPC valve as shown in the figure below.
10-16 D65EX,PX,WX-17
Cooling fan pump
• The relationship between the EPC valve inputcurrent (i) and EPC valve output pressure (F) isas shown in
the figure below.
Operation
• The output oil of the EPC valve flows in the piston chamber (C) to push piston (6). Piston (6) moves spool
(5) to a position where the thrust is balanced with the force of the spring.
• Port (PE) of the servo piston pressure passage is connected to the pump discharge passage (PH) by the
notch of spool (5) and the oil at pump delivery pressure is led to the servo piston.
• The servo piston pushes up the rocker cam. Then a positioning feedback is applied, and the lever moves
to compress the spring.
• If spool (5) is pushed back, the pump discharge pressure passage is disconnected from the servo piston
circuit. The pressure in the servo piston chamber lowers and the rocker cam returns toward the position
for the maximum swash plate angle
• These processes are repeated until the swash plate stabilizes at an angle where the EPC output pressure
is balanced with the force exerted by the spring force.
• As the EPC output pressure increases, the swash plate angle decreases. As the EPC output pressure
lowers, the swash plate angle increases.
D65EX,PX,WX-17 10-17
Cooling fan pump
Self-pressure reducing valve
P: From fan pump delivery port

PR1: To PPC valve
PR2: Fan pump internal pressure
PS: To sequence valve
TS2: To fan pump drain
Cooling fan pump
1. Body
2. Sequence valve
3. Spring
4. Valve (pressure reducing valve)
5. Spring for (pressure reducing valve main)
6. Poppet
10-18 D65EX,PX,WX-17
Cooling fan pump
7. Spring (for pressure reducing valve pilot)

8. Screw
9. Spring (safety valve)
10. Ball
Function
• This valve serves to reduce the delivery pressure of the fan pump and provide it for the PPC valve, the
EPC valve, etc. for use as control pressure.
D65EX,PX,WX-17 10-19
Cooling fan pump
Operation
When engine is stopped (When all the oil pressures in circuit are low)
• Poppet (6) is pressed by spring (7) against the seat so port (PR1) is disconnected from (TS2).
• Valve (4) is pressed to the left by spring (5), so ports (P) is connected to port (PR1).
• Valve (2) is pressed downwards by spring (3), so port (P) is disconnected from port (P1).
10-20 D65EX,PX,WX-17
Cooling fan pump
When load pressure (P1) is lower than output pressure (PR1) of self-pressure reducing valve
• Valve (2) is pushed by spring (3) and pressure (PS) [0 MPa {0 kg/cm2} when the engine is not running] in
the direction to block the passage between ports (P) and (P1). When hydraulic oil enters from port (P), the
valve balances at a position where [Force exerted by pressure (P) CForce of spring (3) + Force (area (d) x
Pressure (PR)] holds, and the area of the opening between ports (P) and (P1) is adjusted so that pressure
(P) is maintained at a certain level higher than pressure (PS).
• When the pressure (PR1) rises above the set pressure, poppet (6) opens and hydraulic oil flows from port
(PR1), through hole (a) in spool (4), and the opening of poppet (6) to the tank port (TS2).
• Differential pressure is generated across hole (a) in spool (4), and then spool (4) moves to close the
opening between ports (P) and (PR1). Pressure (P) is reduced by the opening at this time and adjusted to
a constant pressure (the set pressure), and supplied as pressure (PR1).
D65EX,PX,WX-17 10-21
Cooling fan pump
When load pressure (P1) is high

• If load pressure (P1) of the fan motor increases and the pump delivery also increases, pressure (P) also
increases (pressure (P)> force of spring (3) + (area d x pressure (PR)), so valve (2) moves upward to the
end of the stroke.
• As a result, the amount of opening between port (P) and (P1) increases and the resistance in the passage
is reduced, so the engine horsepower loss is reduced.
• When the pressure (PR1) rises above the set pressure, poppet (6) opens and hydraulic oil flows from port
(PR1), through hole (a) in spool (4), and the opening of poppet (6) to the tank port (TS2).
• Differential pressure is generated across hole (a) in spool (4), and then spool (4) moves to close the
opening between ports (P) and (PR1). Pressure (P) is reduced by the opening at this time and adjusted to
a constant pressure (the set pressure), and supplied as pressure (PR1).
10-22 D65EX,PX,WX-17
Cooling fan pump
When abnormally high pressure is generated

• If pressure (PR1) of the self-pressure reducing valve becomes abnormally high, ball (10) separates from
the seat against the force of spring (9). As a result, hydraulic oil flows from output port (PR1) to (TS2) and
pressure (PR1) lowers. Accordingly, the components (PPC valves, EPC valves, etc.), to which the oil
pressure is supplied, are protected from abnormally high pressure.
D65EX,PX,WX-17 10-23
Cooling fan motor
Cooling fan motor
P: From cooling fan pump

T : To hydraulic oil cooler
TC: To hydraulic tank
10-24 D65EX,PX,WX-17
Cooling fan motor
1. Output shaft
2. Case
3. Thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Center spring
9. Cooling fan speed sensor
10. Suction valve
11. Cooling fan reverse solenoid valve
12. Pilot valve
13. Spool (for reversible valve)
14. Safety valve
Specifications
Model LMF28
Fixed displacement swash plate type
Type
piston pump
Motor capacity (cm3/rev) 28
D65EX,PX,WX-17 10-25
Cooling fan motor
Rated delivery (l/min) 47.6

Safety valve cracking pressure (MPa {kg/cm2}) 24.5 {250}
Check valve cracking pressure (MPa {kg/cm2}) 0.044 {0.45}
Hydraulic motor
Function
• 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
• The pressurized oil sent from the pump flows through valve plate (7) into cylinder block (5). This
pressurized oil can flow into cylinder chambers on only to one side of the (supply side) (Y - Y) line
connecting the top dead center and bottom dead center of the stroke of piston (4).
•
• The pressurized oil sent to one side of cylinder block (5) presses piston (4) [2 or 3 pieces] and generates
force (F1) [F1(kg) = P(kg/cm2)xxD2/4(cm2)].
• This force is applied to thrust plate (2). Since thrust plate (2) is fixed at an angle of ("a" deg.) degrees to
the output shaft (1), the force is divided into components (F2) and (F3).
• Among them, radial component (F3) generates torque (T = F3 x ri) against the (Y - Y) line connecting the
top dead center and bottom dead center.
• The result of this torque [T=s(F3xri)] rotates cylinder block (5) through the piston (4).
• Since this cylinder block (5) is splined to the output shaft (1), the output shaft (1) rotates to transmit the
torque.
10-26 D65EX,PX,WX-17
Cooling fan motor
Suction valve
Suction valve
Function
• When the pump stops rotating, the hydraulic oil does not flow into the motor. Since the motor continues
rotation by the force of inertia, the pressure at the outlet of the motor increases.
• 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), compensating for the lack of oil on that side to prevent cavitation.
Operation
When pump is started
• 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 of the motor returns through port (T) to the tank.
D65EX,PX,WX-17 10-27
Cooling fan motor
At stop
• When the engine stops and the pump input speed becomes 0 rpm, the pressurized oil from the pump will
no longer be supplied to port (P). As the pressurized oil is not supplied to (MA) side of the motor, the motor
speed decreases gradually to stop.
• If the motor shaft is revolved by the force of inertia while the oil flow in the port (P) is reducing, the oil in
port (T) on the outlet side is sent by suction valve (1) to the (MA) side to prevent cavitation.
10-28 D65EX,PX,WX-17
Cooling fan motor
Reversible valve
Operation
When cooling fan reverse solenoid is "de-energized"
• When coil (1) is "de-energized", the pressurized oil from the pump is blocked by spool (2), and port (C)
connects to the tank circuit.
• Spool (3) is pushed to the right by spring (4), the motor port (MA) opens, pressurized oil flows in, and the
motor begins normal rotation (clockwise).
D65EX,PX,WX-17 10-29
Cooling fan motor
When cooling fan reverse solenoid is "energized"
• When coil (1) is "energized", spool (2) switches to allow the pressurized oil from the pump to flow through
port (C) to spool chamber (D).
• The pressurized oil in chamber (D) pushes valve spool (3) to the left against spring (4).
• Motor port (MB) opens and pressurized oil flows in to revolve the motor in reverse (counterclockwise).
10-30 D65EX,PX,WX-17
Cooling fan motor
Safety valve
Function
• When the engine is started, the pressure in port (P) of the fan motor is increased in some cases.
• Safety valve (1) is provided in order to protect the fan system circuit.
Operation
• When the pressure in port (P) rises above the cracking pressure of safety valve (1), its valve (2) opens
and releases pressurized oil to port (T).
• By this operation, the generation of the abnormally high pressure in port (P) is prevented.
D65EX,PX,WX-17 10-31
Power train
Power train
Power train
Outline
• The power from engine (1) is transmitted from universal joint (3) to torque converter (7) after its torsional
vibrations have been reduced with damper (2).
• The power from the engine is transmitted according to the change in load through the oil coupling in the
torque converter (7) to the transmission input shaft.
• Transmission (8) uses a combination of planetary gear mechanisms and hydraulic clutches to give three
forward speeds and three reverse speeds. According to the change in load, two clutches are selected and
engaged to transmit the power from the bevel pinion at the transmission rear end to bevel gear (9).
• The power sent to the bevel gear shaft is then transmitted to HSS unit (10).
HSS pump (4) is driven by PTO (5), and the discharged oil from the HSS pump drives HSS motor (11).
The rotation of the pair of the HSS planetary gears on the right and left is controlled by HSS motor (11).
The turning direction is controlled by generating a difference in speed on the right and left.
It is also possible to use the HSS mechanism to reverse the rotation to the right and left to perform a
counter rotate turn.
• Brake (12) inside HSS unit (10) applies brake to the machine. Brake (12) is of a wet, multiple disc clutch,
spring - loaded type.
The force output from brake (12) is transmitted to final drive (13).
• Final drive (13) consists of a single-stage spur gear and a single-stage planetary gear system. It reduces
the speed and rotates sprocket (14) to drive track shoes (15) and move the machine.
• Cooling fan pump (6) is driven by PTO (5), and discharged oil from the cooling fan pump drives cooling fan
motor (19).
10-32 D65EX,PX,WX-17
Power train
1. Engine
2. Damper
3. Universal joint
4. HSS pump
5. PTO
6. Cooling fan pump
7. Torque converter
8. Transmission
9. Bevel gear
10. HSS unit
11. HSS motor
12. Brake
13. Final drive
14. Sprocket
15. Track shoe
D65EX,PX,WX-17 10-33
Power train
16. Power train pump

17. Steering lubrication pump
18. Scavenging pump
10-34 D65EX,PX,WX-17
HSS system
HSS system
a HSS: Abbreviation for Hydrostatic Steering System
1. Steering, directional, and gear shift lever (PCCS lever)

2. Power train controller
3. Engine controller
4. Control valve
5. EPC valve
6. HSS pump
7. Servo valve
8. HSS motor
9. HSS circuit
10. Engine
11. Final drive
12. Sprocket
D65EX,PX,WX-17 10-35
HSS system
13. Hydraulic tank
Input/Output signal
a. Directional signals
b. Steering signals
c. Engine control information
d. Work equipment hydraulic pressure signals
e. CAN communication network
Function
• The HSS system consists of a control valve (4), HSS pump (6), and HSS motor (8). The system is used to
turn the machine by creating a difference between right and left track speeds without decreasing the travel
speed.
• According to the direction and amount the steering, directional and gear shift lever (1) has been moved,
the power train controller (2) controls the rotation direction and speed of the HSS motor (8) via the EPC
valve (5) of control valve (4).
The HSS motor (8) drives the planetary gear mechanism on the bevel gear shaft and creates a difference
in speed between right and left sprockets (12) to turn the machine.
• The power train controller (2) detects the engine speed and hydraulic pressures to control the HSS pump
(6) and control valve (4) so that the engine (10) will not stall.
• Information such as engine speed are sent through the CAN communication network between engine
controller (3) and power train controller (2).
10-36 D65EX,PX,WX-17
Overall drawing of power train unit
1. HSS motor
2. Transmission
3. Transmission ECMV
D65EX,PX,WX-17 10-37
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
Structure
• The power train unit consists of the torque converter, PTO (4), transmission (2), and HSS unit (12) by
rough classification. Accordingly, after removing the power train unit, it can be divided into torque
converter, PTO (4), transmission (2), and HSS unit (12).
• HSS unit (12) consists of the bevel gear unit, bevel gear shaft, HSS motor (1), planetary gear mechanism,
and brake.
10-38 D65EX,PX,WX-17
Power train mount
Power train mount
*1: Other than power angle power tilt dozers are shown.
*2: Power angle power tilt dozer is shown.
1. Front mount
2. Rear mount
Function
• The mounts are installed at two places in the front section and at two places in the rear section to secure
the main frame and the power train.
D65EX,PX,WX-17 10-39
Power train hydraulic piping drawing
A: Main relief pressure pickup port

B: Torque converter outlet pressure pickup port
C: Torque converter inlet pressure pickup port
D: Brake pressure pickup port
1. Centralized pressure pickup port
2. HSS pump
3. Control valve
4. Hydraulic tank
5. HSS motor
6. Brake valve
7. Power train oil filter
8. Main relief valve and torque converter relief valve
9. Scavenging pump
10-40 D65EX,PX,WX-17
10.Steering lubrication pump

11.Power train pump
12.Power train oil cooler
D65EX,PX,WX-17 10-41
Transmission, steering, and brake control
1. Decelerator pedal
2. Brake pedal
3. Parking brake lever
4. Electric steering lever
6. Fuel control dial
7. Parking brake limit switch
8. Brake valve
10. Parking brake cable
11. Transmission control valve
12. Brake rod
13. Brake pedal potentiometer
14. Decelerator pedal potentiometer
15. UP switch
16. DOWN switch
Function
• The transmission, steering system, and brake are controlled with steering, directional, and gear shift lever
(PCCS lever) (5).
10-42 D65EX,PX,WX-17
• Upon receiving signals from the electric steering lever (5) which is linked with the steering, directional, and
gear shift lever (5), the power train controller (9) sends signals according to the travel of the steering,
directional, and gear shift lever (5) to the EPC valve of the control valve to change the delivery of the HST
pump and control the HST motor.
• Brake pedal (2) operates brake valve (8) through brake rod (12) to control the brake.
• Since the parking brake lever (3) operates brake valve (8) via parking brake cable (10), brake valve (8) is
also used as the parking brake valve.
• If parking brake lever (3) is in the "FREE" position, parking brake limit switch (7) is actuated, thus it is
impossible to start the engine.
a PCCS: Abbreviation for Palm Command Control System
D65EX,PX,WX-17 10-43
Universal joint
Universal joint
1. Spider
2. Yoke
Function
• The universal joint transmits the power output from the damper to the torque converter after absorbing
shocks and vibration.
10-44 D65EX,PX,WX-17
Torque converter and PTO

• PTO: Abbreviation for Power Take Off
D65EX,PX,WX-17 10-45
A: From transmission case

(To power train and lubricating oil pump)
B: To transmission case
(Drain)
10-46 D65EX,PX,WX-17
C: From transmission case

(To scavenging pump)
D: From transmission case
(To torque converter)
E: Torque converter outlet oil pressure pickup port
F: Torque converter inlet oil pressure pickup port
G: To oil cooler
1. PTO lubrication tube
2. HSS pump, cooling fan pump mounting location
3. Torque converter oil temperature sensor mounting location
4. Torque converter oil pressure sensor mounting location
5. Steering lubricating pump, power train pump mounting location
6. Scavenging pump mounting location
7. Coupling
8. Input shaft
(PTO drive gear, 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, steering lubrication pump, power train pump drive gear
(number of teeth: 53)
27. Sleeve
28. Scavenging pump drive gear
(number of teeth: 56)
29. Scavenging pump oil strainer
30. Power train oil strainer
Structure
• The torque converter is a 3-element, single stage, 2 phase type and is integrated with the transmission.
• Pump (15) is united with coupling (7), input shaft (8), and drive case (12), and is rotated by the engine
power.
• Turbine (13) is united with transmission input shaft (19) and is rotated by the oil from pump (15).
• Stator (14) is installed to the stator shaft (16) via outer race (21) and free wheel (20) and is fixed to PTO
case (11).
D65EX,PX,WX-17 10-47
• Pumps installed to the PTO case are driven by the power transmitted from input shaft (8) via PTO idler
gear (10) to pump drive gears (26) and (28).
Power transmitting route
When lockup clutch is "disengaged"
As drive case (4) and turbine (6) are disconnected from each other, the torque converter works as an ordinary
torque converter.
Engine power
O
Coupling (1)
O
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together
O
Oil is used as medium
O
Turbine (6) and boss (7)
O
Transmission input shaft (8)
10-48 D65EX,PX,WX-17
When lockup clutch is "engaged"
Drive case (4) is connected to turbine (6) and torque converter is locked up.
Engine power
O
Coupling (1)
O
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together
O
Lockup clutch (9)
O
Turbine (6) and boss (7)
O
Transmission input shaft (8)
D65EX,PX,WX-17 10-49
Oil flow
• The oil flows through the main relief valve and its pressure is regulated to the set pressure or below by the
torque converter relief valve. It then flows in inlet port (A), goes through the oil passages of housing (1)
and retainer (2), and flows into pump (3).
• The oil is given centrifugal force by pump (3) and flows in turbine (4) to transfer its energy to turbine (4).
• Oil from turbine (4) is sent to stator (5) and enters pump (3) again. A portion of the oil flows between
turbine (4) and stator (5) and is sent from outlet port (B) to the oil cooler to be cooled. It is then used to
lubricate the transmission.
10-50 D65EX,PX,WX-17
Transmission
Transmission
D65EX,PX,WX-17 10-51
Transmission
A: To steering control valve

B: Transmission lubricating oil pressure pickup port
C: Main relief oil pressure pickup 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 steering lubricating pump and power train pump)
K: From steering case
2. Transmission case
3. Main relief valve and torque converter relief valve
4. Transmission lubricating oil relief valve
5. Sleeve
10-52 D65EX,PX,WX-17
Transmission
1. Transmission input shaft

2. R clutch sun gear (number of teeth: 26)
3. Tie bolt
4. R clutch planetary pinion (number of teeth: 22)
5. R clutch ring gear (number of teeth: 70)
6. Disc
7. Plate
8. F clutch planetary pinion (number of teeth: 21)
9. 3rd clutch planetary pinion (number of teeth: 28)
10. 3rd clutch ring gear (number of teeth: 75)
11. Planetary pinion for 2nd clutch (number of teeth: 23)
12. 2nd clutch sun gear (number of teeth: 29)
13. 1st clutch planetary pinion (number of teeth: 18)
14. 1st clutch sun gear (number of teeth: 39)
15. Output shaft
D65EX,PX,WX-17 10-53
Transmission
(3rd clutch sun gear, number of teeth: 17)

16. Rear housing
17. 1st clutch piston
18. 1st clutch carrier
19. 1st clutch ring gear (number of internal gear teeth: 75)
20. 2nd clutch housing
21. 2nd clutch piston
22. 2nd carrier
23. 2nd clutch ring gear (number of internal gear teeth: 75)
24. 3rd clutch housing
25. 3rd clutch piston
26. 3rd clutch carrier
27. F, 3rd clutch housing
28. F clutch sun gear (number of teeth: 34)
29. F clutch ring gear (number of teeth: 76)
30. F clutch piston
31. F clutch carrier
32. R, F clutch housing
33. R clutch piston
34. Return spring
35. R clutch ring gear (hub) (number of internal gear teeth: 75)
36. Carrier for reverse clutch
37. Front housing
Structure
• The transmission is a "forward 3-speed and reverse 3-speed" transmission which consists of the planetary
gear trains and the disc clutches.
• The transmission selects a single rotating direction and a single gear speed by fixing the planetary gear
mechanism and 2 of 5 disc clutches hydraulically by use of ECMV.
• The transmission transfers the power received by the transmission input shaft to the output shaft by
changing the gear speed (forward 1st-3rd or reverse 1st-3rd) with any combination of the forword or
reverse clutch, and one of three speed clutches.
Number of plates and discs used
Clutch name Number of plates Number of discs
R clutch 6 5
F clutch 8 7
3rd clutch 5 4
2nd clutch 5 4
1st clutch 5 4
Gear speeds and engaged clutches
Gear speed Clutches engaged Reduction 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: The 1st, 2nd or 3rd clutch is filled with low-pressure oil.
10-54 D65EX,PX,WX-17
Transmission
Disc clutch
Structure
• The disc clutch consists of piston (2), plates (3), discs (4), pin (5), and return spring (6) to fix ring gear (1).
• Inside teeth of disc (4) are engaged with outside teeth of ring gear (1).
• Plate (3) and clutch housing (7) are assembled with pin (5).
Operation
When clutch is "engaged" (locked)
• The oil from ECMV is routed to the back of piston (2) through oil passage of clutch housing (7) and pushes
piston (2) leftward.
• Piston (2) presses plate (3) closely against disc (4) to stop rotation of disc (4) by using friction force
generated between them.
• Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), the ring gear (1) is locked.
When clutch is "disengaged" (released)

• When the supply of oil from ECMV is shut off, piston (2) is returned rightward by the force of return spring
(6).
• This relieves the frictional force between plates (3) and discs (4), making the ring gear (1) free.
D65EX,PX,WX-17 10-55
Transmission
Oil circuit of speed clutch

• When the steering, directional and gear shift lever is in the "Neutral" position , the 1st, 2nd, or 3rd gear
speed is kept selected.
• The piston chamber of the clutch corresponding to the selected gear speed is filled with oil by
electronically controlling the oil circuit of each clutch.
• When the steering, directional, and gear shift lever is shifted from the "Neutral" position to the "Forward" or
"Reverse" position, the pump is required to supply oil enough to fill the piston chamber of the forward or
reverse clutch.
• When the gear speed is changed from "Forward 1st" to "Forward 2nd", the pump is required to supply oil
enough to press the plates and discs of the 2nd clutch since the forward clutch has been filled with the oil.
• The time lag at shifting gears is reduced by controlling the oil circuit as explained above.
Forward 1st
10-56 D65EX,PX,WX-17
Transmission
F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are locked hydraulically.
The power from torque
converter
O
Input shaft (1)
O
F clutch sun gear (2)
O
F clutch planetary pinion (3)
O
F clutch carrier (10)
O
3rd clutch carrier (11)
O
3rd clutch planetary pinion
o o o O
(12)
O O
3rd clutch ring gear (13)
O
2nd clutch carrier (14) O
O
2nd clutch planetary pinion
o O
(15)
O O
2nd clutch ring gear (16) O
O
1st clutch carrier (17) O
O
1st clutch planetary pinion
(18) O
O O
2nd clutch sun
1st clutch sun gear (20)
gear (21)
O O O
Output shaft (22) i i i i
D65EX,PX,WX-17 10-57
Transmission
Forward 2nd
10-58 D65EX,PX,WX-17
Transmission
F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are locked hydraulically.
The power from torque converter
O
Input shaft (1)
O
O
O
O
O
3rd clutch planetary pinion (12) o O
O O
O O
2nd clutch carrier (14)
O O
2nd clutch planetary pinion (15)
O O
2nd clutch sun gear (21)
O O
Output shaft (22) i O
D65EX,PX,WX-17 10-59
Transmission
Forward 3rd
10-60 D65EX,PX,WX-17
Transmission
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are locked hydraulically.
O
Input shaft (1)
O
O
O
O
O
3rd clutch planetary pinion (12)
O
Output shaft (22)
D65EX,PX,WX-17 10-61
Transmission
Reverse 1st
10-62 D65EX,PX,WX-17
Transmission
R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are locked hydraulically.
O
Input shaft (1)
O
R clutch sun gear (5)
O
R clutch planetary pinion (6)
O
R clutch ring gear (9)
(R carrier (8) is locked with R ring gear
(7). Accordingly R ring gear (9) is
reversed to input shaft (1))
O
O
O
3rd clutch planetary pinion (12) o o o O
O O
O O
2nd clutch carrier (14)
O O
2nd clutch planetary pinion (15) o O
O O O
2nd clutch ring gear (16)
O O O
1st clutch carrier (17)
O O O
1st clutch planetary pinion (18)
O O O
2nd clutch sun
1st clutch sun gear (20)
gear (21)
O O O
Output shaft (22) i i i i
D65EX,PX,WX-17 10-63
Transmission control valve
A: Lockup clutch oil pressure pickup port

B: R clutch oil pressure pickup port
C: 3rd clutch oil pressure pickup port
D: 1st clutch oil pressure pickup port
E: F clutch oil pressure pickup port
F: 2nd clutch oil pressure pickup 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
10-64 D65EX,PX,WX-17
Function
• The oil from the pump flows through the power train oil filter into the transmission case and then is divided
into the main relief circuit and clutch actuation circuit.
• The oil regulated its pressure by the main relief valve and flowed into the clutch actuating circuit goes
through the last chance filter, then used to actuate the clutch, parking brake, and main brake. The oil
relieved from the main relief valve is supplied to the torque converter.
• When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to
the command current from the power train controller to reduce the gear shifting shocks. The ECMV keeps
the clutch pressure constant during travel.
• If the F, R, 1st, 2nd, or 3rd clutch ECMV is selected, the regulated oil pressure is supplied to the selected
clutch to set the transmission in the desired gear speed.
• The lockup ECMV is actuated when the machine travels in 1st, 2nd, or 3rd gear speed and its travel speed
exceeds the travel speed set by the transmission controller.
Identificaton of ECMV units and the differences
Identification Fill switch
Stamp of the name plate Pressure control
color (Actuating pressure: Clutches engaged
(A) valve
(B) MPa {kg/cm2})
Equipped
L******* – Without slit F, R, 1st, 2nd, 3rd
(0.19 {2.0})
Equipped
E******* Pink With slit L/U
(0.26 {2.7})
Table of ECMV operation

ECMV
F R 1st 2nd 3rd L/U
F1 Q Q Q
F2 Q Q Q
Gear speed
F3 Q Q Q
R1 Q Q Q
R2 Q Q Q
R3 Q Q Q
N(*1) (Q) (Q) (Q)
*1: According to the setting, either of the 1st, 2nd, or 3rd clutches will engage.
L/U: Indicates lockup clutch ECMV.
D65EX,PX,WX-17 10-65
Forward and reverse clutch ECMV and gear shift clutch
ECMV
Forward and reverse clutch ECMV and gear shift clutch ECMV
a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble ECMV since adjustment for maintaining the performance will be required.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
Function
• The ECMV consists of a pressure control valve and a fill switch.
• Pressure control valve
The proportional solenoid receives the current from the power train controller, and the valve converts it into
oil pressure.
10-66 D65EX,PX,WX-17
ECMV
• Fill switch
This switch detects that the clutch is filled with oil and has the following functions.
1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with
oil.
2. Keeps outputting signals (fill signals) to the controller while oil pressure is applied to the clutch to notify
whether oil pressure is applied or not.
Phase A: Before shifting gear (oil is drained)

Phase B: Filling phase
Phase C: Pressure build-up phase
Phase D: Filling phase (during triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during triggering (phase D).
ECMV and proportional solenoid

• Each ECMV is equipped with a proportional solenoid.
The proportional solenoid generates thrust as shown below according to the command current from the
controller.
The thrust generated by the proportional solenoid is applied to the pressure control valve spool to
generate a hydraulic pressure as shown below. Thus, the oil flow and pressure is controlled by controlling
the command current to change the thrust and let the pressure control valve operate.
D65EX,PX,WX-17 10-67
ECMV
Current of proportional solenoid - thrust characteristics
Thrust of proportional solenoid - characteristics of hydraulic pressure
ECMV and fill switch

• Each ECMV is equipped with a fill switch.
If the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. This signal allows
the oil pressure to build up.
Operation of ECMV
• ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relation between the proportional solenoid command current for ECMV, clutch input pressure, and fill
switch output signal is shown below.
10-68 D65EX,PX,WX-17
ECMV
Phase A: Before shifting gear (oil is drained)

Phase B: Filling phase
Phase C: Pressure build-up phase
Phase D: Filling phase (during triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during triggering (phase D).
D65EX,PX,WX-17 10-69
ECMV
Before shifting gear [when draining] (range A in chart)
• 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 pressure detection
valve (4).
10-70 D65EX,PX,WX-17
ECMV
During filling (range B in chart)
• When current is passed to proportional solenoid (1) while no oil is present in the clutch, the hydraulic force
balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left.
As a result, pump port (P) and clutch port (A) open and oil starts to flow into the clutch. When the clutch is
filled with oil, oil pressure detection valve (4) actuates and fill switch (5) is turned "ON".
D65EX,PX,WX-17 10-71
ECMV
Pressure regulation (range C in chart)
• When current flows through proportional solenoid (1), the solenoid generates thrust in proportion to the
current. The clutch circuit pressure builds up until the thrust of the solenoid is balanced with the sum of the
force exerted by the oil pressure in clutch port and the force of pressure control valve spring (2), and then
the pressure is settled.
10-72 D65EX,PX,WX-17
Lockup clutch ECMV
Lockup clutch ECMV

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
Function
Function
• This valve is used to switch the clutch in addition to regulate the clutch oil pressure to the set pressure.
D65EX,PX,WX-17 10-73
Lockup clutch ECMV
It forms a modulation wave pattern, so the lockup clutch is engaged smoothly to reduce the shock when
shifting gear. In addition, it prevents generation of peak torque in the power train. As a result, it provides a
comfortable ride for the operator and greatly increases the durability of the power train.
When changing from traveling in torque converter drive mode to traveling in lockup drive mode
Operation
When traveling in torque converter drive mode
• When traveling in torque converter drive mode, current does not blow to proportional solenoid (1).
Pressure control valve (3) drains the oil from clutch port (A) through drain port (T), and lockup clutch is
"released".
Also at this time, fill switch (5) is turned "off" because oil pressure is not applied to pressure detection
valve (4).
When traveling in direct drive mode

(Traveling in torque converter drive mode to traveling in lockup drive mode)
10-74 D65EX,PX,WX-17
Lockup clutch ECMV
During filling
• In direct drive (lockup), current is passed to proportional solenoid (1), the hydraulic force balanced with the
solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. As a result,
pump port (P) and clutch port (A) open. When the clutch is filled with oil, oil pressure detection valve (4)
actuates and fill switch (5) is turned "ON".
D65EX,PX,WX-17 10-75
Lockup clutch ECMV
During pressure regulation
• When current flows through proportional solenoid (1), the solenoid generates thrust in proportion to the
current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in
clutch port and the reaction force of pressure control valve spring (2), and then the pressure is settled.
10-76 D65EX,PX,WX-17
Main relief valve and torque converter relief valve
A: Drain (torque converter relief)

B: Drain
C: From pump
D: Drain
E: To torque converter
P1: Main relief pressure pickup port
P2: Torque converter relief pressure pickup port
1. Body
2. Piston
3. Torque converter relief valve
4. Piston
Main relief valve
Function
• The main relief valve regulates the pressure in the transmission, parking brake, and main brake hydraulic
circuits to the set pressure.
Set pressure: 3.58 MPa {36.5 kg/cm2}
(Engine at rated speed)
D65EX,PX,WX-17 10-77
Operation
• The oil from the hydraulic pump flows to port (C) through the filter. Then it flows to chamber (F) through
orifice (a) in main relief valve (1).
• When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (F) pushes piston (2) and
the reaction force pushes main relief valve (1) leftward. This connects ports (C) and (E).
Then, the oil from pump flows through port (E) into the torque converter.
Torque converter relief valve
Function
• The torque converter relief valve maintains the oil pressure at the torque converter inlet always at the set
pressure or below in order to protect the torque converter from abnormally high pressure.)
Set pressure: 1.02 MPa {10.4 kg/cm2}
(cracking pressure)
Operation
• The oil relieved through the main relief valve flows through port (E) into the torque converter. It also flows
through orifice (b) in torque converter relief valve (3) into chamber (G).
10-78 D65EX,PX,WX-17
• When the oil pressure to the torque converter exceeds the set pressure, the oil conducted to chamber (G)
pushes piston (4) and the reaction force pushes torque converter relief valve (3) rightward. This connects
ports (E) and (A). Then, the oil in port (E) is drained through port (A).
D65EX,PX,WX-17 10-79
Transmission lubricating oil relief valve
A: From oil cooler

B: Drain
C: Drain
1. Piston
2. Spring
3. Forward clutch housing
Function
• The oil flowing out from the torque converter goes through the oil cooler built in the radiator lower tank and
through the lubricating oil relief valve to lubricate the transmission and PTO.
• The transmission lubricating oil relief valve is installed to the left side of the forward clutch housing and
maintains the lubricating oil pressure below the set pressure.
Set pressure : 0.05 to 0.15 MPa {0.5 to 1.5 kg/cm2}
Cracking pressure: 0.29 MPa {3.0 kg/cm2}
10-80 D65EX,PX,WX-17
Bevel gear shaft, HSS, and brake

A: To transmission case (to steering lubricating pump and power train pump)
B: Brake oil pressure pickup port
D65EX,PX,WX-17 10-81
10-82 D65EX,PX,WX-17
1. Brake valve
2. HSS motor
3. Output shaft
4. Brake spring (large)
D65EX,PX,WX-17 10-83
5. Brake spring (small)

6. Spacer
7. Hub
8. Cage
9. Piston
10. Cover
11. Plate (4 plates each side)
12. Disc (5 discs each side)
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
Structure
Bevel gear shaft
• The bevel gear shaft divides the power sent from the engine through the torque converter and
transmission shaft to the right and left at right angles while reducing the rotating speed through the
meshed bevel pinion (31) and bevel gear (19).
• The bevel pinion (31) and bevel gear (19) on the bevel gear shaft are the spiral bevel gear, and they are
splash lubricated by the oil from the lubrication pump and scavenging pump.
• The bevel gear shaft consists of bevel gear (19) which is in mesh with the bevel pinion (31), bevel gear
shaft (18), and bearing (20) and cage (16) which supports the bevel gear shaft.
HSS
• The HSS consists of a transfer part to invert the rotating direction of the HSS motor (2) and transmit the
power to gear A (15), and a planetary part to adjust the input to ring gear (24) and gear A (15) and output
the power to carrier (27).
The steered direction of the machine is switched by letting HSS motor (2) operate or stop, and by
switching its rotating direction.
• The transfer part has a set of reduction spur gears and they are splash lubricated by the oil from the
lubrication pump and scavenging pump.
• The planetary part has the forced lubrication method by the oil from the lubrication pump and scavenging
pump.
• The transfer part consists of the HSS motor drive gear (30) splined to HSS motor (2), gear D (29) in mesh
with HSS motor drive gear, gear C (22) in mesh with the gear D, gear B (17) coupled with shaft (21), gear
10-84 D65EX,PX,WX-17
A (15) supported by bearing on bevel gear shaft, gear A (15) in mesh with gear D (29), and the case
supporting all of these.
• The planetary part consists of gear A (15), planetary pinion (23), pinion shaft (25), hub (26) coupled to
bevel gear shaft (18) and ring gear (24) through gears, and carrier (27) coupled to brake hub (14).
Brake
• The brake is provided to speed down or stop the machine, and is coupled to brake hub (14).
• The brake adopts wet multiple disc type and spring-boosted type, and it is hydraulic actuated type which
activates brake valve (1) by the operation of brake pedal.
• It adopts the forced lubrication method which sends oil from scavenging pump and lubrication pump to
cover (10) and cage (8) through passage inside steering case, and then to disc (12) and plate (11).
• When the engine is stopped, the steering brake is "applied" since the back pressure acting on the brake
piston (9) lowers, even the brake pedal is not depressed. However, the brake is released as the oil
pressure in the circuit goes up when the engine restarts, so the parking brake lever must be set to the
"LOCK" position.
• The brake consists of carrier (27), brake hub (7) coupled with brake hub (14), disc (12) meshed with brake
hub, plate (11) whose outside perimeter is coupled with brake drum (13) with gear, piston (9) and springs
(4) and (5) which press closely disc and plate together, and cage (8), cover (10) and output shaft (3) which
supports all of them.
Brake drum (13) and cover (10) are fixed to the steering case.
Also, output shaft (3) is connected to the hub (7) by splines and held by spacer (6) in the axial direction.
D65EX,PX,WX-17 10-85
Operation of HSS
Steering in "NEUTRAL" (straight-travel)
A: Transmission output
B: HSS motor output (0 rpm)
C: Left bevel gear shaft output (= A ± 0)
D: Right bevel gear shaft output (= A ± 0)
HSS motor rotating direction
PCCS lever steering operation NEU- Right turn
Left turn
TRAL
NEU- NEU-
PCCS lever direction switching TRAL TRAL
Any Forward Reverse Forward Reverse
operation
(*) (*)
HSS motor rotating direction
viewed from left side of Stopped Right Right Left Left Left Right
machine
*: Counter-rotation turn
10-86 D65EX,PX,WX-17
When the PCCS lever is in "NEUTRAL", HSS motor (7) is stopped.

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)
To final drive
D65EX,PX,WX-17 10-87
Direction "NEUTRAL", steering "LEFT" (left counterrotate turn)
A: Transmission output (0 rpm)

B: HSS motor output
C: Left bevel gear shaft output (= 0 – B)
D: Right bevel gear shaft output (= 0 + B)
10-88 D65EX,PX,WX-17
When the PCCS lever is moved from "NEUTRAL" to "LEFT turn", HSS motor (7) rotates clockwise when
viewed from the left side of the machine.
Power from HSS motor (7)
(Clockwise when viewed from left side of
machine)
O
Drive gear (8)
O
Gear D (9) o O
O O
Gear C (10)
O O
Shaft (11)
O O
Gear B (12)
O O
Left gear A (13) Right gear A (13)
(Counterclockwise when viewed from left side of (Clockwise when viewed from left side
machine) of machine)
O O
Planetary pinion (6) i i
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
(Since power from the transmission is not
transmitted, power from the HSS motor (7) is
transmitted in inverse rotation to right and left.)
D65EX,PX,WX-17 10-89
Direction "NEUTRAL", steering "RIGHT" (right counterrotate turn)
A: Transmission output (0 rpm)

B: HSS motor output
C: Left bevel gear shaft output (= 0 + B)
D: Right bevel gear shaft output (= 0 – B)
10-90 D65EX,PX,WX-17
When the PCCS lever is moved from "NEUTRAL" to "RIGHT turn", HSS motor (7) rotates counterclockwise
when viewed from the left side of the machine.
Power from HSS motor (7)
(Counterclockwise when viewed from left side of
machine)
O
Drive gear (8)
O
Gear D (9) o O
O O
Gear C (10)
O O
Shaft (11)
O O
Gear B (12)
O O
Right gear A (13)
Left gear A (13)
(Counterclockwise when viewed from left
(Clockwise when viewed from left side of machine)
side of machine)
O O
Planetary pinion (6) i i
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
(Since power from the transmission is not
transmitted, power from the HSS motor (7) is
transmitted in inverse rotation to right and left.)
D65EX,PX,WX-17 10-91
Direction "FORWARD", steering "LEFT"
B: HSS motor output
C: Left bevel gear shaft output (= A – B)
D: Right bevel gear shaft output (= A + B)
10-92 D65EX,PX,WX-17
When steered "LEFT" while the PCCS lever is in "FORWARD", HSS motor (7) rotates clockwise when viewed
from the left side of the machine.
Power from
HSS motor
(7)
Power from transmission (Clockwise
(forward) when
viewed from
left side of
machine)
O O
Drive gear
Bevel pinion (1)
(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
(Counterclockwise when (Clockwise when viewed
O
viewed from left side of from left side of
machine) machine)
O O O
Planetary pinion (6) 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-17 10-93
Direction "REVERSE", steering "LEFT"
B: HSS motor output
C: Left bevel gear shaft output (= -A + B)
D: Right bevel gear shaft output (= -A – B)
10-94 D65EX,PX,WX-17
When steered "LEFT" while the PCCS lever is in "REVERSE", HSS motor (7) rotates counterclockwise when
Power from
HSS motor
(7)
Power from transmission (Counter-
clockwise
(reverse)
when
viewed from
left side of
machine)
O O
Drive gear
Bevel pinion (1)
(8)
O O
O O O
O O O
Hub (4) Shaft (11)
O O O
O O O
Right gear A (13)
Left gear A (13)
(Counterclockwise when
O (Clockwise when viewed
viewed from left side of
from left side of machine)
machine)
O O O
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
D65EX,PX,WX-17 10-95
Direction "FORWARD", steering "RIGHT"
B: HSS motor output
C: Left bevel gear shaft output (= A + B)
D: Right bevel gear shaft output (= A – B)
10-96 D65EX,PX,WX-17
When steered "RIGHT" while the PCCS lever is in "FORWARD", HSS motor (7) rotates counterclockwise
when viewed from the left side of the machine.
Power from
HSS motor
(7)
Power from transmission (Counter-
clockwise
(forward)
when
viewed from
left side of
machine)
O O
Drive gear
Bevel pinion (1)
(8)
O O
O O O
O O O
Hub (4) Shaft (11)
O O O
O O O
Right gear A (13)
Left gear A (13)
(Counterclockwise
O (Clockwise when viewed
when viewed from left
from left side of machine)
side of machine)
O O O
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
D65EX,PX,WX-17 10-97
Direction "REVERSE", steering "RIGHT"
B: HSS motor output
C: Left bevel gear shaft output (= -A – B)
D: Right bevel gear shaft output (= -A + B)
10-98 D65EX,PX,WX-17
When steered "RIGHT" while the PCCS lever is in "REVERSE", HSS motor (7) rotates clockwise when
Power from
HSS motor
(7)
Power from transmission (Clockwise
(reverse) when
viewed from
left side of
machine)
O O
Drive gear
Bevel pinion (1)
(8)
O O
O O O
O O O
Hub (4) Shaft (11)
O O O
O O O
(Counterclockwise when (Clockwise when
O
viewed from left side of viewed from left side of
machine) machine)
O O O
O
Carrier (14)
O
Brake hub (15)
O
Hub (16)
O
Output shaft (17)
O
To final drive
D65EX,PX,WX-17 10-99
Operation of brake
Brake "released"
• When the brake pedal is released, brake valve is in "Neutral" position, and the back pressure port of piston
(1) is filled with oil.
• As the oil pressure rises, piston (1) is pushed to the left to compress spring (2) and (3), and disc (4) and
plate (5) are released.
• Power transmitted from bevel gear shaft via HSS to brake hub (7) is transmitted from hub (8) to output
shaft (9) and then to final drive.
10-100 D65EX,PX,WX-17
Brake "applied" (brake pedal "depressed")
• When the brake pedal is depressed, the brake valve is switched and the oil of back pressure port of piston
(1) is drained.
• By reducing the oil pressure of back pressure port, piston (1) is moved to the right by the force of springs
(2) and (3), and makes discs (4) and plates (5) pressed against brake drum (6). Brake drum (6) is
connected and fixed to the steering case.
• With discs (4) and plates (5) pressed against the brake drum, the power to brake hub (7) or output shaft
(9) is braked.
• By adjusting the depressing effort of the brake pedal to control the oil pressure given to piston (1), the
braking force can be adjusted.
D65EX,PX,WX-17 10-101
Brake valve
Brake valve
P: From power train pump

T1: To steering case
T2: To steering case
Br(R): To right brake
Br(L): To left brake
1. Parking brake valve
2. Body
3. Main brake valve
4. Piston
5. Shaft
6. Guide
Function
• The brake valve is in the passage between the power train pump and brake piston inside the HSS unit,
and is installed to the upper surface of the HSS unit.
• When the brake pedal is depressed, the main brake valve (3) is actuated. When the parking brake lever is
moved to the "LOCK" position, the parking brake valve (1) is actuated.
• When each valve is actuated, the oil flow to the back pressure port of the brake piston is blocked and the
brakes are "applied".
• In the HSS, the right and left brakes are applied simultaneously since these are used for braking only [not
used for steering].
10-102 D65EX,PX,WX-17
Brake valve
Operation
When brake is "released"(brake pedal is "released" and parking brake lever is in "FREE" position)
• When the brake pedal is "released", parking brake valve (1) is moved by the force of return spring pistons
(2) and connects port (P) and chamber (A).
• Main brake valve (3) is moved by the force of return spring (4) and connects chamber (B) and port (Br).
• Oil from the power train pump is regulated at the main relief valve and flows from port (P) through
chambers (A) and (B) to the back pressure port of the brake piston.
• The brake piston is moved to the left. The brake spring is compressed and the brake is "released".
• At this time, the oil pressure is balanced at 2.84 MPa {29.0 kg/cm 2}, which can be checked at pickup port
(Q).
D65EX,PX,WX-17 10-103
Brake valve
When brake is "applied"(brake pedal is "depressed" and parking brake lever is in "FREE" position)
• When the brake pedal is depressed, guide (5) and shaft (6) are moved to the right.
• When shaft (6) is pressed, it compresses modulating spring (7), and the force of spring moves main brake
valve (3) to the right. Port (Br) and chamber (B) will be blocked and port (Br) and port (T2) will be
connected.
• The oil from the power train pump flows from port (P) into chamber (A) and then be blocked at chamber
(B).
• A portion of the oil to the back pressure port of the brake piston is drained from port (Br) to port (T2). The
rest of this oil flows from port (Br) through orifice (a) into chamber (D).
• When the oil after port (Br) is drained to port (T2) and its pressure decreases, oil in chamber (D) pushes
piston (8). Then, the force that was pushing main brake valve (3) to the right decreases, so main brake
valve (3) is moved to the left by the force of return spring (4).
• When main brake valve (3) is moved to the left, port (Br) and port (T2) are blocked and pressure in port
(Br) will not decrease further.
• When the brake pedal is depressed further, the above operation is repeated and when main brake valve
(3) reaches its stroke end, the brake will be completely "applied".
• The oil pressure after port (Br) is determined by the force of return spring (4), which varies according to the
brake pedal travel.
• When the brake pedal travel short, the pressure after port (Br) will be high and the brake will be "partially
applied". When the brake pedal travel is long, the pressure will be low and the brake will be completely
"applied".
10-104 D65EX,PX,WX-17
Brake valve
When brake is in "parking" (brake pedal is "released" and parking brake lever is in "LOCK" position)
• When the parking brake lever is moved to the "LOCK" position, parking brake valve (1) is pulled to the left.
Port (P) and chamber (A) will be blocked and chamber (A) and chamber (C) will be connected.
• The oil from the power train pump is blocked at port (P).
• The oil flowing to the back pressure port of the brake piston flows from port (Br) through chambers (B), (A),
and (C) and is drained from port (T1).
• Since parking brake valve (1) is still pulled to the left, pressure at the brake piston back pressure port will
decrease further. The brake is completely "applied" and held in this state.
• This state is held during engine restarting.
D65EX,PX,WX-17 10-105
Final drive
Final drive
Structure
• The final drive uses a single stage spur gear and single stage planetary gear reduction system.
• The lubrication is of splash type using the rotation of the gears.
• The final drive can be removed and installed in a single unit.
• 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.
a The drawing shows D65EX-17.
10-106 D65EX,PX,WX-17
Final drive
1. Oil filler plug

2. Oil level plug
3. Drain plug
4. Cover
5. Pinion cover
6. Pinion (number of teeth: 19)
7. Bearing cage
8. Planetary gear shaft
9. Planetary gear (number of teeth: 27)
10. Final drive case
11. Sun gear (number of teeth: 17)
12. Gear hub
13. Carrier
14. Gear (number of teeth: 82)
15. Ring gear (number of teeth: 73)
D65EX,PX,WX-17 10-107
Final drive
16. Floating seal

17. Shaft
18. Sprocket hub
19. Sprocket teeth
Specifications
Reduction ratio -(82/19)x((17+73)/17)=-22.848

a The drawing shows D65EX-17.
Power from HSS

O
Pinion (1)
O
Gear (2)
O
10-108 D65EX,PX,WX-17
Final drive
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-17 10-109
Main frame
Undercarriage and frame
Main frame
a The drawing shows other than power angle power tilt dozers.
10-110 D65EX,PX,WX-17
Main frame
1. Frame assembly
2. Engine mount
3. Power train unit mount
4. Cab mount
5. Cooling assembly mount
6. Undercover 2
7. Undercover 1
8. Underguard
9. Front hook (option)
10. Cylinder yoke
Structure
• The frame assembly (1) has a hull-frame structure, in which the radiator guard, main frame, steering case,
transmission underguard, fenders, and cab mounts are integrated.
D65EX,PX,WX-17 10-111
Suspension
Suspension
a The drawing shows other than the D65EX-17 power angle power tilt dozer.
10-112 D65EX,PX,WX-17
Suspension
Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between pivot dimension Shaft Hole clearance clearance
1 shaft and bushing (large)
-0.145 +0.063 0.145 to
148 1.0
-0.208 0 0.271
Clearance between pivot -0.120 +0.054 0.120 to Replace
2 shaft and bushing (small) 105 1.0 bushing
-0.174 0 0.228
Clearance between center -0.100 +0.174 0.200 to
3 pin and bushing 70 0.5
-0.146 +0.100 0.320
Clearance between side pin -0.030 +0.010 0.010 to
4 and bushing 60 0.5
-0.060 -0.020 0.070
Press fit force of pivot shaft
5 ring (large) 0.98 to 22.6 kN {0.1 to 2.3 ton}
Press fit force of pivot shaft –
6 ring (small) 0.98 to 36.3 kN {0.1 to 3.7 ton}
– Oil quantity at pivot shaft 4.5 l (power line oil: TO30)
Specifications
D65PX-17
D65PX-17(PAT)
D65EX-17 D65WX-17
D65WX-17(PAT)
D65EX-17(PAT)
Amount of Upward 67.6 76.3 65.9
movement at
equalizer bar side Downward 67.6 76.3 65.9
pin center (mm)
PAT: Power angle power tilt dozer
D65EX,PX,WX-17 10-113
Track frame and idler cushion

a The drawing shows D65PX-17.
*1: Machines with conventional type track shoes are shown.

*2: Machines with PLUS type track shoes are shown.
a PLUS: Abbreviation for Parallel Link Undercarriage System
1. Idler
2. Carrier roller (*3)
3. Track frame
4. Sprocket teeth (*3)
10-114 D65EX,PX,WX-17
5. Track roller guard (*3)

6. Track roller (*3)
7. Center roller guard (*3)
8. Yoke
9. Seal
10. Piston
11. Recoil spring
12. Wear ring
13. U-packing
14. Cabin
15. Nut
16. Lubricator
17. Cylinder
18. Bushing
19. Holder
*3: Special parts are provided for machines with PLUS type track shoes.
a Do not mix with parts for machines with conventional type track shoes. Use special parts exclusively to
avoid life shortening.
Specifications
Pcs. per side Type of flange and arrangement
D65EX-17
7 S, S, D, S, D, S, S
D65WX-17
D65PX-17 8 S, S, D, S, S, D, S, S
S: Single flange
D: Double flange
Function
• The idler cushion charges grease from lubricator (16) or let the grease drain to move piston (10) forward or
backward in order to adjust the track tension. The recoil spring (11) acts to dampen any sudden shock
brought to bear on the idler (1).
D65EX,PX,WX-17 10-115
Hydraulic piping drawing
Hydraulic system
Tilt dozer, power tilt pitch dozer, and angle dozer series
a The drawing shows the straight tilt power pitch dozer.
1. Tilt cylinder (ST-T, SGM)

Pitch cylinder (ST-TPP, SGM-PP)
2. Quick drop valve
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)
10-116 D65EX,PX,WX-17
9. Blade PPC valve

10. Hydraulic tank
11. Ripper PPC valve (option)
12. HSS motor
13. Ripper cylinder (option)
16. HSS pump
18. Tilt cylinder (ST-TPP, SGM-PP)
ST-T: Straight tilt dozer
SGM: Sigma dozer
ST-TPP: Straight tilt power pitch dozer
SGM-PP: Sigma power pitch dozer
D65EX,PX,WX-17 10-117
Power angle power tilt dozer series
1. Tilt cylinder
2. Quick drop valve
4. Lift cylinder
5. Control valve
6. Angle control EPC valve
7. Work equipment lock solenoid valve
8. Accumulator
9. Blade PPC valve
10. Hydraulic tank
11. Ripper PPC valve (option)
12. HSS motor
13. Ripper cylinder (option)
10-118 D65EX,PX,WX-17

16. HSS pump
19. Angle cylinder
D65EX,PX,WX-17 10-119
Work equipment control

a The drawing shows the straight tilt dozer specification machine.
1. Work equipment lock limit switch

2. Work equipment lock lever
3. Ripper control lever (machine with ripper)
4. Blade control lever
5. Blade PPC valve
6. Ripper PPC valve (machine with ripper)
7. Control valve
8. Work equipment lock solenoid valve
9. PPC accumulator
10. Hydraulic tank
11. Pitch switch (straight tilt power pitch dozer)
Angle lever (power angle power tilt dozer)
Function
• The work equipment control adopts the PPC system, in which the blade control lever (4) is moved to
control PPC valve (5) or the ripper control lever (3) is moved to control PPC valve (6) in order to move the
respective spools of the control valve.
10-120 D65EX,PX,WX-17
• Work equipment lock lever (2) is interlocked with work equipment lock limit switch (1). When work
equipment lock lever (2) is in "FREE" position, work equipment lock limit switch (1) is turned OFF, and
work equipment lock solenoid valve (8) is energized, thus enabling the control of work equipments.
• When blade control lever (4) is in the "FLOAT" position, the lever is held in this position by the hydraulic
detent of blade PPC valve (5).
• When work equipment lock lever (2) is in the "LOCK" position, the hydraulic detent of blade PPC valve (5)
is released and blade control lever (4) returns to the "HOLD" position.
• When the engine is stopped, the hydraulic detent will not operate even if the blade control lever (4) is in
the "FLOAT" position. Blade control lever (4) returns to the "HOLD" position by itself.
• The PPC accumulator (9) provided in the PPC pilot circuit allows the work equipment to lower by its own
weight even when the engine is not running (the starting switch must be "ON").
• On straight tilt power pitch dozers, when the blade control lever (4) is moved left or right while pressing the
pitch switch (11) on the lever knob, the blade pitches back or forth.
• On power angle power tilt dozers, when the angle lever (11) on the blade control lever (4) is moved, the
blade angles left or right.
D65EX,PX,WX-17 10-121
Hydraulic tank
Hydraulic tank
1. Hydraulic tank
2. Sight gauge
3. Hydraulic oil temperature sensor
4. Hydraulic oil filter element
5. Spring
6. Bypass valve
7. Filler cap
8. Breather
9. Strainer
10. Drain plug
10-122 D65EX,PX,WX-17
Hydraulic tank
Specifications
Tank capacity (l) 80
Oil level in tank (l) 55
Bypass valve set pressure 147 ± 29.4
(kPa {kg/cm2}) {1.5 ± 0.3}
Breather
1. Nut
2. Cover
3. Filter element
4. Case
5. Valve assembly
6. Body
Prevention of negative pressure in tank
• The hydraulic tank is sealed and pressurized. 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.
(Suction valve set pressure:
1.96 ± 0.29 kPa {0.02 ± 0.003 kg/cm2})
Prevention of pressure rise in tank
• When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic
cylinders operate 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.
(Relief valve set pressure:
38.2 ± 5.69 kPa {0.39 ± 0.058 kg/cm2})
D65EX,PX,WX-17 10-123
CLSS
CLSS
CLSS: Abbreviation for Closed center Load Sensing System
Structure of CLSS
Features
The CLSS has the following features.
• Fine control not influenced by load
• Control performance that allows digging even when fine control operation is turned on
• Ease of combined operation ensured by the flow divider function that is determined by the opening areas
of spools during combined operations
• Energy saving by variable pump control
Configuration
• CLSS consists of variable capacity piston pumps, control valves, and respective actuators.
• The pump consists of the main pump, fixed throttle valve, PC valve, and LS valve.
Basic principle
Pump swash plate angle control

• The pump swash plate angle (pump delivery) is controlled so that LS differential pressure (dPLS), which is
the difference between pump delivery pressure (pp) and LS pressure (PLS) (load pressure of actuator) at
control valve outlet, is constant.
[LS differential pressure (dPLS) = Pump delivery pressure (PP) - LS pressure (PLS)]
10-124 D65EX,PX,WX-17
CLSS
• The pump swash plate angle shifts toward the maximum position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high). The pump swash
plate angle shifts toward the minimum position if LS differential pressure is higher than the set pressure
(when the actuator load pressure is low).
LS differential pressure (d
d PLS) and pump swash plate angle
D65EX,PX,WX-17 10-125
CLSS
a See "HSS pump" for the explanation of the operation.
Pressure compensation control
• A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.
• When actuators are operated in combined operations, the pressure difference (dP) between the upstream
(inlet port) and downstream (outlet port) of the spool of each valve are kept the same by the pressure
compensation valve, regardless the size of the load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
10-126 D65EX,PX,WX-17
Scavenging pump
Scavenging pump
A: From scavenging pump oil strainer

B: To steering case
Specifications
Type Gear pump
Theoretical delivery (cc/rev) 61.2
Maximum delivery pressure (MPa {kg/cm2}) 0.29 {3.0}
Maximum speed (rpm) 2,500
Function
• The scavenging pump is installed to the bottom of the PTO case and is driven by engine power.
• The pump sucks oil from the bottom of the transmission case through a strainer and sends it back to the
steering case.
D65EX,PX,WX-17 10-127
Steering lubricating oil pump and power train pump
Steering lubricating oil pump and power train pump
A: From power train oil strainer

B: To steering case
C: To power train oil filter
1. Steering lubrication oil pump
2. Power train pump
Specifications
Pump name Steering lubrication oil pump Power train pump
Model SAL(2)45 SAL(2)45
Type Gear pump Gear pump
Theoretical delivery
43.7 43.7
(cm3/rev)
Max. delivery pressure
20.6 {210} 20.6 {210}
(MPa {kg/cm2)
Max. speed
3,000 3,000
(rpm)
Function
• The steering lubricating oil pump and power train pump are installed to the top of the PTO case and is
driven by engine power.
• The steering lubricating oil pump sucks oil from the bottom of the transmission case through a strainer and
sends it to the steering lubricating oil circuit.
• The power train pump sucks oil from the bottom of the transmission case through a strainer and sends it to
the power train control circuit.
10-128 D65EX,PX,WX-17
HSS pump
HSS pump
IM: PC mode selector current connector

PA: Pump delivery port
D65EX,PX,WX-17 10-129
HSS pump
PB: Pump pressure inlet port

PC: Pump delivery pressure pickup port
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 inlet 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
Structure
• The pump assembly consists of the variable displacement swash-plate type piston pump, PC valve, LS
valve, and EPC valve.
10-130 D65EX,PX,WX-17
HSS pump
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
D65EX,PX,WX-17 10-131
HSS pump
Structure
• Cylinder block (7) is supported by shaft (1) on splined area (12).
• Shaft (1) is supported by each bearing (13).
• The tip of piston (6) has a spherical hollow in which shoe (5) is being held by crimping.
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the
case, and forms a static pressure bearing when it pivots.
(7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation.
• The oil pressure balance on the valve plate is maintained properly.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Specifications
Model HPV95(112)
Variable displacement swash plate type
Type
piston pump
Theoretical delivery
112
(cm3/rev)
10-132 D65EX,PX,WX-17
HSS pump
Rated delivery pressure

41.2 {420}
(MPa {kg/cm2)
Rated speed
2,280
(rpm)
Function
• The pump converts the engine speed and torque transmitted to its shaft into oil pressure and delivers
pressurized oil corresponding to the load.
• It is possible to change the delivery amount by changing the swash plate angle.
Operation of pump
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• If swash plate angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
• Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Each piston (6) sucks and discharges oil by (F) – (E).
• If cylinder block (7) rotates and the volume of chamber (E) is decreased, the oil is discharged from
chamber (E) during this process.
• The volume of chamber (F) is increased and the oil is sucked in chamber (F) during this process.
D65EX,PX,WX-17 10-133
HSS pump
• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is 0),
the difference between volumes (E) and (F) inside cylinder block (7) is 0.
• Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not
performed. (The swash plate angle is not set to 0 actually, however.)
Control of delivery
• When the swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and
also pump delivery (Q) increases.
• Swash plate angle (a) is changed with servo piston (10).
• Servo piston (10) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• This linear reciprocating movement is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• The area of servo piston (10) for receiving the pressure are not identical on the left side and right side.
Main pump delivery pressure (self pressure) (PP) is always brought to the pressure chamber of the small
diameter piston side.
• Output pressure (PEN) of LS valve is supplied to the chamber receiving the pressure at the large diameter
piston end.
• The movement of servo piston (10) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter side (PEN) and by the ratio of the area receiving the pressure
between small diameter piston and large diameter piston.
10-134 D65EX,PX,WX-17
HSS pump
LS valve
a LS: Abbreviation for Load Sensing
D65EX,PX,WX-17 10-135
HSS pump
PA: Pump port

PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: Drain port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut
Function
• The LS valve detects the load and controls the pump delivery.
• This valve controls pump delivery (Q) according to differential pressure (dPLS) [= (PP) - (PLS)], called the
LS differential pressure, the difference between main pump delivery pressure (PP) and control valve outlet
port pressure (PLS).
• This valve receives main delivery pressure (PP), pressure (PLS) (called the LS pressure) coming from the
control valve output.
10-136 D65EX,PX,WX-17
HSS pump
Operation
When control valve is in "NEUTRAL" position
• The LS valve is a 3-way selector valve, and LS pressure (PLS) on the inlet of the control valve is
transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port (H) of sleeve (1).
• 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).
• Before the engine is started, servo piston (10) is pushed to the left. (See the following figure)
• If the control lever is in 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 via the control valve spool)
• Spool (3) is pushed to the right, and port (C) and port (D) is connected.
• Pump delivery pressure (PP) is transmitted to the larger diameter end of pump from the port (K).
• The same pump delivery pressure (PP) is transmitted to the smaller diameter end at the port (J).
• According to the area difference of servo piston (10), the servo piston is moved to the right, in the direction
which makes the swash plate angle minimum. (See the previous figure.)
D65EX,PX,WX-17 10-137
HSS pump
When pump delivery is increased
• When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) decreases (for example, when the control valve open area increases and
pump delivery pressure (PP) decreases), the combined force exerted by LS pressure (PLS) and spring (4)
pushes spool (3) to the left.
• As spool (3) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve and drain port are connected, the pressure between circuits (D) and (K) becomes
drain pressure (PT). (For the details of PC valve operation, see "PC valve".
• The pressure on the large piston diameter side of servo piston (10) becomes drain pressure (PT) and
pump delivery pressure (PP) is constantly transmitted to port (J) on the small diameter end. Accordingly
servo piston (10) is pushed to the left and the swash plate is moved to increase the delivery.
10-138 D65EX,PX,WX-17
HSS pump
When pump delivery is decreased
• When LS differential pressure (dPLS) increases (for example, when the control valve opening area
decreases and the pump delivery pressure (PP) increases), the force exerted by pump delivery pressure
(PP) pushes spool (3) to the right.
• The movement of spool (3) transmits pump delivery pressure (PP) to the large diameter end of the piston
through port (C), port (D) and port (K).
• Pump delivery pressure (PP) is also transmitted to port (J) of the small diameter end of the piston, but
because of the difference in area between the large diameter end and the small diameter end on servo
piston (10), it is pushed to the right. As the result, the servo piston (10) moves the swash plate in the
direction to decrease the delivery.
D65EX,PX,WX-17 10-139
HSS pump
When servo piston is balanced
• The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of
the piston, the area receiving the pressure at the small diameter end and the pressure transmitted to the
large diameter end of the piston, respectively.
• When the force exerted by pump delivery pressure (PP) of the LS valve is balanced with the combined
force exerted by LS pressure (PLS) and spring (4), and the relationship becomes (A0) x (PP) = (A1) x
(PEN), servo piston (10) stops in that position.
• The swash plate of the pump is held at the intermediate position. [The swash plate stops at a position
where the openings from port (D) to port (E) and from port (C) to port (D) of spool (3) are approximately
equal]
• The relationship between the area receiving the pressure at both ends of servo piston (10) is (A0):(A1) =
3:5, and the pressures transmitted to both ends of the piston when the piston is balanced is (PP):(PEN)
C5:3.
• The force of spring (4) is adjusted so that spool (3) can be balanced at the specified center when (PP) -
(PLS) = 1.9 MPa {19 kg/cm2}.
PC valve
a PC: Abbreviation for Pressure Compensation
10-140 D65EX,PX,WX-17
HSS pump
PA: Pump port

PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Seat
8. Plug
9. Cover
10. Wiring
Function
• The PC valve limits the oil flow to a certain level (depends on the delivery pressure) even if the travel of
the control valve is increased extremely when pump delivery pressure (PP) is high.
• If the pump delivery pressure increases due to increased load during work, this valve decreases the pump
delivery.
• And if the pump delivery pressure goes low, it increases the pump delivery.
• The relation between the pump delivery pressure (PP) and pump delivery (Q) is as shown in the following
figure, as a parameter for each current (X) value applied to the PC-EPC valve solenoid.
• The controller continues counting the actual engine speed.
• During low speed, command current flows from the controller to PC-EPC valve solenoid according to the
engine speed to reduce the pump delivery.
D65EX,PX,WX-17 10-141
HSS pump
Operation
When the load on the actuator is small and pump delivery pressure (PP) is low
Actuation of PC-EPC valve solenoid (1)

• Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
• Spool (3) stops at a position where the combined force exerted by spring (4) and (5) is equalized to the
force exerted by pump delivery pressure (PP) acting on spool (3).
• Depending on this position, the pressure output from the PC valve [port (C) pressure] varies.
10-142 D65EX,PX,WX-17
HSS pump
• The amperage of the command current (X) depends on the type of work (lever operation), work mode
selection, engine speed setting, and the actual engine speed.
Action of spring
• The spring force of springs (4) and (5) in the PC valve depends on the position of the swash plate.
• When servo piston (9) compresses or decompresses springs (4) and (5), the spring force varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring forces of springs (4) and (5) are also varied by the PC-EPC valve solenoid command current
(X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Pump pressure (PP) is applied to the small diameter end of servo piston (9), port (A) and port (B).
• When pressures (PP) is low, spool (3) is at the left.
• Port (C) and port (D) are connected, and the pressure entering the LS valve will be drain pressure (PT).
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump delivery goes to increase.
• The movement of servo piston (9) lets spring (4) to expand, and the spring force decreases.
• When the spring force decreases, spool (3) moves to the right. Ports (C) and (D) are blocked, while pump
delivery pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
• Stop position of servo piston (9) (= pump delivery) is determined by a position where the press force
generated by pressure (PP) on spool (3) and the thrust by PC-EPC valve solenoid and the force of spring
(4) are balanced.
D65EX,PX,WX-17 10-143
HSS pump
When the actuator load is large, and the pump delivery pressure is high
Outline
• When the load is large and the pump delivery pressure (PP) is high, the thrust moving spool (3) to the right
increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump delivery pressure (PP),
because a part of the pressure from port (B) flows through the LS valve and port (C) to port (D), as shown
above.
Operation
• When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
• When pump delivery pressure (PP) increases more and spool (3) moves further to the right, pump delivery
pressure (PP) flows to port (C) to minimize the pump delivery.
• When servo piston (9) moves to the right, springs (4) and (5) are compressed, and spool (3) is pushed
back.
• When spool (3) moves to the left, the openings of ports (C) and (D) widen.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
• Servo piston (9) stops at a position further to the right than the position when pump delivery pressure (PP)
is low.
• The relationship between pump delivery pressure (PP) and pump delivery (Q) becomes as shown below.
10-144 D65EX,PX,WX-17
HSS pump
• If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
pump delivery pressure (PP) and pump delivery (Q) is shifted parallel in proportion to the thrust of PC-
EPC valve solenoid.
• Namely, the thrust of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the
pump pressure transmitted to spool (3), so the relationship between the pump delivery pressure (PP) and
pump delivery (Q) moves from (A) to (B) as the command current (X) is increased.
PC-EPC valve
a EPC: Abbreviation for Electromagnetic Proportional Control
D65EX,PX,WX-17 10-145
HSS pump
C: To PC valve
P: From pump
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
Function
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
• When signal current (i) from the controller is received, an EPC output pressure proportional to the
amperage of current is generated and output to the PC valve.
10-146 D65EX,PX,WX-17
HSS pump
Operation
When signal current is zero (coil de-energized)
• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
D65EX,PX,WX-17 10-147
HSS pump
• Port (P) is closed, and the pressurized oil from the pilot pump does not flow to the PC valve.
• The pressurized oil from the PC valve is drained to the tank through port (C) and port (T).
When signal current is small (coil energized)
• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
force of spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and ports (P) and (C) are blocked.
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the pressure at
port (C) and the force of spring (4).
• The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the amperage
of the signal current.
10-148 D65EX,PX,WX-17
HSS pump
When signal current is maximum (coil energized)
• Coil (2) is energized when signal current is supplied to coil (2).

• As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and PC valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.
D65EX,PX,WX-17 10-149
HSS motor
HSS motor
PA: From control valve (steering port)

PB: From control valve (steering port)
T2: To hydraulic tank
1. HSS motor
2. Counterbalance valve
3. Check valve
4. Safety valve
5. Air bleeder
10-150 D65EX,PX,WX-17
HSS motor
1. Output shaft
2. Motor case
3. Thrust plate
4. Piston
5. Cylinder block
6. Valve plate
7. End cover
8. Brake valve assembly
9. Counterbalance valve
10. Safety valve
11. Check valve
12. Sub-bearing
13. Spline
14. Shoe
15. Main bearing
Structure
• The motor consists of a fixed displacement swash plate type piston motor, flushing shuttle valve, bypass
valve, and a charge relief valve.
• Cylinder block (5) is jointed to output shaft (1) by splines (13), and output shaft (1) is supported by main
bearing (15) and sub bearing (12).
D65EX,PX,WX-17 10-151
HSS motor
• The tip of piston (4) has a spherical hollow in which shoe (14) is being held by crimping. Piston (4) and
shoe (14) forms a spherical bearing.
(5).
• Cylinder block (5) seals the pressurized oil to valve plate (6) and performs relative movement.
• This plane is designed so that the oil pressure is balanced correctly.
• The oil in each cylinder chamber of the rotating side [cylinder block] goes in and out through ports of the
fixed side [valve plate].
Specifications
Model HMF95(90)
Motor capacity (cm3/rev) 89.71
Rated delivery (l/min) 233
Safety valve cracking pressure (MPa {kg/cm2}) 38.7 {395}
Check valve cracking pressure (MPa {kg/cm2}) 0.0045 {0.045}
Function
• The pressurized oil sent from the pump is converted into rotating torque and is transmitted to the output
shaft.
Operation
Operation of motor
• The pressurized oil sent from the pump enters cylinder block (5) and pushes piston (4) from its backside.
• In the case of the motor, the center line of plate (3) is always at an angle [swash plate angle (a)] to the
axial direction of cylinder block (5).
• Focusing on one piston (4), oil pressure is applied to the backside of the piston as shown, generating a
piston axial force (F0).
• At shoe (14) which is connected to piston (4) through a spherical joint, a reaction force (FR) is generated
in the direction perpendicular to plane (A). The combined force (FP) of (F0) and (FR) becomes the force to
rotate cylinder block (5).
• The shaft (1) which is connected to the cylinder block (5) by splines (13) transmits this rotating torque to
the output side.
• As the cylinder block (5) rotates and the cylinder chamber expands from state (E) to state (F), pump
pressure oil flows into the cylinder chamber and generates pressure (P) according to the load.
• When the cylinder block (5) rotates further and the cylinder chamber passes state (F) going back to state
(E), oil is pushed out and sent back to the pump.
10-152 D65EX,PX,WX-17
HSS motor
Rotation speed and torque control

• The higher the HSS pump flow (Q), the higher the motor speed (N).
• Since the swash plate angle of the HSS motor is fixed [(a) is constant], the rotating torque (T) increases at
a rate proportional to the circuit pressure (P).
• Swash plate angle (a) is approximately 15.
Q = qN
(q = E–F)
T = Pq/2x
Q: Total flow
q: Flow per rotation
N: Rotating speed
P: Pressure
T: Rotating torque
Brake valve operation

• The brake valve consists of check valve (11), counterbalance valve (9), and safety valve(11) as shown in
the following figure.
• Functions and operations of respective components are as follows.
D65EX,PX,WX-17 10-153
HSS motor
Counterbalance valve, check valve

Function
• When a steering operation is stopped, a high pressure occurs in the motor delivery port. This pressure
tries to steer further.
• Carrying out the steering operations at low engine speed may induce idle run of the HSS motor that allows
the machine to run out of control, which is extremely dangerous.
• These valves serve to prevent the above problems by allowing steering controls that only matches the
engine speed (pump delivery).
Operation when pressurized oil is supplied

• When the steering lever is operated, pressurized 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).
• Since the HSS motor outlet is blocked by check valve (11b) and counterbalance valve (9), the pressure on
the supply side increases.
10-154 D65EX,PX,WX-17
HSS motor
• The pressurized oil at the supply side flows from orifice (E1) in spool (9) to chamber (S1). When the
pressure in chamber (S1) goes above the spool selector pressure, spool (9) is pushed to the right.
• Port (MB) connects to port (PB), and the HSS motor outlet opens and the HSS motor starts to rotate.
D65EX,PX,WX-17 10-155
HSS motor
Braking when steering operation is stopped

• If the machine almost run out of control when steering operation is stopped, the HSS motor runs idle and
the pressure at the HSS motor inlet decreases, causing a pressure drop in chamber (S2) through orifice
(E1).
• If the pressure in chamber (S1) becomes lower than the spool selector pressure, spool (9) returns to the
left by spring (16) and the outlet port (MB) is throttled.
• The pressure in the outlet port increases, resistance to the rotation of the motor is generated, and this
prevents the uncontrolled machine travel.
• The spool moves to a position where the force exerted by the weight of the machine and the pressure at
motor inlet port are balanced with the pressure at motor outlet port (MB). This narrows the outlet circuit
and allows the machine to travel at a speed that matches the pump delivery.
Safety valve
Function
• When the steering is stopped, the counterbalance valve (9) blocks the passage between the inlet and
outlet circuits of the HSS motor.
• Since the HSS motor is rotated by inertial force, pressure in the HSS motor outlet port is abnormally
increased, potentially resulting in damages on the HSS motor and piping.
• The safety valve releases this abnormal pressure to the inlet port of the HSS motor to prevent damage of
the equipment.
10-156 D65EX,PX,WX-17
HSS motor
Operation
• When the steering is stopped, chamber (E) [or chamber (F)]in the outlet circuit is blocked by the check
valve of the counterbalance valve (9), but the pressure in the outlet port increases because of inertia.
• If the pressure in chamber (E) [or chamber (F)] goes above the set pressure, the force of x(D12-D22)/4 x
pressure resulting from the difference in area of (D1) and (D2) [or the force of x(D32-D12)/4 x pressure
resulting from the difference in area of (D3) and (D1)] becomes greater than the force of the spring and
D65EX,PX,WX-17 10-157
HSS motor
moves the poppet to the right. The oil then flows to chamber (F) [or chamber (E)] in the circuit on the
opposite side.
10-158 D65EX,PX,WX-17
Control valve
Control valve
a In this section, only the 5-spool valve (straight tilt power pitch dozer + ripper) is shown.
Structure
The control valves of the following types are available.
• 3-spool valve (lift, tilt, steering)
[For straight tilt dozer]
• 4-spool valve (lift, tilt, ripper, steering)
[For straight tilt dozer]
• 5-spool valve (lift, tilt, angle, ripper, steering)
[For power angle and power tilt dozer]
• 5-spool valve (lift, pitch, tilt-pitch, ripper, steering)
[For straight tilt power pitch dozer]
[For sigma power pitch dozer]
A1: To HSS motor
A2: To lift cylinder head
A3: To pitch cylinder bottom
A4: To tilt cylinder bottom
A5: To ripper cylinder bottom
B1: To HSS motor
B2: To lift cylinder bottom
B3: To pitch cylinder head
B4: To tilt cylinder head
B5: To ripper cylinder head
LS: To HSS pump (port LS)
P: From HSS pump
PP: To HSS pump (LS valve)
PA2: From blade PPC valve (blade RAISE)
PA3: From pitch selector solenoid valve
(from blade PPC valve (blade right tilt))
PA4: From blade PPC valve (blade right tilt)
PA5: From ripper PPC valve (ripper LOWER)
PB2: From blade PPC valve (blade LOWER)
PB3: From pitch selector solenoid valve
(from blade PPC valve (blade left tilt))
PB4: From blade PPC valve (blade left tilt)
PB5: From ripper PPC valve (ripper RAISE)
PEPC: From cooling fan pump (self-pressure reducing valve)
PI: Pump pressure pickup port
SI: Steering LS pressure pickup port
T: To hydraulic tank
TS: To hydraulic tank
CA1: Connector (from controller)
CB1: Connector (from controller)
D65EX,PX,WX-17 10-159
Control valve
10-160 D65EX,PX,WX-17
Control valve
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)
D65EX,PX,WX-17 10-161
Control valve
14. Steering valve

15. Cover (steering valve side)
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
10-162 D65EX,PX,WX-17
Control valve
D65EX,PX,WX-17 10-163
Control valve
1. Unload valve
10-164 D65EX,PX,WX-17
Control valve
1. Centralized safety valve (for work equipment valve)

2. Pressure relief plug
3. Main relief valve (for work equipment valve)
D65EX,PX,WX-17 10-165
Control valve
Hydraulic circuit diagram and valve names
1. Unload valve
Set pressure: 3.4 MPa {35 kg/cm2}
10-166 D65EX,PX,WX-17
Control valve

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. Work equipment relief valve
11. Steering valve
12. Lift valve
13. Tilt valve
14. Pitch valve
15. Ripper valve
16. Back pressure valve
Unload valve
When control valve is in NEUTRAL position
PLS: LS circuit
PP: Pump circuit
T: Tank circuit
1. Sleeve
D65EX,PX,WX-17 10-167
Control valve
2. Spring
3. Spool
Function
• When the control valve is in NEUTRAL position, the valve lets pump delivery (Q) with the swash plate at
the minimum angle escape to the tank circuit. Pump delivery pressure (PP) is set to 3.4 MPa {35 kg/cm 2}
by spring (2) in the valve. [LS pressure (PLS) is 0 MPa {0 kg/cm 2}]
Operation
• Pump delivery pressure (PP) is acting on the left end of spool (3), and LS pressure (PLS) is acting on the
right end of the spool.
• When the control valve is in NEUTRAL position, LS pressure (PLS) is 0 MPa {0 kg/cm 2}, so only pump
delivery pressure (PP) has any effect, and (PP) is set only by the force of spring (2).
• As pump delivery pressure (PP) increases and reaches the force of spring (2) 3.4 MPa {35 kg/cm 2}, spool
(3) moves to the left. Pump delivery pressure (PP) is interconnected to tank circuit (T) through the drilled
hole (a) in sleeve (1).
• Pump delivery pressure (PP) is set to 3.4 MPa {35 kg/cm2}.
When control valve is in fine control range
Function
• When the control valve is in fine control range, if actuator demand flow is less than the pump delivery with
the swash plate at the minimum angle, the unload valve set pump delivery pressure (PP) to "LS pressure
(PLS) + 3.4 MPa {35 kg/cm2}". When the differential pressure between pump delivery pressure (PP) and
LS pressure (PLS) reaches the force of spring (2) 3.4 MPa {35 kg/cm 2}, the unload valve opens and LS
differential pressure (dPLS) is kept at 3.4 MPa {35 kg/cm2}.
Operation
• When the actuator is controlled at a flow less than the pump delivery with the swash plate at the minimum
angle [below (Q) min. in the chart below], if the control valve spool is selected, the LS pressure [(PLS) =
load pressure] is detected, and acts on the left end of spool (3).
10-168 D65EX,PX,WX-17
Control valve
• As the system tries to let full flow of (Q) min. pass through the narrow opening of the control valve spool,
the pump delivery pressure (PP) increases. As a result, the differential pressure between pump delivery
pressure (PP) and LS pressure (PLS) becomes larger.
• When the differential pressure between pump delivery pressure (PP) and LS pressure (PLS) reaches the
force of spring (2) 3.4 MPa {35 kg/cm2}, spool (3) moves to the left and pump circuit (PP) is interconnected
to tank circuit (T).
• Pump delivery pressure (PP) is set to the force of spring 3.4 MPa {35 kg/cm 2} + LS pressure (PLS), and
flow control differential pressure (dPLS) at minimum swash plate angle will be 3.4 MPa {35 kg/cm 2}.
When control valve is operated
Function
• When the control valve is operated, if the actuator demand flow exceeds the pump delivery with the swash
plate at the minimum angle, the unload valve blocks the flow to tank circuit (T) and allows all of pump
delivery (Q) to flow to the actuator circuit.
Operation
• If the control valve is operated by a large stroke, LS pressure (PLS) is generated and applied to the left
end face of spool (3). LS differential pressure (dPLS) is not so much from pump delivery pressure (PP)
because the opening area of control valve spool is wide.
D65EX,PX,WX-17 10-169
Control valve
• Since the differential pressure between pump delivery pressure (PP) and LS pressure (PLS) does not
reach the force of spring (2) 3.4 MPa {35 kg/cm2}, spool (3) is pushed to the right by spring (2).
• Pump circuit (PP) is disconnected from tank circuit (T) and all of pump delivery (Q) flows to the actuator
circuit.
Main relief valve, work equipment relief valve, and centralized safety valve
Function
• These valves drain oil to the hydraulic tank when the oil pressure exceeds the specified pressure. The
valves limit the maximum pressure of the work equipment circuits to protect the circuits.
Operation
• Port (A) is connected to the pump circuit, and port (B) is connected to the drain circuit. Pressurized oil
flows through the diameter (d1) of main valve (2) and hole in the poppet (1) and acts on the diameter (d2)
of main valve (2). Due to the difference in area (d1<d2) main valve (2) is in contact with the sleeve.
• If the oil pressure in port (A) reaches the set pressure of spring (4), pilot poppet (3) opens and the oil flows
around pilot poppet (3), through drilled hole (a), and then drains from port (B).
• As pilot poppet (3) opens, pressure in spring chamber (C) decreases. Poppet (1) moves to the right and
comes in contact with the end of pilot poppet (3). The oil is drained through drilled hole (b).
10-170 D65EX,PX,WX-17
Control valve
• As the pressure in spring chamber (C) is lower than the pressure in port (A), main vavle (2) opens and oil
flows from port (A) to (B) to prevent abnormal pressure.
D65EX,PX,WX-17 10-171
Control valve
Steering priority valve

In combined operation
a: Pump circuit
b: Steering pump circuit
10-172 D65EX,PX,WX-17
Control valve
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
• When the steering valve and a work equipment valve downstream of the steering priority valve are
operated at the same time, priority is given to the flow of oil to the steering valve, and the rest of the pump
delivery goes to the work equipment valve.
Operation
• When steering spool (3) is operated and oil flows, a differential pressure occurs between pump delivery
pressure (PP) and LS pressure (PLS). Steering priority valve (1) is controlled by this differential pressure,
and at the same time, the pump swash plate angle is controlled at (dPLS)[(PP)–(PLS)]=1.96 MPa {20 kg/
cm2}, and the flow of oil to the steering valve is fixed.
• Pressure (PP) is acting on the right end of prioirity spool (1), and pressure (PLS) is acting on the left side
spring chamber (d). Priority spool (1) is pushed to the right by spring (2).
• When the differential pressure of pressure (PP) - pressure (PLS) is below the set pressure of spring, the
opening from chamber (a) to chamber (b) will be maximum. As the differential pressure increases, spool
(1) moves to the left, narrowing the opening to the steering circuit, and widening the opening to the work
equipment circuit.
• If the work equipment spool (4) is operated while steering spool (3) is operated, the pump pressure (PP)
momentarily drops.
• At this time, the differential pressure of (PP)–(PLS) becomes smaller, and priority valve (1) moves to the
right to throttle the opening to the work equipment circuit by the pressure in chamber (d).
• At the same time, (dPLS) becomes smaller, so the pump swash plate angle shifts toward the maximum
position in order to increase the oil flow by the amount which compensates the pressure drop.
When pump swash plate angle does not shifts toward maximum position
• When the maximum flow of oil from the pump is greater than the total of the oil flow demanded by the
steering valve and work equipment valve, the flow of oil corresponding to the opening of steering spool (3)
flows to the steering valve, and the flow of oil determined by the pump pressure, load pressure, and
opening area flows to the work equipment valve.
When pump swash plate angle is maximum

• When maximum pump delivery is less than the total flow demand of the steering valve and work
equipment valve
1. When steering valve loadZwork equipment valve load
• The flow of oil correspondent to the steering spool (3) opening flows to the steering valve, and the rest
of the oil flows to the work equipment valve.
2. When steering valve load > work equipment valve load
D65EX,PX,WX-17 10-173
Control valve
• Pump pressure (P) is determined by the steering valve load, but in this condition, if the downstream
work equipment valve is operated, the difference in pressure will cause the oil to try to flow to the work
equipment valve, so the pump pressure will drop.
• To ensure the flow of oil to the steering system, steering priority valve (1) increases the area of the
opening to the steering system, while at the same time reducing the area of the opening to the work
equipment system.
• In this condition, the flow of oil is divided in proportion to the difference in pressure between differential
pressure (PP)–(P1) and differential pressure (PP)–(P2). The bigger (P1)–(P2) is, the smaller the flow
of oil to the steering system becomes.
Pressure reducing valve
(for work equipment valve)
When work equipment valve is operated independently
a: Work equipment pump circuit

b: Orifice
c: Spring chamber
d: Valve pressure receiving chamber
e: Notch
f: Orifice
g: Pressure chamber
h: Notch
i: Notch
PP: Pump circuit
T: Tank circuit
1. Pressure reducing valve
2. Poppet
3. Spring
10-174 D65EX,PX,WX-17
Control valve
4. Valve
5. Spring
6. Steering priority valve spool
7. Spring
Function
• The valve limits the pump circuit pressure at the work equipment side to max. 28.1 MPa {287 kg/cm 2}
while maintaining the pump circuit pressure at the steering side of 40.2 MPa {410 kg/cm 2} in combined
operation of a work equipment and steering.
Operation
• When a work equipment valve (lift, tilt, angle, etc.) is operated, pressurized oil (PP) in the pump circuit
flows through notch (e) in spool (6) and orifice (f) and acts on right end chamber (g). Spool (6) moves to
the left against spring (7) and notch opening (h) becomes maximum. Pressurized oil flows through notch
(i) in valve (4) to the work equipment pump circuit (a).
• If oil pressure in work equipment pump circuit (a) reaches the set pressure of 28.1 MPa {287 kg/cm 2},
poppet (2) moves to the right agains spring (3), and lets the pressurized oil in spring chamber (c) to
escape to the tank circuit (T). The pressurized oil in pressure chamber (d) flows through orifice (b) and
spring chamber (c) to tank circuit (T). A differential pressure occurs between pressure chamber (d) and
spring chamber (c). Valve (4) moves to the right and notch (i) is closed. As a result, pump circuit (PP) and
work equipment pump circuit (a) are blocked.
• The work equipment pump circuit pressure will not exceed 28.1 MPa {287 kg/cm2} even when steering is
operated and the pump circuit pressure reaches 40.2 MPa {410 kg/cm2}.
D65EX,PX,WX-17 10-175
Control valve
Pressure compensation valve
Function
• When the load pressure of an actuator is lower than that of other actuator and the flow to the actuator is
going to increase during combined operation, this valve allows the load pressure to be compensated. [At
this time, the load pressure of actuator with larger load under combined operation (shown on the upper
side of the previous figure) is higher than that of the actuator with smaller load (shown on the bottom side
of the previous figure).]
10-176 D65EX,PX,WX-17
Control valve
Operation
• When the load pressure of the actuator with larger load (shown on the upper side of the previous figure)
increases during combined operation, flow to actuator circuit (AA) on the actuator with smaller load
(shown on the bottom side of the previous figure) is apt to increase.
• In this case, the LS pressure (PLS) of actuator with larger load is applied to the spring chamber (PLS1)
and pushes the pressure reducing valve (1) and the flow control valve (2) to the left side.
• Flow control valve (2) reduces the open area between pump circuit (PP) and spool upstream (PPA) to
generate a pressure loss between (PP) and (PPA).
• The flow control valve (2)and the pressure reducing valve (1) balance each other where the pressure
difference between (PA) and (PLS) applied to the both end surfaces of the pressure reducing valve (1)
becomes the same as the pressure loss between (PP) and (PPA) around the flow control valve.
• The pressure differences between upstream pressure (PPA) and downstream pressure (PA) of both
spools operated for combined operation is the same and pump delivery is divided in proportion to the
opening area of each spool notch (a).
Suction valve
Function
• This valve prevents generation of negative pressure in the cylinder circuit.
Operation
• Port (A) is connected to the cylinder circuit and port (B) is connected to the drain circuit. When port (A) is
loaded, the area difference between (d1) and (d2) causes main poppet (1) to open and lets oil to flow from
port (B) to port (A) to prevent generation of negative pressure.
D65EX,PX,WX-17 10-177
Control valve
LS shuttle valve
a: LS bypass orifice (steering)

b: LS bypass orifice (work equipment side)
1. LS shuttle valve
2. Ball shuttle valve
Function
• The LS shuttle valve releases the remaining pressure of LS pressure (PLS).
• While moderating increasing rate of LS pressure (PLS), this valve generates pressure loss in the throttle
part between (P) and (LS) of the pressure compensation valve with this discarded throttle flow, decreasing
the effective LS differential pressure and improving stability.
• Selects the higher LS pressure of the steering side or work equipment side and outputs.
Operation
• The steering side circuit pressure (PLS) pushes the ball shuttle valve (2) to the right, and the pressure is
led to the upper output port (PLS). [When the steering is operated independently, or when steering (PLS) >
work equipment (PLS) in combined operation]
• The steering side pressurized oil (PLS) flows through orifice (a) to the tank circuit.
• The pressure in the work equipment PLS circuit pushes the ball shuttle valve (2) to the left, and the
pressure is led to the upper output port (PLS). [When the work equipment is operated independently, or
when work equipment (PLS) > steering (PLS) in combined operation]
• The work equipment side pressurized oil (PLS) flows through orifice (b) to the tank circuit.
10-178 D65EX,PX,WX-17
Control valve
Operation of steering LS relief valve and main relief valve
a: Pump primary circuit

b: Pump secondary circuit
c: LS circuit
1. Steering spool
2. Steering LS relief valve
4. HSS motor
5. Priority valve spool
D65EX,PX,WX-17 10-179
Control valve
6. Priority valve spring

7. Unload valve
Function
• The valves determine the maximum pressure when the HSS motor operates.
• The pump LS valve detects the differential pressure (PP)–(PLS) generated by LS relief valve operation,
and shifts the pump swash plate angle toward the minimum position. The pump delivery is balanced at the
minimum position. As a result, the relief flow will be low.
• The main relief valve cuts pressure peaks that occur due to sudden changes of external load (such as LS
relief valve operation) too fast to deal with pump swash plate angle control.
Operation
• When steering spool (1) is moved, and HSS motor drive pressure (4) increases, steering LS relief valve
(2) will operate and oil in pump circuit (B) will be drained. As a result, the differential pressure between
pump circuit (b) and LS circuit (c) increases.
• For the same reason, when the pressure in LS circuit (c) decreases, priority valve spool (5) moves left
against spring (6). As the pump primary (a) and secondary (b) openings become smaller, the differential
pressure between (a) and (b) increases.
• The pump LS valve detects the differential pressure (PP)–(PLS) generated by LS relief valve (2), and
shifts the pump swash plate angle from the maximum position toward the minimum position. The pump
swash plate angle is balanced at the minimum position when the LS differential pressure X2.0 MPa {20 kg/
cm2}. (See "Pump swash plate angle control".)
• When the pump swash plate angle is minimum (minimum delivery), if the pump circuit pressure (PP) - LS
circuit pressure (PLS) becomes to be greater than or equal (X) to 3.4 MPa {35 kg/cm 2}, unload valve (7)
operates to let the excessive flow to escape to balance the circuit.
LS relief valve set pressure (MPa {kg/cm2}) 37.2 {379}
Main relief valve set pressure (MPa {kg/cm2}) 40.2 {410}
10-180 D65EX,PX,WX-17
Control valve
Operation of 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
Function
• The valves determine the maximum pressure when the work equipment operates.
D65EX,PX,WX-17 10-181
Control valve
• The pump LS valve detects the differential pressure (PP1)–(PP2)C(PLS) generated by the pressure
reducing valve and work equipment relief valve operations, and shifts the pump swash plate angle toward
the minimum position. The pump delivery is balanced at the minimum position. As a result, the relief flow
will be low.
Operation
• When work equipment spool (1) is moved and work equipment operating pressure (PP2) increases,
pressure reducing valve (2) operates and pressure reducing valve spool (5) closes to minimize the
opening (1.1 mm2) for circuits (PP1) and (PP2). As a result, work equipment pump circuit pressure (PP2)
becomes the set pressure of the pressure reducing valve, 28.1 MPa {287 kg/cm2}.
• Work equipment operating pressure (PP2) is determined by the set pressure of the pressure reducing
valve. Since the unloader valve drains the excessive flow, pressure (PP1) is determined by the combined
force of the set pressures of the pressure reducing valve and the unloader valve.
• The work equipment relief valve cuts pressure peaks that occur due to sudden changes of external load
(such as pressure relief valve operation) too fast to deal with pump swash plate angle control.
Pressure reducing valve set pressure (MPa {kg/cm2}) 28.1 {287}
Work equipment relief valve set pressure (MPa {kg/cm2}) 30.1 {307}
Unload valve set pressure (MPa {kg/cm2}) 3.4 {35}
Introduction of LS pressure
Steering valve
Function
• LS pressure means the actuator load pressure on the outlet side of the control valve.
10-182 D65EX,PX,WX-17
Control valve
• At the work equipment vavle, actually, the pump delivery pressure (PP) is reduced by pressure reducing
valve (3) of the pressure compensation valve to the same pressure as actuator circuit pressure (A) and
transmitted to LS circuit (PLS). Also, an orifice (c) is provided in piston (5) between the pump circuit (PP)
and pressure reducing valve (3) to let it work as a damper.
Operation
• When spool (1) is operated, pump delivery pressure (PP) flows from flow control valve (2) and notch (a) in
the spool through bridge passage (b) to actuator circuit (A).
• At the same time, reducing valve (3) also moves to the left, so pump delivery pressure (PP) is reduced
due to the pressure loss at throttle (d) and then transmitted through LS circuit (PLS) to spring chamber
(PLS1).
• LS circuit (PLS) is connected to tank circuit (T) from LS bypass valve (4).
• The areas at both ends of pressure reducing valve (3) are the same [(SA) = (SLS)], and actuator circuit
pressure (PA) = (A) acts on the (SA) end. The reduced pump delivery pressure (PP) acts on (SLS) at the
other end.
• Pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the
pressure of spring chamber (PLS1) are the same. Pump delivery pressure (PP) reduced at notch (d)
becomes actuator circuit pressure (A) and is transmitted into LS circuit (PLS).
Work equipment valve (lift, tilt, angle, ripper)

When blade lift valve is in "RAISE" position
D65EX,PX,WX-17 10-183
Control valve
Operation
• When spool (1) is operated, pump delivery pressure (PP) flows from flow control valve (2) and notch (a) in
the spool through bridge passage (b) to actuator circuit (A).
• At the same time, pressure reducing valve (3) also moves to the right, so pump delivery pressure (PP) is
reduced due to the pressure loss at notch (d) and then transmitted through LS circuit (PLS) to spring
chamber (PLS1).
• LS circuit (PLS) is connected to tank circuit (T) from LS bypass valve (4).
• The areas at both ends of pressure reducing valve (3) are the same [(SA) = (SLS)], and actuator circuit
pressure (PA) = (A) acts on the (SA) end. The reduced pump delivery pressure (PP) acts on (SLS) at the
other end.
• Pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the
pressure of spring chamber (PLS1) are the same. Pump delivery pressure (PP) reduced at notch (d)
becomes actuator circuit pressure (A) and is transmitted into LS circuit (PLS).
When blade lift valve is in "FLOAT" position
Operation
• When the lift valve is in "FLOAT", the cylinder ports and drain port (T) are interconnected, and the system
will be in a no load condition.
• Even when the lift valve is in "FLOAT", the pump circuit and cylinder circuits are isolated to enable
operation of other work equipment (tilt, angle, etc.).
• When the work equipment lever is set in "FLOAT", spool (1) is at its maximum stroke position, port (B) is
interconnected to port (A) via bridge passage (b), and port (A) is interconnected to circuit (T).
• The blade will move freely upward or downward according to external force.
10-184 D65EX,PX,WX-17
Control valve
• In "FLOAT" position, part (a) of spool (1) is blocked. Therefore, when other work equipment (tilt, angle,
etc.) is operated, the pump pressure increases to enable combined operation.
Back pressure valve
Function
• When the steering is operated or stopped, to prevent cavitation in the HSS motor, the steering circuit drain
pressure is raised to enhance the effect of suction valve (3).
Operation
• The steering circuit drain pressure is raised by back pressure valve and spring (2).
D65EX,PX,WX-17 10-185
Blade PPC valve
Blade PPC valve

a PPC: Abbreviation for Proportional Pressure Control
10-186 D65EX,PX,WX-17
Blade PPC valve
P: From work equipment lock solenoid valve

P1: To control valve (blade LOWER port)
P2: To control valve (blade RAISE port)
P3: To control valve (left tilt port)
P4: To control valve (right tilt port)
1. Disc
2. Plate
3. Body
D65EX,PX,WX-17 10-187
Blade PPC valve
Operation
When control lever is in NEUTRAL position
For blade lift
• Ports (PA2) and (PB2) of the blade lift control valve and ports (P1) and (P2) of the PPC valve are
connected respectively through fine control hole (f) of spool (1) to drain chamber (D).
10-188 D65EX,PX,WX-17
Blade PPC valve
For blade tilt
• Ports (PA3) and (PB3) of the blade tilt control valve and ports (P3) and (P4) of the PPC valve are
connected respectively through fine control hole (f) of spool (1) to drain chamber (D).
D65EX,PX,WX-17 10-189
Blade PPC valve
When control lever is in fine control range
(When moved from NEUTRAL to fine control range)
• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
The pilot pressure is transmitted from port (P1) to port (PB2) through the fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
exerted by pressure in port (P1). The positional relationship between spool (1) and valve body (10) [where
fine control hole (f) is located between drain chamber (D) and pump pressure chamber (PP)] does not
change until retainer (9) comes in contact with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel. In addition, the pressure in port
(P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in chamber (PB2) [equal to
the pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.
10-190 D65EX,PX,WX-17
Blade PPC valve
(When control lever is returned)
• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the force
exerted by the pressure in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessibly reduced, spool (1) is depressed by metering spring (2) and fine
control hole (f) is disconnected from drain chamber (D), and almost the same time it is connected to pump
pressure chamber (PP). Then, the pump pressure is supplied until the pressure in port (P1) recovers to
the level corresponding to the lever position.
• When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
chamber (PA2) to replenish the port with pressurized oil.
D65EX,PX,WX-17 10-191
Blade PPC valve
When control lever is moved to stroke end
• Disc (5) depresses piston (4), and retainer (9) depresses spool (1). Fine control hole (f) is disconnected
from drain chamber (D), and it is connected to pump pressure chamber (PP).
• The pilot pressure oil passes through fine control hole (f) and flows from port (P1) to chamber (PB2) and
pushes the control valve spool.
• The oil returning from chamber (PA2) flows from port (P2) through fine control hole (f') into drain chamber
(D).
When control lever is "FLOAT" position

• When piston (4) for blade "LOWER" side of port (P1) is depressed by disc (5), ball (11) touches projection
(a) of the piston in the middle of the stroke (The detent starts to operate).
• When piston (4) is depressed further, ball (11) pushes up collar (12) supported on detent spring (13) and
moves outward to allow projection (a) of the piston to pass.
• At this time, piston (4') on the opposite side is pushed up by spring (14).
• As a result the oil in chamber (F) flows through ports (b) and (c) to chamber (E), allowing piston (4') to
follow disc (5). Since passage (d) is interconnected to port (P1), almost the same pressure is applied to
passage (d) and port (P1).
• Chamber (E) is interconnected to drain chamber (D). When ball (11) passes projection (a) of the piston,
passage (d) which has been blocked is interconnected to chamber (E) and the oil starts flowing to
chamber (E).
• At this time, the control valve moves to the "FLOAT" position and the circuit comes into "FLOAT" condition.
• Since piston (4') is pushed up by the force exerted by the pressure in chamber (E), the "FLOAT" condition
is kept even if the control lever is released.
10-192 D65EX,PX,WX-17
Blade PPC valve
When canceling "FLOAT" condition

• Disc (5) is returned with a force large than the force exerted by the pressure in chamber (E) to cancel the
"FLOAT" condition.
• As a result, chamber (E) is disconnected from passage (d) and connected to the drain chamber, the
pressure in chamber (E) is lost and the "FLOAT" state is cancelled.
D65EX,PX,WX-17 10-193
Ripper PPC valve
Ripper PPC valve

(if equipped)
P: From work equipment lock solenoid valve

P1: To control valve (ripper LOWER port)
P2: To control valve (ripper RAISE port)
T: To tank
1. Spool
2. Piston
10-194 D65EX,PX,WX-17
Ripper PPC valve
3. Lever
4. Plate
5. Retainer
6. Body
Operation
When control lever is in NEUTRAL position
• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected respectively
to drain chamber (D) through fine control hole (f) in spool (1).
(When moved from NEUTRAL to fine control range)

• When piston (4) is pushed by lever (5), retainer (7) is pushed and spool (1) is also pushed by metering
spring (2) and moves downwards.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
The pilot pressure is transmitted from port (P1) to port (PB2) through the fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
exerted by the pressure in port (P1).
• The positional relationship between spool (1) and valve body (8) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (7) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel. In addition, the pressure in port
(P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool.
D65EX,PX,WX-17 10-195
Ripper PPC valve
(When control lever is returned)
• When lever (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the force
exerted by the pressure in port (P1). Fine control hole (f) is connected to drain chamber (D), and the
pressurized oil in port (P1) is released.
10-196 D65EX,PX,WX-17
Ripper PPC valve
• If the pressure in port (P1) is excessibly reduced, spool (1) is depressed by metering spring (2) and fine
control hole (f) is disconnected from drain chamber (D), and almost the same time, it is connected to pump
pressure chamber (PP). Then, the pump pressure is supplied until the pressure in port (P1) recovers to
the level corresponding to the lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
chamber (B) to replenish the port with pressurized oil.
When control lever is moved to stroke end
• Lever (5) depresses piston (4), and retainer (7) depresses spool (1). Fine control hole (f) is disconnected
from drain chamber (D), and it is connected to pump pressure chamber (PP).
• The pilot pressure oil passes through fine control hole (f) and flows from port (P1) to port (A) and pushes
the control valve spool.
• The oil returning from chamber (B) flows from port (P2) through fine control hole (f') into drain chamber (D).
D65EX,PX,WX-17 10-197
Quick drop valve
Quick drop valve
CB1: To L.H. lift cylinder bottom

CB2: To R.H. lift cylinder bottom
CH1: To L.H. lift cylinder head
CH2: To R.H. lift cylinder head
VB: From control valve (blade LOWER port)
VH: From control valve (blade RAISE port)
1. Body
2. Plug
10-198 D65EX,PX,WX-17
Quick drop valve
3. Valve
4. Plug
5. Retainer
6. Plug with operating orifice
7. Plug
8. Piston
Function
• The quick drop valve is installed between the control valve and the lift cylinders. The valve prevents
vacuum in the cylinder bottom when blade "LOWER" is operated, and reduces the time lag before digging
is commenced.
• The blade "LOWER" speed is almost determined by the pump delivery, however, the quick drop valve
enables faster lowering.
Operation
Blade LOWER started
• When the blade control lever is operated to the "LOWER" position, pressurized oil from the control valve
enters port (VB) and flows through ports (CB1) and (CB2) to the cylinder bottom. The cylinder piston is
moved to the left.
• The pressurized oil on the cylinder head end is pushed out by the cylinder piston, and then enters ports
(CH1) and (CH2), flows through port (VH) and control valve to the hydraulic tank.
Blade LOWER in progress
• Pressurized oil pushed out from the cylinder head end flows from ports (CH1) and (CH2) to port (VH). At
this time, the oil flow is restricted by orifice (a) provided in the way, causing a differential pressure across
the orifice.
• When the oil pressure in ports (CH1) and (CH2) becomes higher than the force of springs (1) and (3),
valve (3) and piston (4) moves to the right.
• A portion of the oil flowing from ports (CH1) and (CH2) to port (VH) opens valve (3). The oil then flows to
port (VB) and ports (CH1) and (CH2), merges with the pressurized oil from the control valve and flows to
the cylinder bottom end.
D65EX,PX,WX-17 10-199
Quick drop valve
• The blade lowering speed increases in accordance with the amount of oil that flows to the bottom end of
the cylinder and reduces the formation of vacuum at the bottom end of the cylinder.
10-200 D65EX,PX,WX-17
Work equipment lock solenoid valve

Tilt dozer and angle dozer series
P: From cooling fan pump (from self-pressure reducing valve)

P1: To PPC valve
P2: To control valve, port PEPC
ACC: To accumulator
T: From blade PPC valve port T
1. Solenoid
D65EX,PX,WX-17 10-201
2. Accumulator check valve

3. Block
Power tilt pitch dozer series
10-202 D65EX,PX,WX-17
P1: To PPC valve

P4: To control valve (pitch dump port)
A1: From blade PPC valve port P4
A2: To control valve (right tilt port)
B1: From blade PPC valve port P3
B2: To control valve (left tilt port)
ACC: To accumulator
T2: To control valve (pitch back port)
PS: To pitch selector solenoid valve port P
AS: To pitch selector solenoid valve port A
BS: To pitch selector solenoid valve port B
TS: To pitch selector solenoid valve port T
1. Solenoid
3. Block
D65EX,PX,WX-17 10-203

P1: To PPC valve
10-204 D65EX,PX,WX-17
C1: To control valve (left angle port)

C2: To control valve (right angle port)
ACC: To accumulator
PS1: To left angle control EPC valve port P
PC1: To left angle control EPC valve port C
TE1: To left angle control EPC valve port T
PS2: To right angle control EPC valve port P
PC2: To right angle control EPC valve port C
TE2: To right angle control EPC valve port T
1. Solenoid
3. Block
Function
• The valve is installed in the work equipment control circuit between the self-pressure reducing valve and
the PPC valve.
• When the work equipment lock lever is set in the "FREE" position, the work equipment lock limit switch
energizes the work equipment lock solenoid. The work equipment control circuit is open and the work
equipment becomes operable.
Operation
• Electric signals cause the solenoid (1) to energize. A spool moves, ports (P) and (P1) are interconnected,
and source pressure is supplied to the PPC valve.
D65EX,PX,WX-17 10-205
Pitch selector solenoid valve
Pitch selector solenoid valve

Straight tilt power pitch dozer (ST-TPP)
Sigma power pitch dozer (SGM-PP)
P: From PS port of work equipment lock solenoid valve

A: From AS port of work equipment lock solenoid valve
B: From BS port of work equipment lock solenoid valve
T: From TS port of work equipment lock solenoid valve
1. Block
2. Solenoid
Function
• The valve is installed in the tilt circuit between the blade PPC valve and the control valve.
• While the pitch switch on top of the blade control lever is pressed, solenoid (2) is energized to interconnect
the tilt and pitch pilot circuits.
10-206 D65EX,PX,WX-17
Angle control EPC valve
P: From pump
C: To control valve (angle port)
1. Body
2. Plug
3. Spool
4. Push pin
5. Coil
6. Plunger
7. Connector
Function
• The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion.
• When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the
amperage of current is generated and output to the control valve.
D65EX,PX,WX-17 10-207
Operation
When signal current is zero amp. (coil de-energized)
• When the signal current from the controller is not flowing through coil (1), coil (1) is de-energized.
• Spool (2) is pushed to the right by spring (3).
• Port (P) is closed, and the pressurized oil from the front pump does not flow to the control valve.
• The pressurized oil from the control valve is drained to the tank through port (C) and port (T).
10-208 D65EX,PX,WX-17
D65EX,PX,WX-17 10-209
When signal current is minute (coil is energized)

• When minute signal current flows through coil (1), coil (1) is energized and the thrust pushing plunger (4)
to the left is generated.
• Push pin (5) pushes spool (2) to the left, and the pressurized oil from port (P) flows to port (C).
• The pressure in port (C) increases and the total of the force applied on surface (a) of spool (2) and the
force of spring (3) becomes larger than the thrust of plunger (4).
• Spool (2) is pushed to the right, and port (P) is shut off from port (C), and port (C) is connected to port (T).
• Spool (2) moves to a position where the thrust of plunger (4) becomes equal to the total of the force
exerted by the pressure in port (C) and the force of spring (3).
• The circuit pressure between the EPC valve and the control valve is controlled in proportion to the
amperage of the signal current.
10-210 D65EX,PX,WX-17
When signal current is maximum (coil is energized)

• Coil (1) is energized when the signal current flows to coil (1).
• As the signal current is maximum, the thrust of plunger (4) is also maximized
• Spool (2) is pushed to the left by push pin (5).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and control valve is maximized.
• Port (T) closes, and no pressurized oil flows to the hydraulic tank.
D65EX,PX,WX-17 10-211
Hydraulic oil cooler bypass valve
Hydraulic oil cooler bypass valve
M: From cooling fan motor

C: From hydraulic oil cooler outlet
1. Block
2. Poppet
3. Spring
4. Plug
Specifications
0.78 ± 0.05
Cracking pressure (MPa {kg/cm2})
{8 ± 0.5}
Function
• The valve is installed at the oil cooler outlet. When an abnormal pressure occurs in the oil flow to the oil
cooler, poppet (2) opens to return the oil directly back to the hydraulic tank.
10-212 D65EX,PX,WX-17
PPC accumulator
PPC accumulator
PPC: Abbreviation for Proportional Pressure Control
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas to be used Nitrogen gas
Volume of gas (cc) 300
1.18 {12}
Charged pressure (MPa {kg/cm2})
(at 80°C)
Max. operating pressure (MPa {kg/cm2}) 6.86 {70}
Function
Function
• The accumulator is installed between the self-pressure reducing valve and PPC valve. If the engine is
stopped with the work equipment raised (the starting switch must be "ON"), the pilot pressure is supplied
to the control valve by the pressure of the compressed nitrogen gas in the accumulator. Therefore, the
spool can be operated to lower the work equipment by its own weight.
D65EX,PX,WX-17 10-213
Work equipment
Work equipment
Work equipment
Tilt dozer and power tilt pitch dozer series
*1: Sigma dozer and sigma power pitch dozer are shown.
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)
ST-T: Indicates straight tilt dozer.
SGM: Indicates sigma dozer.
ST-TPP: Indicates straight tilt power pitch dozer.
SGM-PP: Indicates sigma power pitch dozer.
10-214 D65EX,PX,WX-17
Work equipment
1. Tilt cylinder
2. Cutting edge
3. End bit
4. Pitch rod
5. Blade
6. Angle cylinder
7. U-frame
8. Trunnion
D65EX,PX,WX-17 10-215
Work equipment
Angle dozer series
1. Center shaft
2. Cutting edge
3. C-frame
4. End bit
5. Trunnion
6. Joint
7. Blade
8. Arm
9. Brace
10-216 D65EX,PX,WX-17
Ripper
Ripper
(if equipped)
D65EX-17, D65WX-17
1. Ripper cylinder
2. Upper link
3. Shank
4. Point
5. Lower link
6. Support
7. Beam
D65EX,PX,WX-17 10-217
Piston valve
Piston valve
For lift cylinder
Function
• The piston valve is installed to the piston part of the lift cylinder.
• When the piston rod is at its stroke end, the valve releases the oil from the pump to the port on the other
end and the oil pressure being exerted on the piston decreases. The valve also releases the oil to the
other end before the piston reaches the stroke end to relief surge pressure and minimize the shock at the
stroke end.
Operation
Piston valve "CLOSED"
• The pressurized oil from the pump acts on piston (3) and piston valve (1).
Then, piston valve (1) is pushed to the right, and contacts the tapered area (a) of the piston valve seat (2)
to seal in the oil.
As a result, the oil pressure in the cylinder increases and piston (3) is pushed to the right.
Piston valve "OPEN"
• Before piston rod (4) reaches its stroke end, slider (5) contacts cylinder bottom (b) and stops movement.
• Then, slider (5) contacts the end of piston valve (1), and only piston (3) continues to move.
• Pressurized oil that has been sealed in by piston valve (1) is released from the piston valve seat (2) to the
bottom end and the pressure in the cylinder decreases.
For angle cylinder
(For power angle power tilt dozer)
Function
• The piston valve is installed to the piston part of the angle cylinder.
• When the piston rod is at its stroke end, the valve releases the oil from the pump to the port on the other
end and the oil pressure being exerted on the piston decreases.
10-218 D65EX,PX,WX-17
Piston valve
Operation
Piston valve "CLOSED"
• The pressurized oil from the pump pushes piston (2) against spring (4) and the piston (2) moves. Then it
flows into chamber (A).
• Chamber (A) is filled with pressurized oil. Piston valve (5) is pushed to the right, and contacts the tapered
area of the piston valve seat (a) to seal in oil.
• As a result, the oil pressure in the cylinder increases and piston (3) is pushed to the right.
Piston valve "OPEN"
• Before piston rod (1) reaches its stroke end, slider (6) contacts cylinder bottom (b) and stops movement.
• Then, slider (6) contacts the end of piston valve (5), and only piston (3) continues to move.
• Pressurized oil in chamber (A) that has been sealed in by piston valve (5) is released from the piston valve
seat (a) to the bottom end and the pressure in the cylinder decreases.
D65EX,PX,WX-17 10-219
ROPS cab
Cab and its attachments
ROPS cab
a ROPS: Abbreviation for Roll-over Protective Structure
1. Front wiper
2. Front window
3. Additional front light (if equipped)
4. Revolving warning lamp (if equipped)
5. Door glass wiper
6. Door
7. KOMTRAX communication antenna
8. Rear window
9. Rear wiper
10. Additional rear light (if equipped)
11. Radio antenna
10-220 D65EX,PX,WX-17
ROPS cab
12. Camera (if equipped)

13. KOMTRAX GPS antenna
Function
• ROPS cab is a structure which protects the operator fastening a seat belt not to be crushed when the
machine tips over.
D65EX,PX,WX-17 10-221
Cab mount
Cab mount
1. Damper mount (front)

2. Damper mount (rear)
Structure
• The mounts are installed at two places in the front section and at two places in the rear section to secure
the floor frame and the cab.
• Oil-filled dampers are used to absorb vibration.
10-222 D65EX,PX,WX-17
Engine control system
Electrical system
1. Battery disconnect switch

2. Battery
3. Starting switch
4. Engine shutdown secondary switch
D65EX,PX,WX-17 10-223
7. Machine monitor
8. KOMTRAX terminal
9. Fuel control dial
10. Decelerator pedal
11. Parking brake limit switch
12. Parking brake lever
13. Work equipment lock limit switch
14. Work equipment lock lever
15. Electric steering lever
17. Neutral safety relay
18. Personal lock relay
19. Engine
20. Starting motor
21. Engine speed sensor
22. Coolant temperature sensor
23. Engine oil pressure switch
24. Injector
25. Supply pump
Input/Output signal
a. Battery power supply
b. Engine start signal
c. Neutral safety relay signal
d. Personal lock relay signal
e. Starting switch ACC signal (upstream)
f. Starting switch ACC signal (downstream)
g. Parking brake signal
h. Work equipment lock signal
i. Neutral signal
j. 1st throttle signal (fuel dial sensor signal)
k. 2nd throttle signal (decelerator pedal signal)
l. 3rd throttle signal (controller control signal)
m. Controller power supply
n. Engine speed signal
o. Coolant temperature signal
p. Engine oil pressure signal
q. Sensor signal
r. Monitor display signal
Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a Power train controller (6) controls neutral safety relay (17) to disable the engine from starting unless
both the parking brake lever (12) and work equipment lock lever (14) are set in the "LOCK" position,
and steering, directional and gear shift lever (16) is set in "NEUTRAL" position.
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal (8) receives an engine cut command issued through external operation.
• The power train controller (6) calculates a proper engine speed based on auto-deceleration and
momentary engine speed increase information and sends it as the 3rd throttle signal to the engine
controller (5).
10-224 D65EX,PX,WX-17
• The information of engine controller (5) is shared by the other controllers through the network and used for
the optimum control of the engine and machine.
• When you cannot stop the engine due to stuck starting switch (3), engine shutdown secondary switch (4)
is usable for stopping the engine.
Starting the engine

• If starting switch (3) is turned to "ON" position, engine controller (5) sends a command current to supply
pump (25).
For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an
electrical failure occurs.
• A neutral safety mechanism prevents engine starting when either parking brake lever (12) or work
equipment lock lever (14) is set to "FREE" position, or the steering, directional and gear shift lever is not in
"NEUTRAL". In such conditions, neutral safety relay (17) cuts off the starting current to starting motor (20).
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (8) sends the
signal to machine monitor (7).
Machine monitor (7) causes personal lock relay (18) to cut off the starting current to starting motor (20),
therefore the engine does not start.
Engine speed control

• The engine controller (5) receives 1st throttle signals (fuel dial sensor signals), 2nd throttle signals
(decelerator pedal signals), and 3rd throttle signals (controller control signals) from the power train
controller (6), and then controls the fuel supply pump (25) and injectors (24) according to the command
signals having the lowest engine speed.
3rd throttle signals include the following information.
1. Auto-deceleration (F3, R3)
Auto-deceleration is a function of lowering the engine speed temporarily when the travel direction is
changed from F3 or R3.
(for protection of the transmission clutches)
2. Momentary engine speed increase
(Directional selection on a hill)
This is a function of raising the engine speed temporarily when the travel direction is changed while
travelling downhill, according to machine conditions.
(to ensure safety by preventing slip of machine)
Engine stop
• If starting switch (3) is turned to "OFF" position, the current from ACC terminal of starting switch (3) to
engine controller (5) is cut off, and consequently the command current to supply pump (25) is cut off.
Supply pump (25) stops fuel feed, decreasing the engine speed until the engine stops.
Stopping the engine with engine shutdown secondary switch

• If engine shutdown secondary switch (4) is turned to "Stop Engine" position, the current from ACC
terminal of starting switch (3) to engine controller (5) is forcibly cut off.
Above induces the same state as when starting switch (3) is turned to "OFF" position, stopping the engine.
D65EX,PX,WX-17 10-225
Cooling system control system
1. Battery disconnect switch

2. Battery
3. Battery relay
6. Machine monitor
8. Cooling fan pump
9. Power train oil temperature sensor
10. Hydraulic oil temperature sensor
11. Cooling fan speed sensor
12. Engine
14. Coolant temperature sensor
Input/Output signal
a. Controller power supply
b. Power train oil temperature signal
c. Hydraulic oil temperature signal
d. Cooling fan speed signal
e. Engine speed signal
f. Coolant temperature signal
g. CAN signal
h. Pump control signal
i. Cooling fan reverse signal
10-226 D65EX,PX,WX-17
Function
• The system monitors the coolant, power train oil, and hydraulic oil temperatures and uses power train
controller (4) to control the cooling fan speed according to the temperature.
Cooling fan speed control

• Among the coolant, power train oil, and hydraulic oil temperatures, the value which requires the highest
fan speed is selected as the pump control signal and is output from power train controller (4) to cooling fan
pump (8).
• Cooling fan pump (8) shifts its swash plate angle to control the delivery to cooling fan motor (7).
• Power train controller (4) detects the actual cooling fan speed via cooling fan speed sensor (11) and
controls the fan speed at the target speed.
Cooling fan mode selection

• When the starting switch is turned to the "ON" position and the engine is not running, the cooling fan mode
can be set on the machine monitor by selecting "Fan Reverse Mode" on the "User Menu".
There are two cooling fan modes:
1. Normal rotation mode
2. Cleaning mode
Depending on the selected mode, power train controller (4) energizes the reverse rotation solenoid valve
to switch the rotation direction of the cooling fan.
1. Normal rotation mode
The reverse rotation solenoid valve is deenergized and the fan operates in the normal direction. The
speed varies according to the temperature signals.
The cooling fan must usually be used in this mode.
2. Cleaning mode
Regardless of temperature signals, the cooling fan rotate in reverse direction at high speed. In this
mode, the dust in the clogging radiator fins can be removed.
Using this mode periodically can extend the radiator fin cleaning interal periods.
In "Cleaning Mode", the machine will not move even when the steering, directional and gear shift lever
is set in a forward or reverse speed, in order to protect the radiator.
The cooling fan mode returns to "Normal rotation mode" after the starting switch is turned OFF and
then turned ON again.
Inhibition of mode selection

• The cooling fan drive circuit will fail if the rotation direction is switched when the cooling fan is operating.
• To protect the cooling fan drive circuit, the command will be ignored when "Fan Reverse Mode" is selected
on the machine monitor when the engine is running. Machine monitor (6) indicates the message "Cannot
reverse fan." and the fan rotation is not reversed.
D65EX,PX,WX-17 10-227
Palm command control system
1. Machine monitor
6. Torque converter oil pressure sensor
7. Transmission output speed sensor
8. Engine
9. Torque converter
10. Transmission
12. HSS unit
13. Control valve
10-228 D65EX,PX,WX-17
13a. Steering control valve

14. HSS motor
Gear shift mode function
Outline
• There are the auto gearshift mode and manual gearshift mode in the gearshift mode. These modes are
changed to each other each time gearshift mode switch (1) is pressed.
Automatic gear shift mode

• If a load is applied, the gear is shifted down automatically. When the load is reduced, the gear is
automatically shifted up to the maximum usable gear speed automatically.
• The torque converter locks up according to loads and the gear speed is selected automatically within the
maximum usable gear speed. In this mode, fuel consumption and efficiency will be well-balanced.
Manual gear shift mode

• If a load is applied, the gear is shifted down automatically. When the load is reduced, however, the gear is
not shifted up automatically.
Gear shift operation

• By pressing UP switch (1) or DOWN switch (2) on the steering, directional, and gear shift lever, gear shift
operations and presettings can be made.
Screen display
• The gear shift mode is displayed on the gear speed display portion of the machine monitor as shown
below.
D65EX,PX,WX-17 10-229
1. Current gear speed

2. "AUTO" mark which indicates automatic gear shift mode
3. Symbol which indicates automatic gear shift mode
4. Preset gear speed (gear speed at start) or maximum usable gear speed
1. Current gear speed

2. "MAN" mark which indicates manual gear shift mode
3. Symbol which indicates manual gear shift mode
4. Preset gear speed (gear speed at start)
Setting the preset with the shift switch operation in NEUTRAL

• Set the preset gear speed (gear speed at start) or the maximum usable gear speed (for only the automatic
gear shift mode) by using the gear shift switches with travel control lever in neutral.

Setting the preset gear speed (gear speed at start) or maximum usable gear speed
10-230 D65EX,PX,WX-17

Setting the preset gear speed (gear speed at start)
a When the starting switch is turned to "ON" position, the system is set to "F1-R1" of the automatic gear shift
mode.
a When the gear shift mode is changed, the default setting "F1-R1" is selected.
Changing gear speed with the shift switch operation during travel
• By pressing the UP switch or DOWN switch while the machine is traveling, the maximum usable gear
speed (in the auto gear shift mode) or the current gear speed (in the manual gearshift mode) can be
changed.

Changing the maximum usable gear speed while the machine is traveling
When traveling forward The maximum usable gear speed can be set to F1 to F3.
When traveling reverse The maximum usable gear speed can be set to R1 to R3.
Each time this switch is pressed, the maximum usable gear speed is
UP switch shifted up to the next range.
DOWN switch shifted down to the next range.

Changing the current gear speed while the machine is traveling
When traveling forward The current gear speed can be set to F1 to F3.
When traveling reverse The current gear speed can be set to R1 to R3.
UP switch shifted up to the next range.
DOWN switch shifted down to the next range.
Gear speed for hill start or directional selection on hill

• To ensure safety, the machine may start in "2" (2nd) according to machine conditions when starting on an
uphill in "3L" (3rd Low).
• To ensure safety, the machine starts in "1" (1st) and the engine speed is raised temporarily when the travel
direction is changed while travelling downhill, according to machine conditions.
D65EX,PX,WX-17 10-231
Machine monitor system
1. Machine monitor
2. Battery
5. Air conditioner controller
6. KOMTRAX terminal
7. Sensors and switches
8. Camera (for machines equipped with camera)
Input/Output signal
a. Power supply
b. CAN signal
c. Sensor and switch signal
d. Camera signal (for machines equipped with camera)
Outline
• The monitor system keeps the operator informed of all machine functions, by monitoring the machine
conditions by using the sensors and switches installed in various parts of the machine and processing
them instantly to display on the machine monitor.
The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has trouble
10-232 D65EX,PX,WX-17
2. Machine status display (coolant temperature, power train oil temperature, hydraulic oil temperature,
fuel level, etc.)
3. Display of camera image (for machines equipped with camera)
• The switches on the machine monitor control the machine.
Machine monitor
Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If an error occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.
Precautions on the machine monitor display

• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or bright spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this
is not a failure or a defect. Products having 10 or less black or bright spots conform the product
specification; such the condition is quite normal.
• When the engine is started, the battery voltage may drop suddenly depending on the ambient
temperatures and the condition of the battery. In this case, the machine monitor display may go out for a
moment. However, this phenomenon is not a failure.
• Continuous operation of the machine monitor may display blue bright spots on the screen having a black
background; it is quite normal.
Blue bright spots can never be a problem as the screen has usually blue or white background. (White in
the LCD is made up of red, green and blue.)
Input and output signals of machine monitor

070-18P [CN-CM01]
D65EX,PX,WX-17 10-233
Pin No. Signal name Input/Output signal

1 Continuous power supply (24 V) Input
2 Continuous power supply (24 V) Input
3 GND (continuous power supply) –
4 GND (continuous power supply) –
5 External drive signal Input
6 Starting motor cut-off relay Output
7 (*1) –
8 System operating lamp Input
9 Lamp switch Input
10 Starting switch ACC signal Input
11 Starting switch C signal Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 GND (Analog) –
15 Fuel level sensor Input
16 Alternator R signal Input
17 (*1) –
18 (*1) –
*1: Never connect these pins. Malfunctions or failures may occur.
070-12P [CN-CM02]
1 Seat belt alarm switch Input
2 (*1) –
3 (*1) –
4 Air cleaner clogging sensor Input
5 (*1) –
6 (*1) –
7 CAN0 terminating resistor terminal –
8 CAN0_H (KOMNET/c) Input/output
9 CAN0_L (KOMNET/c) Input/output
10 CAN1 terminating resistor terminal –
11 CAN1_H (KOMNET/r) Input/output
12 CAN1_L (KOMNET/r) Input/output
070-20P [CN-CM03]
1 (*1) –
2 (*1) –
3 (*1) –
4 (*1) –
5 (*1) –
6 (*1) –
7 (*1) –
8 (*1) –
9 (*1) –
10 (*1) –
11 (*1) –
12 (*1) –
13 (*1) –
14 (*1) –
15 (*1) –
10-234 D65EX,PX,WX-17

16 (*1) –
17 (*1) –
18 (*1) –
19 (*1) –
20 (*1) –
070-8P [CN-CM04]
1 Camera power supply (8 V) Output
2 Camera NTSC signal Input
3 (*1) –
4 (*1) –
5 GND (Camera power supply) –
6 (*1) –
7 (*1) –
8 GND (Shield) –
Display
a The figures show only a part of caution monitor symbols.
D65EX,PX,WX-17 10-235
A: Standard screen
B: Check before starting screen
C: Maintenance time warning screen
D: Warning screen
E: Guidance screen
F: Camera image screen (for machines equipped with camera)
1. Message monitor
2. KDPF regeneration monitor
3. Work equipment lock monitor
4. Parking brake monitor
5. Engine stop monitor
6. Seat belt monitor
7. Operation mode monitor
8. Air conditioner monitor
9. Preheating monitor
10-236 D65EX,PX,WX-17
10. Fan reverse monitor

11. Reverse slow mode monitor
12. Service meter
13. Multi gauge
• Engine tachometer
• Speedometer
• Hydraulic pump oil pressure gauge
• Battery voltage gauge
• Drawbar pull gauge
• Load display
• Machine body pitch display
• Clock
14. Hydraulic oil temperature gauge
15. Hydraulic oil temperature monitor
16. ECO gauge
17. Fuel consumption gauge
18. Fuel level monitor
19. Fuel level gauge
20. Gear speed display
21. Engine coolant temperature monitor
22. Engine coolant temperature gauge
23. Power train oil temperature monitor
24. Power train oil temperature gauge
25. Water separator monitor
26. Charge level monitor
27. Engine oil pressure monitor
28. Drawbar pull gauge
29. Clock
30. Maintenance time warning monitor
31. Transmission system state monitor
32. Action level monitor
33. ECO guidance
Gauge
Gauge Display item Description Remarks
Tempera- Back- • Indicates corresponding
Range ture ground temperature range.
(°C) color • Alarm buzzer sounds when the
(*1) temperature exceeds 105.°C
W1 105 Red • If the monitor background
Engine coolant W2 102 Red
temperature appears white, warm-up the
gauge W3 100 Blue engine.
W4 85 Blue
W5 60 Blue
W6 30 White
Range ture) ground temperature range.
(*1) (°C) color • Alarm buzzer sounds when the
Power train oil temperature exceeds 130.°C
P1 130 Red • If the monitor background
temperature P2 120 Red
gauge appears white, warm-up the
P3 118 Blue engine.
P4 90 Blue
D65EX,PX,WX-17 10-237

P5 50 Blue
P6 0 White
Range ture ground temperature range.
(°C) color • Alarm buzzer sounds when the
(*1) temperature exceeds 105.°C
H1 105 Red • If the monitor background
Hydraulic oil H2 102 Red
temperature appears white, warm-up the
gauge H3 98 Blue hydraulic components.
H4 70 Blue
H5 20 Blue
H6 0 White
Back- • Indicates corresponding
Range Quantity (l) ground remaining fuel level.
color
(*1) F1 376 Blue
Fuel level F2 297 Blue
gauge F3 219 Blue
F4 140 Blue
F5 102 Blue
F6 61 Red
Rotating • Indicates corresponding engine
Gauge
Range speed speed.
range
(rpm) • If the engine speed exceeds
M1 3,000 Red 2,750 rpm, the engine overrun
(*1, *2)
2,750 monitor lights up.
Engine M2 Red
tachometer M3 2,000 Green
M4 1,500 Green
M5 1,000 Green
M6 500 Green
Travel • Indicates corresponding travel
Gauge
Range speed (km/ speed.
range
h)
(*1, *2) M1 15 Green
Speedometer M2 10 Green
M3 5 Green
M4 0 Green
Pressure Gauge • Indicates corresponding work
Range
(MPa) range equipment pump delivery
(*1, *2) M1 50 Green pressure
Hydraulic pump M2 40 Green
oil pressure M3 30 Green
gauge M4 20 Green
M5 10 Green
M6 0 Green
Output Gauge • Indicates corresponding battery
Range
voltage (V) range voltage.
M1 31 Red
(*1, *2)
M2 30 Red
Battery voltage
M3 25 Green
gauge
M4 20 Green
M5 15 Green
M6 0 Red
10-238 D65EX,PX,WX-17

Gauge • Indicates corresponding drawbar
Range Power (W)
range pull.
M1 1.0 Green
(*1, *2)
M2 0.8 Green
Drawbar pull
M3 0.6 Green
gauge
M4 0.4 Green
M5 0.2 Green
M6 0 Green
Gauge • Indicates drawbar pull by several
Range Power (W)
range seconds.
(*1) M1 0.8 Red • The horizontal axis indicates the
time and the vertical axis
Load display indicates the drawbar pull.
M2 0.24 White (Indicates the latest information
on the right.)
Gauge • Indicates pitch angle by several
Range Angle (1)
range seconds.
20 • The horizontal axis indicates the
M1 Gray time and the vertical axis
(Forward)
(*1) indicates the pitch angle.
10
Machine body M2 Gray (Indicates the latest information
(Forward)
pitch display on the right.)
10
M3 Gray
(Backward)
20
M4 Gray
(Backward)
Segment Load level • Indicates instantaneous fuel
Light to consumption (average of fuel
Green 1– 8 consumption per 3 seconds) in
medium
(*3) 10 steps.
ECO gauge (Displays when "Fuel consume."
Orange 9, 10 Heavy is selected on the item "ECO
Guidance" o "Configurations" o
"ECO Gauge" of the user menu.)
Segment Load level • Indicates instantaneous drawbar
Light to pull (average of drawbar pull per
Green 1– 8 1 second) in 10 steps.
(*3) medium
(Displays when "Traction" is
Drawbar pull selected on the item "ECO
gauge Guidance" o"Configurations"o
Orange 9, 10 Heavy
"ECO Gauge" of the user menu.)
• Indicates accumulated engine

operating hours (the alternator is
Service meter 00000.0 h–99999.9 h running).
(Changes to clock display if F4 is
depressed.)
D65EX,PX,WX-17 10-239

• Displays time.
(Changes to service meter
display if F4 is depressed.)
• 12-hour display (AM/PM)
Clock (When clock is displayed on the
• 24-hour display
multi gauge, the display changes
to engine tachometer if F2 is
depressed.)
• Indicates average fuel
(*3) consumption.
• 1 day (Display can be changed by
Fuel selecting "ECO guidance"
• Split
consumption • Not installed o"Configurations"o"Average
gauge Fuel Consumption Display" of the
user menu.)
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer
disappear.
*2: Is classified into multi gauge, and the display changes every time F2 switch is pressed.
*3: Display can be changed by selecting item "ECO guidance"o "Configurations" of the user menu.
Caution monitor
Description
Monitor
display
Symbol Display item Action level Remarks
Range (Back-
monitor
ground
color)
Lights up • Background color changes
Min. 102 °C (Red) L02 depending on the
(*1) Min. 60 ° Lights up temperature detected.
– • Alarm buzzer sounds when
Engine Cbelow 102.°C (Blue)
the temperature exceeds
coolant 105.°C
temperature Lights up • If the monitor background
Below 60 °C –
(White) appears white, warm-up the
engine.
Min. 50 °C or Lights up temperature detected.
– • Alarm buzzer sounds when
below 120.°C (Blue)
the temperature exceeds
(*1) 130.°C
• If the monitor background
Power train oil appears red, the overheat
temperature prevention system operates
Lights up
Below 50 °C – automatically and the
(White)
engine speed decreases.
• If the monitor background
appears white, warm-up the
engine.
Min. 20 °C or Lights up temperature detected.
(*1) – • Alarm buzzer sounds when
below 102. (Blue)
Hydraulic oil the temperature exceeds
temperature 105.°C
Lights up • If the monitor background
Below 20 °C –
(White) appears white, warm-up the
hydraulic components.
10-240 D65EX,PX,WX-17
Description
Monitor
display
Range (Back-
monitor
ground
color)
Below 102 l –
(*1) (Red) depending on the remaining
Lights up fuel level.
Fuel level –
Min. 102 l (Blue)
When charge is • The monitor lights up on the
defective screen and alarm buzzer
Lights up sounds when an
(*1) (Charge voltage L03
(Red) abnormality is detected
Battery charge < Battery
voltage) while the engine running.
When normal Lights out –
When abnormal • The monitor lights up on the
(*1) Lights up screen and alarm buzzer
(When below (Red) L03
Engine oil specified level) sounds when an
pressure abnormality is detected
When normal Lights out – while the engine running.
(*1) Lights up (*3) screen when an abnormality
(When above (Yellow)
Air cleaner specified level) L01 is detected while the engine
clogging running.
(There is water screen when an abnormality
(*1) Lights up is detected while the engine
collected above –
Water (Red) running.
the specified
separator amount.)
When • The display changes
exceeding Lights up depending on the time to/
–
maintenance (Red) after the maintenance.
time • After the starting switch is
Maintenance (*2) turned to the ON position,
time warning the monitor turns on if the
When Lights up
exceeding – monitor light-up conditions
(Yellow) are met, and then goes out
maintenance
notifying time in 30 seconds.
When action Lights up • The monitor lights up on the
level L04 or L03 (Red) L04 and L03 screen when an abnormality
State of is detected is detected in the machine
system system.
When action Lights up (*3) • When the background color
level L01 is (Yellow) L01 is red, the alarm buzzer
detected
sounds.
State of is detected is detected in the engine
engine system When action system.
Lights up (*3) • When the background color
detected
sounds.
State of level L04 or L03 (Red) L04 and L03 screen when an abnormality
hydraulic is detected is detected in the hydraulic
system When action Lights up (*3) system.
level L01 is (Yellow)
detected L01
D65EX,PX,WX-17 10-241
Description
Monitor
display
Range (Back-
monitor
ground
color)
• When the background color
is red, the alarm buzzer
sounds.
State of is detected is detected in the steering
steering system.
system When action Lights up (*3) • When the background color
detected
sounds.
State of is detected is detected in the
transmission transmission system.
detected
sounds.
State of brake is detected is detected in the brake
system system.
detected
sounds.
State of is detected is detected in the parking
parking brake brake system.
detected
sounds.
level L04 or L03 (Red) L03 screen when an abnormality
State of fan is detected is detected in the fan control
control system When action system.
Lights up (*3) • When the background color
detected
sounds.
State of KDPF is detected is detected in the KDPF
system system.
detected
sounds.
When action Lights up • The monitor lights up when
level L04 or L03 (Red) L03 soot is accumulated inside
Accumulation is detected KDPF or cleaning function is
of soot on abnormally degraded.
When action Lights up (*3)
KDPF • When the background color
detected
sounds.
• The monitor lights up on the
Engine When engine Lights up screen and alarm buzzer
overspeed overspeed is (Red) L02 sounds when engine
detected overspeed is detected.
10-242 D65EX,PX,WX-17
Description
Monitor
display
Range (Back-
monitor
ground
color)
• The monitor lights up on the
When air Lights up (*3) screen when an abnormality
Sate of air
conditioner is (Yellow) is detected in the air
conditioner L01
abnormal conditioner system.
level L04 is (Red) L04 screen when an abnormality
detected is detected on the machine.
When action Lights up When the background color
level L03 is (Red) L03 is red, the alarm buzzer
detected sounds.
Action level
When action Lights up
level L02 is (Red) L02
detected
When action Lights up (*3)
level L01 is (Yellow)
detected L01
*1: It is included in the check before starting items. After the staring switch is turned to the ON position, the
monitor turns on for two seconds, and changes to the standard screen if no abnormality is found.
*2: The notifying time is changeable from the items in "05 Maintenance Mode Setting" o "00 Maintenance
Mode Change" o "02 Maintenance Notice Time Setting" of the service mode.
*3: Monitor goes out after lighting up for 2 seconds.
Pilot monitor
• It operates • Indicates preheat operating
automatically at a low status.
temperature.
(Symbol lights up as
Automatic
long as for
preheating
approximately. 45
seconds)
• It goes out after the
engine is started.
Preheating Elapsed time
after turning
the starting Monitor
switch to display
Manual HEAT
preheating (Preheating)
0 – 30 sec. Lights up
30 – 40 sec. Flashes
After 40 sec.
Lights out
or longer
Lights up: Lock • Indicates the state of work
Work Flashes: When it is necessary to release equipment lock lever.
equipment lock the lock.
Lights out: Free
Lights up: Lock • Indicates the state of
Flashes: When it is necessary to release parking brake lever.
Parking brake
the lock.
Lights out: Free
D65EX,PX,WX-17 10-243

• Indicates air conditioner
Lights up: ON and air blower operating
Air conditioner status.
Lights out: OFF
• Indicates whether seat belt

Lights up: Not fastened is fastened.
Seat belt
Lights out: Fastened
• Indicates the operating

Lights up: When engine is stopped state of engine.
Engine stopped
Lights out: While engine is running
• Indicates the rotating state

Fan rotating in Lights up: Cooling fan reverse rotation of cooling fan.
reverse Lights out: Cooling fan normal rotation
• Indicates regenerating
KDPF Lights up: KDPF is being regenerated state of KDPF.
regeneration Lights out: KDPF regeneration is finished
• Indicates regenerating
state of KDPF.
Lights up: KDPF regeneration is stopped
Stop of KDPF • KDPF soot accumulation
regeneration Lights out: Stop of KDPF regeneration is monitor lights up when
canceled manual stationary
regeneration is required.
• Indicates the state of
Message Lights up: There is unread message. message.
(Unread) Lights out: No message
Message • Indicates the state of

Lights up: There is an already-read
(No return message.
message but return message for it is not
message, sent yet.
already-read
Lights out: No message
message)
• Indicates the state of
Operating P: Heavy-duty operation operating mode setting.
mode E: Low-fuel consumption operation
• Indicates the operating

Reverse slow Lights up: ON state of reverse slow
mode monitor Lights out: OFF mode.
• Excessive engine idling guidance • Guidance for supporting

• Guidance on deterrence of hydraulic the machine operation and
relief control are indicated.
ECO guidance • E-mode recommendation guidance
• Guidance on deterrence of overload
• Auto shift mode recommendation
guidance
Gear speed
See "Palm command control system".
display
10-244 D65EX,PX,WX-17
Switches
No. Model Function Operation

Working mode selector P: Heavy-duty operation
switch Changes the operating
1 E: Low-fuel consumption
mode to P or E.
[Numeric keypad: 1] operation
• Changes the marks on
Gearshift mode selector gear speed display.
switch Changes the gearshift AUTO: Automatic gear
2
mode to Auto or Manual. shift mode
[Numeric keypad: 2] MAN: Manual gear
shift mode
The screen changes to Working Mode: Power /
"Mode Select" screen and Economy
Customize switch you can change and store Gear Shift Mode: Manual
3
[Numeric keypad: 3] the setting of Working Shift mode / Automatic
Mode, Gear Shift Mode Shift mode
and Reverse Slow. Reverse Slow: ON/OFF
• Stops the alarm
Stops the alarm buzzer. buzzer.
Buzzer cancel switch (Some alarm buzzer does • The alarm buzzer
4
[Numeric keypad: 4] not stop even if the switch resumes sounding
is pressed.) when another error is
detected.
5 [Numeric keypad: 5] – –
Reverse slow mode When traveling reverse,
• Reverse slow monitor
switch decreases engine speed
6 lights up under reverse
automatically and reduces
[Numeric keypad: 6] slow mode setting.
the reverse travel speed.
• The air flow increases
Fan switch (increase) Controls the flow rate of immediately after the
7a the air conditioner in 6 air conditioner
[Numeric keypad: 7] levels. adjustment screen
appears.
D65EX,PX,WX-17 10-245
No. Model Function Operation

• The air flow decreases
(Low, Medium 1, Medium immediately after the
7b Fan switch (decrease) 2, Medium 3, Medium 4, air conditioner
and High) adjustment screen
appears.
• The preset
Temperature control temperature increases
switch (raise) immediately after the
8a air conditioner
[Numeric keypad: 8] adjustment screen
Controls the temperature
appears.
inside the cab.
• The preset
(18.0 °C to 32.0 °C:
temperature
Temperature control Adjustable at every 0.5)
decreases
8b switch (lower) immediately after the
[Numeric keypad: 0] air conditioner
adjustment screen
appears.
• Automatically controls
the air flow, air vent,
Operates the air FRESH/RECIRC air
(*2) conditioner and air blower change according to
9 Auto switch with automatic operation. the temperature
[Numeric keypad: 9] AUTO lights up: setting, immediately
Automatic operation after the air
conditioner adjustment
screen appears.
Changes the air • Switches to the air
conditioner ON/OFF. conditioner adjustment
(*3) screen, and pressing it
10 A/C ON lights up: Manual
Air conditioner switch operation again switches ON/
OFF.
Lights out: Stop OFF io ON
• Switches to the air
FRESH/RECIRC selector Changes the FRESH/ screen, and pressing it
11
switch RECIRC. again switches
FRESH/RECIRC.
RECIRC io FRESH
Selects the air vent mode
from 6 modes.
• Switches to the air
1. Front
2. Front and rear screen, and pressing it
12 Vent selector switch 3. Front, rear and foot again switches air vent
vents mode.
4. Foot 1 o 2 o 3o 4 o 5 o
6 o1
5. Foot and defroster
6. Defroster
Stop the fan and air

conditioner. • The fan and air
13 OFF switch conditioner stop.
Lights out: OFF
14a Guidance icon

See "Guidance icon and function switch." section.
14b Function switch
*1: When the working mode is changed, the auto-decelerator function turns ON.
10-246 D65EX,PX,WX-17
*2: If temperature is set to 18.0 °C or 32.0 °C, the air flow from the fan is always set to High and does not
change even if the set temperature is reached.
*3: When the fan is stopped, the air conditioner does not start even if the switch is pressed.
Guidance icon and function switch

• Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
• No function is available if no guidance icon appears above the function switch.
• The following is the list of guidance icons and the functions displayed above the function switches.
Guidance icon Item Function
• Changes to user menu screen.
• Background colors allow confirming the type of
information transmitted.
Gray: When the condition is normal
Changing to user menu screen Red: When soot accumulation abnormality (L03) is
detected, or exceeding maintenance time
Yellow: When soot accumulation abnormality (L01) is
detected, or exceeding maintenance notifying time
Green: When there is unread KOMTRAX message
Switching clock/service meter • Switches clock/service meter display.
Changing to camera image • Changes to camera image.
• Changes the gauge display of multi gauge display

Selection of multi gauge
portion.
• Enters selected/setting item.

Enter information transmitted.
Gray: When the condition is normal
Green: When ECO guidance is displayed
Return • Returns to previous screen or status.
• Moves up one item from current item.

(To the bottom item from the top item.)
Moving select item • Moves the point upward which is under adjustment in
the item of "07 Default"o"03 Camera"o"04 Guide
Line Position Set" of service mode.
• Moves down one item from current item.
(To the top item from the bottom item.)
Moving select item • Moves the point downward which is under adjustment
in the item of "07 Default"o"03 Camera"o"04 Guide
• Green arrow: Moves to the left tab.
• White arrow: Moves left one item from current item.
Moving select item (To the leftmost item from the rightmost item.)
• Moves the point rightward which is under adjustment
in the item of "07 Default" o"03 Camera"o"04 Guide
D65EX,PX,WX-17 10-247

• Green arrow: Moves to the left tab.
• White arrow: Moves left one item from current item.
Moving select item (To the rightmost item from the leftmost item.)
• Moves the point leftward which is under adjustment in
the item of "07 Default"o"03 Camera"o"04 Guide
• Moves up one page from current page.

Moving select item
(To the bottom page from the top page.)
• Moves down one page from current page.

Moving select item
(To the top page from the bottom page.)
Clear • Clears selected/displayed item.
• Sets selected item back to default.

Return to default setting
(Used for screen adjustment.)
Set • Executes setting.
• Executes starting.
Start (Used for starting measurement of spilt fuel
consumption on the fuel consumption display.)
• Executes stopping.
(Used for stopping measurement of spilt fuel
Stop consumption on the fuel consumption display.)
• Stops fan rotation during reverse rotation of cooling
fan.
Saving • Saves setting.
Changing to the name setting • Changes the current screen to the name setting
screen. screen
Changing to the mode memory • Changes the current screen to the "Memory Call"
calling screen screen of the customized mode.
Changing to the mode memory • Changes the current screen to the "Memory Store"
storing screen screen of the customized mode.
• Holds the value of the target item of monitoring.

Hold (Used when monitoring is turned on)
10-248 D65EX,PX,WX-17
• Cancels the currently held value of the target item of

Canceling the hold monitoring.
(Used when monitoring is turned on)
Selecting the fuel consumption • Selects the graphs on the fuel consumption record
record screen screen.
• Changes to the occurred error list screen.

Changing to the occurred error information transmitted.
list screen Red: When an action level of L02, L03 or L04 is
indicated
Yellow: When the action level of L01 is indicated
Display No. 1 camera image • Selects No. 1 camera image.
Display No. 1 and No. 2 camera • Display both images of No.1 and No.2 cameras
images simultaneously.
Operator mode function

• The operator can select the information to be displayed on the standard screen and the function to be
used, by operating the switches.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Cate- Display order (*2)
gory Item
(*1) W X Y Z
Display of KOMATSU logo 1 1 1 1
Display of password input 2 – – –
Display of Check before starting 3 2 2 2
Display of warning after Check before starting – – 3 –
A Display of maintenance time overdue – – – 3
Display of check of preset 4 3 4 4
Display of standard screen 5 4 5 5
Display of engine shutdown secondary switch screen
Display of end screen
Selection of operation mode
Selection of gearshift mode
Customizing operation
B
Operation of customize memory
Operation to stop alarm buzzer
Selection of multi gauge
D65EX,PX,WX-17 10-249
Cate- Display order (*2)

gory Item
(*1) W X Y Z
Operation of air conditioner
Operation of camera mode display (for machines equipped with camera)
Operation of clock display and service meter display
Check of maintenance information
Setting and displaying user menu
• ECO Guidance
• Machine Setting
• KDPF Regeneration
• Maintenance
• Monitor Setting
• Display of message (including KOMTRAX messages for user)
Display of ECO guidance
Display of caution monitor
C
Display of KDPF regeneration
Display of action level and failure code
Function of checking LCD (Liquid Crystal Display) display
D Function of checking service meter
Access restriction setting/password changing function
*1: The items available in the operator mode are classified to the following categories.
A: Displays that appear from starting switch is turned to the ON position until the standard screen appears,
and the displays that appear after starting switch is turned to the OFF position.
B: Displays when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied
D: Displays that require special operation of the switches.
*2: Display sequence from ON of starting switch to the standard screen varies depending on the settings and
conditions of the machine as follows:
W: When the engine start lock is set on
X: When the engine start lock is set off
Y: When an error is detected during check before starting.
Z: When a maintenance time overdue is detected for an item.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)" section in Testing and adjusting.
a For how to set the engine start lock on/off, see "Password setting/cancel manual".
Service mode function

• The functions in this mode are not displayed on the standard screen. The arrangements for the
information display and various setting can be made only by the technician through the special operation
of the switches.
This mode is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring/Pre-defined
Monitoring/Custom
Mechanical Systems
Abnormality Record
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Key-on Mode
Default Unit
Camera
10-250 D65EX,PX,WX-17
Cylinder Cut-out
Diagnostic Tests Regeneration for Service
KDPF Memory Reset
Input ID
Brake Pedal Potentio Initial Set
Adjustment Pitch Angle Sensor Initial Set
S/T Lever N Position Set
T/M Clutch IP Auto Initial Set
No Injection
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem Status
Service Message
a For how to operate the service mode functions, see "Service mode" section in Testing and adjusting.
D65EX,PX,WX-17 10-251
KOMTRAX system
KOMTRAX system
• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
• This system transmits various machine information by use of the radio communication. This system allows
the KOMTRAX operator to reference the information and provide various services to the customers.
• Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
KOMTRAX terminal
Type: TC330
1. GPS antenna connection

2. Machine harness connection (070-18P)
3. Machine harness connection (070-12P)
4. Communication antenna connection
10-252 D65EX,PX,WX-17
KOMTRAX system
KOMTRAX terminal input and output signals

070-18P[CN-CK01]
Input and
Pin No. Signal name
outputsignals
1 (*1) –
2 (*1) –
3 (*1) –
4 (*1) –
5 (*1) –
6 (*1) –
7 (*1) –
8 (*1) –
9 (*1) –
10 CAN_H (KOMNET/c) Input/output
11 CAN_L (KOMNET/c) Input/output
12 (*1) –
13 (*1) –
14 External start signal Input/output
15 System operation lamp Output
16 (*1) –
17 (*1) –
18 (*1) –
070-12P[CN-CK02]
Input and output
Pin No. Signal name
signals
1 GND –
2 GND –
5 (*1) –
6 Power supply Input
7 Power supply Input
8 (*1) –
9 (*1) –
10 (*1) –
11 (*1) –
12 (*1) –
Function
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of “KOMTRAX setting“ in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
D65EX,PX,WX-17 10-253
KOMTRAX system
a When operating the system in Japan, install a terminal dedicated for use in Japan.
10-254 D65EX,PX,WX-17
System component part
Engine controller
Engine controller input and output signals

• The following is the list of the symbols used for signal category in the input/output signal table.
A: Power supply
B: Input
C: Ground / Shield / Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-C1)]
Pin No. Signal name Signal category
1 Lift pump (+) D
2 (*1) –
3 Crankcase pressure sensor B
4 Parking brake switch B
5 Charge temperature sensor B
6 Intake temperature MAF sensor B
7 CAN_C(+) E
8 CAN_B(+)(KOMNET/r) E
9 Bkup (camshaft) speed sensor (+) B
10 (*1) –
11 Lift pump (-) C
12 (*1) –
13 Coolant temperature sensor (-) C
14 Coolant temperature sensor (+) B
15 Charge pressure sensor B
D65EX,PX,WX-17 10-255
Pin No. Signal name Signal category

16 Ambient pressure sensor B
17 CAN_C(-) E
18 CAN_B(-)(KOMNET/r) E
19 (*1) –
20 (*1) –
21 Mass air flow (MAF) sensor (12 V) A
22 Mass air flow (MAF) sensor (GND) C
23 Mass air flow (MAF) sensor (SIG) B
24 Water-in-fuel sensor B
25 (*1) –
26 Ne (crankshaft) speed sensor (+) B
27 (*1) –
28 (*1) –
29 (*1) –
30 IMV (+) D
31 Engine oil pressure switch B
32 Water-in-fuel sensor (GND) C
33 (*1) –
34 (*1) –
35 (*1) –
36 Ne (crankshaft) speed sensor (5 V) A
37 NE (crankshaft) speed sensor (-) C
38 (*1) –
39 (*1) –
40 IMV (–) C
41 (*1) –
42 (*1) –
43 Injector #4 (+) D
49 (*1) –
50 Droop switch B
51 (*1) –
52 (*1) –
53 Injector #4 (–) C
59 Sensor GND C
60 Sensor power supply (5 V) A
DRC26-60P(2)[ECM J2(CN-C28)]
Pin No. Signal name Input/output
1 (*1) –
2 (*1) –
3 (*1) –
10-256 D65EX,PX,WX-17

4 (*1) –
5 (*1) –
6 EGR actuator (+) D
7 (*1) –
8 (*1) –
9 (*1) –
10 KVGT actuator (+) D
11 (*1) –
12 RI switch (+) D
13 (*1) –
14 (*1) –
15 (*1) –
16 EGR actuator (-) C
17 (*1) –
18 EGR orifice temperature sensor (5 V) A
19 (*1) –
20 KVGT actuator (-) C
21 Common rail pressure sensor (GND) C
22 (*1) –
23 (*1) –
24 CAN_B(+) E
25 CAN_B(-) E
26 (*1) –
27 (*1) –
28 (*1) –
29 (*1) –
31 Common rail pressure sensor (5V) A
32 KVGT speed sensor (+) B
33 KVGT speed sensor (-) C
34 Exhaust manifold pressure sensor B
35 (*1) –
36 (*1) –
37 (*1) –
38 KVGT position sensor B
39 (*1) –
40 (*1) –
41 (*1) –
42 (*1) –
43 (*1) –
44 Common rail pressure sensor B
45 (*1) –
46 RI switch (-) C
47 Sensor GND C
48 EGR orifice temperature sensor B
49 (*1) –
50 (*1) –
51 (*1) –
52 (*1) –
53 (*1) –
54 (*1) –
55 (*1) –
D65EX,PX,WX-17 10-257

56 (*1) –
57 (*1) –
58 (*1) –
59 EGR valve lift sensor B
60 (*1) –
DRC26-60P(3)[CN-EGC3]
1 Constant power supply (24 V) A
3 Starting switch ACC signal B
4 Electrical intake air heater relay (+) D
5 (*1) –
6 (*1) –
7 (*1) –
8 (*1) –
9 System operating lamp D
10 (*1) –
13 Intake air heater relay (-) C
14 (*1) –
15 (*1) –
16 (*1) –
17 CAN_A(+)(KOMNET/c) E
18 CAN_A(-)(KOMNET/c) E
19 Analog GND C
20 (*1) –
21 GND C
22 GND C
23 (*1) –
24 (*1) –
25 (*1) –
26 (*1) –
27 (*1) –
28 (*1) –
29 (*1) –
30 (*1) –
31 GND C
32 GND C
33 (*1) –
34 (*1) –
35 (*1) –
36 (*1) –
37 (*1) –
38 (*1) –
39 (*1) –
40 (*1) –
41 Analog GND C
43 Analog GND C
10-258 D65EX,PX,WX-17

44 (*1) –
45 KDOC inlet temperature sensor B
46 (*1) –
47 (*1) –
48 KDOC outlet temperature sensor B
49 (*1) –
50 (*1) –
51 Decelerator pedal potentiometer B
53 (*1) –
54 KDPF outlet temperature sensor B
55 KDPF differential pressure sensor B
56 (*1) –
57 (*1) –
58 KDPF outlet pressure sensor B
59 (*1) –
60 (*1) –
Power train controller
D65EX,PX,WX-17 10-259
Power train controller input and output signals

DRC26-24P [CN-STC1]
1 Hydraulic oil pressure sensor Input
2 Steering lever potentiometer 1 Input
3 Brake pedal potentiometer Input
4 GND (signal) –
5 Upshift switch (NO) Input
6 Fuel control dial Input
7 Directional lever position meter 4 Input
8 Pitch angle sensor Input
9 Power train oil temperature sensor Input
10 GND (signal) –
11 Upshift switch (NC) Input
12 Starting switch C signal Input
13 Directional lever position meter 3 Input
14 Hydraulic oil temperature sensor Input
16 Sensor power supply (+24 V) Output
17 Shift down switch (NO) Input
18 Left angle switch 1 (NO) Input
19 Steering lever potentiometer 2 Input
20 Torque converter oil pressure sensor Input
21 GND (Analog) –
22 Sensor power supply 0 (5 V) Output
23 Shift down switch (NC) Input
24 Left angle switch 2 (NO) Input
DRC26-40P(A) [CN-STC2]
1 Sensor power supply 1 (5 V) Output
2 (*1) –
3 (*1) –
4 RS232C RXD Input
5 Parking brake limit switch (NC) Input
6 Work equipment lock limit switch (NC) Input
7 (*1) –
8 Neutral safety relay Output
9 Cooling fan reverse rotation solenoid valve Output
10 (*1) –
11 (*1) –
12 (*1) –
13 (*1) –
14 RS232C TXD Output
15 Parking brake limit switch (NO) Input
16 Work equipment lock limit switch (NO) Input
17 (*1) –
18 Beacon lamp relay Output
19 Work equipment lock solenoid valve Output
20 (*1) –
21 (*1) –
22 CAN0_L Input/output
23 CAN1_L Input/output
10-260 D65EX,PX,WX-17

24 External start signal Input
25 Transmission R clutch fill switch Input
26 (*1) –
27 Blade control lever lower switch (NC) Input
28 Backup alarm Input
29 GND (pulse) –
30 Transmission output shaft speed sensor Input
31 (*1) –
32 CAN0_H Input/output
33 CAN1_H Input/output
34 RS232C GND –
35 Transmission F clutch fill switch Input
36 Torque converter lockup clutch fill switch Input
37 Blade control lever lower switch (NO) Input
38 (*1) –
39 GND (pulse) –
40 Cooling fan speed sensor Input
DRC26-40P(B) [CN-STC3]
1 Constant power supply (24 V) Input
2 Electric power supply (24 V) Input
3 GND (solenoids common) –
4 For battery relay drive Output
5 Left steering EPC valve Output
6 Transmission 3rd clutch ECMV Output
7 Pitch selector solenoid valve Output
8 HSS pump TVC solenoid valve Output
9 (*1) –
10 Work equipment iB switch (NO) Input
11 Constant power supply (24 V) Input
13 GND (solenoids common) Input
15 Right steering EPC valve Output
16 (*1) –
17 (*1) –
18 Cooling fan reverse rotation solenoid Output
19 Transmission 1st clutch fill switch Input
20 Work equipment iB switch (NC) Input
21 GND (power supply) –
23 GND (solenoids common) –
25 Right angle EPC valve Output
26 Torque converter lockup clutch ECMV Output
27 Transmission 1st clutch ECMV Output
28 Transmission F clutch ECMV Output
29 Transmission 2nd clutch fill switch Input
30 Right angle switch 1 (NO) Input
D65EX,PX,WX-17 10-261

34 System operating lamp Output
35 Left angle EPC valve Output
36 (*1) –
37 Transmission 2nd clutch ECMV Output
38 Transmission R clutch ECMV Output
39 Transmission 3rd clutch fill switch Input
40 Right angle switch 2 (NO) Input
10-262 D65EX,PX,WX-17
Electric steering lever

1. Boot
2. Bracket
3. O-ring
4. Bolt
5. Lever
6. Connector
D65EX,PX,WX-17 10-263
Function
Operating effort characteristics
Operation for forward and reverse travel
• The control lever is held at 3 positions: "FORWARD", "NEUTRAL" and "REVERSE".

Operation for left and right steering
10-264 D65EX,PX,WX-17
• Free return
Output voltage characteristics
• The lever is installed to the left control stand and the control lever (knob) is fixed directly onto it.
• The operating angle (travel) of the control levers is sensed with potentiometers and signal voltages are
output to the power train controller.
• A potentiometer is installed to detect each of longitudinal displacement and lateral displacement. Each
potentiometer outputs two signal voltages which are opposite in phase as shown in the figure.
D65EX,PX,WX-17 10-265
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The fuel control dial is installed at the left side of the driver's seat.
• When knob (1) is turned, potentiometer shaft (5) is turned and the resistance of the variable resistor
changes to send variable throttle signals to the engine controller.
• The hatched area in the following chart is the abnormality detection area and the engine speed is set to
the medium (half) speed.
10-266 D65EX,PX,WX-17
Brake pedal potentiometer
1. Element
2. Contact
3. Shaft
4. Connector
Function
• The brake pedal potentiometer is installed to the front lower part of the floor and connected directly to the
brake pedal.
• When the pedal is depressed, shaft (3) of the potentiometer rotates to change the resistance of the
variable resistor to send signals in voltages according to the pedal travel.
Output characteristics
D65EX,PX,WX-17 10-267
Decelerator pedal potentiometer
1. Element
2. Contact
3. Shaft
4. Connector
Function
• The decelerator pedal potentiometer is installed to the front lower part of the floor and connected directly
to the decelerator pedal.
• When the pedal is depressed, shaft (3) of the potentiometer rotates to change the resistance of the
variable resistor to send signals in voltages according to the pedal travel.
CAN terminating resistor

CAN: Abbreviation for Controller Area Network
10-268 D65EX,PX,WX-17
1. Connector (with built-in resistor)
Specifications
Resistance: 120 z
Function
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine can not be operated.
Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Specifications
Contact type: Normally closed
Function
• This oil pressure switch is installed to the engine front cover. It detects engine oil pressure, and turns the
switch to “ON“ position when the pressure goes below the specified value.
D65EX,PX,WX-17 10-269
Sensors
Sensors
Ambient pressure sensor
1. Connector
2. Sensor
Function
• This sensor is installed to the air intake cover at the engine top side. It detects senses the atmospheric
pressure to output the corresponding variable voltage.
Charge (boost) pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
10-270 D65EX,PX,WX-17
Sensors
Function
• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its
temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for
temperature.
a “Charge pressure and temperature“ are the engine intake air pressure and temperature of a turbocharged
engine. These are also referred to as “boost pressure and temperature“ or “intake air pressure and
temperature“.
Coolant temperature sensor
1. Connector
2. Sensor
3. O-ring
Function
• This sensor, installed to the engine cylinder head, converts the temperature variation into change in
resistance variation, and outputs the corresponding signals.
D65EX,PX,WX-17 10-271
Sensors
Ne (crankshaft) speed sensor
1. O-ring
2. Sensor
3. Connector
Function
• This sensor, installed to the rear left side of the engine cylinder block, outputs the pulse voltage due to the
gear rotation.
Bkup (camshaft) speed sensor
1. O-ring
2. Sensor
3. Connector
Function
• This sensor, installed to the ring part of the camshaft at the engine front cover, outputs pulse voltage due
to the rotation of the gear.
10-272 D65EX,PX,WX-17
Sensors
Common rail pressure sensor
1. Sensor
2. Connector
Function
• The sensor is installed to the common rail. It detects the fuel pressure and outputs variable voltage.
Exhaust manifold pressure sensor
1. O-ring
2. Sensor
3. Connector
Function
• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects
the exhaust pressure to output the corresponding variable voltage.
EGR orifice temperature sensor
EGR: Abbreviation for Exhaust Gas Recirculation
D65EX,PX,WX-17 10-273
Sensors
1. Connector
2. Sensor
3. Washer
Function
• This sensor, installed on the EGR gas piping between EGR cooler and EGR valve of the engine, converts
the temperature variation into the resistance variation, and outputs the corresponding signals.
EGR valve lift sensor
EGR: Abbreviation for Exhaust Gas Recirculation
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function
• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the
corresponding variable voltage.
• The relation between stroke and output voltage is as shown in the following graph.
Turbo speed sensor

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
10-274 D65EX,PX,WX-17
Sensors
1. Sensor
2. O-ring
3. Connector
Function
• This sensor, installed to KVGT in the engine, outputs the pulse voltage due to the rotation of KVGT
turbine.
a The 3-pole connector is applied for this sensor, however, available pins are the pin No. 1 and No. 2 only,
and it has no pin No. 3.
KVGT position sensor
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
• The relation between stroke and output voltage is as shown in the following graph.
D65EX,PX,WX-17 10-275
Sensors
Mass air flow and temperature sensor
1. Connector
2. O-ring
3. Sensor
Function
• This sensor, installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The “MAF (Mass Air Flow)“ means the “intake air flow“.
KDPF differential pressure and outlet pressure sensor
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter
10-276 D65EX,PX,WX-17
Sensors
1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor
Function
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
corresponding variable voltage.
• The outputted pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is outputted as a pressure which is detected at low-pressure port (2).
KDOC inlet temperature sensor
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function
• This sensor, installed to the inlet side of the KDOC which is built in KDPF, converts the temperature
variation into the resistance variation, and outputs the corresponding signals.
KDOC outlet temperature sensor
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function
• This sensor, installed to the outlet side of the KDOC which is built in KDPF, converts the temperature
variation into the resistance variation, and outputs the corresponding signals.
KDPF outlet temperature sensor
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter
D65EX,PX,WX-17 10-277
Sensors
1. Sensor
2. Connector
Function
• This sensor, installed to the outlet side of the KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
Crankcase pressure sensor
1. Connector
2. Sensor
3. O-ring
Function
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
Power train oil temperature sensor
1. Connector
2. Plug
10-278 D65EX,PX,WX-17
Sensors
3. Thermistor
Function
• This sensor is installed to the block at the left side of the torque converter.
• This sensor detects the oil temperature and converts it into corresponding electric signals, and outputs the
signals.
Hydraulic oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
• This sensor is installed to the hydraulic tank.
• This sensor detects the oil temperature and converts it into corresponding electric signals, and outputs the
signals.
Hydraulic oil pressure sensor
1. O-ring
2. Sensor
3. Connector
Function
• This sensor is installed to the block at the delivery side of the HSS pump.
• This sensor detects the hydraulic oil pressure and converts it into electric signals, and outputs the signals.
D65EX,PX,WX-17 10-279
Sensors
Torque converter oil pressure sensor
1. O-ring
2. Sensor
3. Connector
Function
• This sensor is installed to the block at the left side of the torque converter.
• This sensor detects the torque converter oil pressure and converts it into electric signals, and outputs the
signals.
10-280 D65EX,PX,WX-17
Sensors
Transmission output shaft speed sensor
1. Pole piece
2. Magnet wire
3. Bobbin
4. Magnet
5. Housing
6. Grommet
7. Connector
Function
• This sensor is installed to the bevel gear portion at the rear side of the steering case.
• This sensor detects the gear speed and outputs corresponding pulse signals.
Cooling fan speed sensor
1. Sensor
2. Connector
Function
• This sensor is installed to the cooling fan motor.
• This sensor detects the gear speed and outputs corresponding pulse signals.
D65EX,PX,WX-17 10-281
Sensors
Pitch angle sensor
1. Body
2. Tube
3. Tube
4. Ring
5. Wire
6. Connector
Function
• The sensor is installed in the engine compartment at the right side of the machine.
• Several electrodes and oil are enclosed in the sensor. When the machine inclines, the oil level inside the
sensor changes, the sensor detects the capacitance variation between the electrodes. The capacitance is
converted into voltage.
10-282 D65EX,PX,WX-17
Sensors
Fuel level sensor
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
Function
Function
• This sensor is installed on the front surface of the fuel tank.
• This sensor detects the fuel level and converts it into an electric signal, and outputs the corresponding
signal.
• The float moves up and down according to the fuel level.
• The movement of the float activates the variable resistor through the arm.
D65EX,PX,WX-17 10-283
Sensors
Air cleaner clogging sensor
1. Adapter
2. hood
3. Indicator
4. Connector
Function
• This sensor is installed on the outlet side of the air cleaner.
• The sensor is turned the “ON“ position if the air cleaner is clogged and the pressure level drops to the
specified level (negative pressure).
Water-in-fuel sensor
1. Connector
2. conduit
3. Sensor
Function
• This sensor is installed to the cup of fuel prefilter.
• This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.
10-284 D65EX,PX,WX-17
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
20 Standard value table
D65EX,PX,WX-17 20-1
Table Of Contents
20 Standard value table ..................................................................................................................... 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
1 20 Standard value table
20-2 D65EX,PX,WX-17
Standard value table for engine
Standard service value table

Performance
Engine SAA6D114E-5
Standard
Item Measurement condition Unit value for new Repair limit
machine
Max. speed with no load rpm 2,100 ± 50 2,100 ± 50
Engine speed Min. speed with no load rpm 825 ± 25 825 ± 25
Rated speed rpm 1,950 –
Necessary speed 0 °C rpm – –
for starting -20 °C rpm 80 –
Air intake and exhaust system
Engine SAA6D114E-5
Standard
machine
Air intake kPa Max. 3.73 7.47
Whole speed range
resistance {mmH2O} {Max. 380} {762}
Boost pressure kPa 120 to 160 93
At rated horsepower
(aftercooler inlet) {mmHg} {900 to 1,200} {700}
Exhaust
temperature Whole speed range (20 °C) °C Max. 650 Max. 700
(turbine outlet)
Engine outlet
(between Bosch
(Coolant temperature: Max.1.2 Max. 1.5
turbocharger and index
Exhaust gas Within operating range) KDPF inlet)
color 5 sec. after torque KDPF outlet
converter stall Bosch
(exhaust pipe – Max. 0.5
index
outlet)
Intake valve mm 0.305 0.152 to 0.559
Valve clearance
Exhaust valve mm 0.559 0.381 to 0.813
EGR valve and MPa 1.2 1.2
KVGT drive Low idle
pressure {kg/cm2} {12} {12}
KVGT control Whole speed range MPa 0.3 to 1.0 0.3 to 1.0
pressure Oil pressure fluctuation range {kg/cm2} {3 to 10} {3 to 10}
Main body
Engine SAA6D114E-5
Standard
machine
Compression Engine oil temperature: 40 to 60 °C MPa Min. 2.6 2.1
pressure Engine speed: Min. 170 rpm {kg/cm }
2 {Min. 26.5} {21.4}
(Coolant temperature: Within operating range) kPa Max. 1.96 Max. 2.94
Blowby pressure
At rated horsepower {mmH2O} {Max. 200} {Max. 300}
D65EX,PX,WX-17 20-3
Lubrication system
Engine SAA6D114E-5
Standard
machine
(Coolant temperature:
Within operating range)
SAE30 or MPa 0.34 to 0.59 0.21
At rated horsepower
SAE15W-40 {kg/cm2} {3.5 to 6.0} {2.1}
Engine oil temperature:
Hydraulic Min. 80 °C
(Coolant temperature:
Within operating range)
SAE30 or MPa Min. 0.15 0.08
At low idle
SAE15W-40 {kg/cm2} {Min. 1.5} {0.8}
Engine oil temperature:
Min. 80 °C
Oil temperature Whole speed range (inside oil pan) °C 80 to 110 120
At continuous rated horsepower
Oil consumption % Max. 0.15 0.3
Ratio to fuel consumption
Cooling system
Engine SAA6D114E-5
Standard
machine
Radiator kPa
Cracking pressure (differential pressure) – –
pressure valve {kg/cm2}
– (machine
Fan speed At rated speed rpm side) –
Between alternator belt

Deflection when Auto-tensioner –
and crankshaft pulley
pressed with finger
Belt tension Between air conditioner mm
force of 98 N
compressor and {approx. 10 kg} 15 to 18 –
crankshaft pulley
20-4 D65EX,PX,WX-17
Standard value table for machine

D65EX-17
Engine speed
Standard value
Item Measurement condition Unit for new Repair limit
machine
Decelerator pedal • Engine coolant temperature: Within
1,000 ± 25 1,000 ± 25
speed operating range
• Power train oil temperature: Within
operating range
• Hydraulic oil temperature: Within
operating range
Auto-decelerator • Engine at high idle
• Operating mode: P mode 1,900 ± 50 1,900 ± 50
speed
• Decelerator pedal speed: Pedal
pressed
• Auto-decelerator speed: All NEUTRAL rpm
position
• Engine coolant temperature: Within
operating range
operating range
Torque converter
• Hydraulic oil temperature: Within 1,770 ± 100 1,650
stall speed
operating range
• Engine at high idle
• Operating mode: P mode
• Torque converter stall speed: F3
Travel of control lever and pedal
Standard value
machine
NEUTRAL o
30 ± 10 30 ± 10
Forward and FORWARD
PCCS lever
reverse NEUTRAL o
30 ± 10 30 ± 10
• Engine stopped REVERSE
NEUTRAL o 40 ± 15 40 ± 15
• Center of lever knob
LEFT (Play: Max. 3) (Play: Max. 3)
Steering
NEUTRAL o 40 ± 15 40 ± 15
RIGHT (Play: Max. 3) (Play: Max. 3)
Decelerator pedal • Engine stopped
55 ± 11 55 ± 11
• Engine at low idle
Brake pedal Full stroke 68 ± 11 68 ± 11
• Center of pedal
mm
NEUTRAL o
• Engine at low idle RAISE, 63 ± 10 63 ± 10
• Hydraulic oil LOWER
NEUTRAL o
Blade control lever temperature: 45 to 55 ° 88 ± 13 88 ± 13
FLOAT
C NEUTRAL o
• Center of lever knob LEFT/RIGHT 53 ± 8 53 ± 8
TILT
Ripper control • Hydraulic oil NEUTRAL o
lever temperature: 45 to 55 ° RAISE, 54 ± 8 54 ± 8
(if equipped) C LOWER
D65EX,PX,WX-17 20-5
Operating effort of control lever and pedal

Standard value
machine
NEUTRAL o 46.1 ± 19.6 46.1 ± 19.6
FORWARD,
Forward and REVERSE {4.7 ± 2.0} {4.7 ± 2.0}
PCCS lever
reverse FORWARD, 46.1 ± 19.6 46.1 ± 19.6

• Engine stopped REVERSEo
{4.7 ± 2.0} {4.7 ± 2.0}
• Center of lever knob NEUTRAL
NEUTRAL o 24.5 ± 9.8 24.5 ± 9.8
LEFT {2.5 ± 1.0} {2.5 ± 1.0}
Steering
NEUTRAL o 24.5 ± 9.8 24.5 ± 9.8
RIGHT {2.5 ± 1.0} {2.5 ± 1.0}
• Engine at low idle 62.7 ± 19.6 62.7 ± 19.6
Decelerator pedal N {kg}
• Center of pedal {6.4 ± 2.0} {6.4 ± 2.0}
• Engine at low idle 392 ± 39 510
Brake pedal
• Center of pedal {40 ± 4.0} {52}
NEUTRAL o 29.4 ± 9.8 29.4 ± 9.8
RAISE,
• Engine at low idle LOWER {3.0 ± 1.0} {3.0 ± 1.0}
• Hydraulic oil 74.5 ± 19.6 74.5 ± 19.6
NEUTRAL o
Blade control lever temperature: 45 to 55°
FLOAT {7.6 ± 2.0} {7.6 ± 2.0}
C
• Center of lever knob NEUTRAL o 25.5 ± 9.8 25.5 ± 9.8
LEFT/RIGHT
{2.6 ± 1.0} {2.6 ± 1.0}
TILT
• Engine at low idle NEUTRAL o 25.5 ± 9.8 25.5 ± 9.8
Ripper control • Hydraulic oil RAISE {2.6 ± 1.0} {2.6 ± 1.0}
lever temperature: 45 to 55° N {kg}
NEUTRAL o 25.5 ± 9.8 25.5 ± 9.8
(if equipped) C
• Center of lever knob LOWER {2.6 ± 1.0} {2.6 ± 1.0}
20-6 D65EX,PX,WX-17
Power train oil pressure

Standard value
machine
Engine at low 0.03 – 0.49 0.03 – 0.49
Torque converter idle {0.3 – 5.0} {0.3 – 5.0}
inlet pressure Engine at Max. 0.98 Max. 0.98
high idle {Max. 10} {Max. 10}
Engine at low 0.02 – 0.29 0.02 – 0.29
Torque converter idle {0.2 – 3.0} {0.2 – 3.0}
outlet pressure Engine at 0.39 – 0.89 0.39 – 0.89
high idle {4.0 – 9.0} {4.0 – 9.0}
Engine at low 3.3 ± 0.2 Min. 3.01
Transmission main idle {33.7 ± 2.0} {Min. 30.7}
relief pressure Engine at 3.45 ± 0.2 Min. 3.17
high idle {35.3 ± 2.0} {Min. 32.3}
Engine at low 1.42 ± 0.15 1.42 ± 0.15
Torque converter idle {14.5 ± 1.5} {14.5 ± 1.5}
lockup clutch
pressure Engine at 1.42 ± 0.15 1.42 ± 0.15
high idle {14.5 ± 1.5} {14.5 ± 1.5}
Transmission F idle {29.5 ± 1.5} {Min. 26.5}
clutch pressure Engine at 2.89 ± 0.15 Min. 2.60
• Power train oil high idle {29.5 ± 1.5} {Min. 26.5}
temperature: Within
operating range MPa
Transmission R • Engine at high idle on idle {33.5 ± 1.5} {Min. 30.5}
clutch pressure engine deceleration cut Engine at {kg/cm2} 3.28 ± 0.15 Min. 2.99
mode (adjustment high idle {33.5 ± 1.5} {Min. 30.5}
code: 0007) 3.23 ± 0.15 Min. 2.94
Engine at low
Transmission 1st idle {33.0 ± 1.5} {Min. 30.0}
high idle {33.0 ± 1.5} {Min. 30.0}
Transmission 2nd idle {25.0 ± 1.5} {Min. 22.0}
high idle {25.0 ± 1.5} {Min. 22.0}
Transmission 3rd idle {33.5 ± 1.5} {Min. 30.5}
high idle {33.5 ± 1.5} {Min. 30.5}
Transmission
lubricating oil Engine at 0.05 to 0.25 0.05 to 0.25
pressure high idle {0.5 to 2.5} {0.5 to 2.5}
(reference)
Engine at low 2.55 to 2.94 2.55 to 2.94
idle {26 to 30} {26 to 30}
Brake pressure
Engine at 2.55 to 2.94 2.55 to 2.94
high idle {26 to 30} {26 to 30}
D65EX,PX,WX-17 20-7
HSS oil pressure

Standard value
machine
36.6 to 39.5 Min. 34.3
relief pressure
• Hydraulic oil temperature: 45 to 55°C MPa {373 to 403} {Min. 350}
LS pressure (load • Engine at high idle {kg/cm2} 34.6 to 37.6 Min. 32.4
sensing pressure) {353 to 383} {Min. 330}
Power train performance
Standard value
machine
F1 3.6 ± 0.2 3.6 ± 0.2
• Level ground
• Engine coolant temperature: F2 5.6 ± 0.3 5.6 ± 0.3
Within operating range F3L 7.3 ± 0.4 7.3 ± 0.4
• Power train oil temperature: 70 F3 11.3 ± 0.6 11.3 ± 0.6
Travel speed km/h
to 80 °C R1 4.5 ± 0.3 4.5 ± 0.3
• Engine at high idle R2 6.7 ± 0.3 6.7 ± 0.3
• Run up distance: 10 to 30 m
• Measuring distance: 20 m R3L 8.7 ± 0.4 8.7 ± 0.4
R3 13.6 ± 0.7 13.6 ± 0.7
Work equipment oil pressure
Standard value
machine
Engine at 3.23 to 4.9 3.23 to 4.9
Unload pressure
high idle {33 to 50} {33 to 50}
Engine at low Min. 28.4 Min. 27.4
• Hydraulic oil
Blade tilt relief temperature: 45 to 55 ° idle {Min. 290} {Min. 280}
pressure C Engine at 28.9 to 32.4 Min. 27.9
• Unload pressure: high idle {295 to 330} {Min. 285}
All NEUTRAL position Min. 28.4 Min. 27.4
Engine at low
• Relief pressure:
Ripper lift relief idle {Min. 290} {Min. 280}
Tilt or ripper cylinder
pressure rod stroke end Engine at 28.9 to 32.4 Min. 27.9
MPa
• LS pressure: high idle {295 to 330} {Min. 285}
{kg/cm2}
Tilt or ripper cylinder Engine at low Min. 26.5 Min. 25.5
LS pressure rod stroke end idle {Min. 270} {Min. 260}
(load sensing 26.9 to 30.4 Min. 26.0
pressure) Engine at
high idle {275 to 310} {Min. 265}
Control circuit
3.97 ± 0.29 3.97 ± 0.29
source pressure
• Hydraulic oil temperature: 45 – 55°C {40.5 ± 3.0} {40.5 ± 3.0}
(HSS, PPC, Fan)
PPC valve output 3.19 to 4.17 3.19 to 4.17
pressure {32.5 to 42.5} {32.5 to 42.5}
20-8 D65EX,PX,WX-17
Work equipment
Standard value
machine
Straight tilt
dozer 2.5 ± 0.3 3.1
a See Fig. A Sigma dozer
RAISE
• Hydraulic oil Power angle
temperature: 45 to power tilt 2.5 ± 0.3 3.1
55 °C dozer
Blade lift • No load on blade Straight tilt
• Between ground dozer 1.9 ± 0.2 2.3
level and rising Sigma dozer
end of blade LOWER
Power angle
power tilt 1.6 ± 0.2 2.0
dozer
Straight tilt
dozer 1.6 ± 0.3 2.1
a See Fig. B Sigma dozer
Left tilt
55 °C dozer
Blade tilt • No load on blade Straight tilt
• Between left tilt dozer 1.6 ± 0.3 2.1
end and right tilt Sigma dozer
end Right tilt
Work equipment speed
Power angle
power tilt 1.7 ± 0.3 2.2
dozer
Left angle 4.0 ± 0.5 5.0
a See Fig. C sec.
• Hydraulic oil
temperature: 45 to
Blade 55 °C
angle • No load on blade Right angle 4.0 ± 0.5 5.0
• Between left angle
end and right
angle end
a See Fig. D RAISE 1.5 ± 0.5 2.5
• Hydraulic oil
temperature: 45 to
Ripper lift 55 °C
(if • No load on blade LOWER
equipped) • Between ground 1.5 ± 0.5 2.5
level and rising
end of ripper
a See Fig. E Pitch in 1.6 ± 0.3 2.1
• Hydraulic oil
Pitch temperature: 45 to
speed (if 55 °C
equipped) • No load on blade Pitch back 1.6 ± 0.3 2.1
• Between pitch in
and pitch back
D65EX,PX,WX-17 20-9
Work equipment
Standard value
machine
• Hydraulic oil temperature: 45 to 55 °C
• Lever full stroke
Time lag
• Start lowering operation at blade max.

Blade raising position and measure time from sec. Max. 1.0 Max. 1.5
when blade reaches ground until idler
rises
• High idle
a See Fig. F
Hydraulic drift • Hydraulic oil temperature: 45 to 55 °C
Max. 35 Max. 35
of lifted blade • Engine stopped
• Measuring reduction of blade bottom
height "h"
a See Fig. G Left tilt Max. 70 Max. 70
Hydraulic drift
• Hydraulic oil temperature:

Hydraulic drift
45 to 55 °C
of machine mm/5 min
• Engine stopped Right tilt Max. 70 Max. 70
tilted by blade
• Measuring reduction of
blade cutting edge height
"h"
a See Fig. H
of lifted ripper • Engine stopped Max. 35 Max. 35
• Measuring reduction of shank bottom
height "h"
Blade tilt
cylinder 5 20
Cylinder internal oil leakage

• Measuring oil leakage for 1 minute cc/min
Ripper lift
cylinder while relieving cylinder 5 20
20-10 D65EX,PX,WX-17
Cooling fan
Standard value
machine
• Engine at low
idle
• Hydraulic • Coolant Min.
oil temperature, speed 700 ± 50 600
tempera- power train oil
Fan speed ture: temperature: rpm
45 to 55 °C Max. 80 °C
• Fan normal • Engine at high
rotation idle Max.
1,700 ± 25 1,600
• Fan 100% speed
speed mode
Fan pump • Fan normal rotation MPa 14.2 to 17.2 13.2
pressure • Fan 100% speed mode {kg/cm2} {145 to 175} {135}
D65EX,PX,WX-17 20-11
D65PX-17
Engine speed
Standard value
machine
1,000 ± 25 1,000 ± 25
operating range
operating range
speed
pressed
position
operating range
operating range
Torque converter
stall speed
operating range
Standard value
machine
NEUTRAL o
30 ± 10 30 ± 10
Forward and FORWARD
PCCS lever
reverse NEUTRAL o
30 ± 10 30 ± 10
REVERSE
• Engine stopped
• Center of lever knob NEUTRAL o 40 ± 15 40 ± 15
Steering
NEUTRAL o 40 ± 15 40 ± 15
55 ± 11 55 ± 11
• Center of pedal
mm
NEUTRAL o
RAISE, 63 ± 10 63 ± 10
LOWER
• Hydraulic oil
NEUTRAL o
FLOAT
C
NEUTRAL o
LEFT/RIGHT 53 ± 8 53 ± 8
TILT
lever temperature: 45 to 55 ° RAISE, – –
20-12 D65EX,PX,WX-17

Standard value
machine
NEUTRAL o 46.1 ± 19.6 46.1 ± 19.6
FORWARD,
REVERSE {4.7 ± 2.0} {4.7 ± 2.0}
Forward and
PCCS lever
reverse FORWARD, 46.1 ± 19.6 46.1 ± 19.6

REVERSEo
• Engine stopped {4.7 ± 2.0} {4.7 ± 2.0}
NEUTRAL
NEUTRAL o 24.5 ± 9.8 24.5 ± 9.8
LEFT {2.5 ± 1.0} {2.5 ± 1.0}
Steering
NEUTRAL o 24.5 ± 9.8 24.5 ± 9.8
RIGHT {2.5 ± 1.0} {2.5 ± 1.0}
• Center of pedal {6.4 ± 2.0} {6.4 ± 2.0}
Brake pedal
• Center of pedal {40 ± 4.0} {52}
NEUTRAL o 29.4 ± 9.8 29.4 ± 9.8
RAISE,
• Hydraulic oil 74.5 ± 19.6 74.5 ± 19.6
NEUTRAL o
FLOAT {7.6 ± 2.0} {7.6 ± 2.0}
C
LEFT/RIGHT
{2.6 ± 1.0} {2.6 ± 1.0}
TILT
• Engine at low idle NEUTRAL o – –
Ripper control • Hydraulic oil RAISE
NEUTRAL o – –
(if equipped) C
LOWER
D65EX,PX,WX-17 20-13

Standard value
machine
Torque converter idle {0.3 to 5.0} {0.3 to 5.0}
outlet pressure Engine at 0.39 to 0.89 0.39 to 0.89
high idle {4.0 to 9.0} {4.0 to 9.0}
high idle {35.3 ± 2.0} {Min. 32.3}
Engine at low 1.42 ± 0.15 1.42 ± 0.15
lockup clutch
high idle {14.5 ± 1.5} {14.5 ± 1.5}
temperature: Within
operating range MPa
clutch pressure engine deceleration cut {kg/cm2} 3.28 ± 0.15 Min. 2.99
Engine at
code: 0007)
high idle {33.0 ± 1.5} {Min. 30.0}
high idle {25.0 ± 1.5} {Min. 22.0}
high idle {33.5 ± 1.5} {Min. 30.5}
Transmission
(reference)
idle {26 to 30} {26 to 30}
Brake pressure
Engine at 2.55 to 2.94 2.55 to 2.94
high idle {26 to 30} {26 to 30}
20-14 D65EX,PX,WX-17
HSS oil pressure

Standard value
machine
36.6 to 39.5 Min. 34.3
relief pressure
Standard value
machine
F1 3.6 ± 0.2 3.6 ± 0.2
• Level ground
Travel speed km/h
to 80 °C R1 4.5 ± 0.3 4.5 ± 0.3
R3 13.6 ± 0.7 13.6 ± 0.7
Standard value
machine
Engine at 3.23 to 4.9 3.23 to 4.9
Unload pressure
high idle {33 to 50} {33 to 50}
• Hydraulic oil Engine at low Min. 28.4 Min. 27.4
All NEUTRAL position – –
• Relief pressure: Engine at low
Ripper lift relief Tilt or ripper cylinder idle – –
pressure rod stroke end Engine at – –
MPa
• LS pressure: high idle – –
{kg/cm2} Min. 26.5 Min. 26.5
Tilt or ripper cylinder Engine at low
LS pressure rod stroke end idle {Min. 270} {Min. 270}
(load sensing
Engine at 27.0 to 30.4 Min. 26.0
pressure)
high idle {275 to 310} {Min. 265}
Control circuit
3.97 ± 0.29 3.97 ± 0.29
source pressure
• Hydraulic oil temperature: 45 – 55°C {40.5 ± 3} {40.5 ± 3}
(HSS, PPC, Fan)
pressure {32.5 to 42.5} {32.5 to 42.5}
D65EX,PX,WX-17 20-15
Work equipment
Standard value
machine
Straight tilt
dozer 2.4 ± 0.3 3.0
RAISE
55 °C dozer
level and rising
Sigma dozer
end of blade LOWER
• Engine at high idle Power angle
power tilt 1.6 ± 0.2 2.0
dozer
Straight tilt
dozer 1.6 ± 0.3 2.1
Left tilt
55 °C dozer
end and right tilt
Sigma dozer
end Right tilt

power tilt 1.7 ± 0.3 2.2
dozer
Left angle sec. 4.0 ± 0.5 5.0
a See Fig. C
• Hydraulic oil
temperature: 45 to
Blade 55 °C
end and right
angle end
RAISE – –
a See Fig. D
• Hydraulic oil
temperature: 45 to
Ripper lift 55 °C
equipped) • Between ground – –
level and rising
end of ripper
Pitch in 1.6 ± 0.3 2.1
a See Fig. E
• Hydraulic oil
speed (if 55 °C
and pitch back
20-16 D65EX,PX,WX-17
Work equipment
Standard value
machine
Time lag

rises
• High idle
a See Fig. F
Max. 35 Max. 35
height "h"
Left tilt Max. 70 Max. 70
a See Fig. G
Hydraulic drift

Hydraulic drift
45 to 55 °C
of machine mm/5 min
tilted by blade
"h"
a See Fig. H
– –
of lifted ripper • Engine stopped
height "h"
Blade tilt
cylinder 5 20

Ripper lift
D65EX,PX,WX-17 20-17
Cooling fan
Standard value
machine
• Engine at low
idle
45 to 55 °C Max. 80 °C
rotation idle Max.
1,700 ± 25 1,600
• Fan 100% speed
speed mode
20-18 D65EX,PX,WX-17
D65WX-17
Engine speed
Standard value
machine
1,000 ± 25 1,000 ± 25
operating range
operating range
speed
pressed
position
operating range
operating range
Torque converter
stall speed
operating range
Standard value
machine
NEUTRAL o
30 ± 10 30 ± 10
Forward and FORWARD
PCCS lever
reverse NEUTRAL o
30 ± 10 30 ± 10
REVERSE
• Engine stopped
• Center of lever knob NEUTRAL o 40 ± 15 40 ± 15
Steering
NEUTRAL o 40 ± 15 40 ± 15
55 ± 11 55 ± 11
• Center of pedal
mm
NEUTRAL o
RAISE, 63 ± 10 63 ± 10
LOWER
• Hydraulic oil
NEUTRAL o
FLOAT
C
NEUTRAL o
LEFT/RIGHT 53 ± 8 53 ± 8
TILT
lever temperature: 45 to 55 ° RAISE, 54 ± 8 54 ± 8
D65EX,PX,WX-17 20-19

Standard value
machine
NEUTRAL o 46.1 ± 19.6 46.1 ± 19.6
FORWARD,
REVERSE {4.7 ± 2.0} {4.7 ± 2.0}
Forward and
PCCS lever
reverse FORWARD, 46.1 ± 19.6 46.1 ± 19.6

REVERSEo
• Engine stopped {4.7 ± 2.0} {4.7 ± 2.0}
NEUTRAL
NEUTRAL o 24.5 ± 9.8 24.5 ± 9.8
LEFT {2.5 ± 1.0} {2.5 ± 1.0}
Steering
NEUTRAL o 24.5 ± 9.8 24.5 ± 9.8
RIGHT {2.5 ± 1.0} {2.5 ± 1.0}
• Center of pedal {6.4 ± 2.0} {6.4 ± 2.0}
Brake pedal
• Center of pedal {40 ± 4.0} {52}
NEUTRAL o 29.4 ± 9.8 29.4 ± 9.8
RAISE,
• Hydraulic oil 74.5 ± 19.6 74.5 ± 19.6
NEUTRAL o
FLOAT {7.6 ± 2.0} {7.6 ± 2.0}
C
LEFT/RIGHT
{2.6 ± 1.0} {2.6 ± 1.0}
TILT
• Engine at low idle NEUTRAL o 25.5 ± 9.8 25.5 ± 9.8
Ripper control • Hydraulic oil RAISE {2.6 ± 1.0} {2.6 ± 1.0}
NEUTRAL o 25.5 ± 9.8 25.5 ± 9.8
(if equipped) C
• Center of lever knob LOWER {2.6 ± 1.0} {2.6 ± 1.0}
20-20 D65EX,PX,WX-17

Standard value
machine
outlet pressure Engine at 0.39 to 0.89 0.39 to 0.89
high idle {4.0 to 9.0} {4.0 to 9.0}
high idle {35.3 ± 2.0} {Min. 32.3}
Engine at low 1.42 ± 0.15 1.42 ± 0.15
lockup clutch
high idle {14.5 ± 1.5} {14.5 ± 1.5}
temperature: Within
operating range MPa
clutch pressure engine deceleration cut {kg/cm2} 3.28 ± 0.15 Min. 2.99
Engine at
code: 0007)
high idle {33.0 ± 1.5} {Min. 30.0}
high idle {25.0 ± 1.5} {Min. 22.0}
high idle {33.5 ± 1.5} {Min. 30.5}
Transmission
(reference)
idle {26 to 30} {26 to 30}
Brake pressure
Engine at 2.55 to 2.94 2.55 to 2.94
high idle {26 to 30} {26 to 30}
D65EX,PX,WX-17 20-21
HSS oil pressure

Standard value
machine
36.6 to 39.5 Min. 34.3
relief pressure
Standard value
machine
F1 3.6 ± 0.2 3.6 ± 0.2
• Level ground
Travel speed km/h
to 80 °C R1 4.5 ± 0.3 4.5 ± 0.3
R3 13.6 ± 0.7 13.6 ± 0.7
Standard value
machine
Engine at 3.23 to 4.9 3.23 to 4.9
Unload pressure
high idle {33 to 50} {33 to 50}
Engine at low Min. 28.4 Min. 27.4
• Hydraulic oil
All NEUTRAL position Min. 28.4 Min. 27.4
Engine at low
• Relief pressure:
Ripper lift relief idle {Min. 290} {Min. 280}
Tilt or ripper cylinder
pressure rod stroke end Engine at 28.9 to 32.4 Min. 27.9
MPa
• LS pressure: high idle {295 to 330} {Min. 285}
{kg/cm2}
Tilt or ripper cylinder Min. 26.5 Min. 25.5
Engine at low
LS pressure rod stroke end
idle {Min. 270} {Min. 260}
(load sensing
Engine at 26.9 to 30.4 Min. 25.9
pressure)
high idle {275 to 310} {Min. 265}
Control circuit
3.97 ± 0.29 3.97 ± 0.29
source pressure
• Hydraulic oil temperature: 45 – 55°C {40.5 ± 3.0} {40.5 ± 3.0}
(HSS, PPC, Fan)
pressure {32.5 to 42.5} {32.5 to 42.5}
20-22 D65EX,PX,WX-17
Work equipment
Standard value
machine
Straight tilt
dozer 2.5 ± 0.3 3.1
RAISE
55 °C dozer
level and rising
Sigma dozer
end of blade LOWER
power tilt 1.6 ± 0.2 2.0
dozer
Straight tilt
dozer 1.6 ± 0.3 2.1
Left tilt
55 °C dozer
end and right tilt
Sigma dozer
end Right tilt

power tilt 1.7 ± 0.3 2.2
dozer
Left angle sec. 4.0 ± 0.5 5.0
a See Fig. C
• Hydraulic oil
temperature: 45 to
Blade 55 °C
end and right
angle end
RAISE 1.5 ± 0.5 2.5
a See Fig. D
• Hydraulic oil
temperature: 45 to
Ripper lift 55 °C
equipped) • Between ground 1.5 ± 0.5 2.5
level and rising
end of ripper
Pitch in 1.6 ± 0.3 2.1
a See Fig. E
• Hydraulic oil
speed (if 55 °C
and pitch back
D65EX,PX,WX-17 20-23
Work equipment
Standard value
machine
Time lag

rises
• High idle
a See Fig. F
Max. 35 Max. 35
height "h"
Left tilt Max. 70 Max. 70
a See Fig. G
Hydraulic drift

Hydraulic drift
45 to 55 °C
of machine mm/5 min
tilted by blade
"h"
a See Fig. H
of lifted ripper • Engine stopped Max. 35 Max. 35
height "h"
Blade tilt
cylinder 5 20

Ripper lift
20-24 D65EX,PX,WX-17
Cooling fan
Standard value
machine
• Engine at low
idle
45 to 55 °C Max. 80 °C
rotation idle Max.
1,700 ± 25 1,600
• Fan 100% speed
speed mode
Posture of machine for measuring performance and measurement procedure

Fig. A
Fig. B
D65EX,PX,WX-17 20-25
Fig. C
Fig. D
Fig. E
20-26 D65EX,PX,WX-17
Fig. F
Fig. G
Fig. H
D65EX,PX,WX-17 20-27
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
30 Testing and adjusting
D65EX,PX,WX-17 30-1
Table Of Contents
30 Testing and adjusting .................................................................................................................... 30-3
General information on testing and adjusting................................................................................. 30-4
Tools for testing, adjusting, and troubleshooting ...................................................................... 30-4
Testing engine speed ........................................................................................................... 30-8
Measuring boost pressure................................................................................................... 30-10
Measuring exhaust gas temperature .................................................................................... 30-11
Measuring exhaust gas color............................................................................................... 30-13
Measuring and adjusting valve clearance ............................................................................. 30-15
Measuring compression pressure ........................................................................................ 30-17
Measuring blowby pressure ................................................................................................ 30-19
Measuring engine oil pressure............................................................................................. 30-21
Measuring EGR valve and KVGT oil pressure....................................................................... 30-22
Releasing remaining pressure from fuel system .................................................................... 30-23
Measuring fuel pressure ..................................................................................................... 30-24
Measuring fuel delivery, return rate and leakage ................................................................... 30-31
Handling cylinder cutout mode operation.............................................................................. 30-35
Handling no injection cranking operation .............................................................................. 30-36
Bleeding air from fuel system .............................................................................................. 30-37
Checking fuel circuit for leakage .......................................................................................... 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Replacing alternator belt ..................................................................................................... 30-40
Adjusting fuel dial and decelerator pedal .............................................................................. 30-41
Power train system ................................................................................................................... 30-43
Measuring power train oil pressure ...................................................................................... 30-43
Adjusting transmission output shaft speed sensor (replacement procedure) ............................ 30-48
Simple test procedure for brake performance ....................................................................... 30-49
Adjusting brake pedal ......................................................................................................... 30-50
Adjusting parking brake lever .............................................................................................. 30-52
Retrieval of disabled machine using brake release device ..................................................... 30-54
Adjusting idler clearance..................................................................................................... 30-57
Checking sprocket wear ..................................................................................................... 30-58
Checking and adjusting track shoe tension........................................................................... 30-59
Releasing remaining pressure in work equipment cylinder ..................................................... 30-60
Measuring and adjusting work equipment and HSS oil pressure............................................. 30-61
Measuring source pressure of control circuit ......................................................................... 30-64
Measuring PPC valve output pressure ................................................................................. 30-65
Adjusting play of work equipment PPC valve ........................................................................ 30-68
Isolating the parts causing hydraulic drift in blade and ripper .................................................. 30-70
Measure internal oil leakage of work equipment cylinder........................................................ 30-71
Checking fan speed ........................................................................................................... 30-72
Measuring fan circuit oil pressure ........................................................................................ 30-73
Bleeding air from hydraulic circuit ........................................................................................ 30-74
Work equipment ....................................................................................................................... 30-76
Adjusting work equipment lock lever .................................................................................... 30-76
Adjustment of straight tilt dozer............................................................................................ 30-77
Cab and its attachments ............................................................................................................ 30-79
Adjusting operator's cab ..................................................................................................... 30-79
Adjusting play of blade center ball........................................................................................ 30-82
Electrical system ...................................................................................................................... 30-83
Special functions of machine monitor ................................................................................... 30-83
Handling voltage circuit of engine controller........................................................................ 30-143
Adjustment method when controller has been replaced ....................................................... 30-144
Testing diodes ................................................................................................................. 30-146
Pm clinic ................................................................................................................................ 30-147
Pm Clinic service ............................................................................................................. 30-147
30-2 D65EX,PX,WX-17
Pm Clinic check sheet ...................................................................................................... 30-153
1 30 Testing and adjusting
D65EX,PX,WX-17 30-3
General information on testing and adjusting

Tools for testing, adjusting, and troubleshooting
Testing and Sym-
Q'ty
adjusting item Part No. Part Name Remarks
bol
Measuring boost -101 to 200 kPa {-760 to 1,500
pressure A 799-201-2202 Boost gauge kit 1 mmHg}
Measuring coolant
temperature, oil
temperature, and B 799-101-1502 Digital thermometer 1 -99.9 to 1,299 °C
exhaust
temperature
1 799-201-9002 Handy smoke checker 1
Measuring exhaust
gas color C Commercially Bosch index: 0 to 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting of valve
D Commercially
clearance 2 Feeler gauge 1
available
1 795-502-1590 Gauge assembly 1
Measuring 2 795-799-6700 Puller 1
compression E 3 795-790-6111 Adapter 1 For 114E-5
pressure 4 6754-11-3130 Gasket 1
5 795-799-8150 Remover 1
1 799-201-1506 Blowby checker 1 0 to 10 kPa {0 to1,000 mmH2O}
Measuring blowby 795-790-3300
pressure F
2 or Blowby testing tool 1
799-201-1511
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600 kg/
Measuring engine 790-261-1204 Digital hydraulic tester 1 cm2}
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
1 799-401-3100 Adapter 1
2 799-401-3200 Adapter 1
{25, 60, 400, 600 kg/cm2}
Measuring EGR 799-101-5160 • Nipple 1 R 1/8
valve and KVGT oil W 3 799-101-5150 • Hose 1
pressure
799-261-1150 • Hose 1
Pressure gauge: 2.5 MPa {25 kg/
799-101-5140 • Gauge 1 cm2}
4 790-261-1204 Digital hydraulic tester 1 cm2}
30-4 D65EX,PX,WX-17
Testing and Sym-
Q'ty
bol
{25, 60, 400, 600 kg/cm2}
1
790-261-1204 Digital hydraulic tester 1 cm2}
6732-81-3170 Adapter 1 10 x 1.0 mm o R1/8
2
6215-81-9710 O-ring 1
3 795-790-5110 Screw 1
Measuring fuel 4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
pressure H
M10 computer check
5 795-790-6210 fitting 1
795-790-1500 1 (0 to 30 inHg)
6 or Vacuum gauge
1 -107 to 0 kPa {-800 to 0 mmHg}
799-201-1201
7 795-790-5200 Adapter kit 1
8 795-790-4530 Fitting 1
9 795-790-1150 Pressure gauge 1 (0 to 75 inHg)
1 795-790-4800 Hose kit 1
Measuring fuel
return rate and J 2 795-790-6700 Adapter 1
leakage Commercially Measuring cylinder
4 1
available
{25, 60, 400, 600 kg/cm2}
1
Power train oil 790-261-1204 Digital hydraulic tester 1 cm2}
pressure K
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
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 7824-66-6430 Resistor 1
retrieval of disabled 2
machine due to L 7827-10-1520 Resistor 1
power train failure 3 790-190-1601 Pump assembly 1
799-101-5220 Nipple (10 x 1.25 mm) 1
4
07002-11023 O-ring 1
Measuring and {25, 60, 400, 600 kg/cm2}
1
adjusting work Pressure gauge: 60 MPa {600 kg/
equipment and M 790-261-1204 Digital hydraulic tester 1 cm2}
HSS oil pressure 799-101-5220 Nipple (10 x 1.25 mm) 1
2
07002-11023 O-ring 1
Measuring source {25, 60, 400, 600 kg/cm2}
1
pressure of control N Pressure gauge: 60 MPa {600 kg/
circuit 790-261-1204 Digital hydraulic tester 1 cm2}
2 799-401-3100 Adapter (size: 02) 1
Measuring PPC {25, 60, 400, 600 kg/cm2}
1
valve output O Pressure gauge: 60 MPa {600 kg/
pressure 790-261-1204 Digital hydraulic tester 1 cm2}
2 799-401-3100 Adapter (size: 02) 1
D65EX,PX,WX-17 30-5
Testing and Sym-
Q'ty
bol
Measure internal oil
leakage of work Commercially Measuring cylinder
P 1
equipment cylinder available
{25, 60, 400, 600 kg/cm2}
1
Measuring fan 790-261-1204 Digital hydraulic tester 1 cm2}
circuit oil pressure R
2 799-401-3400 Adapter (size: 05) 1
799-101-5220 Nipple (10 x 1.25 mm) 1
3
07002-11023 O-ring 1
79A-264-0021 0 to 294 N {0 to 30 kg} 1
Operating effort S
79A-264-0091 0 to 490 N {0 to 50 kg} 1
Stroke and Commercially
hydraulic drift T Ruler 1
available
Work equipment Commercially
U Stopwatch 1
speed available
Voltage and Commercially
V Multimeter 1
Resistance available
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 connector
799-601-9300 T-adapter assembly 1 DRC26-24, (40-pin)
799-601-7360 Adapter 1 Relay (5 pins)
799-601-7370 Adapter 1 Relay (6-pin)
799-601-4101 T-adapter assembly 1 Connector related to engine
795-799-5530 • Socket 1 Engine coolant temperature
Boost air temperature/pressure
799-601-4230 • Socket 1
sensor
• T-adapter
Diagnosis for 799-601-4130 assembly 1 Ne sensor, CAM sensor
controller and – • T-adapter
actuator 799-601-4160 assembly 1 Oil pressure sensor
• T-adapter
799-601-4211 assembly 1 Controller (50 poles)
• T-adapter
• T-adapter
799-601-4140 assembly 1 Ambient pressure sensor
• T-adapter
799-601-9020 assembly 1 Pump actuator
• T-adapter
799-601-4190 • Socket 1 Common rail pressure sensor
30-6 D65EX,PX,WX-17
Testing and Sym-
Q'ty
bol
Removal and
installation of 19 mm (width across flats) deep
– 795T-981-1010 Socket 1
coolant socket
temperature sensor
Measuring voltage – Commercially
Multimeter 1
and resistance available
Removal and
installation of 3.26 mm TORX wrench
charge (boost) – Commercially
TORX wrench 1
pressure and available (KTC Q4T15 or equivalent)
temperature sensor
Removal and
installation of – 795-799-6210 Socket 1 27 mm deep socket
engine oil pressure
switch
Removal and
installation of 19 mm deep socket
– 795T-981-1010 Socket 1
engine coolant (MITOLOY 4ML-19 or equivalent)
temperature sensor
D65EX,PX,WX-17 30-7

Testing engine speed
k Place the machine on a level ground and
lower the work equipment to the ground,
then set the parking brake lever and work
equipment lock lever to the LOCK position.
a Check the engine speed under the following

conditions.
• Engine coolant temperature: within operating
range
• Power train oil temperature: within operating
range
• Hydraulic oil temperature: within operating
range
2. Testing low idle speed
• Working mode: P-mode
• Gearshift mode: either auto or manual 1) Start the engine and set the fuel control dial
in the low speed (MIN) position.
Testing 2) Set the PCCS lever, blade control lever, and
1. Preparation work ripper control lever in NEUTRAL and check
Check the engine speed with the Adjustment the engine speed.
function in the service mode of the machine a The parking brake lever and work
monitor. equipment lock lever may be kept in the
a For the operating method, see "Special LOCK position.
functions of machine monitor (EMMS)". 3. Testing high idle speed
1) Testing low idle speed, auto-deceleration 1) Start the engine and set the fuel control dial
speed, decelerator pedal speed, and torque in the full speed (MAX) position.
converter stall speed 2) Set the PCCS lever, blade control lever, and
• Adjustment code: 0530 (stall mode) ripper control lever in NEUTRAL and check
the engine speed.
a When stalling the torque converter for a
purpose other than measuring the engine a The parking brake lever and work equipment
speed, be sure to use this adjustment lock lever may be kept in the LOCK position.
code, as well. a High idle speed must be tested at adjustment
code [0007].
(If it is tested at adjustment code [0530], the
check speed is auto-deceleration speed.)
4. Testing decelerator pedal speed
1) Start the engine and set the fuel control dial
in the full speed (MAX) position.
2) Set the PCCS lever, blade control lever, and
ripper control lever in NEUTRAL, press the
decelerator pedal to the stroke end, and
check the engine speed.
a The parking brake lever and work
equipment lock lever may be kept in the
2) Testing high idle speed LOCK position.
• Adjustment code: 0007 (engine 5. Testing auto-deceleration speed
deceleration cut) 1) Start the engine and set the fuel control dial
a The engine can be operated and tested in the full speed (MAX) position.
with the auto-decelerator turned off, only 2) Set the PCCS lever, blade control lever, and
with this adjustment code. ripper control lever in NEUTRAL and check
the engine speed.
30-8 D65EX,PX,WX-17
a The parking brake lever and work the NEUTRAL position and lower the
equipment lock lever may be kept in the power train oil temperature with the
LOCK position. engine at high idle.
6. Testing of torque converter stall speed
a While measuring, perform the work
equipment circuit relief on occasion to keep
the hydraulic temperature above 45 °C .
If the hydraulic temperature drops below 40 °
C , fan speed varies and correct stall speed
cannot be obtained.
1) Start the engine and set the fuel control dial
in the low speed (MIN) position.
2) Operate the shift up (UP) switch of the PCCS
lever and set the preset mode display section
to [F3-R3].
a The preset mode display (at the right
bottom of the screen) can be set to [F3-
R3] only while the [Adjustment function] is
selected.
3) With the brake pedal depressed securely
and the parking brake lever in the “FREE”
position, set the PCCS lever directional
selection directional selection 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 position of PCCS lever
in NEUTRAL.
4) Press the decelerator pedal and set the fuel
control dial in the full speed (MAX) position.
5) Return the decelerator pedal slowly to stall
the torque converter with the engine at full
speed.
k Keep the brake pedal securely

depressed and keep your right foot on the
decelerator pedal for safety until the work
is finished.
6) Immediately after the power train oil
temperature gauge (T/C TEMPERATURE)
indicates 118 to 120 °C , return the PCCS
lever directional selection to the NEUTRAL
position.
a The top of the green range of the power
train oil temperature gauge indicates
approximately 118 to 120 °C .
7) Repeat above Steps 3) – 6) three times.
8) Perform Steps 3) to 5) again and check the
engine Speed 5 seconds after when the
power train oil temperature gauge (T/C
TEMPERATURE) indicates 118 to 120 °C.
a Immediately after finishing testing, return
the PCCS lever directional selection to
D65EX,PX,WX-17 30-9
Measuring boost pressure

a Testing tools for boost pressure a For the procedure of torque converter stall,
Sym- see "Testing engine speed".
Part No. Part name
bol a Normally, the boost pressure should be
799-201-2202 Boost gauge kit tested while the engine is running at the
A
799-401-2220 Hose rated output. In the field, however, an
approximate value can be obtained by
k Place the machine on a level ground and stalling the torque converter.
then set the parking brake lever and work a The boost pressure can also be checked by
equipment lock lever to the LOCK position. using the "Monitoring / Pre-defined" function
of machine monitor in service mode.
k Be careful not to touch a hot part of the
a For the operating method, see "Special
engine when installing and removing the
functions of monitor panel".
testing tool.
a The boost pressure displayed on the monitor
a Measure the boost pressure under the following panel is an absolute value (includes ambient
condition. pressure). Therefore, take measurement of
• Engine coolant temperature: within operating the ambient pressure to calculate the
range difference between the indicated boost
• Power train oil temperature: within operating pressure, in order to obtain the actual boost
range air pressure.
• Hydraulic oil temperature: within operating • Example
range When the measured value on the monitor is
247 kPa,
Testing 247 kPa – 101 kPa (ambient pressure) = 146
1. Install plug (1) and gauge (2) of boost gauge kit kPa (actual boost pressure)
A to boost pressure pickup port (1) at the
aftercooler inlet.
2. Start the engine, and measure the boost

pressure while the torque converter is stalling at
engine full speed.
30-10 D65EX,PX,WX-17
Measuring exhaust gas temperature

a Testing tool for exhaust temperature
Sym-
Part No. Part name
bol
B 799-101-1502 Digital thermometer

k Remove and install the testing tool after the

exhaust manifold temperature has lowered.
a Measure the exhaust temperature under the

following conditions.
range
• Power train oil temperature:
within operating range
range
Testing
1. Open the engine right side cover, and remove
heat insulation cover (1).
3. A procedure of measuring the maximum value in
troubleshooting
Measure the maximum exhaust gas temperature.
a Use the digital temperature gauge in the
PEAK mode.
a As the exhaust gas temperature differs
greatly depending on the ambient
temperature (intake air temperature of the
engine), correct the value using the following
formula if an abnormal value is recorded.
• Corrected value [ °C ] = Measured value + 2
x (20 - Ambient temperature)
2. Remove the exhaust temperature pickup plug,
4. A procedure of measuring exhaust gas
install sensor [1] of digital thermometer B to the
temperature periodically for preventive
plug hole, and then connect the sensor to
maintenance services (Pm clinic)
thermometer B.
a If the torque converter is stalled simply, the
a Clamp the wiring harness of the digital
torque converter oil is overheated before the
thermometer so that it does not touch a hot
exhaust temperature is stabilized. Therefore,
part during measurement.
measure according to the following
procedure.
1) Turn the starting switch ON and set the
machine monitor to Adjustment function of
the service mode.
• Adjustment code: 0530 (stall mode)
a For the operating method, see Special
functions of machine monitor (EMMS).
D65EX,PX,WX-17 30-11
2) Start the engine and set the fuel control dial 8) From the condition in Step 7, discontinue
in the low speed (MIN) position. only the blade tilt relief, and let the exhaust
3) Operate the shift up (UP) switch of the PCCS temperature decrease by torque converter
lever and set the preset mode display section stall only (Condition (b) in the figure).
to [F3-R3].
a If the exhaust temperature does not go
a The preset mode display section (at the down but rises, make the set temperature
right bottom of the screen) can be set to at Step 7 higher.
[F3-R3] only while the adjustment 9) When the exhaust temperature has lowered
function is selected. and stabilized, take the reading of the
4) Set the work equipment lock lever in the exhaust temperature (Condition (c) in the
FREE position and operate the blade control figure).
lever to extend the blade tilt cylinder rod to its
maximum length. k If the power train oil temperature (T/C
5) With the brake pedal depressed securely TEMPERATURE) reaches approximately
and the parking brake lever in the “FREE” 120 °C , return directional selection to the
position, set the PCCS lever directional NEUTRAL position immediately and let
selection in the “FORWARD” position. the power train oil temperature cool down
a Before going to the next step, check that at high idle.
[F3] is displayed in the gear speed a The temperature at the border between
display section (at the right bottom of the the green range and red range is
screen). approximately 120 °C .
a Keep the steering position of PCCS lever 5. After finishing test, remove the testing tools and
in NEUTRAL. restore the machine.
6) Press the decelerator pedal and set the fuel
7) Return the decelerator pedal slowly, stall the
torque converter with the engine at full speed,
relieve the blade tilt circuit, and raise the
exhaust temperature to approximately 450 °
C . (Condition (a) in the figure)
k Keep the brake pedal securely

depressed and keep your right foot on the
decelerator pedal for safety until the work
is finished.
30-12 D65EX,PX,WX-17
Measuring exhaust gas color

a Testing tools for exhaust gas color measurement
Sym-
Part No. Part name
bol
1 799-201-9002 Handy smoke checker
C
Commercially
2 Smoke meter
available

5) Remove the filter paper and compare it with
k Be careful not to touch any hot part when
the attached scale for adjustment.
removing or installing the checking tools.
6) After finishing test, remove the testing tools
k After KDPF regeneration is started, high- and restore the machine.
temperature exhaust gas spurts from the 3. Testing by using smoke meter C2
inspection port, potentially causing burn 1) Insert probe [1] of smoke meter C2 into the
injury. Therefore, you must stop KDPF port for the removed plug.
regeneration from the machine monitor
before starting the inspection.
(For the stopping procedure of KDPF
regeneration, see the Operation and
Maintenance Manual.)
a If an air source and an electric power source are

not available in the field, use handy smoke
checker C1. When recording official data, etc.,
use smoke meter C2.
a Measure the exhaust gas color under the
following condition.
• Engine coolant temperature: within operating 2) Connect the probe hose, receptacle of the
range accelerator switch, and air hose to smoke
meter C2.
Testing
a Limit the supplied air pressure to 1.5 MPa
1. Open the engine right side cover.
{15 kg/cm2} or below.
2. Testing by using handy smoke checker C1
3) Connect the power cable to an AC 100 V
1) Fit a sheet of filter paper to handy smoke receptacle.
checker C1.
2) Insert the exhaust gas intake pipe in the port a Before connecting the power cable, make
for the removed plug. sure that the power switch of the smoke
3) Start the engine. meter is turned OFF.
4) As increasing the engine speed rapidly or 4) Loosen the cap nut of the suction pump and
running it at high idle, operate the handle of fit the filter paper.
handy smoke checker C1 so that the filter a Fit the filter paper securely so that the
paper absorbs the exhaust gas. exhaust gas does not leak.
5) Turn on the power switch of smoke meter
C2.
D65EX,PX,WX-17 30-13
6) Start the engine.

7) While accelerating the engine rapidly or
letting it run at high idle,
depress the accelerator switch of the smoke
meter to collect exhaust gas on the filter
paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
and restore the machine.
30-14 D65EX,PX,WX-17
Measuring and adjusting valve clearance

a Testing tools for valve clearance
Sym-
Part No. Part name
bol
1 795-799-1131 Gear
D Commercially Feeler gauge
2
available

Testing
2) Align the TDC stamp line a of front gear
1. Perform removal (and installation) of the engine cover with stamp line b of the supply pump
hood assembly, muffler assembly, and cylinder gear.
head cover assembly by referring to
Disassembly and assembly, "Removal (and a The No. 1 cylinder is set to the
installation) of cylinder head assembly". compression top dead center.
2. Remove cap (1) of the front gear cover.
4. While the No. 1 cylinder is set to the

3. Set the No. 1 cylinder to the compression top compression top dead center, adjust the valve
dead center. clearances marked with q in the valve
1) Remove cap (2) of the flywheel housing, and arrangement figure.
then insert gear D1 to rotate the crankshaft to
normal direction.
Adjusting
After testing, adjust the valve clearance according
to the following procedure, if necessary.
1. Insert feeler gauge D2 into the clearance
between rocker arm (3) and crosshead (4).
2. Loosen lock nut (5) and adjust the valve
clearance with adjustment screw (6).
D65EX,PX,WX-17 30-15
a With the feeler gauge inserted, turn the

adjustment screw to a degree that you can
move feeler gauge D2 lightly.
3. Fix adjustment screw (6) and tighten locknut (5).
3 Locknut:
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 the valves

marked with q, rotate the crankshaft a whole
turn in the normal direction and align stamp line
C of the front gear cover to stamp line b of the
supply pump gear.
a The No. 6 cylinder is set to the compression
top dead center.
5. While the No. 6 cylinder is set to the

compression top dead center, adjust the valve
clearances marked with Q in the valve
arrangement figure.
a Procedure for adjustment is the same as for
steps 1) to 3).
6. After finishing adjustment, return the removed
parts.
[*1]
3 Cylinder head cover mounting bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}
30-16 D65EX,PX,WX-17
Measuring compression pressure

a Measuring tools for compression pressure
Sym-
Part No. Part name
bol
1 795-502-1590 Gauge assembly
2 795-799-6700 Puller
E 795-790-6110 Adapter
3
6754-11-3130 Gasket
4 795-799-8150 Remover
k When testing the compression pressure,

take care not to get yourself burned by
touching the exhaust manifold or muffler, or
get caught in a rotating part. 7. Remove retaining nut (5) and remove inlet
connector (6).
a Measure the compression pressure while the
engine is warmed up. a Before removing the inlet connector,
thoroughly remove dust from around the inlet
(Engine oil temperature: 40 to 60°C)
connector so that dust will not enter the holes
a For details of disassembly and assembly of the cylinder and inlet connector.
procedures, see "Disassembly and assembly".
a Use remover E4 to remove the inlet
Testing connectors.
8. By using tool E2, remove injector (7).
1. Remove cylinder head cover.
2. Disconnect the injector wiring harness.
3. Loosen the injector terminal nuts, disconnect the
harness terminals from the injector, and then
remove rocker cover (1).
9. Install adapter E3 to the injector mounting hole

by using the injector holder, and connect
compression gauge E1.
a Be sure to install the gasket to the end of the
4. Bring the cylinder to be tested to the adapter.
compression top dead center.
a Tighten the holder mounting bolts alternately.
a See "Adjusting valve clearance".
3 Injector holder mounting bolt:
5. Remove the mounting bolts of rocker arm
assembly (2) on the exhaust side, and then 10 ± 2.0 Nm {1.0± 0.2 kgm}
remove rocker arm assembly (2) and crosshead a If a small amount of engine oil is applied to
(3). the connecting portions of the adapter and
6. Disconnect high-pressure fuel pipe (4). gauge, air will not leak easily.
10.Install crosshead (3) and rocker arm assembly
(2). Adjust the valve clearance.
3 Rocker arm assembly mounting bolt:
64.7 ± 4.9 Nm {6.6± 0.5 kgm}
a See "Adjusting valve clearance".
D65EX,PX,WX-17 30-17
11.Install the hood and restore the engine so that it

can be cranked.
12.Install a fuel drain hose to the common rail at
where the tube is disconnected to let injected
fuel drain to a container.
13.Select the no injection cranking mode by
operating the machine monitor.
a See the section of "Special functions of
machine monitor".
k If the engine is not set in the no injection

cranking mode, it starts during measurement
and that is dangerous. Accordingly, be sure
to set the engine in this mode.
14.Measure the compression pressure while
cranking the engine by the starting motor.
a Read the pressure gauge pointer when it is
stabilized.
15.After finishing test, remove the testing tools and
restore the machine.
30-18 D65EX,PX,WX-17
Measuring blowby pressure

a Measuring tools
Sym-
Part No. Part name
bol
1 799-201-1504 Blowby checker
Commercially Plug (hose inside
2 diameter: 24 mm)
available
F
Plug (pipe outside
Commercially diameter: 25.4 mm, pipe
3
available inside diameter: 20.4 mm)

lower the work equipment to the ground.
a Measure the blowby pressure under the

following condition.
range
range
k After KDPF regeneration is started, high-
temperature exhaust gas spurts from the
inspection port, potentially causing burn
injury. Therefore, you must stop KDPF
regeneration from the machine monitor
before starting the inspection.
4. Run the engine at high idle and measure the
(For the stopping procedure of KDPF blow-by pressure when the torque converter
regeneration, see the Operation and stalls.
Maintenance Manual.)
a For the torque converter stalling procedure,
Testing see "Testing engine speed".
1. Open the engine left side cover. a Normally, the blowby pressure should be
2. Disconnect hose (1) on the KCCV gas outlet measured while the engine is operated at the
side and plug the hose by using plug F2, and rated output. In the field, however, an
plug the KCCV hose insertion pipe by using plug approximate value can be obtained by
F3. stalling the torque converter.
3 Clamp: a If rated output operation or torque converter
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm} stalling is not possible, measure the blowby
3. Disconnect hose (2) on the KCCV gas inlet side, while the engine is running at high idle.
plug the KCCV hose insertion pipe by using plug In this case, approximately 80% of blowby
F3, install tool and adapter [1] of blowby checker pressure of the rated horsepower can be
F1 to hose (2), and then connect gauge [2]. obtained.
3 Clamp: a Blowby pressure varies greatly with the
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm} condition of the engine. Therefore, if the
value by the test is considered unusual,
make a check for excessive oil consumption,
bad color of exhaust gas, early oil
deterioration, early oil contamination, etc.,
which are related to improper blowby
pressure.
D65EX,PX,WX-17 30-19
5. After finishing measurement, remove the

measuring tools and restore the machine.
30-20 D65EX,PX,WX-17
Measuring engine oil pressure

a Measuring tools for engine oil pressure
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
2 799-401-2320 Gauge (1 MPa {10 kg/cm2})
G
Adapter (10 x 1.0 mm o
6732-81-3170 R1/8)
3
6215-81-9710 O-ring

then set the parking brake lever and work 4. Start the engine and measure the oil pressure
equipment lock lever to the LOCK position. when the engine is running at low idle and when
the torque converter is stalling.
a Measure the engine oil pressure under the
following condition. a For the torque converter stalling procedure,
see "Testing engine speed".
range
Testing
1. Open the engine hood right side cover.
2. Remove oil pressure pickup plug (1).
3. Install adapter G3 and nipple [1] of hydraulic

tester G1 to the plug mount, and then connect
them to gauge G2.
D65EX,PX,WX-17 30-21
Measuring EGR valve and KVGT oil pressure

a Testing tools
Sym-
Part No. Part name
bol
1 799-401-3100 Adapter
2 799-401-3200 Adapter
799-101-5160 • Nipple
W
3 799-101-5150 • Hose
790-261-1150 • Hose
799-101-5140 • Gauge
4 790-261-1204 Digital hydraulic tester
k Place the machine on level ground and lower 5. Install the inner and outer elements of the air
the work equipment to the ground. cleaner.
6. Start the engine and measure the EGR valve
• Engine coolant temperature: within operating and KVGT drive oil pressure and KVGT control
range oil pressure.
• Hydraulic oil temperature: within operating range
Testing
1. Open engine side covers (right and left).
2. Remove the inner and outer elements of the air
cleaner.
a Work cannot be done without removing the
inner and outer elements.
3. Disconnect hoses (1) and (2).
• Hose (1): KVGT control hydraulic circuit
• Hose (2): EGR valve and KVGT drive
hydraulic circuit
7. After finishing test, remove the testing tools and
3 Hose (1):
15 ± 1.0 Nm {1.53 ± 0.10 kgm}
3 Hose (2):
25 ± 1.0 Nm {2.55 ± 1.0 kgm}
4. Install adapter W1 and nipple [1] and hose [2] of

hydraulic tester W2, and then connect them to
gauge [3].
3 Adapter W1:
15 ± 1.0 Nm {1.53 ± 0.10 kgm}
3 Adapter W2:
25 ± 1.0 Nm {2.55 ± 1.0 kgm}
a Use gauge [3] of 2.5 MPa {25 kg/cm2}.
a The nipple and hose for digital hydraulic
tester W3 can also be used.
30-22 D65EX,PX,WX-17
Releasing remaining pressure from fuel system

a Pressure is generated in the low-pressure circuit
and high-pressure circuit of the fuel system
while the engine is running.
Low-pressure circuit: Between feed pump, fuel
main filter and supply pump
High-pressure circuit: Between supply pump,
common rail and injector
a The pressures in both the low-pressure circuit
and the high-pressure circuit lower to the safe
level automatically after 30 seconds when the
engine stops.
a Before the fuel circuit is tested and its parts are
removed, the remaining pressure in the fuel
circuit must be released completely. Accordingly,
observe the following.
k Before testing the fuel system or removing
its parts, wait at least 30 seconds after
stopping the engine until the pressure
remaining in the fuel circuit is released. (Do
not start the work just after stopping the
engine because there is the remaining
pressure.)
D65EX,PX,WX-17 30-23
Measuring fuel pressure

a Testing tools k When removing and installing the fuel
Sym- system testing tool, stop the engine and wait
Part No. Part name for at least 30 seconds until the remaining
bol
799-101-5002 Hydraulic tester pressure is released from the fuel circuit. (Do
1 not start the work immediately after the
Adapter engine is stopped since there is remaining
6732-81-3170 pressure.)
2 (10 x 1.0 mmoR1/8)
6215-81-9710 O-ring k Place the machine on level ground, lower the
3 795-790-5110 Screw work equipment to the ground, stop the
Gauge: 1 MPa {10 kg/ engine, and set the parking brake lever and
4 799-401-2320 cm2})
H work equipment lock lever in the LOCK
5 795-790-6210 M10 computer check fitting position.
795-790-1500
6 or Vacuum gauge a Measure only the fuel pressure in the low-
pressure circuit from the feed pump through the
799-201-1201
main fuel filter to the supply pump, and in the
7 795-790-4900 Adapter kit
return circuit between the supply pump/common
8 795-790-5010 Fitting rail/ injector and fuel tank.
9 795-790-1150 Pressure gauge
k Since the pressure in the high-pressure
circuit from the supply pump through the
common rail to the injector is very high and
dangerous, do not measure it.
A: Low-pressure circuit measuring position (main fuel filter inlet side)

B: Low-pressure circuit measuring position (main fuel filter outlet side)
C: Return circuit measuring position (supply pump drain port)
D: Negative pressure circuit measuring position (fuel supply connector)
E: Negative pressure circuit measuring position (supply pump inlet)
30-24 D65EX,PX,WX-17
F: Fuel feed pump outlet pressure measuring position (inlet of supply pump)
D65EX,PX,WX-17 30-25
Testing {Min. 1.07 kg/cm2}

Min. 0.48 MPa
Testing low-pressure circuit (main fuel filter inlet At high idle
side) {Min. 4.9 kg/cm2}
1. Open the engine left side cover and remove fuel
pressure pickup port plug (1) on the main fuel
filter inlet side.

2. Install adapter H2, install the nipple and hose of 3 Fuel pressure pickup plug (1):
hydraulic tester H1, and then connect them to 20 to 22 Nm {2.0 to 2.2 kgm}
gauge [3].
Testing low-pressure circuit (pressure
a When installing adapter H2, be sure to install difference)
the O-ring. 1. Remove fuel pressure pickup plug (1) at the
main fuel filter inlet side and fuel pressure pickup
3 Adapter H2:
plug (2) on the outlet side.
20 to 22 Nm {2 to 2.2 kgm}
a Use gauge [3] of 2.5 MPa {25 kg/cm2}.
tester H1 can also be used.
2. Install adapters H2 to the inspection holes on

the inlet side and outlet side, and then install
nipples [1] and hoses [2] of hydraulic tester H1
and connect them to gauges [3].
3. Start the engine and measure the pressure in a When installing adapters H2, be sure to
the low-pressure circuit with the engine at high install the O-rings.
idle.
3 Adapter H2:
a If the engine cannot be started, you can 20 to 22 Nm {2.0 to 2.2 kgm}
measure the fuel pressure while rotating the
engine using the starting motor. However, to a Use gauges [3] of 2.5 MPa {25 kg/cm2}.
protect the starting motor, do not rotate the a The nipple and hose for digital hydraulic
engine for more than 20 seconds tester H1 can also be used.
continuously.
a When the pressure in the low-pressure circuit
(on the main fuel filter inlet side) is in the
following range, it is normal.
During cranking Min. 0.105 MPa
30-26 D65EX,PX,WX-17
Testing return circuit

1. Remove joint bolt (1) from the fuel return hose of
the supply pump.
3. Start the engine and measure the pressure on

the inlet side and outlet side of the low-pressure
circuit with the engine at high idle.
a If the engine cannot be started, you can 2. In place of joint bolt (1), install screw H3 and
measure the fuel pressure while rotating the nipple and hose of hydraulic tester H1, and then
engine using the starting motor. However, to connect them to gauge H4.
protect the starting motor, do not rotate the
a When installing screw H3, be sure to install
engine for more than 20 seconds
the seal washer.
continuously.
3 Screw H3:
36 ± 5Nm {3.67 ± 0.5 kgm}
tester H1 can also be used.
4. Calculate the pressure difference in the low-

pressure circuit.
a Pressure difference in low-pressure circuit =
Pressure on main fuel filter inlet side -
Pressure on main fuel filter outlet side 3. Start the engine and measure the pressure in
the return circuit with the engine at high idle.
a When the pressure difference in the low-
pressure circuit is in the following standard a If the engine cannot be started, you can
range, it is normal. measure the fuel pressure while rotating the
Max. 0.08 kPa engine using the starting motor. However, to
At high idle protect the starting motor, do not rotate the
{Max. 0.8 kg/cm2}
a If the pressure is higher than the criteria, the continuously.
main fuel filter may be clogged. In this case, a When the pressure in the return circuit is in
replace the main fuel filter and measure the following range, it is normal.
again.
At high idle Max. 18.6 kPa
restore the machine. During cranking {Max. 0.19 kg/cm2}
3 Fuel pressure pickup plugs (1), (2):

20 to 22 Nm {2.0 to 2.2 kgm}
D65EX,PX,WX-17 30-27
• Standard pressure value in the fuel

H4 negative pressure circuit (fuel supply
connector): -27.1 to 0 kPa {-203 to 0
mmHg}
MP a
3 Fuel pressure pickup plug:
20 to 22 Nm {2.0 to 2.2 kgm}
2. Testing the negative pressure circuit (supply
pump inlet)
B4 D1 9 2 9 0 1) Remove air conditioner compressor and air
intake hose.
2) Disconnect fuel tube(1) from supply pump
(2).
3 Joint bolt (2): 3) Remove fitting (3) mounted to supply pump
36 ± 0.5 Nm {3.67 ± 0.5 kgm} (2).
Testing negative-pressure circuit

1. Measuring pressure in the fuel negative
pressure circuit (fuel supply connector)
1) Remove fuel pressure pickup plug (1) of the
fuel supply connector.
4) Install hose assembly [1] of adapter kit H7 to

fitting H8, and install them to supply pump
(2).
3 Fitting H8:
24 ± 4 Nm {2.4 ± 0.4 kgm}
5) Reconnect fuel tube (1).
2) Connect M10 computer check fitting H5 to 6) Connect vacuum gauge H6 to hose
fuel vacuum gauge H6. assembly [1].
3) Run the engine and measure the pressure in 7) Install the air intake hose.
the fuel negative pressure circuit with the 8) Start the engine and measure the pressure in
engine at high idle. the fuel negative pressure circuit with the
a When the pressure in the fuel negative engine at high idle.
pressure circuit is in the following range, it
is normal.
30-28 D65EX,PX,WX-17
a When the pressure in the fuel negative then stops. Measure the pressure while the
pressure circuit is in the following range, it pump is operating.
is normal.
a If the fuel feed pump outlet pressure is in the
• Standard pressure value in the fuel following standard range, it is normal.
negative pressure circuit (supply pump
• Standard fuel feed pump outlet pressure
section): -33.9 to 0 kPa {-254 to 0
(supply pump section): Min. 34 kPa {10.0
mmHg}
inHg}
and restore the machine. a If the fuel feed pump outlet pressure is not in
the standard range, perform the following
3 Fitting (3):
checks.
24 ± 4 Nm {2.4 ± 0.4 kgm}
• Check that fuel is sent to the fuel feed
• Replace fuel tube (1) with a new one at pump.
reassembly. • If fuel is not in the fuel feed pump just
3 Intake hose clamp: after the fuel filter is replaced or a fuel
system part is removed and returned,
10.5 ± 0.5 Nm {107 ± 5 kgcm}
operate the fuel feed pump 3 to 4 times
Measuring fuel feed pump outlet pressure with the starting switch to bleed air from
(supply pump section) the fuel circuit and fill the pump with fuel
1. The measuring position is same as fuel negative and then measure the outlet pressure
pressure circuit pressure test (supply pump again.
section) however, only a different gauge H9 is • If the fuel feed pump outlet pressure is
used. not in the standard range while fuel is in
the fuel feed 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 feed

pump (10), and measure the fuel feed pump
outlet pressure.
Reference: Fuel feed pump (10) is installed to 3. After finishing test, remove the testing tools and
cooling plate (12) on the back side of engine restore the machine.
controller (11). 3 Fitting (3):
24 ± 4 Nm {2.4 ± 0.4 kgm}
• Replace fuel tube (1) with a new one at
reassembly.
3 Intake hose clamp:
10.5 ± 0.5 Nm {107 ± 5 kgcm}
a The fuel feed pump operates for 60 seconds

after the starting switch is turned ON and
D65EX,PX,WX-17 30-29
30-30 D65EX,PX,WX-17
Measuring fuel delivery, return rate and leakage

a Testing tools k Place the machine on a level ground and
Sym- lower the work equipment to the ground.
Part No. Part name
bol
a Prepare the container of about 20 20 liter to
1 795-790-4800 Tester kit
receive the fuel flowing out during measurement.
2 6164-81-5790 Joint
3 07206-30812 Joint bolt k When removing or installing testing tools,
4 6745-71-1130 Seal washer stop the engine and wait for at least 30
Commercially Stopwatch seconds until the remaining pressure is
5
J available released from the fuel circuit. (Do not start
Commercially Hose (inside diameter: the work immediately after the engine is
6 about 14 mm)
available stopped since there is remaining pressure.)
Commercially Measuring cylinder
7
available
Commercially Hose (inside diameter:
8 about 8 mm)
available
A: Supply pump delivery measuring position

B: Supply pump return rate measuring position
C: Injector return rate measuring position
D: Leakage from pressure limiter measuring position
E: Fuel feed pump delivery measuring position
D65EX,PX,WX-17 30-31
Testing
Testing supply pump delivery
1. Remove air conditioner compressor, aftercooler
return hose, and air conditioner receiver tank,
referring to "Disassembly and assembly".
2. Remove the fuse for the electric priming pump.
a This ceases operation when the engine
starting switch is in the ON position.
3. Disconnect high-pressure pipe (1) from the
supply pump discharge side.
a When the supply pump delivery is in the

following standard range, it is normal.
During cranking Min. 75 cc/30 seconds
4. Install hose J6 to the connector on the discharge

side of the supply pump.
a Hose J6 may be clamped with a hose band
to prevent it from coming off.
a Adjust the route of hose J6 so that it will not 7. After finishing test, remove the testing tools and
become slack and put its end in the oil pan. restore the machine.
Testing supply pump return rate
1. Remove the air conditioner compressor together
with the bracket.
a For the removal procedure, see Disassembly
and assembly, "Removal and installation of
air compressor assembly".
2. Remove the tube mounting bolt and disconnect
return tube (1).
5. Install the aftercooler return hose.

6. Crank the engine for 30 seconds and measure
the delivery by using measuring cylinder J7.
a In order to protect the starting motor, it is
prohibited to continue cranking for more than
20 seconds. Crank the engine for 15
seconds, then stop for 15 seconds and crank
it again for 15 seconds. Do the measurement
in this manner.
3. Connect hose kit J1 to the supply pump side,
and insert its end into measuring cylinder J4.
4. Connect adapter J2 to the fuel return connector
side to prevent leakage of the fuel.
30-32 D65EX,PX,WX-17
5. Start the engine and measure the return rate 2. Connect hose kit J1 to the pressure limiter side,
from the supply pump with the engine at low idle. and insert its end into measuring cylinder J4.
3. Connect adapter J2 to the return tube joint
a When the return rate from the supply pump is
connection of the cylinder block side to prevent
in the following range, it is normal.
leakage of the fuel.
At low idle 350 cc/30 sec.
During cranking 320 cc/30 sec.
k If the engine cannot be started, you may

perform the measurement while rotating the
engine by the starting motor. However, do
not crank the engine continuously for more
than 30 seconds for protection of the starting
motor.
4. Restore the condition of the engine to the level it

can be started.
5. Run the engine at low idle and measure the fuel
return rate in 30 seconds by using measuring
cylinder J7.
a If the return rate from the pressure limiter is in
the following range, it is normal.
At low idle
Max. few drops
6. After finishing test, remove the testing tools and (For 1 minute)
restore the machine. 6. After finishing test, remove the testing tools and
Testing leakage from pressure limiter
a If failure code [CA559] or [CA2249] is displayed, Testing return rate from injector
perform troubleshooting for it first. a The fuel return rate from the injector is measured
1. Disconnect return tube (2) of the pressure while spill tube of the pressure limiter is
limiter. connected. Accordingly, before measuring the
return rate from the injector, check that the
a For procedures necessary to remove the leakage from the pressure limiter is normal.
return tube (removal of hood, etc.), see
"Disassembly and assembly". 1. Disconnect the supply pump and return tube (1)
referring to "Measuring return rate from supply
pump".
D65EX,PX,WX-17 30-33
a When the return rate from the fuel injector is

in the following range, it is normal. (Since the
measured leakage includes pressure limiter
leakage, it must be subtracted.)
At low idle
Max. 70 cc
(For 1 minute)
During cranking
Max. few drops
(For 30 sec)
2. Connect a vinyl tube [1] or the like to return tube

(1) side.
a Since the return side of the supply pump is
opened, a vinyl tube or the like must be
connected to collect the fuel into measuring
cylinder J7.

3. Start the engine and measure the fuel return rate

in 30 seconds by using measuring cylinder J7
with the engine at low idle.
a When the engine cannot be started, you can
measure the fuel pressure while rotating the
engine using the starting motor. However, to
protect the starting motor, do not rotate the
continuously. Crank the engine for 15
seconds, then stop for 15 seconds and crank
it again for 15 seconds. Do the measurement
in this manner.
30-34 D65EX,PX,WX-17
Handling cylinder cutout mode operation

a The cylinder cut-out test mode operation means
to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for the Cylinder Cut-
out Mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston or piston ring
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.
D65EX,PX,WX-17 30-35
Handling no injection cranking operation

a No-injection cranking means to crank the engine
by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
30-36 D65EX,PX,WX-17
Bleeding air from fuel system

a If fuel is used up or if a fuel circuit part is • The lift pump operates automatically for 60
removed and installed, bleed air from the fuel seconds.
circuit by using the electric lift pump according to
the following procedure. k Do not turn the starting switch to START
(For the air bleeding procedure after running out position.
of fuel, see Operation and maintenance 4. Return the starting switch to the OFF position
manual.) and keep it there for 10 seconds.
1. When fuel main filter (1) and fuel pre filter (2) are 5. Repeat above Steps 3) and 4) four times.
removed and installed or replaced, install them 6. Start the engine by cranking with the starting
according to the following procedure. motor.
Do not let the starting motor operate
continuously for more than 20 seconds. Wait for
about 2 minutes and then try to start again.
7. If you fail to start the engine after performing
Steps 3 to 6, turn the starting switch to the OFF
position and wait for about 10 minutes (if outside
air temperature is lower than 5 °C , wait for
about 15 minutes) and then repeat Steps 3 to 6.
a The air in the high-pressure circuit is bled
automatically by cranking the engine.
a If the engine does not start, there still may be
air in the low-pressure circuit. In this case,
1) Regarding main fuel filter (1), do not feed fuel repeat the above procedure from Step 2.
to inside of the filter. a If the machine is used with air remaining in
2) Regarding fuel pre-filter (2), fill the filter with the fuel system, fuel system errors (CA559,
fuel. CA2249) may be issued. In this case,
• Fill the fuel pre-filter with clean fuel and perform the above procedure, and then start
take care that dirt does not enter it. the engine and let it run at low idle for about
• Feed fuel through inlet ports a (eight 3 minutes. When air is eliminated from the
places) of the filter. fuel system, the engine rotation will stabilize
Do not feed fuel through port b because and errors will be cleared.
this is the outlet port for filtered fuel.
3) When installing the filter, apply a thin film of

oil to the filter packing surface and install to
the filter head. When the sealing surfaces
come in contact, turn the filter another 3/4
turn. (For the replacing procedure of fuel filter
cartridge, see Operation and Maintenance
Manual.)
2. Fill up the fuel tank with fuel.
3. Turn the starting switch to the ON position.
D65EX,PX,WX-17 30-37
Checking fuel circuit for leakage

a Testing tools a Place the torque converter in the stalled
Sym- state.
Part No. Part name 9. Check the fuel piping and devices for fuel
bol
Developer leakage.
Commercially
L for dye penetrant check a Check the high-pressure circuit for fuel
available
(color checker) leakage focusing on the area to which color
checker L is sprayed.
k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel a If any fuel leakage is detected, repair it and
leaks while the engine is running, it presents check again from Step 1.
a serious danger that could result in a fire. a If no fuel leakage is detected, check is
After checking the fuel system and removing completed.
or installing its parts, check it for fuel
leakage according to the following procedure.

lower the work equipment to the ground.
a Clean and degrease the engine and the parts

around it in advance so that you can check it
easily for fuel leakage.
Testing
1. Spray color checker (developer) L to the fuel
supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
3. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
a If any fuel leakage is detected, repair it and
check again from Step 1.
4. Start the engine and keep it running at low idle.
leakage.
6. Start the engine and keep it running at high idle.
leakage.
8. Start the engine and keep it running at high idle,
then load the engine.
30-38 D65EX,PX,WX-17
Testing and adjusting air conditioner compressor belt tension

Testing
• Press the intermediate point between air
conditioner pulley and drive pulley with a finger
and measure deflection a.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection (a): 15 to 18 mm
Adjusting
a If the belt deflection is improper, adjust it
according to the following procedure.
1. Loosen 4 compressor bracket mounting bolts
(1).
2. Loosen locknut (2) and adjust the belt tension by
turning adjustment bolt (3).
3. After adjusting the belt tension to the standard
value, tighten locknut (2), then tighten 4
compressor bracket mounting bolts (1).
D65EX,PX,WX-17 30-39
Replacing alternator belt

a The auto-tensioner is provided for the alternator
belt. Thus, checking and adjusting of the belt is
usually not necessary.
a Disconnect air conditioner compressor belt
before replacing the alternator belt.
Replacing
1. Open left cover (1) on engine hood and remove 3. Replace alternator belt (4).
side cover (2). • Check each pulley for breakage and crack.
2. Set a wrench to portion A (width across flats:

T12.7 mm) of the tensioner assembly (3), and
turn the wrench in the direction opposite to the
winding-up direction to decrease the alternator
belt (4) tension.
k Firmly set wrench [1] on tensioner assembly

(3) at portion A before applying turning force
to the wrench. (If you try to rotate the wrench
before it is fully inserted, it can disengage
and cause serious physical injuries due to
strong spring force of tensioner assembly
(3).)
k After removing the alternator belt (1), slowly

and carefully restore tensioner assembly (5).
k Be careful not to get your fingers caught

between the pulley and alternator belt (4)
during work.
30-40 D65EX,PX,WX-17
Adjusting fuel dial and decelerator pedal
k Place the machine on a level ground and lower the work equipment to the ground, then set the
parking brake lever and work equipment lock lever to the LOCK position.
1. Outline of fuel control system [3] Power train controller

• The following signals are inputted as rotation [4] Decelerator pedal
command signals to the engine controller. [5] Decelerator potentiometer
[6] Engine (CRI system)
• Decelerator pedal potentiometer signal
[7] 3rd throttle signal
• 3rd throttle signal
2. Preparation work
• The engine controller controls the fuel control
Measure the engine speed with the "Adjustment"
system of the engine (CRI system) according
function in the service mode of the machine
to the lowest engine speed signal among
monitor.
those input signals.
• Adjustment code: 0530 (stall mode)
• Adjust the deceleration slow speed by
adjusting the decelerator pedal stopper bolt. a For the operating method, see "Special
functions of machine monitor (EMMS)".
[1] Fuel control dial

[2] Engine controller 3. Measuring high idle speed
D65EX,PX,WX-17 30-41
• Adjustment code: 0007 (Engine decelerator

cutting)
a The engine can be operated and tested
with the auto-decelerator turned off with
this adjustment code only.
4. Adjusting decelerator pedal engine speed

With the fuel control dial set at high idle (MAX)
position, press decelerator pedal (1) until it
touches stopper bolt (2), and check that the
decelerator pedal engine speed is normal.
• Decelerator pedal engine speed: 1,000 ± 25
rpm
a If the decelerator pedal engine speed is not
correct, adjust installed dimension (a) of
stopper bolt (2).
• Standard installed dimension (a) of stopper
bolt: 22.0 mm
5. Adjusting high idle speed
With the fuel control dial set at high idle (MAX)
position and decelerator pedal (1) completely
released, check that the high idle speed is
normal.
a High idle speed is always checked with
adjustment code [0007].
• High idle speed: 2,100 ± 50 rpm
a If the high idle speed is abnormal, adjust it
• When engine speed is 2,000 rpm or above:
To remove the play of the decelerator pedal,
use stopper bolt (3) to adjust the engine
speed to less than 1,950 rpm, then adjust to
the high idle speed.
• When engine speed is below 2,000 rpm:
Raise the speed to the high idle speed by
stopper bolt (3).
• Standard installed dimension (b) of stopper
bolt: 28.0 mm
6. Work after finishing adjustment
After finishing all adjustment, restore the
machine.
30-42 D65EX,PX,WX-17
Power train system
Power train system

Measuring power train oil pressure
a Testing tools for power train oil pressure
Sym-
Part No. Part name
bol
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 Place the machine on a level ground, lower

the work equipment to the ground, then set
the parking lever and work equipment lock 1. Measuring brake pressure (BR)
lever to the LOCK position. 1) Remove the plug of oil pressure pickup port
(1), attach nipple K3, and connect oil
Testing pressure gauge [1] of hydraulic tester K1.
a Measure the power train oil pressure under the
following condition. a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.
• Power train oil temperature:
within operating range
a The power train oil pressure pickup port
(centralized pressure pickup port block) is
installed inside inspection cover (1) at right side
of the operator's cab.
2) Start the engine and set the parking lever in

the FREE position.
3) Perform the test with the service mode of
machine monitor at adjustment code "0007"
(engine deceleration cut mode).
4) Measure the oil pressure with the engine at
low idle and high idle.
a List of oil pressure measuring points and gauges
to be used a Check that the oil pressure becomes 0
Gauge when the brake pedal is depressed or the
No. Mark Check point parking brake lever is set to the LOCK
(MPa {kg/cm2})
position.
1 BR Brake pressure 6 {60}
Torque converter
2 IN 2.5 {25}
inlet pressure
Torque converter
3 OUT 1 {10}
outlet pressure
Transmission main
4 MAIN 6 {60}
relief pressure
D65EX,PX,WX-17 30-43
Power train system
3. Measuring torque converter outlet pressure

(OUT)
1) Remove the plug of oil pressure pickup port
(3), attach nipple K3, and connect hydraulic
tester K2.
a Use the oil pressure gauge of 1 MPa {10
kg/cm2}.

2. Measuring torque converter inlet pressure
(IN)
pressure gauge [1] of hydraulic tester K1.
a Use the oil pressure gauge of 2.5 MPa
2) Start the engine and set the PCCS lever in
{25 kg/cm2}.
the full NEUTRAL position.

4. Measuring transmission main relief pressure
(MAIN)
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.

30-44 D65EX,PX,WX-17
Power train system

1) Measuring transmission F clutch pressure

1] Remove the plug of oil pressure pickup
port (5), attach nipple K3, and connect oil
a Use an oil pressure gauge of 6 MPa
5) After finishing test, remove the testing tools {60 kg/cm2}.
and restore the machine. 2] Start the engine and set the parking lever
5. Measuring clutch control pressure in the FREE position.
• Remove the operator's seat assembly and 3] With the brake pedal depressed, set the
measure the pressure from the top of the direction to forward with PCCS lever and
floor frame. the gear speed to the 3rd.
• Remove the top cover of the transmission. 4] Run the engine at high idle and measure
the pressure.
a List of oil pressure measuring points and
gauges to be used k Since the torque converter is stalled,
Gauge keep depressing the brake pedal
No. Check point securely.
(MPa {kg/cm2})
Transmission F clutch 5] After finishing test, remove the testing
5 6 {60}
pressure tools and restore the machine.
Transmission R clutch 2) Measuring transmission R clutch pressure
6 6 {60}
pressure 1] Remove the plug of oil pressure pickup
Transmission 1st clutch port (6), attach nipple K3, and connect oil
7 6 {60}
pressure pressure gauge [1] of hydraulic tester K1.
Transmission 2nd clutch
8 6 {60} a Use an oil pressure gauge of 6 MPa
pressure
Transmission 3rd clutch {60 kg/cm2}.
9 6 {60} 2] Start the engine and set the parking lever
pressure
Torque converter lockup in the FREE position.
10 2.5 {25} 3] With the brake pedal depressed, set the
clutch pressure
direction to forward with PCCS lever and
the gear speed to the 3rd.
D65EX,PX,WX-17 30-45
Power train system
4] Run the engine at high idle and measure 1] Remove the plug of oil pressure pickup
the pressure. port (9), attach nipple K3, and connect oil
k Since the torque converter is stalled, a Use an oil pressure gauge of 6 MPa
keep depressing the brake pedal {60 kg/cm2}.
securely. 2] Start the engine and set the parking lever
5] After finishing test, remove the testing in the FREE position.
tools and restore the machine. 3] With the brake pedal depressed, set the
3) Measuring transmission 1st clutch pressure direction to forward with PCCS lever and
1] Remove the plug of oil pressure pickup the gear speed to the 3rd.
port (7), attach nipple K3, and connect oil 4] Run the engine at low idle and measure
pressure gauge [1] of hydraulic tester K1. the pressure.
a Use an oil pressure gauge of 6 MPa k Since the torque converter is stalled,
{60 kg/cm2}. keep depressing the brake pedal
2] Start the engine and set the parking lever securely.
in the FREE position.
3] With the brake pedal depressed, set the k Do not increase the engine speed to
direction to forward with PCCS lever and high idle during testing.
the gear speed to the 1st.
4] Run the engine at low idle and measure 5] After finishing test, remove the testing
the pressure. tools and restore the machine.
6) Measuring torque converter lockup clutch
k Since the torque converter is stalled, pressure (LU)
keep depressing the brake pedal 1] Remove the plug of oil pressure pickup
securely. port (10), attach nipple K3, and connect
oil pressure gauge [1] of hydraulic tester
k Do not increase the engine speed to K1.
high idle during testing. a Use the oil pressure gauge of 2.5 MPa
5] After finishing test, remove the testing {25 kg/cm2}.
tools and restore the machine. 2] Start the engine, raise the machine to the
4) Measuring transmission 2nd clutch pressure height which allows the track to run idle
1] Remove the plug of oil pressure pickup off ground by using blade and ripper.
port (8), attach nipple K3, and connect oil
pressure gauge [1] of hydraulic tester K1. k After raising the machine, set the
work equipment lock lever to the
a Use an oil pressure gauge of 6 MPa LOCK position.
{60 kg/cm2}.
2] Start the engine and set the parking lever
3] With the brake pedal depressed, set the
direction to forward with PCCS lever and
the gear speed to the 2nd.
4] Run the engine at low idle and measure
the pressure.
k Since the torque converter is stalled,

keep depressing the brake pedal
securely.
k Do not increase the engine speed to 3] Set the gearshift mode and preset range
high idle during testing. as follows with the gearshift mode
5] After finishing test, remove the testing selector switch and shiftup or shiftdown
tools and restore the machine. switch.
5) Measuring transmission 3rd clutch pressure • Gearshift mode: Automatic gear shift
(dozing)
• Preset mode: F2 - R1
30-46 D65EX,PX,WX-17
Power train system
4] Set the machine monitor to "Monitoring"

function of the service mode.
• Monitoring code:
(Code: 31520 T/M Fill Sw Input 2)
a For the operating method, see
"Special functions of machine monitor
(EMMS)".
5] Run the track idle off ground by setting

the direction to forward with PCCS lever.
k Take care not to get caught by

rotating part of track shoe during
testing.
a Keep the steering unit in NEUTRAL.
6] Run the engine at high idle, measure the
lockup clutch pressure when [L/U Fill Sw]
of monitoring item turns ON.
7] After finishing test, remove the testing
tools and restore the machine.
D65EX,PX,WX-17 30-47
Power train system
Adjusting transmission output shaft speed sensor (replacement

procedure)
k Place the machine on a level ground, lower (Insert securely until a click is heard.)
the work equipment to the ground, then set 3) Install connector assembly (6) to bracket (4).
the parking brake lever and work equipment
3 Bolt (7):
lock lever to the LOCK position.
4.9 to 6.9 Nm {0.5 to 0.7 kgm}
1. Remove cover from rear of the main frame and 4) Install sensor assembly (1) to steering case
remove transmission speed sensor assembly (1) (2).
from steering case (2). 2 O-ring:
a Before adjusting, remove the transmission Grease (G2-LI)
output shaft speed sensor to check its tip for • Standard clearance between bevel gear
adherence of iron particles or presence of and sensor tip
scratches. Reinstall the sensor after x: 0.84 to 1.76 mm
confirming it is intact. 5) After finishing adjustment, restore the
machine.
6) Start the engine, set the machine monitor to
"Monitoring" function of the service mode,
and check that the transmission speed is
indicated normally.
a Monitoring code:
31400 (T/M output shaft speed)
a To rotate the transmission output shaft,
travel the machine actually or run the
2. Measure the installed dimension L of the track idle off ground.
removed sensor (3).
a Always measure dimension L when the
sensor is replaced.
3. Assembly procedure of sensor

1) Install sensor (3) to bracket (4).
3 Lock nut (5):
39.2 to 49.1 Nm {4 to 5 kgm}
a Sensor installed dimension:
Dimension measured at removal L ± 0.2
mm
2) Pull out the connector of sensor (3) from hole
in flange of bracket (4), and insert it into
connector assembly (6).
30-48 D65EX,PX,WX-17
Power train system
Simple test procedure for brake performance

the parking brake lever and work equipment
lock lever to the LOCK position.
a Perform the simple brake performance test

under the following condition.
• Power train oil temperature: within operating
range
1. Set the blade and ripper (if equipped) in the
travel posture on a level place.
2. Start the engine and set the parking brake lever

3. Set the gearshift mode and preset range as
follows with the gearshift mode selector switch
and shiftup or shiftdown switch.
• Gear shift mode: manual gearshift
• Preset gear speed: F2-R2
4. While the engine is running at low idle and the
brake pedal is 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 is overloaded.
Accordingly, be sure to carry it out in the 2nd
gear speed.
a Check that [F2] is displayed in the gear
speed display section.
a Keep the steering position of PCCS lever in
NEUTRAL.
5. Depress the decelerator pedal and set the fuel
6. Return the decelerator pedal slowly and check
that the machine does not start when the engine
speed reaches the full speed.
k Since the torque converter is stalled, keep

pressing the brake pedal securely and keep
your right foot on the decelerator pedal for
safety until the work is finished.
D65EX,PX,WX-17 30-49
Power train system
Adjusting brake pedal
k Place the machine on a level ground, lower the work equipment to the ground, then set the parking
brake lever and work equipment lock lever to the LOCK position.
k Securely tighten the locknut of the rod and cable and bend the cotter pin securely.
Adjusting
1. Adjust stroke a of brake pedal (1) by adjusting
installed dimension b of bumper (2).
• Pedal stroke a: 68 mm
• Installed dimension b of bumper: 23 mm
2. Adjust installed dimension c of valve side rod (3)
and connect it to brake valve lever (4).
• Installed dimension c of rod: 938 mm
a Screw joint (5) fully to the valve side.
3. Adjust installed dimension d of pedal side rod (6)
and connect it to brake pedal (1).
• Installed dimension d of rod: 175 mm
4. Push the valve side rod (3) lightly toward the
rear of the machine, and turn only joint (7) to
connect rod (3) and rod (6).
a Push rod (3) with a force of approximately
9.8 to 19.6 N {1 to 2 kg}.
3 Joint:
34.3 to 58.8 Nm {3.5 to 6.0 kgm}
30-50 D65EX,PX,WX-17
Power train system
5. With brake pedal (1) released, adjust its play by

adjusting distance e between pins of rod
assembly (8).
• Play of pedal: 3 to 8 mm (at center of
pedal)
• Distance e between pins of rod assembly:
1,143 mm
a Adjust by turning joints (5) and (7)
simultaneously in the same direction.
6. With brake pedal (1) released, check that brake
pedal (1) is in contact with bumper (2).
7. Checking brake oil pressure
Oil pressure MPa
{kg/cm2} Remarks
Brake Min. 2.55 {Min. 26} Engine at full
released throttle
Brake applied 0
8. After adjusting the pedal, turn the starting switch
to the ON position and set the machine monitor
to "Adjustment" function display of the service
mode to perform adjustment.
D65EX,PX,WX-17 30-51
Power train system
Adjusting parking brake lever
Adjusting Check that the brake oil pressure becomes as

1. Assembling and installing of lever assembly follows, when the parking brake lever is set in
the FREE and LOCK positions.
1) Assemble lever assembly (1) and adjust the
operation of limit switch (2). a For the testing method of the brake oil
pressure, see "Measuring power train oil
a When assembling the lever assembly, pressure".
disconnect the parking brake cable from
the lever. • LOCK position: 0, FREE position: specified
pressure
• Lever raised: OFF, lever lowered: ON 4. Checking limit switch
• Limit switch operation stroke: 3 mm
2) Install lever assembly (1). 1) Turn the starting switch ON and set the
2. Adjusting installed length of parking brake machine monitor to "Monitoring" function of
cable the service mode.
1) Connect parking brake cable (3) to the lever a Monitoring code:
side and valve side, then adjust installed 40905 T/M Con. SwInput 1
dimensions a and b.
• Installed dimension a of cable: 148.5 mm functions of machine monitor (EMMS)".
• Installed dimension b of cable: 166 mm
2) Operate parking brake lever (10) between
the FREE and LOCK positions, and adjust
rod end (6) so that spool stroke h of brake
valve (5) becomes normal.
• Spool stroke h: 13.3 mm
3. Checking brake oil pressure
30-52 D65EX,PX,WX-17
Power train system
2) Check that the limit switch signal is input

normally when parking brake lever (4) is set
in the FREE position and LOCK position.
• FREE position:
Travel lock NC ON, Travel lock NO OFF
• LOCK position:
Travel lock NC OFF, Travel lock NO ON
D65EX,PX,WX-17 30-53
Power train system
Retrieval of disabled machine using brake release device

a Tools for emergency escape
Sym-
Part No. Part name
bol
1 790-190-1601 Pump assembly
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
L 19M-06-32820 Switch assembly
3
14X-06-52930 Wiring harness
7824-66-6430 Redundant resistor
4
7827-10-1520 Redundant resistor
1. Retrieval of disabled machine using brake
release device (Use L1) 5) Turn the starting switch to the ON position
a If the engine cannot be started and the and set the parking brake lever in the FREE
parking brake cannot be released, carry out position.
the emergency escape according to the 6) Operate the volume pump to raise the brake
following procedure. releasing oil pressure to the initial pressure.
• Initial pressure: Approx. 2.74 MPa
a If the machine is placed on a slope, put the {Approx. 28 kg/cm2}
block to the tracks before commencing work.
1) Assemble pump assembly L1. a Since an accumulator is installed in the
2) Install volume pump [1] of pump assembly circuit, the handle must be operated 30 to
L1 to the outside of the operator’s cab. 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 lowers
gradually because of internal leakage
and the brake is applied again
approximately one minute after.
Therefore, work quickly.
a If the brake releasing pressure lowers to
approximately 1.57 MPa {16 kg/cm2}, 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 the work
is done, loosen the screw slowly and do not
stand in the direction of oil that may spurt
out.
2. Retrieval of disabled machine due to power
train failure using switch box (Use L3)
a If the machine cannot be moved because of
a trouble in the electrical system of the power
train control unit (travel direction, gear speed,
steering), retrieve the situation according to
3) Remove the brake oil pressure pickup plug the following procedure.
which is located behind the cover at the right a The engine can be started by using this
outer side of the operator's cab. procedure.
4) Install nipple L4 and connect hose [2] of
pump assembly L3 to it. a If the engine cannot be started, see
"Retrieval of disabled machine using brake
release device".
30-54 D65EX,PX,WX-17
Power train system
1) Connect switch assembly L3 [1] and L4 to 4) Disconnect neutral safety relay (NSF) (3),
wiring harness L3 [2] of emergency escape and then connect pin [3] and pin [5] of the
device L3. connector (female) at the wiring harness end
directly.
k In order to prevent mistaken actuation,
set all the gear speed switches of switch k When the engine is started with this
assembly L3 [1] to the OFF position and method, the neutral safety relay function
the directional switch to the P position. will not work, so before starting the
engine, set the parking brake lever to the
LOCK position and all the PCCS lever
functions to the NEUTRAL position.
k Use this method to start the engine only

when carrying out the emergency escape.
In all other cases when the engine does
not start, always carry out troubleshooting
and repair the cause.
2) Open the battery cover on the left side of the

machine, and connect wiring harness L3 [2]
to connector (PL1).
a The male housing and female housing of
connector (PL1) are fixed with a screw.
a Connect the wiring harness to both the
male and female halves of connector
(PL1).
5) Start the engine and set the parking brake
lever in the FREE position.
6) Operate switch assembly [1] and move the
machine to a safe place.
a The gear speed switch has an electric
circuit that gives priority to operation of
the low speed switch.
k Take care that the L.H. and R.H. steering

directions are opposite when traveling in
reverse.
3) Remove cover (2) from the front side of the

left console box.
7) After the machine is moved, remove the tools

and restore the original condition.
D65EX,PX,WX-17 30-55
Power train system
a Regarding connector PL1, make sure the

seal at the joint is not protruding or
missing, and then tighten the screw to the
specified torque.
3 Screw of connector PL1:
2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
30-56 D65EX,PX,WX-17

Adjusting idler clearance
a If runout or inclination occurs in the idler due to wear of the idler's guide plate, make adjustents according
to the following procedure.
Adjusting
1. Move the machine for 1 to 2 m on a flat ground, and then measure clearance a between the track frame
and guide plate (at four places: right, left, inside, and outside).
2. If clearance a is larger than 4 mm, adjust it by loosenening bolt (1) and reducing shims (2).
• Standard clearance a on each side: 0.5 to 1.0 mm
• Shim thickness: 1.0 mm
D65EX,PX,WX-17 30-57
Checking sprocket wear

Testing
a Use the "Full-scale drawing of sprocket profile"
in the section "Sprocket" in Structure, function
and maintenance standard, "Sprocket" as a
gauge for checking wear of the sprocket.
a Make a copy of the "Full-scale 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.
30-58 D65EX,PX,WX-17
Checking and adjusting track shoe tension

the parking lever and work equipment lock
lever to the LOCK position.
Testing
1. Move the machine forward slowly on a level
ground, then stop it.
a Do not apply the brake when stopping.
2. Place straight steel bar [1] between the idler and
front carrier roller, and measure clearance a
between the bottom of the steel bar and track
shoe grouser. 4. After finishing adjustment, restore the machine
• Standard clearance a: 20 to 30 mm
Adjusting
a If the track shoe tension is abnormal, adjust it
1. Remove cover (1).
2. When tension is too high:
Loosen plug (2) to discharge the grease.
k Do not loosen the plug more than one turn. If

it is loosened more, it ma jump out because
of the internal high-pressure grease.
3 Plug:
59 to 88 Nm {6 to 9 kgm}
3. When tension is too low:
Pump in grease through grease fitting (3).
a If the track shoe is not tensed well, move the
machine forward and in reverse slowly.
D65EX,PX,WX-17 30-59
Hydraulic system
Hydraulic system
Releasing remaining pressure in work equipment cylinder
a When disconnecting the piping between the
control valve and work equipment cylinder,
release the remaining pressure in the circuit
1. Loosen hydraulic tank cap (1) gradually to

release the remaining pressure in the tank.
2. Turn the starting switch to the ON position and

set the work equipment lock lever in the FREE
position.
3. Operate the blade control lever and ripper
control lever in all directions.
a After the levers are operated 2 to 3 times, the
remaining pressure in the accumulator is fully
released.
4. Start the engine, run at low idle for
approximately 5 seconds, and then stop the
engine.
5. Repeat above Steps 2 to 4 by two or three
times.
30-60 D65EX,PX,WX-17
Hydraulic system
Measuring and adjusting work equipment and HSS oil pressure

a Testing tools for work equipment and HSS oil a Oil pressure gauge
pressure Work equipment oil pressure: 60 MPa {600
Sym- kg/cm2}
Part No. Part name
bol HSS oil pressure: 60 MPa {600 kg/cm2}
1
M
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

a When performing the measuring and adjusting

for 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.
• Hydraulic oil temperature: Within operating
range
a Unload pressure, work equipment and HSS oil
pressure are measured by using "monitoring
function" of service mode on the machine
monitor.
a LS pressure is measured directly through the
pressure pickup port of the equipment.
1. Testing with machine monitor
1) Turn the starting switch ON and set the
machine monitor to "Monitoring" function of
the service mode.
• Monitoring code: 70700 work equipment
oil pressure 1
3. Measuring unload pressure

Start the engine and run it at full speed and set
the blade control lever and ripper control lever in
NEUTRAL, then measure the unload pressure.
a The work equipment lock lever may be set in
the LOCK position.
a Unload pressure can be tested with machine
2. Measuring main valve LS pressure monitor.
Remove pickup plug (1) of main valve at the 4. Measuring work equipment oil pressure
center side of the machine, and measure the oil 1) Install nipple M2 and connect it to oil
pressure. pressure gauge [1] of hydraulic tester M1.
D65EX,PX,WX-17 30-61
Hydraulic system
2) Start the engine and set the work equipment 4) After finishing test, remove the testing tools
lock lever in the FREE position. and restore the machine.
3) Run the engine at full speed, operate the Adjusting
blade control lever and ripper control lever to
relieve each cylinder at a stroke end, and 1. Adjusting unload pressure
measure the work equipment relief pressure a The unload pressure cannot be adjusted.
and work equipment LS relief pressure. 2. Adjusting work equipment oil pressure
a Unload pressure can be tested with a The work equipment oil pressure cannot be
machine monitor. adjusted.
3. Adjusting HSS oil pressure
a If the HSS oil pressure is abnormal, adjust
work equipment LS relief valve (2) according

5. Measuring HSS oil pressure
1) Install nipple M2 and connect it to oil
pressure gauge [1] of hydraulic tester M1.
1) While fixing adjustment screw (7), loosen
a Measuring point of HSS oil pressure is
lock nut (6).
the same as that of work equipment oil
2) Turn adjustment screw (7) to adjust oil
pressure.
pressure.
2) Start the engine, set the parking brake lever
to the FREE position, and keep depressing a If the adjustment screw is
the brake pedal. • rotated to the right, the pressure
3) Run the engine at full speed, operate the increases.
steering of PCCS lever toward left or right to • rotated to the left, the pressure
relief the steering, then check the oil decreases.
pressure of HSS and HSS LS.
a Quantity of adjustment per turn of
k Since the steering circuit is relieved, keep adjustment nut:
depressing the brake pedal securely and Approx. 15.1 MPa {Approx. 154 kg/
keep your right foot on the decelerator cm2}
pedal for safety until the work is finished. 3) While fixing adjustment screw (7), tighten
lock nut (6).
a HSS oil pressure can be tested with
machine monitor. 3 Locknut:
68.6 to 78.5 Nm {7 to 8 kgm}
30-62 D65EX,PX,WX-17
Hydraulic system
4) After finishing adjustment, check the work

equipment oil pressure according to the
above measuring method.
D65EX,PX,WX-17 30-63
Hydraulic system
Measuring source pressure of control circuit

a Testing tools for control circuit source pressure
Symbol Part No. Part name
1
N 790-261-1204 Digital hydraulic tester
2 799-401-3200 Adapter (size: 02)
a The control circuit source pressure is the

pressure 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) circuits.
Testing 5. Start the engine, run it at full speed, and
k Place the machine on a level ground, lower measure the oil pressure when the blade lever
the work equipment to the ground, stop the and ripper lever are in NEUTRAL.
engine, and set the parking brake lever and
work equipment lock lever in the LOCK
position.
a Measure the control circuit basic pressure under

the following condition.
range
1. Remove the control valve cover from the right
side of the operator's cab.
2. Disconnect hose (1).

Adjusting
a The self pressure reducing valve cannot be
adjusted.
3. Install oil pressure pickup adapter N2 and

connect the disconnected hose again.
4. Attach nipple [1] of hydraulic tester N1 and
connect it to oil pressure gauge [2].
a Use an oil pressure gauge with the capacity
of 6 MPa {60 kg/cm2}.
30-64 D65EX,PX,WX-17
Hydraulic system
Measuring PPC valve output pressure

a Measuring tools for PPC valve output pressure
Sym-
Part No. Part name
bol
1
O 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)

the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the LOCK
position.
a Before measuring the PPC valve output

pressure, check that the source pressure in the
control circuit is normal.
a Measure the PPC valve output pressure under
the following condition.
range
Testing
1. Remove the control valve cover from the right
side of the operator's cab.
2. Disconnect PPC valve output hose (1).
a For the circuit to be tested, see the drawing
on the next page.
5. Start the engine and set the work equipment

lock lever in the FREE position.
6. Run the engine at full speed, operate the control
lever of the circuit to be tested, and measure the
oil pressure.
a When measuring, set the lever to the stroke
3. Install oil pressure pickup adapter O2 and
end.
connect the disconnected hose again.
4. Attach nipple [1] of hydraulic tester O1 and a On the blade lowering side, operate the lever
connect it to oil pressure gauge [2]. to the FLOAT position.
D65EX,PX,WX-17 30-65
Hydraulic system

30-66 D65EX,PX,WX-17
Hydraulic system
1. Main valve
3. PPC lock valve
4. Blade PPC valve
5. Ripper PPC valve (if equipped)
A. Blade LEFT tilt
B. Blade LOWER
C. Ripper RAISE
D. Ripper LOWER
E. Blade RAISE
F. Blade RIGHT tilt
D65EX,PX,WX-17 30-67
Hydraulic system
Adjusting play of work equipment PPC valve

Adjusting
Biaxial PPC valve
(Hatched area R cannot be disassembled)
k Place the machine on a 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 position.
a If play at the blade control lever end is excessive, adjust the PPC valve according to the following
procedure.
a The ripper valve cannot be adjusted.
30-68 D65EX,PX,WX-17
Hydraulic system
1. Check the play in directions of ports P3 and • Check the clearance in the direction of
P4 port P1 (full stroke)
Check play x of the lever in NEUTRAL at the y: 0.03 to 0.3 mm
position 240 mm away from lever rotation center. 4) Tighten nut (3).
x: Max. 24 mm
a Fix disc (4) and tighten nut (3).
a If out of the standard range, replace joint (1)
3 Nut (3):
since it may be worn.
Replacement procedure of joint (1) 93.1 to 112.7 Nm {9.5 to 11.5 kgm}
1) Remove boot (2), nut (3), disc (4), and nut 3. Applying grease
(5). 1) Apply grease to the sliding parts of joint (1)
2) Replace joint (1). and to the contact surfaces on disc (4) and
piston (6).
a Install joint (1) to valve body (7) according
to the following procedure. 2 : Grease (G2-LI)
1] Thoroughly degrease and dry the threads 2) Amount of grease
of the joint and body. 1] Sliding parts of joint (1): 7 to 10 ml /all
2] Apply one drop (approximately 0.02 g) of around
LOCTITE (No. 262) each to two places at 2] Contact parts of disc (4) and piston (6)
distance (a) from the end of the body (4 places): 0.3 to 0.8 ml /place
screw hole. 4. Install boot (2).
a
• Distance (a): 5 to 7 mm
3 Joint (1):
39 to 49 Nm {4 to 5 kgm}
3) Install nut (5) and disc (4).
a Be careful of the direction of disc (4)
when installing it.
(Note the shape at Q)
4) Install nut (3).
2. Adjusting play at lever end
1) Remove boot (2) and nut (3).
2) Screw in disc (4) and tighten nut (3) lightly.
a Be careful of the direction of disc (4)
when installing it.
(Note the shape at Q)
3) Check the play at the lever end.
• Check the play in directions of ports
P3 and P4
Check play x of the lever in neutral at the
position 240 mm away from lever rotation
center.
x: 0.6 to 3.6 mm
D65EX,PX,WX-17 30-69
Hydraulic system
Isolating the parts causing hydraulic drift in blade and ripper

a When the hydraulic drift of the blade or ripper
occurs, check if the cause for the drift is in the
cylinder packing or in the control valve according
Testing
1. Set the cylinder to be inspected to the following
posture, then stop the engine.
1) Blade lift cylinder
Push the blade against the ground to raise
the front of the machine.
a Do not extend the blade lift cylinder rod to
the stroke end since it is equipped with 2. Turn the starting switch to the ON position and
the piston valve. set the work equipment lock lever in the FREE
position.
3. Operate the control lever in the direction to
extend the cylinder rod, and check the
movement of the cylinder.
• When the lowering speed is increased at this
time, the cylinder packing is defective.
• When the lowering speed does not change
at this time, the control valve is defective.
a When there is no more pressure in the
accumulator, run the engine at low idle for
approximately 10 seconds to charge the
accumulator.
[Reference] Reasons why the lowering speed is
2) Blade tilt cylinder
increased by the above operation when the cylinder
Retract the tilt cylinder rod fully, then push
packing is the cause of the hydraulic drift:
the blade against the ground to raise the right
side of the machine. 1. When the machine is set in the above posture
(where the holding pressure is applied to the
bottom side), the oil leaks from the bottom side
to the head side. Since the volume on the head
side is less than that on the bottom side by the
volume of the rod, the pressure in the head side
is increased by the oil flowing in from the bottom
side.
2. As the internal pressure on the head side
increases, both pressures come to balance at a
certain level of pressure (depending on leakage),
and the lowering speed becomes slower.
3. If the circuit on the head side is opened to the
drain circuit by the above operation of the lever
3) Ripper lift cylinder (the bottom side is closed by the check valve at
Push the ripper against the ground to raise this time), the oil in the head side flows in the
the rear of the machine. drain circuit. As a result, the pressure is
inbalanced and the lowering speed is increased.
30-70 D65EX,PX,WX-17
Hydraulic system
Measure internal oil leakage of work equipment cylinder

a Testing tools for internal oil leakage of work
equipment cylinder
Symbol Part No. Part name
Commercially Measuring cylinder
P
available

lower the work equipment and set firmly on
the ground, then set the parking brake lever
and work equipment lock lever to the LOCK
position.
Testing
a Test for oil leakage inside the hydraulic cylinder
under the following conditions.
a The blade lift cylinder and the blade angle
cylinder (for power angle tilt dozer) have a built-
in piston valve, so the internal leakage cannot
be measured.
1. Fully extend the cylinder to be tested, and set to
the test posture.
1) Blade tilt cylinder
Lower the blade end to the ground.
2) Ripper lift cylinder 3. Run the engine at full speed and apply the relief
Pull out the shank pin and lower the ripper to pressure to the bottom side of the cylinder.
the end. • Blade tilt cylinder: LEFT tilt operation
2. Disconnect hoses (1) and (2) on the head side • Ripper lift cylinder: LOWER operation
for the cylinder to be tested and plug the control 4. After 30 seconds have elapsed, measure the
valve side. amount of leakage for 1 minute by using
measuring cylinder P.
a When checking the blade tilt cylinder hoses,
remove piping cover (3) from the frame.
k Take care not to disconnect the hose on the a Bleed air from the cylinder circuit by referring
bottom side. to "Bleeding air from work equipment
cylinders".
• Hose (1): Blade tilt cylinder
Plug: 07376-70315 (#03 size)
O-ring: 02896-11009 (#03 size)
• Hose (2): Ripper lift cylinder

Plug: 07376-70522 (#05 size)
O-ring: 02896-11015 (#05 size)
D65EX,PX,WX-17 30-71
Hydraulic system
Checking fan speed

lower the work equipment and set firmly on
the ground, then set the parking brake lever
and work equipment lock lever to the LOCK
position.
a Check the fan motor speed under the following

condition.
• Hydraulic oil temperature: min. 45 °C
Testing
1. Start the engine and switch the machine monitor
to the "Adjustment" function display of the
service mode.
a Adjustment code: 1005 (fan 100% mode)
a When this adjustment code is displayed, the
fan speed is kept at 100% speed in
accordance with the engine speed,
regardless of the state of the machine.
a When using this adjustment code, keep the
hydraulic oil temperature above 45 °C. If the
hydraulic oil temperature becomes lower
than 40 °C , the fan speed will fluctuate.
2. While running the engine at low idle and high

idle, measure the fan speed
30-72 D65EX,PX,WX-17
Hydraulic system
Measuring fan circuit oil pressure

a Testing tools for fan circuit oil pressure k Make sure to close the radiator mask before
Sym- starting the engine. Do not start the engine
Part No. Part name with the radiator mask opened.
bol
799-101-5002 Hydraulic tester 6. Start the engine and switch the machine monitor
1
790-261-1204 Digital hydraulic tester to the "Adjustment" function display of the
R 2 799-401-3400 Adapter (05) service mode.
799-101-5220 Nipple (10 x 1.25)
3 a Adjustment code: 1005 (fan 100% mode)
07002-11023 O-ring
k Place the machine on a level ground and functions of machine monitor (EMMS)".
a If this adjustment code is displayed, the fan
speed is kept at 100% speed in accordance
with the engine speed, regardless of the
a Measure the fan circuit pressure under the state of the machine.
following condition. a When using this adjustment code, keep the
• Hydraulic oil temperature: min. 45 °C hydraulic oil temperature above 45 °C . If the
hydraulic oil temperature becomes lower
Testing than 40 °C ,the fan speed will fluctuate.
1. Open the radiator mask and remove the fan net.
2. Disconnect supply hose (1) from the fan motor.
7. While running the engine at high idle, measure

the fan circuit oil pressure.
3. Install adapter R2 and connect the disconnected
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}.

5. Close the radiator mask.
D65EX,PX,WX-17 30-73
Hydraulic system
Bleeding air from hydraulic circuit

Bleeding air a Remove operator's seat (1) and move it
1. Bleeding air from fan pump toward the dashboard.
1) Remove the bottom cover from the
a If the fan pump is removed and installed or its operator's seat.
piping is disconnected and connected, bleed 2) Loosen air bleeder (3) of HSS pump (2) and
air from the pump case according to the leave it for 15 minutes.
following procedure.
a Before bleeding air, check that the hydraulic
oil level is proper.
a Remove operator's seat (1) and move it
toward the dashboard.
1) Remove the bottom cover from the
operator's seat.
2) Loosen air bleeder (3) of fan pump (2) and
leave it for 15 minutes.
3) After 15 minutes, start the engine and run it

at low idle.
4) Steer alternately to right and left two or three
times.
5) After oil oozes out, tighten air bleeder (3).
3 Bleeder:
8.8 ± 1.0 Nm {0.9 ± 0.1 kgm}
3. Bleeding air from work equipment cylinders
a If the work equipment cylinder was removed
3) After 15 minutes, start the engine and run it and installed or its piping was disconnected
at low idle. and connected, bleed air from its circuit
4) After oil oozes out, tighten air bleeder (3). according to the following procedure.
3 Bleeder: a Before bleeding air, check that the hydraulic
8.8 ± 1.0 Nm {0.9 ± 0.1 kgm} oil level is proper.
2. Bleeding air from HSS pump 1) Start the engine and run it at low idle for
a If the HSS pump is removed and installed or approximately 5 minutes.
its piping is disconnected and connected, 2) Running the engine at low idle, extend and
bleed air from the pump case according to retract the cylinder to be bled 4 to 5 times.
the following procedure. a Stop the piston about 100 mm before the
a Before bleeding air, check that the hydraulic ends of the stroke. Never operate it to the
oil level is proper. relief position.
3) Running the engine at high idle and carry out
the operation in Step 2.
30-74 D65EX,PX,WX-17
Hydraulic system
4) Running the engine at low idle, move the

cylinder to the stroke end to relieve the oil.
D65EX,PX,WX-17 30-75
Work equipment
Work equipment
Adjusting work equipment lock lever
k Place the machine on a level ground and lower the work equipment to the ground, then set the
parking brake lever and work equipment lock lever to the LOCK 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.
Adjusting
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.
3. Set work equipment lock lever (1) in the FREE
position and check that limit switch (2) operates
normally.
• Stroke of limit switch: 2.5 to 3 mm
4. Turn the starting switch ON and set the machine 5. Check that the limit switch signal is input
monitor to "Monitoring" function of the service normally when work equipment lock lever (1) is
mode. set in the FREE position and LOCK position.
a Monitoring code: • FREE position:
70300 Blade Sw Input Work equipment lock NC ON, Work
equipment lock NO OFF
a For the operating method, see "Special • LOCK position:
functions of machine monitor (EMMS)" Work equipment lock NC OFF, Work
section. equipment lock NO ON
30-76 D65EX,PX,WX-17
Work equipment
Adjustment of straight tilt dozer

a When the blade has been removed and 2. Adjusting with shims when assembling the
reinstalled or disassembled and reassembled, blade
make adjustments according to the following 1) After assembling the blade, make
procedures. adjustments at tilt joint (3), center joint (4), lift
Adjusting joint (5) and trunnion joint (6) by using shims.
1. Adjusting blade tilt Adjust shim Unit: mm

Adjustment location
1) After the blade is installed, adjust brace (1)
Trun-
mounting dimension A by using handle (2). Tilt joint Center Lift joint
nion
• Brace mounting dimension A (3) joint (4) (5)
joint (6)
PX EX Clear- a c
b d
A (mm) 1,150 1,150 ance
Standard
clearance 0.2 to 0.2 to 0.2 to 0.2 to
Item
(note) 0.7 0.7 0.7 1.2
Standard
shim 5 5 4 10
thickness
Note: Play in axial direction of ball at
spherical portion
2) Lubricate each adjustment points and check
for smooth rotation.
2 Adjustment points (3), (4), (5):
Grease (G2-T)
2) Check LEFT and RIGHT tilt B1 and B2.

PX EX
RIGHT tilt
Approx. 430 Approx. 440
B1(mm)
LEFT tilt
Approx. 430 Approx. 440
B2(mm)
3) If the tilt is not the same on the left and right
sides, adjust brace (1) mounting dimension
A according to the following procedure.
• B1 > B2: Carry out fine adjustments to
make mounting dimension A longer.
• B1 < B2: Carry out fine adjustments to 3. Adjusting center braces
make mounting dimension A shorter. a Adjust the length of center braces according
1) Adjust clearance b of ball joint (7) using
shims (8).
• Clearance b: 0.2 to 0.5 mm
2) Loosen bolt (9).
3) Operate the blade control lever to put the
blade in floating state.
k After this operation, securely lock the

blade control lever with the safety lever.
4) Insert a bar in the hole of center brace (10),
and turn it in the direction that lets the brace
become taut.
a Torque to adjust the length of center
brace (10)
D65EX,PX,WX-17 30-77
Work equipment
3 Center brace:
24.5 to 49 Nm {2.5 to 5 kgm}
5) Center brace (10) mounting dimension

Standard length C
PX EX
C (mm) 991.5 990.5
a Make adjustments so that clearance e

between the track and frame becomes
the same at both sides.
30-78 D65EX,PX,WX-17

Adjusting operator's cab
a If the operator's cab has been removed and 7) Fix hose [1] to the outside of cab with tape,
reinstalled, or transported in the disassembled and confirm that the water level is at the
condition and locally assembled, inspect and same height at both sides.
adjust the operator's cab according to the
following procedures.
testing
1. Testing pressure in cab
a Criteria
Criteria: Measured value X 68.6 Pa {7
mmH2O}
a Testing conditions
• Engine speed: high idle
• Fan speed: fan 100% mode
• Air conditioner FRESH/RECIRC setting:
FRESH 8) Start the engine and switch the machine
• Air-conditioner fan setting: high (full monitor to the "Adjustment" function display
speed) of the service mode.
1) Prepare a transparent vinyl hose. a Adjustment code: 1005 (Fan 100% mode)
• Outside diameter: 6 mm a For the operating method, see "Special
Length: 3,000 mm functions of machine monitor (EMMS)"
2) Secure the end of the hose inside the cab to section.
the top of the backrest with tape.
3) Remove bolt (1) (for harness grounding) from
the rear of left console box, insert the other
end of the hose through the bolt hole, and
then pull the hose end out from inside of the
battery cover at the left side of cab.
9) Run the engine at high idle and measure the

water level difference (c) in hose [1].
• (a): Inside cab (pressurized)
• (b): Outside cab (ambient pressure)
• (c): Measured value (pressure inside cab)
4) Seal the clearance between bolt (2) hole and a If the measured value (pressure inside
hose [1] with tape (3) or the like. cab) does not meet the judgement criteria,
5) Connect ground terminal (2) which has been check the seals at wiring harness feed-
disconnected in step 3 to the adjacent throughs and accessory mounting holes
ground terminal (4) (closer front side of in the cab.
vehicle) together with the original grounding Note) After finishing the test, restore the ground
at terminal (4). (This is a temporal connection terminal.
made to enable the air conditioner to 2. Testing and adjusting door locks (damper
operate.) rubbers)
6) Pour water in hose [1] up to approximately a Close the doors and check the relationship
half of the length, and bend the hose in a "U" between the cab and doors (damper rubbers).
shape. If there is any fault, make adjustments.
D65EX,PX,WX-17 30-79
Testing Testing
1) Stick a piece of sealing tape [2] to the 1) While moving door (5) in the closing direction,
contacting surface of damper rubber (6) on check the engaging condition of latch (8) and
door (5). striker (9).
a Two places each at both sides. a Check deviation (f) of latch center (d) and
2) Open and close door (5) two to three times. striker center (e) from each other.
3) Check the contact between sealing tape [2] • Normal: Deviation (f) is 0.5 mm or less.
and the cab.
• Normal:
When the door is closed, they come in
contact lightly (adjustment not needed)
• Abnormal:
When the door is closed, they do not
come in contact at all or contacts heavily
enough to peel the seal tape (adjustment
needed)
Adjusting
1) Temporarily tighten the mounting bolts of
striker (9), open and close door (5) two to
three times in order to align latch (8) with
striker (9).
2) Check the engaging condition of latch (8)
and striker (9).
3) Tighten the mounting bolts of striker (9) to the
specified torque.
Adjusting 4) Open and close door (5), and check if door
1) Loosen the mounting bolt of damper rubber can be smoothly unlocked.
(6).
a If the door is not unlocked smoothly (knob
a The shim can be removed or installed is heavy), perform the adjustment
without removing the mounting bolt. procedure from the first.
2) Increase or decrease the number of shims
a Operating effort of door knob: 53.9 ± 19.6
(7) installed under damper rubber (6) to
N {5.5 ± 2 kg}
properly adjust the height of damper rubber
5) Apply grease to latch (8).
(6).
• If latch (6) runs out of grease, the knob
becomes heavy. Apply plenty of grease.
2 Latch:
Grease(G2-LI)
4. Testing and adjusting open locks (latches
and strikers)
a With the doors at the open-locked state
(locked open), check the relationship
between the cab and doors (latches and
strikers). If there is any fault, make
adjustments.
Testing
3. Testing and adjusting door locks (latches 1) Check the relationship between the open
and strikers) lock latch and striker from the direction of B.
a Close the doors and check the relationship a While moving the door in the opening
between the cab and doors (latches and direction, check the engaging condition of
strikers). If there is any fault, make the latch and striker.
adjustments.
30-80 D65EX,PX,WX-17
2) Check that striker (10) is not inclined against 5) Adjust the height of stopper rubbers (12) and
latch (11). (13) as necessary.
3) Check that striker (10) and latch (11) are not
a If there is any play, project (raise) the
misaligned.
stopper rubber until the play is eliminated.
• Normal: Deviation is 0.5 mm or less
Adjusting a If the door is not locked easily or the
1) Loosen the mounting bolts of striker (10). unlock lever is heavy, return (lower)
2) Adjust striker (10) to eliminate inclination and stopper rubber within the range that the
then tighten the mounting bolts. door does not have any play.
6) While holding stopper rubbers (12) and (13),
tighten the lock nuts.
5. Testing and adjusting open locks (damper

rubbers)
a With the doors at the open-locked state
(locked open), check the relationship
between the cab and doors (stopper rubbers).
If there is any fault, make adjustments.
1) Lock the door open and shake it in the
forward and reverse directions to see if it has
any play.
a Two places each at both sides.
2) Check that the operating effort of unlock
lever is not heavy.
3) Loosen lock nut of stopper rubber (12)
(upper).
4) Loosen lock nut of stopper rubber (13)
(lower).
D65EX,PX,WX-17 30-81
Adjusting play of blade center ball

a When the blade is reassembled after 8. Tighten mounting bolts (2)and (3).
disassembled, or transported in the
3 Cap mounting bolt:
disassembled condition, adjust the play of the
center ball according to the following procedure. 785 to 980 Nm {80 to 100 kgm}
Adjusting
1. Install cap(1) and tighten mounting bolts (2) and
(3) without inserting any shim.
2. Measure clearance (a) between cap (1) and
blade (4).
3. Calculate the thickness of shims (5) to be
inserted from measured clearance (a), and then
select shims to be used.
• Thickness of shims to be inserted =
(Measured clearance (a)) + (0.5 mm)
• Available shim thicknesses: 0.5 mm, 1.0 mm
• Standard shim thickness (Reference):
8 mm (2 pieces of 0.5 mm shim and 7
pieces of 1.0 mm shim)
4. Loosen mounting bolt (2) and remove mounting

bolt (3).
5. Insert selected shims (5).
6. Tighten the mounting bolts (2) and (3) lightly.
7. Angle and tilt the blade, and check that no
unusual noise is heard and the blade moves
smoothly.
a If the blade does not move smoothly or
unusual noise is heard, return to Step 2 and
select shims (5) again.
30-82 D65EX,PX,WX-17
Electrical system
Electrical system
Special functions of machine monitor
For machine equipped with air conditioner
D65EX,PX,WX-17 30-83
Electrical system
Upper part of machine monitor (display portion) Lower part of machine monitor (switch portion)
(a): Multi-information display [1]: Numeral 1 input switch/Operation mode selector
switch
a The figure shows an example of display of
symbols and gauges in the ordinary display [2]: Numeral 2 input switch/Gearshift mode selector
mode (The contents of display depend on the switch
condition of the machine and operating method). [3]: Numeral 3 input switch/Customize switch
a When the engine is started, the battery voltage [4]: Numeral 4 input switch/Buzzer cancel switch
may lower suddenly, depending on the ambient [5]: Numeral 5 input switch
temperature and the condition of the battery. [6]: Numeral 6 input switch/Reverse slow mode
In this case, the display of the machine monitor switch
goes out for a moment. This phenomenon is not [7]: Numeral 7 input switch/Air conditioner switch
a failure, however.
[8]: Numeral 8 input switch/Air conditioner switch
Upper part of machine monitor (switch portion)
[F1]: F1 function switch
Switch having no numerals Air conditioner switch
[F3]: F3 function switch a Each switch has the function indicated by the
icon on it and the function of inputting a numeral.
[F5]: F5 function switch a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of the multi-
a The function of each function switch is indicated information display (a).
by the icon in multi-information display (a) above
each function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.
30-84 D65EX,PX,WX-17
Electrical system
Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function 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
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information 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 function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
Operator mode (Outline) Service mode

A Display of KOMATSU logo 01 Monitoring / Pre-defined
A Display of password input 02 Monitoring

Mechanical systems
A Display of "Check before starting" abnormality record
03 Abnormality
Display of warning after "Check before record Electrical systems abnormality
A starting"
record
A Display of maintenance time overdue 04 Maintenance record
A Display of check of preset 05 Maintenance mode setting
A Display of standard screen 06 Phone number entry
A Display of end screen Key-on mode
Display of engine shutdown secondary
A switch operation screen 07 Default Unit
B Selection of operation mode Camera
B Selection of gear shift mode (Special Cylinder cut-out
opera- 08 Diagnostic Regeneration for service
B Selection of reverse slow mode
tion) tests
B Operation of customizing o
KDPF memory reset
B Operation of customize memory 09 Adjustment
B Operation to cancel alarm buzzer 10 No injection
B Operation of air conditioner Terminal status
Operation to display camera mode (if 11 KOMTRAX
B camera is installed) GPS & communication status
settings
Operation to display clock and service
B Modem status
meter
B Checking of maintenance information 12 Service message
Setting and display of user mode
B
(including KOMTRAX messages for user)
C Display of ECO guidance
C Display of alarm monitor
C Display of KDPF regeneration
C Display of action level and failure code
O (Special operation)
D Checking LCD (Liquid Crystal Display)
D Checking service meter
Usage limitation setting / maintenance
D password changing function
D65EX,PX,WX-17 30-85
Electrical system
a Classification of operator mode

A: Display or function that is indicated or enabled from the time when the starting switch is turned to the
ON position to the time when display changes to the standard screen, and display after starting switch is
turned to the OFF position
B: Display or function when the machine monitor switch is operated
C: Display or function when certain condition is met
D: Display or function when operation of special switches is required
30-86 D65EX,PX,WX-17
Electrical system
Operator mode (outline) a Display pattern of operator mode

a Only outline of the operator mode is described in The contents of display from the time when
this section. starting switch is turned ON to time when screen
changes to ordinary screen depends on the
For details of contents and operations of each
setting and condition of the machine.
function and display, see "Structure and function
standard", or the "Operation and Maintenance a: When engine start lock is enabled
Manual". b: When engine start lock is disabled
a The following are the displays or functions of the c: When there is abnormal item in "Check before
operator mode explained in this section starting" items
(including some items which need special d: When there is maintenance item which is near
operations). specified time or overdue
Display
pattern
a b c d
Display of KOMATSU logo 1 1 1 1
Display of password input 2 – – –
Display of "Check before starting" 3 2 2 2
Display of warning after "Check
– – 3 –
before starting"
Display of maintenance time – – – 3
overdue
Display of check of preset 4 4 4 4
Display of standard screen 5 4 5 5
Display of engine shutdown secondary switch
operation screen
Selection of gear shift mode
Selection of reverse slow mode
Operation of customizing
Operation to cancel alarm buzzer
Operation of air conditioner
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Checking maintenance information
Setting and display of user mode
(including KOMTRAX messages for user)
Display of alarm monitor
O (Special operation)
Checking LCD (Liquid Crystal Display)
Checking service meter
Usage limitation setting/maintenance password
changing function
D65EX,PX,WX-17 30-87
Electrical system
Display of KOMATSU logo a If this screen is displayed, call the person

When starting switch is turned to ON position, responsible for the operation of KOMTRAX in
KOMATSU logo is displayed for 2 seconds. your Komatsu distributor and ask for remedy.
a After the KOMATSU logo screen is displayed for
2 seconds, the screen changes to "Password
input" screen, or "Check before starting" screen.
Display of "Check before starting"

When the screen changes to the check before
starting screen, the check before starting is
performed for 2 seconds.
Display of inputting password
After the KOMATSU logo screen is displayed, the a If any abnormalities are detected in the check
screen to input the engine start lock password is before starting, the screen changes to "Warning
displayed. after the check before starting" screen or
"Overdue Maintenance" screen.
a This screen is displayed only when the engine
start lock function is enabled. a If no abnormality is detected by the check before
starting, the screen changes to "Display of
a If correct password is input, the screen changes
check of preset".
to "Check before starting" screen.
a The monitors (3 monitors) on the screen shows
a The machine monitor has some password
the items currently subjected to the check before
protect functions other than the engine start lock.
starting.
Those functions are independent from one
another.
Display of warning after Check before starting

a The following screen may be displayed instead If any abnormalities are detected in the check
of the above "Password input" screen. before starting, the alarm monitor is displayed on
the screen.
a The following figure shows that the water
separator monitor (a) is warning of water
accumulated in the water separator.
30-88 D65EX,PX,WX-17
Electrical system
Display of maintenance time overdue Display of standard screen

If the check before starting detected a maintenance If the machine monitor starts normally, the ordinary
item that is near or overdue the set interval, the screen is displayed.
maintenance monitor is displayed for 30 seconds to
a Service meter (a) or a clock is displayed at the
urge the operator to perform maintenance.
center upper section of the screen (use [F4] to
a This screen is displayed only when the switch the display between the service meter
maintenance function is enabled. and clock).
If the remaining time of any item is 30 hours or a Engine speed (b) is displayed on the multi-
less, the yellow icon is displayed. If the gauge (The switching of the display is made with
remaining time of any item is 0 hour or less, the [F2]).
red icon is displayed.
a ECO gauge (c) is displayed at the right end of
a The maintenance function is enabled or disabled the screen (The switching of the display is made
by using the machine monitor in the service in user mode).
mode. After this screen display is finished, the
screen changes to the standard screen.

When starting switch is turned to OFF position, the
Display of check of preset end screen is displayed for 5 seconds.
If the check before starting is finished normally, the
screen to check the preset (gear speed at start) is a Another message may be displayed on the end
displayed for 2 seconds. screen due to the message display function of
KOMTRAX.
a After the display of check of preset is finished,
the screen changes to the standard screen.
D65EX,PX,WX-17 30-89
Electrical system
Display of engine shutdown secondary switch Selection of gear shift mode

screen When the gear shift mode selector switch is pressed
Turning on the secondary engine stop switch while the standard screen is displayed, the gear
displays the "Secondary Engine Stop Switch in shift mode monitor (a) in the gear speed display
Operation" screen on every screen except the end section changes.
screen.
a Each time the switch is pressed, the gear shift
a Secondary engine stop switch is provided in the mode changes between [Automatic gear shift]
lower left side corner of the operator's seat. It is and [Manual gear shift].
used when you cannot stop the engine by
turning the starting switch to the OFF position. a When dozing (automatic gear shift) is selected,
an AUTO symbol (b) is also displayed at the
gear speed display area.
If you turn OFF the secondary engine stop switch,

the KOMATSU logo mark appears once and then
the standard screen is restored. Selection of reverse slow mode
When the reverse slow mode switch is pressed
while the standard screen is displayed, the reverse
When the operation mode selector switch is
slow mode monitor (a) is displayed.
pressed while the standard screen is displayed, the
operation mode monitor (a) changes.
a Each time the switch is pressed, the operation
mode changes between [P (Power)] and [E
(Economy)].
30-90 D65EX,PX,WX-17
Electrical system
a Each time the reverse slow mode switch is Operation to cancel alarm buzzer
pressed, the status switches between [Reverse While the alarm buzzer is sounding, When the
Slow Mode ON] and [Reverse Slow Mode OFF]. buzzer cancel switch is pressed, the alarm buzzer
stops.
a Even if the buzzer cancel switch is pressed, the
display on the screen does not change.
Operation of air conditioner/heater

While the standard screen is displayed, if the air
conditioner switch is pressed, "Air-conditioner
Adjustment" screen is displayed.
a While "Air-conditioner Adjustment" screen is
displayed, if you do not touch any switch for 5
seconds, the screen changes to the standard
screen.
Operation of customizing
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.
Operating to display camera mode

When a camera is installed, the multi-display
changes to the camera image by pressing [F3].
a Set the connection of the camera in the service
mode.

By operating the customize switch and selecting F1
"LOAD" when the standard screen is displayed, and
you can select the recorded customized setting.
D65EX,PX,WX-17 30-91
Electrical system
a Up to 3 cameras can be connected. If the a The time adjustment, 12-hour or 24-hour display
camera mode is selected, however, only the setting, and summer time setting of the clock are
image of camera 1 is always displayed. made with user mode functions.
a Display of service meter
a If a caution is generated in the camera mode,

the caution monitor is displayed at the left upper
a Display of clock
of the screen.
a If an "action level present" error occurs in the Checking maintenance information

camera mode and the machine stops for more You can check the maintenance information on the
than 10 seconds, the screen changes to the maintenance screen by pressing [F6] while the
standard screen and displays the error maintenance monitor is displayed. When the
information. maintenance monitor does not displayed, press [F6]
and then press [F1] or [F2] to switch to the
a When two or more cameras are connected, the maintenance screen.
image of one of them or the images of two of
them can be displayed.
a If 2-camera image display is selected with [F4],
the image of camera 1 is displayed on the left
side of the screen and the image of camera 2 is
displayed on the right side. The image of camera
3 is displayed only singly.
a If 2-camera image display operation is made, the
images are displayed frame by frame at intervals
of approximately one second on the right and left
side of the screen.
Operation to display clock and service meter

When [F4] is pressed while the standard screen is a To reset the time left after finishing maintenance,
displayed, the display at section (a) is alternately more operations are necessary.
switched between service meter and clock.
30-92 D65EX,PX,WX-17
Electrical system
• For user:
It denotes the messages transmitted from the
KOMTRAX base station to users. Upon
receiving a message, the message monitor is
displayed on the standard screen. Operate this
"Check mail" when viewing contents of a
message.
• For technician:
It denotes the messages transmitted to the
technicians from the KOMTRAX base station.
Even if it is received, no sign is displayed in the
standard screen. To view contents of a message,
operate "Display service message" of the
Setting and display of user mode (including service menu in the service mode.
KOMTRAX messages for user)
To enter the user mode, press [F6] to display the
When the machine is set in a certain operating
"User Menu" screen while the standard screen is
condition, the ECO Guidance screen is displayed
displayed.
automatically to urge the operator to perform
energy-saving operation.
a "ECO Guidance" screen is displayed when the
following conditions are met while this display
function is set to enabled in operator mode.
Conditions for display
• Idle stop guidance
When no lever is operated for a period of at least
5 minutes and the engine keeps running at idle
during this period, the guidance on idle stop is
displayed on the monitor. This function helps
reduce unnecessary fuel consumption by
alerting the operator to stop the engine while
a There are following items in the user menu. waiting for the next operation, or during a break.
ECO Guidance a The lamp for the idle stop guidance goes out
Machine setting automatically when the lever operation is
KDPF regeneration resumed, or if the function switch [F5] is
pressed.
Maintenance
Monitor setting a Idle stop guidance is displayed when the
Check mail engine coolant temperature is 30 °C or
higher and the hydraulic oil temperature is 20
(Example of ECO guidance) °C or higher.
[KOMTRAX message] • Guidance on deterrence of hydraulic relief

• There are two types of KOMTRAX message; If relieving lasts for 10 or more seconds during
one is for the user and the other is for the operation, guidance on deterrence of hydraulic
technician. relief is displayed on the monitor.
D65EX,PX,WX-17 30-93
Electrical system
a The lamp for the guidance on deterrence of

hydraulic relief goes out automatically after 5
seconds has passed since it appeared, or if
the function switch [F5] is pressed.
a Guidance on deterrence of hydraulic relief is
displayed when the engine coolant
temperature is 30 °C or higher and the
hydraulic oil temperature is 20 °C or higher.
• Auto shift mode recommendation guidance

If the machine is operated in manual gear shift
mode for more than an hour, the auto shift mode
(recommended) guidance is displayed on the
monitor. During normal dozing work, the
optimum gear speed is selected in the automatic
shift mode to reduce fuel consumption.
a The auto shift mode (recommended)
guidance goes out automatically after 5
• E-mode recommendation guidance
When light-load work continues for 10 or more
minutes in P-mode, E-mode recommendation
guidance is displayed. This function helps
reduce unnecessary fuel consumption in light-
load work by alerting the operator to switch to E-
mode.
a The lamp for the E-mode recommendation
guidance goes out automatically after 5
Display of alarm monitor

If an error that is serious enough to display Action
Level "L01" alarm monitor on the standard screen or
camera mode screen occurs, a large alarm monitor
is displayed on the screen once and is continuously
shown in window (a).
a On the camera mode screen, the alarm monitor
flashes at the left upper of the screen when the
• Guidance on deterrence of overload caution is generated.
If too much load is applied to the machine during
work, overload deterrence guidance is displayed
on the monitor. Fuel consumption can be
reduced by operating the machine carefully to
avoid shoe slipping and keep the eco gauge
indication in the green zone.
a The overload deterrence guidance goes out
automatically after 5 seconds has passed
since it appeared, or if the function switch
[F5] is pressed.
30-94 D65EX,PX,WX-17
Electrical system
period of time, the regeneration may be

performed to protect the KDPF system,
regardless of the accumulated soot.
If an error serious enough to display an alarm

monitor of Action Level [L02], [L03], or [L04] occurs,
the alarm monitor is displayed at the center of the
monitor screen until the error is eliminated. During the KDPF regeneration, KDPF
regeneration monitor (1) lights up in the standard
screen.
a Even if KDPF regeneration monitor (1) lights
up, the machine does not need to be stopped
and the operator can continue work normally,
as long as the alarm monitor is not displayed
at the center of the standard screen.

1. KDPF regeneration
k During the KDPF regeneration, the exhaust

temperature may become higher than that of
conventional models. To prevent being burnt,
do not stand near the exhaust pipe. In
addition, to prevent a fire, do not bring any The KDPF regeneration is performed
combustible matter near the exhaust pipe automatically in the normal state, but the soot
outlet. may not be burnt or the filtering function may not
be recovered sufficiently, depending on the
k If there is a thatched roof, dead leaves, paper, operating condition. Since KDPF soot
or other combustible matter near the accumulation monitor (2) lights up in this case,
machine, set KDPF regeneration to stop to stop the machine in a safe place and perform
prevent a fire caused by the high- the manual stationary regeneration process. For
temperature exhaust gas during the KDPF the execution procedure, see the Operation and
regeneration. For the setting procedure, see Maintenance Manual.
the Operation and Maintenance Manual.
KDPF (Komatsu Diesel Particulate Filter) is a
device used to capture soot in exhaust gas and
purify the gas. If any soot has accumulated to a
certain level inside the filter, it is burnt
automatically to keep the KDPF performance
high. This purification process is called
"regeneration".
If an operation that may lower the filtering
function of the KDPF has continued for a long
D65EX,PX,WX-17 30-95
Electrical system
position or the travel lever is set in NEUTRAL,

the "KDPF Regeneration" screen is
displayed after 3 seconds for only the first
time. However, if manual stationary
regeneration operation is not performed, the
screen returns to the standard screen after
30 seconds.
2. Manual stationary regeneration

There are 2 levels of monitor displays to request
the manual stationary regeneration, depending
on the degree of emergency.
k If the work is continued while the red KDPF

soot accumulation monitor (2) is displayed,
the KDPF or engine may encounter a
problem. If KDPF soot accumulation monitor
(2) lights up, be sure to perform the manual
stationary regeneration process.
1) When the degree of emergency is low
When KDPF soot accumulation monitor (2) is
yellow (Action Level (3): L01), the following
screen is displayed first.
a If KDPF soot accumulation monitor (2) is

yellow, stop the work, and then stop the
machine in a safe place and perform the
manual stationary regeneration process.
2) When the degree of emergency is high
k If the work is continued without

performing manual stationary
The action level goes out in 2 seconds and regeneration and the soot quantity
the following standard screen appears. exceeds the allowable limit, action level
monitor "L04" lights up and the machine
needs to be repaired.
When the travel lock lever and work

equipment lock lever are set to the LOCK
30-96 D65EX,PX,WX-17
Electrical system
a If KDPF soot accumulation monitor (2) is machine in a safe place and perform the
red, the engine maximum output and manual stationary regeneration process.
maximum speed are limited to protect the
engine and KDPF system.
If KDPF soot accumulation monitor (2) is red
(Action Level (3): L03), the following screen
is displayed.
When the travel lock lever and work

equipment lock lever are set to the LOCK
position or the travel lever is set in NEUTRAL,
the "KDPF Regeneration" screen is
displayed after 3 seconds. Then, until the
manual stationary regeneration process is
performed, the "KDPF Regeneration" screen
or the standard screen with the alarm
monitor lighted is displayed automatically
according to the position of the lever.
a If KDPF soot accumulation monitor (2)

becomes red, immediately stop the
D65EX,PX,WX-17 30-97
Electrical system

If an abnormality that displays an action level and a displayed, move to "Occurred error list" from the
failure code occurs on the standard screen or standard screen side.
camera mode screen, the alarm monitor lights up.
If the alarm monitor lights up, press function switch

[F5] to display the "Occurred error list".
[F1]: Moves to next page (screen) (if displayed)
[F2]: Moves to previous page (screen) (if displayed)
[F3]: Returns to standard screen
On the "Occurred error list" screen, the following
information is displayed.
(a): Alarm monitor
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a This screen display appears only when a
problem (failure code) for which an action level
is set occurs.
a The telephone No. is displayed only when the
telephone number is registered in the service
mode.
a If multiple abnormalities occur simultaneously, all
the codes are displayed repeatedly in order.
a Because the information of the displayed failure
code is logged in the abnormality record in the
service mode, check the details in the service
mode.
a The "Occurred error list" automatically returns to
the standard screen after 30 seconds.
a Since "Occurred error list" cannot be displayed
from the screen on which the camera mode is
30-98 D65EX,PX,WX-17
Electrical system
Remedies required to operator by displayed action levels (The following table is an excerpt from the
Operation and Maintenance Manual)
Degree of
emergen- alarm Remedy
Action level Buzzer
cy monitor
Stop immediately and perform checking and
Q
maintenance.
High L04 (Continu- Q
Ask your Komatsu distributor for testing and
ous)
repair services.
Q Stop work, move machine to safe place, stop it,
and perform checking and maintenance. Ask
L03 (Intermit- Q
your Komatsu distributor for testing and repair
tent)
services.
I Stop work, and then run the engine at medium
O Q speed with no load, or stop it.
L02 (Intermit- Q If the condition does not improve, ask your
tent) Komatsu distributor for testing and repair
services.
Some functions are restricted, but the machine
can operate.
L01
Low – Q After finishing work, perform checking and
(For 2 seconds only)
maintenance. Ask your Komatsu distributor to
perform testing or repairs as necessary.
D65EX,PX,WX-17 30-99
Electrical system
Function of checking display of LCD (Liquid

Crystal Display)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
• Switch operations (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release "F2" first.
a If there is a display error in the LCD, only that
part is indicated in black.
a To return to the former screen, press any one of
the function switches. Usage limitation setting/maintenance
password changing function
Reference: An LCD panel, as one of its Selecting the Usage Limitation Setting displays the
characteristics, sometimes shows black spots password input screen when you proceed to
(spots that remain unlit) and bright spots (spots that maintenance resetting. Observe the following
do not go off). procedure when using the Usage Limitation Setting.
If the number of the bright points and black points 1. While the ordinary screen is displayed, perform
does not exceed 10, The LCD panel is not faulty or the following operation with the numeral input
defective. switches.
• 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.
Function of checking service meter

When checking the service meter with the starting
switch in the OFF position, operate the numeral
input switches as follows to display only the service
meter section.
• Switch operations (simultaneous): [4] + [1]
a There is some time lag in start of the LCD, so 2. After the "Usage Limitation Password" screen is
hold down the switches until the service meter is displayed, input the current password using the
displayed. numeral input switches and enter it using the
function switch.
a If you release one of the switches, the monitor
• [F5]: Clears input numbers/Returns to
goes off.
standard screen
Reference: After the machine monitor is used • [F6]: Enters input password
continuously over a long period of time, blue points
(points that remain lit) may appear on this screen. It a Default password: [000000]
does not indicate that the LCD panel is faulty or a When the input password is correct, the
defective. screen changes to the next screen.
a When the input password is incorrect, the
message to request inputting the password
again is displayed.
30-100 D65EX,PX,WX-17
Electrical system
a The password for the Usage Limitation

and the engine start lock password are
not identical.
4. Changing a password
After the "Usage Limitation New Password
Input" screen is displayed, input a new
password with the numeral input switches and
enter it with the function switch.
• [F5]: Deletes input numbers/Returns the
display to the preceding screen
• [F6]: Enters input password
a Default password: [000000]
3. After the "Usage Limitation Setting" screen is
a When the input password is correct, the
displayed, select a setting using the function
screen changes to the next screen.
switch.
• [F3]: Moves to lower item a When the input password is incorrect, the
• [F4]: Moves to upper item message to request inputting the password
• [F5]: Cancels the selection and returns the again is displayed.
display to the preceding screen a Set a new password of 4 to 6 digits (If it has
• [F6]: Enters selection only 3 or less digits or has 7 or more digits, it
is not accepted).
Usage limitation ON/OFF

After the "Usage Limitation ON/OFF" screen is After the "Usage Limitation New Password
displayed, select a desired one using the Input" screen is displayed again, input the new
function switch. password again with the numeral input switches
• OFF: Password input screen is not displayed and enter it with the function switch.
• ON: Displays the password input screen • [F5]: Deletes the entered numbers/Returns
when you proceed to maintenance resetting. the standard screen
• [F3]: Moves to lower item • [F6]: Enters input password
• [F4]: Moves to upper item
• [F5]: Cancels the selection and returns the a If the input password is different from the one
display to the preceding screen input before, the message to request
• [F6]: Enters selection inputting again is displayed.
D65EX,PX,WX-17 30-101
Electrical system
If the screen to notify completion of setting is

displayed and then the ordinary screen is
displayed, the password is changed
successfully
30-102 D65EX,PX,WX-17
Electrical system
Service mode 2. Selecting service menu

To change the operator mode to the service mode, When the "Service Menu" screen is displayed,
perform the following operation. the service mode is selected. Select a service
This operation is always required when you use the menu you use by using the function switches or
service mode. numeral input switches.
• [F3]: Moves to lower item
1. Check of screen display and operation of
switches
• [F5]: Returns to standard screen (operator
While the ordinary screen is displayed, perform
mode)
the following operation with the numeral input
• [F6]: Enters the selection
switches.
• Operation of switches (While pressing [4], a If you input a 2-digit code by using the
perform the operation in order): numeral input switches, the corresponding
[4] + [1] o [2] o [3] menu is directly selected. This will allow you
to enter the selection by using [F6].
a This operation of the switches is accepted
only while the ordinary screen is displayed.
a The items which can be selected in the

service menu are as follows.
01 Monitoring / Pre-defined
02 Monitoring
Mechanical systems abnormality
03 Abnormality record
record Electrical systems abnormality
record
04 Maintenance record
05 Maintenance mode setting
06 Phone number entry
Key-on mode
07 Default Unit
Camera
Cylinder cut-out
08 Diagnostic Regeneration for service
tests
KDPF memory reset
09 Adjustment
10 No injection
Terminal status
11 KOMTRAX
settings GPS & communication status
Modem status
12 Service message
a Items with 2-digit codes are the menus

displayed on the service menu screen. The
items on their right are the menus on the next
hierarchy.
D65EX,PX,WX-17 30-103
Electrical system
Troubleshooting support
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.
In the monitoring / pre-defined, monitoring items
that are used frequently in daily work are selected
beforehand.
1. Selecting the menu
Select "01 Monitoring / Pre-defined" on the
"Service Menu" screen.
2. Checking monitoring / pre-defined

information
After the "Monitoring / Pre-defined" screen is
displayed, you can check the items displayed in
the screen by using the function switches.
• [F1]: Moves to next page (screen)
• [F2]: Moves to previous page (screen)
• [F4]: Selects hold or releasing hold
(If hold is selected, a diagonal line is
displayed on the HOLD portion)
• [F5]: Returns to Service menu screen
a You can select and check any items not
displayed in "Monitoring / Pre-defined" from
the "Monitoring items."
• See next page for list of Monitoring / Pre-

defined items.
30-104 D65EX,PX,WX-17
Electrical system
List of Monitoring / Pre-defined items

Monitoring / Pre-defined screen (1/12) Engine oil temperature and coolant temperature related items
Applicable
No. ID Item name Unit (SI)
component
1 01002 Engine speed r/min ENG
2 04107 Engine coolant temperature °C ENG
3 37212 Engine oil pressure switch OFF/ON ENG
4 18400 Intake air temperature °C ENG
5 30100 T/C (P/L) oil temperature °C P/T
6 04401 Hydraulic oil temperature °C P/T
Monitoring / Pre-defined screen (2/12) Battery related items
Applicable
component
2 03204 Battery voltage V ENG
3 04300 Battery charge voltage V ENG
Monitoring / Pre-defined screen (3/12) T/C related items
Applicable
component
2 32600 T/C average pressure MPa P/T
3 70700 Work equipment oil pressure 1 MPa P/T
Monitoring / Pre-defined screen (4/12) Hydraulic fan related items
Applicable
component
4 30100 T/C (P/L) oil temperature °C P/T
5 10007 Fan speed r/min P/T
6 31624 Fan Pump Solenoid (F/B) mA P/T
Monitoring / Pre-defined screen (5/12) Engine fuel injection related items
Applicable
component
2 47300 KDOC 1 inlet temperature °C KDPF
3 36400 Common rail pressure MPa ENG
4 36200 Rail press command MPa ENG
Monitoring / Pre-defined screen (6/12) Engine EGR and VGT related items
Applicable
component
2 48100 Turbo speed r/min ENG
3 18100 EGR valve position mm ENG
4 48600 EGR solenoid current mA ENG
5 48700 KVGT position mm ENG
6 48800 KVGT solenoid current mA ENG
Monitoring / Pre-defined screen (7/12) Engine intake temperature related items
D65EX,PX,WX-17 30-105
Electrical system
Applicable
component
5 18500 Boost air temperature °C ENG
Monitoring / Pre-defined screen (8/12) Engine intake air pressure related items
Applicable
component
3 37400 Ambient pressure kPa ENG
4 36500 Boost pressure kPa ENG
6 48200 Mass air flow kg/min ENG
Monitoring / Pre-defined screen (9/12) Post treatment-related items
Applicable
component
1 47000 KDPF outlet pressure kPa KDPF
2 47100 KDPF differential pressure kPa KDPF
3 47200 KDPF 1 outlet temperature °C KDPF
4 47300 KDOC 1 inlet temperature °C KDPF
5 47400 KDOC 1 outlet temperature °C KDPF
Monitoring / Pre-defined screen (10/12) T/M clutch related items
Applicable
component
1 31622 T/M clutch F ECMV(F/B) mA P/T
2 31616 T/M clutch R ECMV(F/B) mA P/T
3 31612 T/M clutch 1st ECMV(F/B) mA P/T
4 31613 T/M clutch 2nd ECMV(F/B) mA P/T
5 31614 T/M clutch 3rd ECMV(F/B) mA P/T
6 31400 T/M output speed r/min P/T
Monitoring / Pre-defined screen (11/12) S/T operation related items
Applicable
component
1 50600 HSS solenoid LH (F/B) mA P/T
2 50601 HSS solenoid RH (F/B) mA P/T
3 50400 Brake potentiometer voltage mV P/T
Monitoring / Pre-defined screen (12/12) Blade related items
* PAT specification machines only
Applicable
component
1 71011 Blade angle RH EPC(F/B) mA P/T
2 71013 Blade angle LH EPC(F/B) mA P/T
3 70700 Work equipment oil pressure 1 MPa P/T
30-106 D65EX,PX,WX-17
Electrical system
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.
The monitoring function allows you to select a
desired monitoring item.
Select "02 Monitoring" on the "Service Menu"
screen.
3. Deciding monitoring item

After selecting monitoring items, execute
monitoring with the function switch or numeral
input switch.
a Execution with function switch: Doubleclick
or keep presssing [F6] (for approximately 2
seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only two items, for example,
2. Selecting monitoring item select them and enter them by using [F6]. If
After the "Monitoring selection menu screen" is [F6] is pressed once more at this time,
displayed, select items to be monitored by using monitoring is executed.
the function switches or numeral input switches. a When monitoring items are selected up to the
• [F1]: Moves to left item limit number, monitoring is executed
• [F2]: Moves to right item automatically.
• [F5]: Clears input numbers/Returns to
service menu screen
• [F6]: Enters selection
a Each time function switch [F1] is pressed, the
monitoring setting switches among [ENG] o
[KDPF] o [P/T] o [MON] o [ENG] in this
order. (Pressing [F2] induces the sequential
switching in the reverse order.)
a Selection with function switches: Select an
applicable equipment using [F1] or [F2], and
select an item using [F3] or [F4] and 4. Executing monitoring
determine it using [F6]. After the "Executing monitoring screen" is
a Selection with numeral input switches: Input displayed, perform the necessary operation of
a 5-digit code, and the item of that code is the machine and check the monitoring
selected directly. Enter that item with [F6]. information.
a If the color of the selected box changes from a Monitoring information is indicated by value,
yellow to red, selection of the item of that box ON/OFF, or special display.
is entered. a The unit of display can be set to SI unit,
a Up to six monitoring items can be selected at metric unit, or inch unit with the Default
a time. You may not be able to set up to six function in the service mode.
items, however, depending on the display
form of selected items.
D65EX,PX,WX-17 30-107
Electrical system
A function switch lets you save and delete the

selected monitoring item.
• [F1]: MEMORY
• [F2]: CLEAR
•
5. Holding monitoring information

The monitoring information can be held and
reset with the function switches.
• [F4]: selects hold or releasing hold
(If hold is selected, a diagonal line is
displayed on the HOLD portion)
• [F5]: Returns to monitoring selection menu a When you saved a monitoring item, selecting
screen "Monitoring" again displays the screen that
• confirms whether you want to display the
once saved item.
6. Changing machine setting mode

To change the setting of the working mode or a When you saved an item, you can display it
gear shift mode during monitoring, operate the as may times as you want until it is cleared.
corresponding switch under the current
condition to turn on the applicable mode. a In case you save an item when another item
is saved already, the currently saved item is
a If the setting is changed during monitoring, overwritten by the last one.
the new setting is held even after the screen
returns to the ordinary screen after
monitoring is finished.
7. Saving monitoring item
30-108 D65EX,PX,WX-17
Electrical system
Monitoring items list

Unit (Default: SI) Applic-
Code Monitoring item (Display on screen) able
Remarks
No. SI Metric Imperial compo-
nent
04300 Battery charge voltage V V V MON
04200 Fuel Level Sensor Volt V V V MON
Key switch ON, OFF MON
Start ON, OFF MON
04500 Monitor Input 1
Preheating ON, OFF MON
Light ON, OFF MON
Air cleaner ON, OFF MON
04501 Monitor Input 2
Battery charge volt ON, OFF MON
ENG Shutdown
ON, OFF MON
04502 Monitor Input 3 Secondary SW
Seat Belt SW ON, OFF MON
F1 ON, OFF MON
F2 ON, OFF MON
Monitor Function F3 ON, OFF MON
04503
Switch F4 ON, OFF MON
F5 ON, OFF MON
F6 ON, OFF MON
SW1 ON, OFF MON
SW2 ON, OFF MON
Monitor 1st & 2nd SW3 ON, OFF MON
04504
Row Switch SW4 ON, OFF MON
SW5 ON, OFF MON
SW6 ON, OFF MON
SW7 ON, OFF MON
SW8 ON, OFF MON
Monitor 3rd & 4th SW9 ON, OFF MON
04505
Row Switch SW10 ON, OFF MON
SW11 ON, OFF MON
SW12 ON, OFF MON
SW13 ON, OFF MON
Monitor 5th Row ON, OFF
04506 SW14 MON
Switch
SW15 ON, OFF MON
00500 Monitor model code – MON
20227 Monitor Ass'y P/N – MON
20402 Monitor Serial No – MON
20228 Monitor Prog. P/N – MON
20221 Monitor Prog. Version – MON
55300 Aircon Compressor Status ON, OFF MON
55000 Aircon Outside Temp. Code – MON
55100 Aircon Inside Temp. Code – MON
55200 Aircon Mode Data (Mon) – MON
A/C Mode Data
55201 – MON
(A/C ECU)
20260 KOMTRAX Ass'y P/N – MON
20418 KOMTRAX Serial No – MON
20261 KOMTRAX Prog. P/N – MON
20273 KOMTRAX Prog. Version – MON
00201 Selected machine model name – ENG
01002 Engine speed r/min rpm rpm ENG
04107 Engine coolant temperature °C °C °F ENG
D65EX,PX,WX-17 30-109
Electrical system

Remarks
nent
03204 Battery voltage V V V ENG
37212 Engine oil pressure switch ON, OFF ENG
36400 Common rail pressure MPa kg/cm2 psi ENG
37400 Ambient pressure kPa kg/cm2 psi ENG
18400 Intake air temperature °C °C °F ENG
18500 Boost air temperature °C °C °F ENG
Absolute value
indication
36500 Boost pressure kPa kg/cm2 psi ENG (including
atmospheric
pressure)
48100 Turbo Speed r/min rpm rpm ENG
48200 Mass Air Flow kg/min kg/min lb/min ENG
48400 Crankcase Pressure kPa mmAq psi ENG
18100 EGR Valve Position mm mm in ENG
48600 EGR Solenoid Current mA mA mA ENG
48500 EGR orifice temperature °C °C °F ENG
48501 EGR orifice temp sens volt V V V ENG
48700 KVGT Position mm mm in ENG
48800 KVGT Solenoid Current mA mA mA ENG
48300 Exhaust manifold pressure kPa kg/cm2 psi ENG
48301 Exh manifold press. sens volt V V V ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine output torque Nm kgm lbft ENG
Engine coolant temperature sensor
04105 voltage V V V ENG
37401 Ambient pressure sensor voltage V V V ENG
18401 Intake Temp Sensor Volt V V V ENG
18501 Boost air temperature sensor voltage V V V ENG
36501 Boost Pressure Sensor Volt V V V ENG
36401 Common rail pressure sensor V V V ENG
48401 Crankcase Pressure Volt V V V ENG
18101 EGR Valve Pos Sensor Volt V V V ENG
48701 KVGT position sensor V V V ENG
17500 Engine mode selection – ENG
48900 Engine Operation Mode – ENG
31701 Decel pedal position % % % ENG
Final accelerator pedal operating
31706 degree % % % ENG
Final injection volume command (in
18600 mg/st mg/st mg/st ENG
weight)
36200 Rail press command MPa kg/cm2 psi ENG
Instantaneous fuel consumption (Note
37300 l/h l/h gal/h ENG
1)
ON, OFF WIF: Water In
18800 WIF sensor state ENG
Fuel
20216 ECM Build Version – ENG
20217 ECM CAL Data Ver – ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM S/N – ENG
31703 Decel Pedal Pos Sensor Volt V V V ENG
38100 Key Switch (ACC) ON, OFF ENG
38200 Engine status – ENG
30-110 D65EX,PX,WX-17
Electrical system

Remarks
nent
38300 OFC Limit mg/st mg/st mg/st ENG
48000 IMV current A A A ENG
48001 IMV Current Command A A A ENG
47000 KDPF Outlet Pressure kPa kg/cm2 psi KDPF
47001 KDPF Out Pressure Sensor Volt V V V KDPF
47100 KDPF Delta Pressure kPa kg/cm2 psi KDPF
47101 KDPF Delta Press. Sensor Volt V V V KDPF
47300 KDOC 1 Inlet Temperature °C °C °F KDPF
47301 KDOC 1 Inlet Temp Sens Volt V V V KDPF
47400 KDOC 1 Outlet Temperature °C °C °F KDPF
47401 KDOC 1 Outlet Temp Sens Volt V V V KDPF
47200 KDPF 1 Outlet Temperature °C °C °F KDPF
47201 KDPF 1 Outlet Temp Sens Volt V V V KDPF
47500 Dosing Fuel Rate l/h l/h gal/h KDPF
47700 Soot Level Estimation g/L g/L g/gal KDPF
47800 Ash Level Estimation g/L g/L g/gal KDPF
20242 P/T Con Ass'y P/N – P/T
20243 P/T Con Prog P/N – P/T
20404 P/T Con Serial No – P/T
32900 Pitch Angle deg deg deg P/T
60100 Pitch Angle Sensor mV mV mV P/T
03000 Fuel Dial Sensor Volt mV mV mV P/T
03001 Fuel Dial Throttle % % % P/T
30100 T/C Oil Temperature °C °C °F P/T
30101 T/C Temp. Sens Volt mV mV mV P/T
32600 T/C AVR Pressure MPa kg/cm2 psi P/T
32605 T/C AVR Pressure Sensor mV mV mV P/T
50200 T/M Lever1 Potentio mV mV mV P/T
50201 T/M Lever2 Potentio mV mV mV P/T
50300 S/T Lever1 Potentio mV mV mV P/T
50301 S/T Lever2 Potentio mV mV mV P/T
50400 Brake potentiometer voltage mV mV mV P/T
31400 T/M Output Speed r/min rpm rpm P/T
70200 T/M Output Speed Sensor mV mV mV P/T
Forward ON, OFF P/T
Reverse ON, OFF P/T
40906 T/M Fill Sw Input1 1st ON, OFF P/T
2nd ON, OFF P/T
3rd ON, OFF P/T
31520 T/M Fill Sw Input2 L/U ON, OFF P/T
Shift up NC ON, OFF P/T
Shift up NO ON, OFF P/T
Shift down NC ON, OFF P/T
40905 P/T SW Input 1
Shift down NO ON, OFF P/T
Parking lock NC ON, OFF P/T
Parking lock NO ON, OFF P/T
C-sig ON, OFF P/T
40912 P/T SW Output
R-sig ON, OFF 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
D65EX,PX,WX-17 30-111
Electrical system

Remarks
nent
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
31642 L/U ECMV (F/B) mA mA mA P/T
50600 HSS Solenoid LH (F/B) mA mA mA P/T
50601 HSS Solenoid RH (F/B) mA mA mA P/T
Backup alarm ON, OFF P/T
P/T SW Output N-safety ON, OFF P/T
40909
Fan Reverse ON, OFF P/T
Solenoid
40001 Travel Speed km/h km/h mile/h P/T
60000 Traction W W W P/T
70700 Work Equipment Oil Pressure 1 MPa kg/cm2 psi P/T
Work Equipment Oil Pessure Sensor 1
70701 Voltage mV mV mV P/T
04401 Hydraulic oil temperature °C °C °F P/T
04402 Hydr. Temp. Sensor Volt V V V P/T
10000 Fan Speed command r/min rpm rpm P/T
10007 Fan speed r/min rpm rpm P/T
10013 Fan Speed sensor V V V P/T
W/E Lock NC ON, OFF P/T
W/E Lock NO ON, OFF P/T
70300 Blade Sw Input 1
Weq pitch Sw NO ON, OFF P/T
Weq pitch Sw NC ON, OFF P/T
iB Sw NC ON, OFF P/T
iB Sw NO ON, OFF P/T
Angle RH Sw NO1 ON, OFF P/T
70306 Blade Sw Input 2
Angle RH Sw NO2 ON, OFF P/T
Angle LH Sw NO1 ON, OFF P/T
Angle LH Sw NO2 ON, OFF P/T
01300 TVC Solenoid (F/B) mA mA mA P/T
01301 TVC Solenoid 2 (F/B) mA mA mA P/T
31624 Fan Pump Solenoid (F/B) mA mA mA P/T
60600 Battery relay operation voltage mV mV mV P/T
71011 Blade Angle RH EPC (F/B) mA mA mA P/T
71013 Blade Angle LH EPC(F/B) mA mA mA P/T
a Listing order of monitoring items in table

The monitoring items are listed in the order of display on the monitoring item selection menu screen.
a Unit
The display unit can be set to SI, meter, or inch as required (select a desired unit from "Unit" of "Default").
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Applicable component
ENG: The engine controller detects monitoring information.
KDPF: The KDPF detects monitoring information.
P/T: The power train controller detects monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: Instantaneous fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it
is a theoretical value, it is a little different from the actual fuel consumption ratio).
30-112 D65EX,PX,WX-17
Electrical system
Abnormality Record (Mechanical Systems) (a): Occurrence order of abnormalities from

The machine monitor classifies and logs the failures latest one/Total number of abnormalities in the
which occurred in the past or which are occurring at log
present into the mechanical system abnormality, (b): Failure codes
and electrical system abnormality. (c): Detail of failure
To check the mechanical system abnormality record, (d): Number of occurrences (displayable range:
perform the following procedures. 0 to 65,535 times)
(e): Service meter reading at first occurrence
a For the failure code list, see "40 Failure code list (f): Service meter reading at last occurrence
for troubleshooting". • [F1]: Move to next page (screen) (if
1. Selecting the menu displayed)
Select "Abnormality Record" on the "Service • [F2]: Move to previous page (screen) (if
Menu" Screen. displayed)
• [F5]: Return to the "Abnormality Record"
screen
a If no failure is logged, the message of "No
Error" is displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrences is one (first
occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
2. Selecting sub menu When the latest service meter reading is
After the "Abnormality Record" screen is recovered, the value at the recovery time is
displayed, select "Mechanical Systems" by displayed, thus the above readings may not
using the function switches or numeral input be the same.
switches. a If [E] is displayed on the left of a failure code,
• [F3]: Moves to lower item the abnormality is still occurring or
• [F4]: Moves to upper item restoration of it has not been confirmed.
• [F5]: Return the display to the service menu
screen a For all the failure codes that the machine
• [F6]: Validate the selection monitor can record, see the "Failure code
table".
a You may enter a 2-digit code by using the
numeral input switches to select the item of
that code and enter it by using [F6].
4. Clearing abnormality record

A contents of the mechanical system
abnormality record cannot be cleared.
3. Information displayed on abnormality record
screen
On the "Mechanical Systems" abnormality
record screen, the following information is
displayed.
D65EX,PX,WX-17 30-113
Electrical system
Abnormality Record (Electrical Systems) (b): Failure codes

The machine monitor classifies and logs the failures (c): Detail of failure
which occurred in the past or which are occurring at (d): Number of occurrences (displayable range:
present into the mechanical system abnormality, 0 to 65,535 times)
and electrical system abnormality. (e): Service meter reading at first occurrence
To check the electrical system abnormality record, (f): Service meter reading at last occurrence
perform the following procedures. • [F1]: Move to next page (screen) (if
displayed)
a For the failure code list, see "40 Failure code list • [F2]: Move to previous page (screen) (if
for troubleshooting". displayed)
1. Selecting the menu • [F3]: Moves to lower item
Select "Abnormality Record" on the "Service • [F4]: Moves to upper item
Menu" Screen. • [F5]: Return to the "Abnormality Record"
screen
a If no failure is logged, the message of "No
Error" is displayed.
a In the electrical systems abnormality record
screen, up to 20 cases currently stored are
displayed.
If the number of the cases reaches 21, the
code that occurred most recently is displayed
and the oldest code is deleted.
a If the number of occurrences is one (first
occurrence), the service meter reading at the
2. Selecting sub menu first occurrence and that at the last
After the "Abnormality Record" screen is occurrence are the same.
displayed, select "Electrical Systems" by using a If [E] is displayed on the left of a failure code,
the function switches or numeral input switches. the abnormality is still occurring or
• [F3]: Moves to lower item restoration of it has not been confirmed.
• [F5]: Return the display to the service menu a For all the failure codes that the machine
screen monitor can record, see the "Failure code
• [F6]: Validate the selection table".
a You may enter a 2-digit code by using the
that code and enter it by using [F6].
4. Clearing abnormality record

1) While the "Electrical Systems" abnormality
record screen is displayed, press the
numeral input switches as follows.
3. Information displayed on abnormality record
screen • Operation of switches (While pressing [4],
On the "Electrical Systems" abnormality record press the switches in order):
screen, the following information is displayed. [4]＋[1] o [ 2 ] o [ 3 ]
(a): Occurrence order of abnormalities from a Operate the switches similarly to the
latest one/Total number of abnormalities in the procedure for changing the ordinary
log display to the service mode.
30-114 D65EX,PX,WX-17
Electrical system
screen displayed when all the items are

cleared together).
2) Check that the screen is set in the clear

mode, and then clear the items one by one or
together by using the function switches.
4) If the screen to notify completion of clearing
a If the screen is set in the clear mode, icon is displayed and then the "Electrical
[CLEAR] is indicated above [F2]. Systems" (clear mode) screen is displayed,
• [F2]: Delete all items the clearing of the abnormality record is
• [F3]: Moves to lower item completed.
• [F4]: Moves to upper item a After a while, the screen returns to the
• [F5]: Return to the "Abnormality Record" "Electrical Systems" screen of
screen abnormality record.
• [F6]: Delete items one by one
a To clear items one by one: Select the item
to be cleared by using [F3] or [F4] and
press [F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the information is not cleared.
Maintenance record
The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
When maintenance is carried out, if the data are
reset in the operator mode, the number of the times
of maintenance is recorded in this section.
Select "04 Maintenance Record" on the "Service
Menu" screen.
3) After the "Electrical Sys. Error Reset" screen
is displayed, press the function switches.
• [F5]: Return to "Electrical Systems
Abnormality Record" screen (delete
mode)
• [F6]: Perform deletion
a The following figure shows the screen
displayed when the items are cleared one
by one (which is a little different from the
D65EX,PX,WX-17 30-115
Electrical system
3. Items displayed on maintenance record

screen
(a): Maintenance items
(b): Number of times of replacement up to now
(c): Service meter reading (SMR) at previous
replacement
2. Selecting maintenance record item

After the "Maintenance Record" screen is
displayed, select a maintenance item to be
checked by using the function switches or
numeral input switches.
• [F1]: Moves to next page (screen)
• [F3]: Moves to lower item Maintenance mode setting
• [F4]: Moves to upper item The actuating condition of the maintenance
• [F5]: Returns to Service menu screen reminder function in the operation mode can be set
and changed by using this menu.
a You may enter a 2-digit code with the
numeral input switches to select the item of • Enable or disable the function
that code. • Change set replacement interval (by items)
• Initialize all set change intervals
Select "05 Maintenance Mode Setting" on the
a The following items can be selected in the

maintenance record.
49 Air Cleaner Cleaning/Change
01 Engine Oil Change 2. Selecting sub menu
02 Engine Oil Filter Change After the “Maintenance Mode Setting” screen is
03 Fuel Main Filter Change displayed, select an item to change the setting
41 Fuel Pre Filter Change with the function switches or the numeral input
04 Hyd Oil Filter Change switches.
07 Damper Case Oil Check/Change • [F1]: Moves to next page (screen)
08 Final Drive Oil Change
05 H/Tank Breather Change • [F4]: Moves to upper item
44 F/Tank Breather Change • [F5]: Returns to Service menu screen
10 Hydraulic Oil Change • [F6]: Enters selection
19 P/L Oil Change
a You may enter a 2-digit code with the
20 P/L Oil Filter Change
47. KCCV Filter Change that code and enter it with [F6].
48 KDPF Filter Cleaning
30-116 D65EX,PX,WX-17
Electrical system
4. Contents of “Maintenance Notice Time

a The following items can be selected on the
Setting”
“Maintenance Mode Setting” screen.
After selecting “Maintenance Notice Time
00 Maintenance Mode Change Setting" and the screen is displayed, select the
49 Air Cleaner Cleaning and Change Int. desired setting with the function switches.
01 Engine Oil Change Interval
02 Eng Oil Filter Change Interval
03 Main Fuel Filter Change Interval
41 Fuel Pre-filter Change Interval
04 Hydraulic Oil Filter Change Interval
07 Damper Case Oil Change Interval
08 Final Drive Oil Change Interval
05 H/Tank Breather Change Interval
44 F/Tank Breather Change Interval
10 Hydraulic Oil Change Interval
19 P/L Oil Change Interval
20 P/L Oil Filter Change Int.
99 Initialize All Items • Default value: “Maintenance Notice Time” set
3. Contents of “Maintenance Mode Change” in machine monitor (Recommended by the
After selecting “00 Maintenance Mode Change” manufacturer and not changeable).
and the screen is displayed, select the desired • Set value: Maintenance notice time which
setting with the function switches. can be set freely between 10h and 200h.
• ON: Functions of all maintenance items are Operates on basis of this set time (which is
set effective in operator mode increased or decreased by 10 hours).
• OFF: Functions of all maintenance items are • [F3]: Decreases set value
set ineffective in operator mode • [F4]: Increases set value
• [F3]: Moves to lower item • [F5]: Cancels setting before confirmation and
• [F4]: Moves to upper item return to “Maintenance Mode Change”
• [F5]: Cancels selection and returns to screen.
Maintenance Mode Change screen • [F6]: Enters setting and returns to
• [F6]: Enters selection and returns to "Maintenance Mode Change" screen
Maintenance Mode Change screen a After entering the selection with the [F6] key,
a Even if ON/OFF of each item has been set, if return to the "Maintenance Mode Setting"
the above setting is changed, it overrides the screen by pressing [F5], and the setting will
individual setting. be made.
a If the set value of an item of which
maintenance reminder function is set to "ON"
is changed after one operating hour or more
from the setup, the change is recognized as
a reset of the remaining time.
D65EX,PX,WX-17 30-117
Electrical system
5. Setting of each maintenance item • Default value: “Maintenance Notice Time” set
After selecting each maintenance item, if the in machine monitor (Recommended by the
screen is displayed, set the item with the manufacturer and not changeable).
function switches. • Set value: Maintenance interval that can be
freely set. Maintenance reminder function
works according to this set time in operator
mode (which is set in increments of 25
hours).
• [F3]: Decreases set value
• [F4]: Increases set value
• [F5]: Cancels setting before entering and
returns to "Maintenance Mode Change"
screen.
• [F6]: Enters setting and returns to
Maintenance Mode Change screen
a After entering the setting with the [F6] key,
• ON: Functions of all maintenance items are return to the "Maintenance Mode Setting"
screen by pressing [F5], and the setting will
set effective in operator mode
be made.
• OFF: Functions of all maintenance items are
set ineffective in operator mode a If the set value of an item of which
• [F3]: Moves to lower set value maintenance reminder function is set to "ON"
• [F4]: Moves to upper set value is changed after one operating hour or
• [F5]: Cancels selection and returns to the more from the setup, the change is
"Maintenance Mode Change" screen recognized as a reset of the remaining time.
• [F6]: Enters selection and returns to the
"Maintenance Mode Change" screen
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
6. Contents of setting of set value of each
maintenance item
After selecting the set value of each
maintenance item, if the screen is displayed,
perform the setting for the item with the function
switches.
a Notifying time can be set at Maintenance

Notice Time Setting in "49 Air Cleaner
Cleaning / Change Interval", however,
perform cleaning or replacement of the air
cleaner element when the air cleaner
clogging monitor of the monitor panel lights
up.
30-118 D65EX,PX,WX-17
Electrical system
7. Function of All Default Value

After selecting "99 All Default Value" and the
screen is displayed, set with the function
switches.
2. Registering and changing phone number

After the "Phone Number Entry" screen is
displayed, register or change the phone number
• [F2]: Delete all input No.
• [F3]: Move to left position (if not blank)
• If this function is executed, the set values of • [F4]: Move to right position (if not blank)
all the maintenance items are initialized. • [F5]: Reset input digit/Return the display to
• [F5]: Returns to “Maintenance Mode Setting” the service menu screen
screen • [F6]: Confirm input
• [F6]: Enters initialization
a A while after [F6] is pressed, the initialization
completion screen is displayed. Then, if the
“Maintenance Mode Setting” screen is
displayed, initialization is completed.
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 (its background changes to orange)
and overwrite it to correct.
Phone Number Entry
The telephone number, which is displayed together a If [F6] is pressed without inputting a digit,
with the "Occured error list" in the operator mode, there is not information of phone number
can be input and changed according to the following Accordingly, no phone number is displayed
procedure. in the operator mode.
If a telephone number is not input by using this
function, no telephone number is displayed in the
operator mode.
Select "Phone Number Entry" on the "Service
Menu" screen.
D65EX,PX,WX-17 30-119
Electrical system
Default (Key-on mode) • Default (All OFF): Default mode settings

Use the menu of "Default" to check or change (working mode P: P, other items: OFF) are
various settings of the machine monitor and displayed when starting switch is turned to
machine. the ON position
The function of Key-on Mode is used to set the • [F3]: Moves to lower item
initial mode displayed on the machine monitor when • [F4]: Moves to upper item
the starting switch is turned ON. • [F5]: Cancels selection and returns to Default
screen
• [F6]: Enters selection and returns to Default
Select "07 Default" on the "Service Menu"
screen
screen.
a Factory default is "Mode at Previous Key-off".
2. Selecting sub menu

After the "Default" screen is displayed, select
"01 Key-on Mode" by using the function Default (Unit)
switches or numeral input switches. Use the menu of "Default" to check or change
various settings of the machine monitor and
a Select this item similarly to an item on the machine.
Use the sub menu of "Unit" to select the unit of the
a This function sets the following mode items data displayed for monitoring, etc.
(which are the items set with the customize 1. Selecting the menu
switch in the operator mode). Select "Default" on the "Service Menu" screen.
• Working mode: P/E
• Gear shift mode: Manual gear shift mode /
• Reverse slow mode: ON/OFF

After the "Default" screen is displayed, select
"Unit" by using the function switches or numeral
input switches.
3. Selecting mode
After the "Key-on Mode" screen is displayed, a Select this sub menu as in the case of
select the mode to be set by using the function selecting a menu on the "Service Menu"
switches. screen.
• Mode at previous key-off: Final modes in
previous operation are displayed when
starting switch is turned to the ON position
30-120 D65EX,PX,WX-17
Electrical system
3. Selecting unit 2. Selecting sub menu

After the "Unit" screen is displayed, select the After the "Default" screen is displayed, select
unit to be set by using the function switches. "03 Camera" using the function switch or
• [F3]: Moves to lower item numeral input switches.
a Select this item similarly to an item on the
• [F5]: Cancels the selection and returns the
display to the default screen
• [F6]: Validates the selection and returns the
display to the default screen
a Factory default is "SI Unit".
3. Selecting camera setting

After the "Camera" setting screen is displayed,
select the setting by using the function switches.
• [F3]: Moves to left item
• [F4]: Moves to right item
Default (Camera) • [F5]: Cancels settings before confirmation
Use the menu of "Default" to check or change and returns to Default setting screen
various settings of the machine monitor and • [F6]: Enters selection in each line
machine.
a After "Camera" screen is displayed, camera
The camera setting function is used to set default 1 can be always set.
setting and removal of a camera.
When two or more cameras are connected,
1. Selecting the menu camera 1 is entered first being followed by
Select "07 Default" on the "Service Menu" camera 2.
screen.
a After entering the setting of each line with
[F6], return to the "Default" screen with [F5],
and the setting is effective.
a If a camera is connected but not set normally
with this function, the graphic mark of
camera is not displayed at [F3] in the
operator mode. Accordingly, the image of the
camera cannot be used.
D65EX,PX,WX-17 30-121
Electrical system
a If the camera is installed, check that the right a The simultaneous display function
and left portions of the displayed image are of two images becomes effective
correct. when camera 1 and camera 2 are
set for use.
• OFF: Camera is not connected

• ON: Image from connected camera is • Two screens simultaneous
displayed in normal position. display
• OFF: Camera is not used

• Normal image: Image of connected
camera is displayed in normal position
(as viewed in a mirror, used for back
monitor)
• Reverse image: Image of connected
camera is displayed in reverse
position (as seen directly, when used
as front or side monitor)
4. Adjustment of reference line

1) After the "Guide Line Position Set" screen is
displayed, select the unit to be set.
a The reference line is configured in the
"Guide Line" mode of the operator mode.
OFF, outline, center line, and outline +
center line are available.
a The selection method is the same as that
of the "Service Menu" screen.
a If two or more cameras are
connected, be sure to set the use
of them from camera 1 in order.
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Electrical system
a When not yet set, "Guide Line Position

Setting Fix" items are displayed.
Selecting the Center Line
2) After the setting screen of the item is

displayed, operate as follows using the
function switches.
• [F1]: Moves selected point to the lower
item
• [F2]: Moves selected point to the upper
item
• [F3]: Moves selected point or center line
to the left
• [F4]: Moves selected point or center line
to the right
• [F5]: Returns to the "Guide Line Position 3) After selecting "Camera Setting Initialization"
Set" screen and the screen is displayed, set with the
• [F6]: Enters the position function switches.
Selecting the point
D65EX,PX,WX-17 30-123
Electrical system
• If this function is executed, all of the 2. Selecting sub menu

camera setting values are initialized. After the "Diagnostic Tests" screen is displayed,
• [F5]: Return to Camera screen select "Cylinder Cut-out" by using the function
• [F6]: Executes initialization switches or numeral input switches.
a A while after [F6] is pressed, the a Select this item similarly to an item on the
initialization completion screen is "Service Menu" screen.
displayed. Then, when the “Camera”
screen is displayed, initialization is
completed.
3. Selecting cylinder to be cut out

After the "Cylinder Cut-out" screen is displayed,
select a cylinder to be Cut out by using the
function switches.
Diagnostic tests (Cylinder cut-out mode • [F1]: Moves to left item
operation) • [F2]: Moves to right item
The operator can perform "Cylinder Cut-out mode" • [F4]: Selects hold or releasing hold
operation and KDPF regeneration/reset operation (If hold is selected, a diagonal line is
with the machine monitor. displayed on the HOLD portion)
Cylinder Cut-out mode operation means to run the • [F5]: Returns to the testing screen
engine with one or more fuel injectors disabled • [F6]: Enters selection
electrically to reduce the number of effective a This operation may be performed while the
cylinders. This operation is used to identify a engine is running.
cylinder that does not output power normally
(combustion in it is abnormal). a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white, the
cylinder is cut out.
Select "08 Diagnostic Tests" on the "Service
Menu" screen. a If the machine monitor cuts out a cylinder but
the engine controller cannot cut out that
cylinder, the background (a) of the cylinder
No. becomes yellow.
a One or more cylinders can be cut out.
30-124 D65EX,PX,WX-17
Electrical system
• If a normally operating cylinder is cut out, the

following phenomena occur.
1. The engine speed lowers.
2. The value (quantity) of final injection rate
command increases.
• If the engine is running near the high idle,
however, the engine speed may not lower for the
reason of engine control.
• In this case, lower the engine speed by using the
fuel control dial and judge by increase of the
injection rate command.
Diagnostic Tests (Regeneration for Service)

4. Resetting cut-out cylinder
The operator can perform "Cylinder Cut-out mode"
When changing a cylinder to be cut out or when
operation and KDPF regeneration/reset operation
Cylinder Cut-out operation is finished, select a
with the machine monitor.
cut-out cylinder to be reset with the function
switches. The forced regeneration for service means the
method of burning soot by performing the KDPF
a This operation may be performed while the regeneration, regardless of the soot accumulation.
engine is running.
a When [F6] is pressed, if background (a) of Select "Testing" on the "Service Menu" screen.
the selected cylinder No. becomes blue, the
cylinder is reset.
a If the machine monitor resets a Cut-out
cylinder but the engine controller cannot
reset that Cut-out cylinder, the background
(a) of the cylinder No. becomes red.
a The cut-out cylinder mode operation is not
automatically reset after the screen returns to
the operator mode. Accordingly, be sure to
perform the resetting operation after the
reduced cylinder mode operation is finished.
5. Holding displayed information
If [F4] is pressed during the cylinder cut-out 2. Selecting sub menu
operation, the displayed information is newly After the "Testing" screen is displayed, select
held (b) (The real-time information is kept "Regeneration for Service" by using the function
displayed on the left side). switches or numeral input switches.
While the data is held, if [F4] is pressed, the data
holding function is reset. a Select this sub menu as in the case of
selecting a menu on the "Service Menu"
a The holding function is effective, regardless screen.
of setting or canceling the cylinder cut-out
mode operation. a While the KDPF is in the stationary manual
regeneration or stopped in the KDPF
regeneration mode, "Regeneration for
Service" cannot be selected.
[Reference]
D65EX,PX,WX-17 30-125
Electrical system
if the regeneration is started when the

soot accumulation is above 4 g/L and if
the soot accumulation is above 1.9 g/L
after 40 minutes, the automatic manual
regeneration is started and continued
until the soot accumulation decreases to
1.9 g/L.
3. Setting regeneration for service

If the "Regeneration for Service" screen is
displayed, the following information is displayed
as well as the KDPF regeneration condition. Set
the KDPF regeneration according to the given
messages.
(a): Soot accumulation level
(b): KDPF is being regenerated
2) Finish of regeneration
(c): Selectable items
If the forced regeneration for service is
(d): Message
completed, "Regeneration completed." is
displayed on the screen.
1) KDPF forced regeneration (Stationary

manual regeneration) 3) Stopping of regeneration
Select "Stationary manual regeneration" on If [F6] is pressed during the stationary
the "Regeneration for Service" screen. manual regeneration, "Stop manual
• [F5]: Return to the testing screen stationary regeneration?" is displayed on the
• [F6]: Perform the stationary manual screen. Confirm the stop with the function
regeneration. switch.
a The forced regeneration for service can • [F5]: Do not stop regeneration (Continue
be performed only when the lock lever is manual stationary regeneration)
in the LOCK position and the fuel control • [F6]: Stop regeneration
dial is the low idle (MIN) position.
a When performing the stationary manual
regeneration, confirm the surrounding
area is safe and check that there is no
person or combustible matter around. If
the machine needs to be moved again,
move it to a safe place to ensure safety,
and then perform the operation from the
first.
a The forced regeneration for service stops
automatically after 40 minutes. However,
30-126 D65EX,PX,WX-17
Electrical system
3. Setting KDPF memory reset

On the "KDPF Memory Reset" screen, select an
item to be reset.
• [F3]: Move the selection mark to the lower
item
• [F4]: Move the selection mark to the upper
item
• [F5]: Return to the testing screen
• [F6]: Validate the selection
Diagnostic Tests (KDPF Memory Reset)

The operator can perform "Cylinder Cut-out mode"
operation and KDPF regeneration/reset operation
KDPF information reset operation means to reset
the information on KDPF saved in the machine. This
operation should be performed when the KDPF is
cleaned or replaced or when the engine controller is
replaced.
After "Do you want to reset?" is displayed,
1. Selecting the menu confirm the reset with the function switch.
Select "Testing" on the "Service Menu" screen. • [F5]: Return to the previous screen
• [F6]: Enter reset

After the "Testing" screen is displayed, select If the reset was finished normally, "Reset
"KDPF Memory Reset" by using the function completed." is displayed on the screen. If the
switches or numeral input switches. reset was finished abnormally, "Reset failed." is
a Select this sub menu as in the case of displayed on the screen.
selecting a menu on the "Service Menu" a Perform the KDPF replacement reset after
screen. replacing the KDPF.
a Perform the KDPF cleaning reset after
cleaning the KDPF.
a Perform the KDOC replacement reset after
replacing or cleaning KDOC.
Adjustment
You can adjust various items related to the machine
When using an adjustment item, select it according
D65EX,PX,WX-17 30-127
Electrical system
Select "09 Adjustment" on the "Service Menu" a If an improper adjustment ID is input,

screen. "Adjustment not allowed," is displayed and
the screen does not switch from the Input ID
screen (ID can be re-entered by using
numeral keys).
Select "01 Input ID" on the "Adjustment" screen.
3. Displaying adjustment screen

After the "Adjustment" screen for the adjustment
ID is displayed, you can start adjustment.
a In the figure, adjustment ID [0002] is selected
and displayed as an example.
a "000", "00", and "0" on the left of the
adjustment ID must be filled but they are not
displayed on the adjustment screen.
a The functions given to function switches [F3]
to [F6] vary depending on the adjustment
2. Selecting adjustment items
item.
Input ID:
After the "Adjustment" screen is displayed, input a For the method of operating each adjustment
the 4-digit adjustment ID of the adjustment item item, see the explanation of its adjustment
to be used by using the numeral input switches. ID.
• [F5]: Cancels adjustment and returns to
Service Menu screen
• [F6]: Enters input adjustment ID and goes to
Adjustment screen
a For the adjustment ID and its adjustment
items, see the adjustment items table.
a For the adjustment items other than the input
procedure of the ID, item selection method is
the same as that of the "Service Menu"
screen.
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Electrical system
Adjustment items table

Adjust- Disassembly
ment Adjustment item Remarks and
ID reassembly
0002 Power train controller initialization q
0007 Engine decelerator cutting Auto-deceleration is cancelled
0010 Fan 70% mode
Recommended mode of torque
0530 Stall mode
converter stall
1005 Fan 100% mode
1013 Steering lever leftmost position q
1014 Steering lever rightmost position q
2021 Power train controller voltage check mode
2222 HSS minimum current value setting mode
6001 Reverse slow (R1) speed setting Fine adjustment of reverse slow mode
Transmission clutch IP manual initial
7843
correction
7845 Transmission clutch IP learning display
Transmission clutch fill time manual initial
7847
correction
9997 High idle cut mode
9998 Max. gear speed setting mode
—— Brake pedal potentiometer initial setting q
—— Pitch angle sensor initial setting q
—— Steering lever NEUTRAL position setting q
—— Transmission clutch IP and fill time
q
automatic initial correction
k For items marked with q in the Disassembly and reassembly column, adjustment is required after
machine assembly or replacement of controllers (for adjustment procedures, see "Adjustment
method when controller has been replaced").
Adjustment ID: 0002 (Power train controller [F3]: Unused

initialization) [F4]: Unused
[F5]: Returns to adjustment item selection
screen (ID input screen)
[F6]: Saves setting
• Operating method:
1. Press [F6] and check that the alarm buzzer
sounds.
2. Check that the displayed specification code
[CODE] has changed from [5x5] to [555].
a If specification code [555] is not displayed,
the controller wiring harness or the controller
unit may be defective.
a Even if this adjustment code is turned off, the
• This adjustment code is used to initialize the setting is effective.
specification code recognized by the power train
controller and the set values of the memory in
the controller.
a After the power train controller is replaced, be
sure to perform this adjustment once.
• Functions of function switches
D65EX,PX,WX-17 30-129
Electrical system
Adjustment ID: 0007 (Engine decelerator [F5]: Returns to adjustment item selection
cutting) screen (ID input screen)
[F6]: Unused
The function is effective at the time when this
adjustment is displayed and the cooling fan
speed is controlled to approximately 70% of the
maximum speed.
a After this adjustment code is turned OFF, its
function is ineffective.
Adjustment ID: 0530 (Stall mode)
• This adjustment code is used to stop the auto-

deceleration function of the engine and check
the high idle speed of the engine unit.
a Use this adjustment code for testing, adjusting,
or troubleshooting as needed.
[F3]: Unused
[F4]: Unused
• This adjustment code is used to set the fan
[F6]: Unused
speed in the 100% mode automatically and
make it possible to set the preset (gear speed at
When this adjustment code is displayed, its
start) to [F3-R3] to stall the torque converter.
function is effective and the auto-deceleration
function is stopped. a The preset (gear speed at start) can be set to
[F3-R3] only when this adjustment code is
selected.
Adjustment ID: 0010 (Fan 70% mode) or troubleshooting as needed.
[F3]: Unused
[F4]: Unused
[F6]: Unused
• Mode setting information within screen
[P-AUTO SFT MODE]: Automatic gear shift in P
mode
[E-AUTO SFT MODE]: Automatic gear shift in E
mode
[P-MANUAL SFT MODE]: Manual gear shift in P
mode
• This adjustment code is used to forcibly set the [E-MANUAL SFT MODE]: Manual gear shift in E
cooling fan speed to approximately 70%. mode
a Use this adjustment code for testing, adjusting, a When using this adjustment code, be sure to
or troubleshooting as needed. select "P-MANUAL SET MODE".
• Functions of function switches • Operating method:
[F3]: Decreases adjustment value [FAN 70% when this adjustment code is displayed, its
SPEED MODE] function is effective and the preset (gear speed
[F4]: Increases adjustment value [FAN 70% at start) is set to [F3-R3].
SPEED MODE]
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Electrical system
k This adjustment code does not stall the a When using this adjustment code, keep the
torque converter automatically. Accordingly, hydraulic oil temperature above 45 °C . (If the
operate the levers and pedals securely when hydraulic oil temperature becomes lower
stalling the torque converter (For the than 40 °C , the fan speed will fluctuate.)
procedure for stalling the torque converter,
see "Testing engine speed").
function is ineffective but the set adjustment
a When using this adjustment code, keep the value is effective.
hydraulic oil temperature above 45 °C . (If the
hydraulic oil temperature becomes lower Adjustment ID: 1013 (Steering lever leftmost
position adjustment)
than 40 °C , the fan speed will fluctuate.)
Adjustment ID: 1005 (Fan 100% mode)
• This adjustment code is used to make the power

train controller recognize the leftmost position of
the steering potentiometer of the PCCS lever.
a After the power train controller or PCCS lever is
• This adjustment code is used to forcibly set the replaced, be sure to perform this adjustment
cooling fan speed to approximately 100%. once.
It can also set the adjustment value of the • Functions of function switches
maximum speed. [F3]: Unused
a Use this adjustment code for testing, adjusting, [F4]: Unused
or troubleshooting as needed. [F5]: Returns to adjustment item selection
a Functions of function switches [F6]: Saves adjustment value
[F3]: Decreases adjustment value [FAN 100% • Operating method:
SPEED MODE] 1. Operate the PCCS lever in the steering
[F4]: Increases adjustment value [FAN 100% direction to the left stroke end and keep it
SPEED MODE] there.
[F5]: Returns to adjustment item selection 2. Press [F6] and check that the alarm buzzer
screen (ID input screen) sounds.
[F6]: Saves adjustment value a Even if this adjustment code is turned off, the
• Operating method: adjustment is effective.
a When this adjustment code is displayed, its a This adjustment code is used to make the
function is effective and the cooling fan controller recognize the leftmost position of
speed is controlled to approximately 100% of the potentiometer. It is not used to adjust the
the maximum speed. steering performance.
1. increase Or decrease the adjustment value
by pressing [F3] or [F4].
2. when confirming the adjustment value, press
[F6] and check that the alarm buzzer sounds.
a Since the [FAN SPEED] for this adjustment
code differs from the actual fan speed, refer
to Testing and adjusting, "Testing fan speed"
for the method to check the fan speed.
D65EX,PX,WX-17 30-131
Electrical system
Adjustment ID: 1014 (Steering lever rightmost • This adjustment code is used to check the
position adjustment) continuous power supply voltage and switched
power supply voltage applied to the power train
controller.
or troubleshooting as needed.
[F3]: Unused
[F4]: Unused
[F6]: Unused
• Information displayed on screen
[PT CONTROLLER UNSWITCHED POWER]:
Continuous power supply voltage
[PT CONTROLLER SWITCHED POWER]:
train controller recognize the rightmost position
Switched power supply voltage
of the steering potentiometer of the PCCS lever.
a After the power train controller or PCCS lever is When this adjustment code is displayed, its
replaced, be sure to perform this adjustment function is effective and the continuous power
once. supply voltage and switched power supply
• Functions of function switches voltage are displayed simultaneously.
[F3]: Unused a After this adjustment code is turned OFF, its
[F4]: Unused function is ineffective.
screen (ID input screen) Adjustment ID: 2222 (HSS minimum current
[F6]: Saves adjustment value value setting mode)
1. Operate the PCCS lever in the steering
direction to the right stroke end and keep it
there.
sounds.
adjustment is effective.
a This adjustment code is used to make the
controller recognize the rightmost position of
the potentiometer. It is not used to adjust the
steering performance.
• This adjustment code is used to make
Adjustment ID: 2021 (Power train controller adjustments to the turning radius at the start of
voltage check mode) steering when the initial steering response is not
the same between steering right and left.
a Use this adjustment code for work as needed.
[F3]: Unused
[F4]: Unused
[F6]: Saves adjustment value
1. Put the parking brake lever in the FREE
position.
30-132 D65EX,PX,WX-17
Electrical system
2. Gradually move the PCCS lever right or left • This adjustment code is used to adjust the travel
until the target current value is displayed, speed applied to travel at gear speed R1 with
and then hold the lever at that position. the reverse slow mode ON.
• When the lever is moved to the left, a a Use this adjustment code for work as needed.
negative current value will be indicated.
• When the lever is moved to the right, a
[F3]: Decreases adjustment value
positive current value will be indicated.
[F4]: Increases adjustment value
sounds.
4. When [F6] is pressed while the PCCS lever
is in the NEUTRAL, the setting is initialized to
• Information displayed on screen
the factory default values.
The reverse limit speed is displayed (km/h x 10)
a The current value (mA) varies form -395 (left and the adjustment value can be increased or
end) to 395 (right end). decreased in 1 (km/h x 10) units.
a The larger the absolute value of the current a The factory default value of the speed limit is
setting, the smaller the turning radius at the 40 km/h x 10.
start of steering (steering becomes sharper). (The value indicated on the screen is 10
a It is not necessary to steer the machine times of the actual value. 4.0 km/h = 40 km/h
during adjustment. After finishing adjustment, x 10)
however, steer the machine and check that • Operating method:
there is no problem in the actual steering 1. Increase or decrease the adjustment value
performance. by pressing [F3] or [F4].
a The following figure shows an example of an
sounds.
adjustment made to the left steer current
setting by decreasing the absolute value to a If an adjustment has been performed, the
increase the turning radius. adjustment value is displayed. It can be
adjusted again within the allowable range.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment,
however, drive the machine at R1 with the
reverse slow mode ON and check that there
is not a problem in the actual travel speed.
Adjustment ID: 6002 (R2 reverse slow setting)

setting is effective.
• This adjustment code is used to adjust the travel

speed at gear speed R2 with the reverse slow
mode ON.
D65EX,PX,WX-17 30-133
Electrical system
[F3]: Decreases adjustment value a The factory default value of the speed limit is
[F4]: Increases adjustment value 120 (km/h x 10).
[F5]: Returns to adjustment item selection (The value indicated on the screen is 10
screen (ID input screen) times of the actual value. 12.0 km/h = 120
[F6]: Saves adjustment value km/h x 10)
• Information displayed on screen • Operating method:
a The factory default value of the speed limit is 1. Increase or decrease the adjustment value
60 (km/h x 10). by pressing [F3] or [F4].
(The value indicated on the screen is 10 2. Press [F6] and check that the alarm buzzer
times of the actual value. 6.0 km/h = 60 km/h sounds.
x 10) a If an adjustment has been performed, the
• Operating method: adjustment value is displayed. It can be
1. Increase or decrease the adjustment value adjusted again within the allowable range.
a It is not necessary to drive the machine
sounds.
however, drive the machine at R2 with the
a If an adjustment has been performed, the reverse slow mode ON and check that there
adjustment value is displayed. It can be is not a problem in the actual travel speed.
adjusted again within the allowable range.
a It is not necessary to drive the machine adjustment is effective.
however, drive the machine at R2 with the Adjustment ID: 7843 (Transmission clutch IP
reverse slow mode ON and check that there manual initial correction)
is not a problem in the actual travel speed.
• Use this adjustment to perform the correction

manually when the correction is not finished
successfully by the IP automatic correction.
(Adjustment ID: 7842).
a Use this adjustment code after the IP correction
• This adjustment code is used to adjust the travel work as needed.
speed at gear speed R3 with the reverse slow • Functions of function switches
mode ON. [F3]: Decreases adjustment value
a Use this adjustment code for work as needed. [F4]: Increases adjustment value
• Functions of function switches screen (ID input screen)
[F3]: Decreases adjustment value [F6]: Saves adjustment value
[F5]: Returns to adjustment item selection a If [F2] is pressed while [F1] is pressed, all the
screen (ID input screen) correction values are set to 0.
[F6]: Saves adjustment value • Functions of shift up/down switches
• Information displayed on screen You can select a clutch to be corrected manually
with the shift-up and shift-down switches.
• Conditions for correction work
30-134 D65EX,PX,WX-17
Electrical system
Same as the conditions for IP automatic Adjustment ID: 7847 (Transmission clutch fill
correction (Adjustment ID: 7842). time manual initial correction)
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.
3. Increase or decrease the adjustment value
sounds.
a The machine does not move during the
correction work.
a Even if this adjustment code is turned off, the • Use this adjustment to perform the correction
adjustment is effective. manually when the correction is not finished
successfully by the fill time automatic correction.
Adjustment ID: 7845 (Transmission clutch IP (Adjustment ID: 7842).
learning display)
a Use at the fill time correction work as needed.
[F3]: Decreases adjustment value
a If [F2] is pressed while [F1] is pressed, all the
correction values are set to 0.
• Functions of shift up/down switches
You can select a clutch to be corrected manually
with the shift-up and shift-down switches.
• This adjustment code is used to check the a The value displayed when the clutch is selected
information of correction made by the IP is correction information set automatically or
automatic correction (Adjustment ID: 7842) or IP manually before.
manual correction (Adjustment ID: 7843). • Conditions for correction work
Same as the conditions for fill time automatic
a Use this adjustment code for testing, adjusting, correction (Adjustment ID: 7842).
or troubleshooting as needed. • Operating method:
• Functions of function switches 1. Start the engine and keep its speed in the
[F3]: Changes display specified range of condition with the fuel
[F4]: Changes display control dial.
[F5]: Returns to adjustment item selection 2. Select a clutch to be corrected manually with
screen (ID input screen) the shift-up or shift-down switches.
[F6]: Unused 3. Increase or decrease the adjustment value
• Operating method: by pressing [F3] or [F4].
When this adjustment code is displayed, its 4. Press [F6] and check that the alarm buzzer
function is effective and the correction sounds.
a After this adjustment code is turned OFF, its correction work.
D65EX,PX,WX-17 30-135
Electrical system
Adjustment ID: 9997 (High idle cut mode) • Functions of function switches
[F3]: Decreases the adjustment value [MAX
SHIFT]
[F4]: Increases the adjustment value [MAX
SHIFT]
sounds.
a When resetting the limitation of the maximum
• This adjustment code is used to limit the high gear speed, set the adjustment value to the
idle speed. maximum gear speed (3rd) which is the initial
a Use this adjustment code for work as needed. setting at shipment.
• Functions of function switches a Setting with this adjustment code becomes
[F3]: Decreases adjustment value [HI IDLE RPM effective only after the starting switch is
SET MODE] turned to the OFF position and then to the
[F4]: Increases adjustment value [HI IDLE RPM ON position again.
SET MODE]
[F5]: Returns to adjustment item selection (Brake pedal potentiometer initial setting)
a Screen displayed after selection at the
Adjustment menu
sounds.
a To reset the high idle speed limit, set it to the
original high idle speed (2,100 rpm).
setting is effective.
Adjustment ID: 9998 (Max. gear speed setting

mode)

train controller recognize the zero point of the
brake pedal potentiometer.
a After the power train controller or brake pedal
potentiometer is replaced or the brake pedal
linkage is disconnected and connected, be sure
to perform this adjustment once.
[F3]: Unused
[F4]: Unused
• This adjustment code is used to limit the [F6]: Saves corrected value
maximum transmission gear speed. • Operating method:
• The limited gear speed is applied in both
1. Check that the brake pedal is in the
automatic gear shift mode and manual gear shift
NEUTRAL position (it is not depressed) and
mode.
keep it in that position.
30-136 D65EX,PX,WX-17
Electrical system

sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
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 performance.
(Pitch angle sensor initial setting)

a Screen displayed after selection at the train controller recognize the NEUTRAL position
Adjustment menu of the steering potentiometer of the PCCS lever.
replaced, be sure to perform this adjustment
once.
[F3]: Unused
[F4]: Unused
1. Check that the PCCS lever is in the
NEUTRAL position of the steering direction
• This adjustment code is used to make the power and keep it in that position.
train controller recognize the zero point of the 2. Press [F6] and check that the alarm buzzer
pitch angle sensor and to correct the installation sounds.
error. a Even if this adjustment code is turned off, the
a After the power train controller is replaced or the adjustment is effective.
inclination angle sensor is removed and installed a This adjustment code is used to make the
or replaced, be sure to perform this adjustment controller recognize the neutral position of
once. the potentiometer. It is not used to adjust the
• Functions of function switches steering performance.
[F3]: Unused
[F4]: Unused (Transmission clutch IP and fill time automatic
[F5]: Returns to adjustment item selection initial correction)
screen (ID input screen) a Screen displayed after selection at the
[F6]: Saves corrected value Adjustment menu
1. Check that the machine is level.
sounds.
a If the adjustment is performed, displayed
item [BODY PITCH ANGLE] changes to [0.0
deg.] (No other displayed item changes).
correction is effective.
(Steering lever NEUTRAL position setting)

a Screen displayed after selection at the
Adjustment menu
D65EX,PX,WX-17 30-137
Electrical system

train controller recognize the mechanical
condition of the transmission.
replaced, be sure to perform this adjustment
once.
[F3]: Unused
[F4]: Unused
[F6]: Starts automatic correction
• Conditions for correction work 2. Confirmation screen
When the "No injection" screen is displayed, the
1. [Engine speed]: 1,800 to 2,100 rpm
message to ask if no injection cranking should
2. [T/C (P/L) Oil Temperature]: 65 to 85 °C
be performed appears. Answer with the function
3. Parking brake lever: LOCK position
switch.
a When using this adjustment code, keep the • [F5]: Do not perform (Return to Service menu
above conditions (In particular, increase the screen)
power train oil temperature sufficiently before • [F6]: Perform
starting adjustment).
1. Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2. Press [F6] to start the correction and check
that [1/11] is newly displayed on the screen.
3. When the alarm buzzer sounds when [1/11]
is displayed, correction is complete.
correction work.
correction is effective. 3. Starting no injection cranking
If no injection cranking (fuel injection in no
No Injection cylinders) becomes effective, "No Injection." is
If the engine is operated after long storage of the displayed on the screen. Under this condition,
machine, it may be worn or damaged because of crank the engine by using the starting motor.
insufficient lubrication with oil. To prevent this, the
machine monitor allows for cranking the engine a While the screen is changing to the following
without injecting fuel to lubricate the engine before screen, the screen of "Getting Ready." is
starting it. displayed.
Set the no injection cranking while the engine is a Limit the duration of cranking to 20 seconds
stopped. to protect the starting motor.
Select "No Injection" on the "Service Menu"
screen.
4. Finishing no injection cranking
30-138 D65EX,PX,WX-17
Electrical system
After cranking is finished, turn the key to the

OFF position.
Switching from the above screen to another is
not available.
5. Prohibiting no injection cranking
If the operator tries to perform the no injection
cranking while the engine is running, the
message "Engine is running" is displayed and
the no injection cranking is not enabled.
a This function can be selected even while
engine is running. If no injection cranking is
attempted, however, the message, "Engine
is running. Turn the key OFF once." is 2. Selecting submenu
displayed on the screen. After the “KOMTRAX Settings” screen is
displayed, select “Terminal Status” with the
function switches or numeral input switches.
a Select this submenu as in the case of
screen.
And the "Confirmation screen" appears to

disable the attempted no injection cranking in
the following cases.
• Communication between the monitor and
engine controller is not normal.
• Engine was started before the message "No 3. Contents displayed on the terminal status
injection cranking is available" appears on screen
the screen. On the "Terminal Status" screen, the following
• Terminal: Model name of the KOMTRAX
communication modem
• Sign-up test: Status of sign-up test underway
• GMT time: Greenwich Mean Time (add 9
hours to it for Japan time)
• [F5]: Returns the display to the KOMTRAX
settings screen
KOMTRAX Settings (Terminal Status)

The setting and operating status of KOMTRAX can
be checked by using the menu of "KOMTRAX
Settings".
"KOMTRAX Settings" is used to check the setting
condition of the KOMTRAX terminal.
Select "KOMTRAX Settings" on the "Service
Menu" screen.
D65EX,PX,WX-17 30-139
Electrical system
KOMTRAX Settings (GPS and Communication

Status)
Settings".
"GPS & Communication Status" is used to check
the positioning and communication status of the
KOMTRAX terminal.
Menu" screen.
KOMTRAX Settings (Modem Information)

Settings".
Modem status is used to check the IP address of
the KOMTRAX communication modem.
Menu" screen.

After the "KOMTRAX Settings" screen is
displayed, select "GPS & Communication
Status" with the function switches or numeral
input switches.
a Select this sub menu as in the case of
screen.

After the "KOMTRAX Settings" screen is
displayed, select "Modem Status" with the
function switches or numeral input switches.
a Select this sub menu as in the case of
screen.
3. Contents displayed on GPS & Communication

Status screen
On the "GPS & Communication Status" screen,
the following items are displayed.
• Positioning: GPS positioning status
• Communication: Communication
environment and connection status of the
communication modem
• Number of message(s) not yet sent: Number
of mails that are saved on the machine
monitor and have not yet been transmitted 3. Modem status displayed
settings screen
30-140 D65EX,PX,WX-17
Electrical system
IP addresses (2 addresses) of the modem are

displayed.
settings screen
a An IP address is a unique number assigned
to each modem that is used when
communication between the modem and
server is turned on.
3. Displaying message (with return mail

function)
If a message provides the Numeric Input line
under the text, input a proper number by using
the numeral input switches and enter it by using
the function switch, and the information is
returned to the KOMTRAX base station.
• [F5]: Returns to KOMTRAX settings screen
• [F6]: Enters and returns the input value.
Service message a This message is different from that sent for
Special messages for the technician sent from the the operator with the machine monitor in the
KOMTRAX base station (a distributor, etc.) can be operator mode
checked by using this function.
a Since this message is special for the
If a received message has return mail setting, a technician, the message monitor is not
return mail can be sent by using the numeral input displayed when it is received with the
switches. machine monitor in the operator mode.
1. Selecting menu
Select "12 Service Message" on the Service
Menu screen.
• [F5]: Returns to previous screen

• [F6]: Proceeds to next scree (after sending)
2. Displaying message (read-only)
If a message is received, the content is
displayed. If there is no message, "No message"
is displayed.
• [F5]: Returns to Service Menu screen
a This message is different from that sent for
the operator with the machine monitor in the
operator mode
a Since this message is special for the
technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
D65EX,PX,WX-17 30-141
Electrical system
30-142 D65EX,PX,WX-17
Electrical system
Handling voltage circuit of engine controller

1. Disconnect connector between the engine
controller and engine. (Be sure to turn the
starting switch to the OFF position when
performing the connecting work.)
2. If a T to adapter is inserted in or connected to
the connector between the engine controller and
engine harness for troubleshooting, do not start
the engine.
a You can turn the starting switch to the OFF or
ON position, but must not turn it to the
START position.
D65EX,PX,WX-17 30-143
Electrical system
Adjustment method when controller has been replaced

a After the machine is assembled or the power
train controller is replaced, adjust the system
k If the system is not adjusted, the machine
may not operate normally but may move
unexpectedly. Accordingly, be sure to adjust
it.
a Precautions for replacing a controller:

If a controller is replaced, the value of the
following items will be reset to the initial factory
settings. If necessary, note down the values
before replacement. 3. Turning power on again
• Fan 100% mode: (1005) Turn the starting switch OFF and then turn ON.
• HSS minimum current value setting mode: Again, turn the starting switch OFF and ON, and
(2222) then switch the machine monitor to "09
• R1 reverse slow setting: (6001) Adjustment" of the service mode.
• R2 reverse slow setting: (6002) 4. Adjusting brake pedal potentiometer
• R3 reverse slow setting: (6003) Select "Brake Pedal Potentio Initial Set" (0005)
• High idle cut mode: (9997) and perform adjustment.
• Max. gear speed setting mode: (9998)
a Precautions for replacing a controller:
When replacing the controller, place the
machine on a safe place and turn the starting
switch to the OFF position.
1. Switching to service mode
Turn the starting switch to the ON position and
set the machine monitor to "09 Adjustment" of
the service mode.
5. Adjusting pitch angle sensor

Select "Pitch Angle Sensor Initial Set" (0009)
and perform adjustment.
2. Adjusting power train controller

Select "Initialization of power train controller"
(0002) and perform adjustment.
6. Adjusting steering lever NEUTRAL position

Select "S/T Lever N Position Set" (1012) and
perform adjustment.
30-144 D65EX,PX,WX-17
Electrical system
7. Adjusting steering lever leftmost position 10.Turning power on again

Select "S/T Lever Leftmost Position Set" (1013) Turn the starting switch OFF and turn ON again.
and perform adjustment. 11.Checking failure code
1) Switch the machine monitor to "Abnormality
Record" of the service mode.
2) Check to see if there is any failure code
being indicated. If there is not any, clear all
the recorded failure codes.
a If any active failure codes exist, eliminate
the cause of the incident by
troubleshooting, then carry out Steps 11
and 12 again.
a Precautions after replacing controller:
If necessary, set the values noted down
before replacement to the new controller.
8. Adjusting steering lever rightmost position
Select "S/T Lever Rightmost Position Set"
(1014) and perform adjustment.
9. Adjusting transmission clutch IP and fill time

Select "Transmission Clutch IP and Fill Time
Automatic Initial Correction (7842) and perform
adjustment.
D65EX,PX,WX-17 30-145
Electrical system
Testing diodes
a Test the diode array (8-pin) and the single diode 2) Apply the leads of the multi meter as
(2-pin) according to the following procedure. explained below and check the movement of
the pointer.
a The continuity directions of the diode array are
as follows. 1] Apply the red (+) lead of the multimeter to
the anode (P) of the diode and apply the
black (–) lead to the cathode (N).
2] Apply the red (+) lead of the multimeter to
the cathode (N) of the diode and apply
the black (–) lead to the anode (P).
3) Judge the quality of the diode by the
movement of the pointer.
• The pointer does not move in 1] but
moves in 2]: The diode is normal (The
moving range (resistance) depends on
the type and selected range of the tester,
however).
• The pointer moves in both 1] and 2]: The
diode is defective (internal short circuit).
a The continuity direction of the single diode is
• The pointer moves in neither of 1] and 2]:
indicated on the surface of the diode.
The diode is defective (internal
Testing discontinuity).
1. When using a digital multi meter
1) Set the multi meter to the diode range and
read the indicated value.
a When an ordinary circuit tester is used,
the voltage of the tester-internal battery is
indicated.
2) Apply the red (+) lead of the multimeter to the
anode (P) of the diode and apply the black
(–) lead to the cathode (N), and check the
indicated value.
3) Judge the quality of the diode by the
indicated value.
• Displayed value does not change: No
continuity (defect)
• Displayed value changes: Continue
(normal) (note)
Note: In the case of a silicon diode, a
value in the range from 460 to 600 is
indicated.
2. When using an analog multi meter

1) Set the multi meter in the resistance range.
30-146 D65EX,PX,WX-17
Pm clinic
Pm clinic
Pm Clinic service
Model Serial No. Service meter
T D65EX-17
T D65PX-17 h
T D65WX-17
User name Inspector Service meter
/ /
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 915 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 (specific Type of work
T Coal T Construction, civil gravity) T Dozing, excavating %
T Gold engineering T Rock T Side cutting %
T Limestone T Roads T Gravel T Leveling %
T T Tunnels T Sand T Travel %
T T Clay soil
Existence of abnormalities
Check of oil/coolant level
T Engine coolant level When necessary T Damper case
T Engine oil level T Power train T( )
T Hydraulic oil level T Final drive
Ambient temperature Height above sea level
Max.
°C
Min.
Operator's comment
Result of visual inspection
Failure code record

[ ] h [ ] h
Content: Content:
[ ] h [ ] h
Content: Content:
D65EX,PX,WX-17 30-147
Pm clinic
a Max. range of engine coolant temperature gauge a Max. range of power train oil temperature gauge
30-148 D65EX,PX,WX-17
Pm clinic
Measuring points for Pm clinic (1/2)
For the measurement procedures.

*1. Engine speed: Testing and adjusting
*2. Blowby pressure: Testing and adjusting
D65EX,PX,WX-17 30-149
Pm clinic
*3. Engine oil pressure: Testing and adjusting

*4. Boost pressure: Testing and adjusting
*5. Exhaust gas temperature: Testing and adjusting
30-150 D65EX,PX,WX-17
Pm clinic
Measuring points for Pm clinic (2/2)
For the measurement procedures.

*6. Torque converter parts: Testing and adjusting
*7. Transmission parts: Testing and adjusting
D65EX,PX,WX-17 30-151
Pm clinic
*8. Steering brake parts: Testing and adjusting

*9. Work equipment and HSS parts: Testing and adjusting
30-152 D65EX,PX,WX-17
Pm clinic
Pm Clinic check sheet

T D65EX-17 #
Serial No. T D65PX-17 #
T D6WPX-17 #
Work order No. Date of inspection Service meter Inspector
Year Month Day h
Standard
Testing conditions Measured OK NO
Item Unit value for new Repair limit
value
machine
Low idle 800 to 850 800 to 850
Decelerator cutting
2,050 to 2,050 to
(Adjustment ID:
2,150 2,150
0007)
Engine High idle Normal rpm 1,850 to 1,850 to
speed (deceleration) 1,950 1,950
975 to
Decelerator pedal 975 to 1,025
1,025
1,670 to
T/C stall (P mode) 1,650
1,870
kPa
Engine
Blowby Max. 1.96 2.94

pressure T/C stall <mmH2-
<Max. 200> <300>
O>
Min. 0.15 0.08
Low idle MPa
Engine oil SAE30 <Min. 1.5> <0.8>
pressure <kg/ 0.34 to 0.59 0.21
High idle SAE15W-40
cm2>
<3.5 to 6.0> <2.1>
kPa 120 to 160
Boost 93
pressure T/C stall <mmH- <900 to
g> 1,200> <700>
Exhaust
tempera- T/C stall °C Max. 600 Max. 650
ture
Standard
value
machine
Inlet oil Max. 0.98 Max. 0.98
Torque converter
pressure Transmis-
<Max. 10> <Max. 10>
sion: High idle MPa
NEUTRAL
(Adjustment ID: <kg/ 0.39 to
Outlet oil Oil 0.39 to 0.78
0007) cm2> 0.78
pressure temperature: <4 to 8>
70 to 90 °C <4 to 8>
Standard
value
machine
3.10 to 3.50 Min. 3.01
Transmission
Low idle <31.7 to <Min.

Main relief Transmis- MPa
35.7> 30.7>
sion: High idle <kg/
pressure 3.25 to 3.65 Min. 3.17
NEUTRAL cm2>
(Adjustment ID: <33.3 to <Min.
0007) 37.3> 32.3>
Min.
Cooling fan
• Engine at low idle 650 to 750 600

speed
Fan speed • Fan 100% speed rpm
Max. 1,675 to
mode 1,600
speed 1,725
D65EX,PX,WX-17 30-153
Pm clinic
T D65EX-17 #
Serial No. T D65PX-17 #
T D65WX-17 #
Year Month Day h
Standard
Item Testing conditions Unit value for new Repair limit Measured OK NO
value
machine
34.6 to 37.6 Min. 32.4
Steering
Steering load sensing pressure

High <353 to 383> <Min. 330>
idle 36.6 to 39.5 34.3
Steering relief operating pressure
MPa <373 to 403> <Min. 350>
High
idle <kg/
cm2> 2.55 to
(Adjust- 2.55 to 2.94
Brake actuating pressure 2.94
ment
Brake
<26 to 30>
ID: <26 to 30>
0007)
Brake
Brakes applied, T/M in F2, engine at high
perfor- Machine must not move
idle
mance
Standard
value
machine
Work
equipment
High 26.9 to 30.4 Min. 25.9
load Blade tilt relief
sensing idle <275 to 310> <Min. 265>
pressure
Min. 28.4 Min. 27.4
Hydraulic system
Ripper lift relief

Low idle <Min. 290> <Min. 280>
HSS, MPa Min. 28.4 Min. 27.4
Blade tilt relief
work <kg/ <Min. 290> <Min. 280>
equipment Ripper lift relief cm2> 28.9 to 32.3 Min. 27.9
pump <295 to 330> <Min. 285>
28.9 to 32.3 Min. 27.9
Blade tilt relief
High <295 to 330> <Min. 285>
idle 3.19 to
PPC valve 3.19 to 4.17
4.17
output Blade tilt relief <32.5 to
pressure <32.5 to
42.5>
42.5>
Standard
value
machine
Straight tilt doser EX:2.2 to 2.8 Max. 3.1
Blade Sigma dozer PX:2.1 to 2.7 Max. 3.0

RAISE Power angle
2.2 to 2.8 Max. 3.1
power tilt doser
Straight tilt doser High sec. 1.3 to 1.9 Max. 2.1
Tilt (Left o Sigma dozer idle
Right) Power angle
1.4 to 2.0 Max. 2.2
power tilt doser
Angle (Left o Right) 3.5 to 4.5 Max. 5.0
Ripper Raise 1.0 to 2.0 Max. 2.5
30-154 D65EX,PX,WX-17
Pm clinic
Testing Standard
Measured OK NO
Item condi- Unit value for new Repair limit
value
tions machine
Hydraulic oil temperature °C 45 to 55 –
Hydraulic drift
Blade lift cylinder Max. 35 Max. 35

Engine
stopped mm/
Blade tilt cylinder 5min. Max. 70 Max. 70
Testing Standard
Measured OK NO
Item condi- Unit value for new Repair limit
value
tions machine
Engine There must be no
Visual check of final drive drain plug –
stopped 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-17 30-155
Pm clinic
Undercarriage check sheet T D65EX-17 #

Serial No.
T D65WX-17 #
Year Month Day h
• Measure the bushing temperature immediately after the work.
Left side of machine
Right side of machine
a Check results Left A: Clearance Right A: Clearance

track between links track between links
OK NO
Pin Pin
Left side of 1.4 1.4
No. No.
machine
Right side of
machine
• Opening of track link
30-156 D65EX,PX,WX-17
Pm clinic
Undercarriage check sheet Serial No. T D65PX-17 #

Year Month Day h

OK NO
Pin Pin
No. No.
machine
Right side of
machine
D65EX,PX,WX-17 30-157
Pm clinic
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) (Program form No. NJLA195001)
30-158 D65EX,PX,WX-17
Pm clinic
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) (Program form No. NJLA195001)
D65EX,PX,WX-17 30-159
Pm clinic
Undercarriage check sheet for PLUS T D65EX-17 #

Serial No.
specification T D65WX-17 #

Year Month Day h

OK NO
Pin Pin
No. No.
machine
Right side of
machine
30-160 D65EX,PX,WX-17
Pm clinic
Undercarriage check sheet for PLUS Serial No. T D65PX-17 #

specification

Year Month Day h

OK NO
Pin Pin
No. No.
machine
Right side of
machine
D65EX,PX,WX-17 30-161
Pm clinic
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL, IMPACT) FOR PLUS SPECIFICATION

(Program form No. NJLA195001)
30-162 D65EX,PX,WX-17
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-1
Table Of Contents
40 Troubleshooting............................................................................................................................ 40-8
General information on troubleshooting ........................................................................................ 40-9
Instruction on troubleshooting ............................................................................................... 40-9
How to proceed troubleshooting .......................................................................................... 40-11
Check before troubleshooting.............................................................................................. 40-12
Testing procedure before troubleshooting............................................................................. 40-14
Classification and procedure for troubleshooting ................................................................... 40-23
Classification and procedures for troubleshooting numbers.................................................... 40-25
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 40-30
Connector list and layout .................................................................................................... 40-32
Connector contact identification........................................................................................... 40-45
T-branch box and T-branch adapter table ............................................................................. 40-82
Fuse locations table ........................................................................................................... 40-88
Precautions for cleaning and replacing KDPF (KCSF, KDOC) ................................................ 40-91
Troubleshooting by failure code (Display of code) ........................................................................ 40-93
Failure codes table............................................................................................................. 40-93
Failure code [1500L0] Transmission clutch:Abnormal.......................................................... 40-104
Failure code [15SAL1] Forward clutch:Fill High................................................................... 40-105
Failure code [15SALH] Forward clutch:Fill Low ................................................................... 40-107
Failure code [15SBL1] Reverse clutch:Fill High................................................................... 40-109
Failure code [15SBLH] Reverse clutch:Fill Low....................................................................40-111
Failure code [15SEL1] Speed 1st clutch:Fill High ................................................................ 40-113
Failure code [15SELH] Speed 1st clutch:Fill Low ................................................................ 40-115
Failure code [15SFL1] Speed 2nd clutch:Fill High ............................................................... 40-117
Failure code [15SFLH] Speed 2nd clutch:Fill Low ............................................................... 40-119
Failure code [15SGL1] Speed 3rd clutch:Fill High ............................................................... 40-121
Failure code [15SGLH] Speed 3rd clutch:Fill Low................................................................ 40-123
Failure code [15SJL1] L/U :Fill Hihg ................................................................................... 40-125
Failure code [15SJLH] L/U :Fill low .................................................................................... 40-127
Failure code [1800MW] P/L clutch:Slip ............................................................................... 40-129
Failure code [879AKA] Air Conditioner Inner Sensor Disconnection...................................... 40-130
Failure code [879AKB] Air Conditioner Inner Sensor Disconnection...................................... 40-131
Failure code [879BKA] Air Conditioner Outside Air Sensor Disconnection ............................. 40-132
Failure code [879BKB] Air Conditioner Outside Air Sensor Disconnection ............................. 40-133
Failure code [879CKA] Ventilating Sensor Disconnection .................................................... 40-134
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-135
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-136
Failure code [879EMC] Ventilation Abnormal ...................................................................... 40-137
Failure code [879FMC] A/M Damper Abnormal ................................................................... 40-138
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-139
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-140
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-141
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-142
Failure code [A1U0N3]: KDPF Dry Request (HC Release)................................................... 40-143
Failure code [A1U0N4] KDPF Dry Request (HC Release).................................................... 40-145
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-147
Failure code [AB00KE] Battery Charge Voltage Low ........................................................... 40-148
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-150
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-151
Failure code [B@CENS] P/L Oil Overheat .......................................................................... 40-152
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-153
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-154
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-155
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-157
Failure code [CA131] Throttle Sensor High Error................................................................. 40-159
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-161
40-2 D65EX,PX,WX-17
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-163
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-165
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-167
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-169
Failure code [CA234] Eng Overspeed ................................................................................ 40-173
Failure code [CA221] Ambient Press Sens High Error ......................................................... 40-174
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-176
Failure code [CA238] Ne Speed Sens Supply Volt Error ...................................................... 40-179
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-180
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-182
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-184
Failure code [CA281] Pump Press Balance Error ................................................................ 40-186
Failure code [CA295] Ambient Pressure Sensor In Range Error ........................................... 40-187
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-200
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-201
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-204
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-206
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-209
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-211
Failure code [CA435] Eng Oil Press SW Error .................................................................... 40-213
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-214
Failure code [CA442] Battery Voltage High Error................................................................. 40-216
Failure code [CA449] Rail Press Very High Error................................................................. 40-217
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-219
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-221
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-223
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-224
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-226
Failure code [CA553] Rail Press High Error ........................................................................ 40-228
Failure code [CA555] Crankcase Press High Error 2 ........................................................... 40-229
Failure code [CA556] Crankcase Pressure High Error 3 ...................................................... 40-230
Failure code [CA559] Rail Pump Press Low Error ............................................................... 40-231
Failure code [CA595] Turbocharger Speed High Error 2 ...................................................... 40-235
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-236
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-238
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-242
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-244
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-246
Failure code [CA698] ECM Internal Temp Sensor Low Error ................................................ 40-247
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-248
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-250
Failure code [CA1117] Engine Controller Partial Data Lost Error........................................... 40-255
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-256
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-258
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-261
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-262
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-264
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-266
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-268
D65EX,PX,WX-17 40-3
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-270
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-272
Failure code [CA1942] Crankcase Press Sensor In Range Error .......................................... 40-281
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-282
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-283
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-285
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-287
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-288
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-290
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-292
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-294
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-297
Failure code [CA2311] lMV Solenoid Error.......................................................................... 40-298
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-299
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-301
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-303
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-304
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-306
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-308
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-310
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-312
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-314
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-316
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-318
Failure code [CA2387] KVGT Valve Servo Error ................................................................. 40-320
Failure code [CA2554] Exh Manifold Press Sens In Range error .......................................... 40-321
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-322
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-324
Failure code [CA2637] KDOC Blocked............................................................................... 40-326
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-328
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-331
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-332
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-333
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-335
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-337
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-340
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-343
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-344
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-347
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-349
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-353
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-356
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-360
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-364
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-367
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-371
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-375
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-379
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-382
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-386
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-388
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-390
Failure code [D130KA] Neutral relay:Open ......................................................................... 40-391
Failure code [D130KB] Neutral relay:Short circuit................................................................ 40-393
Failure code [D19DKA] Amber light relay:Open .................................................................. 40-395
40-4 D65EX,PX,WX-17
Failure code [D19DKB] Amber light relay:Short circuit ......................................................... 40-397
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-399
Failure code [D811MC] KOMTRAX Error............................................................................ 40-402
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-403
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX) ....................................... 40-404
Failure code [D8ALKB] Operating Lamp Short Circuit(KOMTRAX) ....................................... 40-406
Failure code [D8AQKR] CAN2 Discon(KOMTRAX) ............................................................. 40-407
Failure code [DAF0MB] Monitor Memory Error.................................................................... 40-408
Failure code [DAF0MC] Monitor Malfunction....................................................................... 40-409
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-410
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-412
Failure code [DAFGMC] GPS Module Error........................................................................ 40-413
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-414
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) ............................................ 40-416
Failure code [DAFQKR] CAN2 Discon ............................................................................... 40-417
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-418
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-419
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-423
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-428
Failure code [DBE0KT] PT controller:Abnormality in controller.............................................. 40-433
Failure code [DBE1KK] PT controller:Source voltage low..................................................... 40-434
Failure code [DBE2KK] PT controller:Output voltage low ..................................................... 40-436
Failure code [DBE6KK] PT:Sensor volt 24V Out of normal range .......................................... 40-440
Failure code [DBE9KQ] PT controller:Type select signal ...................................................... 40-444
Failure code [DBELKA] Operating Lamp Open Circuit(PT Con)............................................ 40-445
Failure code [DBELKB] Operating Lamp Short Circuit(PT Con) ............................................ 40-447
Failure code [DBEQKR] CAN2 Discon (PT Con) ................................................................. 40-448
Failure code [DBERKR] CAN1 Discon (PT Con) ................................................................. 40-449
Failure code [DD12KA] Shift up Sw:Open .......................................................................... 40-450
Failure code [DD12KB] Shift up Sw:Short circuit ................................................................. 40-452
Failure code [DD13KA] Shift down Sw:Open ...................................................................... 40-454
Failure code [DD13KB] Shift down Sw:Short circuit ............................................................. 40-456
Failure code [DD14KA] Parking lever Sw:Open .................................................................. 40-458
Failure code [DD14KB] Parking lever Sw:Short circuit ......................................................... 40-460
Failure code [DDKFL4] Left Angle Sw:Signal mismatch ....................................................... 40-462
Failure code [DDKGL4] Right Angle Sw:Signal mismatch .................................................... 40-464
Failure code [DDKHKA] iB Sw:Open.................................................................................. 40-466
Failure code [DDKHKB] iB Sw:Short circuit ........................................................................ 40-468
Failure code [DDN7KA] Weq pitch SW: Open ..................................................................... 40-470
Failure code [DDN7KB] Pitch select solenoid:Short circuit ................................................... 40-472
Failure code [DDNLKA] Weq lock Sw:Open ....................................................................... 40-474
Failure code [DDNLKB] Weq lock Sw:Short circuit .............................................................. 40-476
Failure code [DGS1KA] Hyd oil temp sensor:Open ............................................................. 40-478
Failure code [DGS1KX] Hyd oil temp: signal abnormal ........................................................ 40-479
Failure code [DGT1KA] T/C oil temp sensor:Open .............................................................. 40-481
Failure code [DGT1KX] T/C oil temp sensor:Out of normal range ......................................... 40-482
Failure code [DH21KA] Weq pressure sensor:Open............................................................ 40-484
Failure code [DH21KB] Work equipment pressure sensor:Hot Short..................................... 40-486
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ....................................... 40-488
Failure code [DHTDKA] T/C pressure sensor:Open............................................................. 40-489
Failure code [DHTDKB] T/C pressure sensor:Hot Short....................................................... 40-491
Failure code [DK10KA] Fuel control Dial:Open ................................................................... 40-493
Failure code [DK10KB] Fuel control Dial:Short circuit .......................................................... 40-495
Failure code [DK30KB] ST lever:Hot Short ......................................................................... 40-499
Failure code [DK30KX] ST lever:Main and Sub Error........................................................... 40-501
Failure code [DK30KZ] ST lever:Main and Sub Error ........................................................... 40-502
D65EX,PX,WX-17 40-5
Failure code [DK30L8] ST lever:Signal mismatch................................................................ 40-503
Failure code [DK31KB] ST lever2:Hot Short ....................................................................... 40-506
Failure code [DK40KA] Brake potentiometer:Open.............................................................. 40-508
Failure code [DK40KB] Brake potentiometer:Hot Short........................................................ 40-510
Failure code [DK55KX] FR lever:Main and Sub Error .......................................................... 40-512
Failure code [DK55KZ] FR lever:Main and Sub Error........................................................... 40-513
Failure code [DK55L8] FR lever:Signal mismatch ............................................................... 40-514
Failure code [DKH1KA] Pitch angle sensor:Open................................................................ 40-523
Failure code [DKH1KB] Pitch angle sensor:Hot Short.......................................................... 40-525
Failure code [DLM3KA] Fan rev. sensor:Open .................................................................... 40-527
Failure code [DLM3MB] Fan control:Mismatch.................................................................... 40-529
Failure code [DLT3KA] T/M out-speed sensor:Open............................................................ 40-530
Failure code [DLT3KB] T/M out-speed sensor:Short circuit .................................................. 40-532
Failure code [DV20KB] Back-up alarm :Short Circuit ........................................................... 40-533
Failure code [DW5AKA] Pitch select solenoid:Disconnection ............................................... 40-535
Failure code [DW5AKB] Pitch select solenoid:Short circuit................................................... 40-536
Failure code [DW5AKY] Pitch select solenoid:Hot short....................................................... 40-537
Failure code [DW7BKA] Fan reverse solenoid:Open ........................................................... 40-539
Failure code [DW7BKB] Fan reverse solenoid:Short circuit .................................................. 40-541
Failure code [DWN1KA] Hss EPC RH:Open....................................................................... 40-542
Failure code [DWN1KB] Hss EPC RH:Short circuit ............................................................. 40-543
Failure code [DWN1KY] Hss EPC RH:Hot short ................................................................. 40-544
Failure code [DWN2KA] Hss EPC LH:Open ....................................................................... 40-546
Failure code [DWN2KB] Hss EPC LH:Short circuit .............................................................. 40-547
Failure code [DWN2KY] Hss EPC LH:Hot short .................................................................. 40-548
Failure code [DWN5KA] Fan pump solenoid 1 :Open .......................................................... 40-550
Failure code [DWN5KB] Fan pump solenoid 1 :Short circuit ................................................. 40-551
Failure code [DWN5KY] Fan pump solenoid 1: Hot short ..................................................... 40-552
Failure code [DXA2KA] TVC solenoid 1: Open ................................................................... 40-554
Failure code [DXA2KB] TVC solenoid 1: Short circuit .......................................................... 40-555
Failure code [DXA2KY] TVC solenoid 1: Hot short .............................................................. 40-556
Failure code [DXH1KA] Lock-up ECMV:Open..................................................................... 40-558
Failure code [DXH1KB] Lock-up ECMV: Short circuit .......................................................... 40-560
Failure code [DXH1KY] Lock-up ECMV: Hot short .............................................................. 40-561
Failure code [DXH4KA] 1st clutch ECMV:Open .................................................................. 40-563
Failure code [DXH4KB] 1st clutch ECMV:Short circuit ......................................................... 40-564
Failure code [DXH4KY] 1st clutch ECMV:Hot short ............................................................. 40-565
Failure code [DXH5KA] 2nd clutch ECMV:Open ................................................................. 40-567
Failure code [DXH5KB] 2nd clutch ECMV:Short circuit ........................................................ 40-568
Failure code [DXH5KY] 2nd clutch ECMV:Hot short ............................................................ 40-569
Failure code [DXH6KA] 3rd clutch ECMV:Open .................................................................. 40-571
Failure code [DXH6KB] 3rd clutch ECMV:Short circuit......................................................... 40-572
Failure code [DXH6KY] 3rd clutch ECMV:Hot short ............................................................. 40-573
Failure code [DXH7KA] R clutch ECMV:Open .................................................................... 40-575
Failure code [DXH7KB] R clutch ECMV:Short circuit ........................................................... 40-576
Failure code [DXH7KY] R clutch ECMV:Hot short ............................................................... 40-577
Failure code [DXH8KA] F clutch ECMV:Open..................................................................... 40-579
Failure code [DXH8KB] F clutch ECMV:Short circuit............................................................ 40-580
Failure code [DXH8KY] F clutch ECMV:Hot short................................................................ 40-581
Failure code [DXJ4KA] Weq lock Sol.:Open ....................................................................... 40-583
Failure code [DXJ4KB] Weq lock Sol.:Short circuit .............................................................. 40-585
Failure code [DXJCKA] Blade angle left EPC:Open............................................................. 40-586
Failure code [DXJCKB] Blade angle left EPC:Short circuit ................................................... 40-587
Failure code [DXJCKY] Blade angle left EPC:Hot short ....................................................... 40-588
40-6 D65EX,PX,WX-17
Failure code [DXJDKA] Blade angle right EPC:Open .......................................................... 40-590
Failure code [DXJDKB] Blade angle right EPC:Short circuit ................................................. 40-591
Failure code [DXJDKY] Blade angle right EPC:Hot short ..................................................... 40-592
Troubleshooting of electrical system (E-mode) .......................................................................... 40-594
E-1 Engine does not start (Engine does not crank) .............................................................. 40-594
E-2 Manual preheating does not work ................................................................................ 40-600
E-3 Automatic preheating does not work ............................................................................ 40-603
E-4 While preheating is working, preheating monitor does not light up .................................. 40-605
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-607
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor
lights up ............................................................................................................. 40-610
E-7 Air cleaner clogging monitor lights up in yellow while engine is running ........................... 40-611
E-8 Charge level monitor lights up while engine is running ................................................... 40-612
E-9 Engine coolant temperature monitor lights up while engine is running ............................. 40-614
E-10 Engine oil pressure monitor lights up while engine is running ....................................... 40-615
E-11 Power train oil temperature monitor lights up while engine is running ............................ 40-616
E-12 Hydraulic oil temperature monitor lights up while engine is running ............................... 40-617
E-13 Engine coolant temperature gauge does not indicate correct temparature ..................... 40-618
E-14 Fuel level gauge does not indicate correct level .......................................................... 40-619
E-15 Power train oil temperature gauge (multi-gauge) does not indicate correct
temperature ....................................................................................................... 40-621
E-16 Hydraulic oil temperature gauge (multi-gauge) does not indicate correct
temperature ....................................................................................................... 40-622
E-17 Operation mode does not change .............................................................................. 40-623
E-18 Gearshift mode does not change ............................................................................... 40-624
E-19 Operating customize switch does not display customize screen ................................... 40-625
E-20 Modifying setting on customize screen does not change setting of machine .................. 40-626
E-21 Reverse slow mode does not function properly ........................................................... 40-627
E-22 Alarm buzzer does not sound or does not stop sounding ............................................. 40-628
E-23 While starting switch is in OFF position, service meter is not displayed ......................... 40-629
E-24 Service mode cannot be selected .............................................................................. 40-630
E-25 Horn does not sound ................................................................................................ 40-631
E-26 Horn does not stop sounding..................................................................................... 40-632
E-27 Backup alarm does not sound ................................................................................... 40-633
E-28 Backup alarm does not stop sounding........................................................................ 40-635
E-29 Headlamp does not light up....................................................................................... 40-636
E-30 Rear lamp does not light up....................................................................................... 40-639
E-31 No wiper operates continuously or intermittently.......................................................... 40-641
E-32 Front wiper does not operate (Failure in both continuous and intermittent
operations)......................................................................................................... 40-644
E-33 Rear wiper does not operate (Failure in both continuous and intermittent
operations)......................................................................................................... 40-647
E-34 Left door wiper does not operate (Failure of both continuous and intermittent
operations)......................................................................................................... 40-650
E-35 Right door wiper does not operate (Failure of both continuous and intermittent
operations)......................................................................................................... 40-653
E-36 KOMTRAX system does not operate properly............................................................. 40-656
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-658
Information mentioned in troubleshooting table (H mode) .................................................... 40-658
System diagram of hydraulic and mechanical system.......................................................... 40-659
List of Failure Mode and Cause ......................................................................................... 40-661
H-1 Machine lacks power (insufficient drawbar pull) ............................................................ 40-664
H-2 Machine cannot travel (at 2nd or 3rd speed) ................................................................. 40-666
H-3 Machine does not start at all gear speeds..................................................................... 40-667
H-4 Machine travels only in one direction, either forward or in reverse .................................. 40-668
H-5 Large time lag at gear shifting or directional selection.................................................... 40-669
H-6 Machine cannot be steered (machine does not turn left or right) ..................................... 40-670
H-7 Steering speed or power is insufficient ......................................................................... 40-671
H-8 Brake does not operate .............................................................................................. 40-672
D65EX,PX,WX-17 40-7
40 Troubleshooting
H-9 Torque converter does not lock up ............................................................................... 40-673

H-10 Power train oil overheats .......................................................................................... 40-674
H-11 Unusual noise is heard from around HSS and work equipment pump or HSS
motor ................................................................................................................. 40-675
H-12 All work equipment operates slowly ........................................................................... 40-676
H-13 All work equipment does not operate ......................................................................... 40-677
H-14 Blade lift speed or power is low ................................................................................. 40-678
H-15 Blade tilt speed or power is low ................................................................................. 40-679
H-16 Blade angle speed or power is low............................................................................. 40-680
H-17 Ripper lift speed or power is low ................................................................................ 40-681
H-18 Hydraulic drift of lifted blade is large........................................................................... 40-682
H-19 Hydraulic drift of tilted blade is large........................................................................... 40-683
H-20 Hydraulic drift of lifted ripper is large .......................................................................... 40-684
H-21 Fans speed is abnormal (high, low, or no rotation)....................................................... 40-685
H-22 Unusual noise is heard from around fan ..................................................................... 40-687
Troubleshooting of engine (S-mode)......................................................................................... 40-688
Information contained in troubleshooting table (S mode)...................................................... 40-688
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-689
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-690
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
does not start) .................................................................................................... 40-691
S-4 Startability is poor....................................................................................................... 40-692
S-5 Engine does not pick up smoothly ............................................................................... 40-694
S-6 Engine stops during operation ..................................................................................... 40-696
S-7 Engine runs rough or is unstable ................................................................................. 40-698
S-8 Engine lacks power .................................................................................................... 40-699
S-9 Exhaust gas is black (KDPF gets clogged in a short time) .............................................. 40-701
S-10 Engine oil consumption is excessive .......................................................................... 40-703
S-11 Engine oil becomes contaminated early...................................................................... 40-704
S-12 Fuel consumption is excessive .................................................................................. 40-705
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-706
S-14 Oil pressure drops .................................................................................................... 40-707
S-15 Fuel mixes into engine oil.......................................................................................... 40-708
S-16 Water mixes into engine oil (milky) ............................................................................. 40-709
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-710
S-18 Unusual noise is made ............................................................................................. 40-711
S-19 Vibration is excessive ............................................................................................... 40-712
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-713
S-21 Frequent active regeneration..................................................................................... 40-714
S-22 Active regeneration is long ........................................................................................ 40-715
S-23 White smoke is exhausted during active regeneration ................................................. 40-716
1 40 Troubleshooting
40-8 D65EX,PX,WX-17
40 Troubleshooting
General information on troubleshooting

Instruction on troubleshooting
(Rev. 2010/03)
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with two or more service technician, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe radiator cap is removed when the engine is hot, hot water 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 and the like, turn the battery disconnect switch to OFF position while
the system operating lamp is turned off.
k When removing the plug or cap from a component which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to
understand 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
symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• 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 procedure.
2. Points to ask the 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)Are abnormal symptoms detected in the machine?
2)Make checks before starting day's work.
3)Make checks of other items.
4)Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Confirming failure
See the extent of the failure by yourself, and judge whether it is a real failure or a problem caused by the
handling or operating the machine.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure,
then use the troubleshooting flowchart to locate the failure exactly.
D65EX,PX,WX-17 40-9
40 Troubleshooting
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 removed, 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.
40-10 D65EX,PX,WX-17
40 Troubleshooting
How to proceed troubleshooting

(Rev. 2007/12)
D65EX,PX,WX-17 40-11
40 Troubleshooting
Check before troubleshooting

No. Item Criterion Remedy
1 Check for abnormal sounds and smells – Repair
2 Check for dirt around engine – Remove
3 Check for water leakage around engine – Repair
a: Engine, lubricating oil and coolant
4 Check for oil leakage around engine – Repair

5 Check for leakage from fuel line – Repair
6 Check of radiator for clogging – Remove
7 Check of level and type of fuel – Refilling
8 Check for foreign matter in fuel – Clean and drain
9 Check of fuel pre filter – Replace
10 Check of fuel main filter – Replace
Between
11 Check of level (in oil pan) and type of engine oil Refill
H and L
Between
12 Check of coolant level (in sub tank) Refill with coolant
H and L
No
clogging
13 Check of air cleaner for clogging indication Clean or replace
on
monitor
1 Check for unusual sounds and smells – Repair
2 Check for oil leakage – Repair
b: Hydraulic and mechanical equipment
Check of hydraulic oil Between

3 Refill
H and L
4 Check of hydraulic oil strainer – Clean and drain
5 Check of hydraulic oil filter – Replace
Check of power train case oil level Between
6 Refill
H and L
7 Check of power train pump strainer – Clean and drain
8 Check of transmission oil filter and torque converter oil filter – Clean and drain
Check of damper case oil level Between
9 Refill
H and L
Between
10 Check of final drive case oil level Refill
H and L
11 Execution of air bleeding operation – Air bleed
40-12 D65EX,PX,WX-17
40 Troubleshooting
No. Item Criterion Remedy

Retighten or
1 Check of battery terminals for looseness and corrosion –
replace
Retighten or
2 Check of alternator terminals for looseness and corrosion –
replace
Retighten or
3 Check of starting motor terminals for looseness and corrosion –
replace
Check of battery voltage (with engine stopped) 20 to 30 Charge or replace
4
V
Check of battery electrolyte level Between Add or replace
5
H and L
Check of wiring harness for discoloration, burnt areas and cover
c: Electrical equipment
6 – Repair or replace
peeling
Check for removal of wiring harness clamp and sagging of wiring – Repair
7
harness
8 Check of grounding – Repair
9 Check for loose connector and damaged lock – Repair or replace
10 Check of connector pin for corrosion, bend and deformation – Repair or replace
Dry, clean or
11 Check for water and foreign matter in connector –
replace
12 Check of wiring harness for open and short circuit – Repair or replace
13 Check of fuse for breakage and corrosion – Replace
After
several
Check of alternator voltage (When engine speed is medium or minutes
14 higher) Replace
operation:
27.5 to
29.5 V
Check of battery relay operation sound (When starting switch is
15 turned to ON or OFF position) – Replace
1 Check of undercarriage – Repair
d. Exterior parts
2 Check of handrails and steps – Repair
3 Check of mirrors – Clean or repair
1 Check of gauges and monitors – Clean or replace

e. Interior parts
2 Check of seat belt – Repair
D65EX,PX,WX-17 40-13
40 Troubleshooting
Testing procedure before troubleshooting

Walk-around check
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated combustibles around hot engine parts such as the engine, KDPF, and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
failures.
a1. and b1. Check for unusual sounds and smells

Check for unusual sounds and smells.
Some causes of unusual sounds and smells can damage the machine if they are left as they are. Therefore,
stop the machine immediately when you find any unusual sounds and smells.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.)
on hot engine parts such as the KDPF, turbocharger, etc.
a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check any oil leaks from the engine and any water leaks from the coolant system. If any of them is unusual,
perform a repair.
a5. Check for leakage from fuel line
Check the hoses and tubes for any fuel leaks and damages. If any of them is abnormal, perform a repair.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the radiator.
For removal of dirt from the radiator, see the Operation and Maintenance Manual, "Cleaning and testing of
radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner condenser fins (machine with
the air conditioner)".
b2. Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage and hoses for cracks and excessive wear, check that each
clearance is within the normal range, and then repair any unusual parts.
b3. Check of hydraulic equipment, hydraulic tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the battery.
d1. Check of undercarriage (tracks, sprockets, idlers and guards) for defect, wear, loose bolts and oil
leakage from roller
Repair any unusual parts.
d2. Check of handrails and steps for unusual conditions and loose bolts
Repair any unusual conditions and retighten any loose bolts.
d3. Check and cleaning of rear view mirrors
Check and repair any unusual conditions and breakage of the rear view mirrors.
Clean the mirror surfaces and adjust their angles so that the operator can see the area behind him at the
operator's seat.
e1. Check of gauges and monitors for unusual conditions
Check the gauges and monitors inside the operator cab. If any of them is unusual, replace it.
Clean up the surfaces.
e2. Check of seat belt and mounting hardware
Check the hooks, locks and hook fittings for damage. If any of them has a problem, repair the damage.
40-14 D65EX,PX,WX-17
40 Troubleshooting
Checks according to checking procedure

c. Electrical equipment
c1. Check of battery terminal for looseness and corrosion
1. Open the battery cover.
2. Check the battery cable terminals for looseness and corrosion.
c2. Check of alternator terminal for looseness and corrosion
• Open right engine hood.
• Check terminal B (AL/B), ground terminal (AL/E), and terminal R (AL/R) of alternator for breakage,
looseness and corrosion.
c3. Check of starting motor terminal for looseness and corrosion

• Check starting motor terminal B (ST/B) and connector ST for breakage, looseness and corrosion.
c4. Testing of battery voltage (when engine stops)

Test the battery voltage by using the battery tester while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k Do not use the battery while its electrolyte level is below LOWER LEVEL. If it is used under that
condition, its inside will deteriorate, its service life will be shortened and it may lead to an
explosion.
k Since the battery produces combustible gas that can explode, do not bring any open flame near it.
k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or skin.
If it does, wash it away with large amount of water and contact your doctor.
a Do not add battery electrolyte beyond the UPPER LEVEL mark. Excessive addition to overflow can
damage the painted surface and corrode the parts.
a As refined water (Example: Commercially available battery fluid) added to the battery may freeze, add it
before starting work for the day so that it does not freeze.
D65EX,PX,WX-17 40-15
40 Troubleshooting
• When checking the electrolyte level through the side face of the battery
1. Clean around the electrolyte level lines with a cloth soaked in water, and check that the electrolyte level is
between UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.)
a Do not clean the battery with a dry cloth since static electricity may cause an explosion.
2. If the electrolyte level is below the center between the U.L. and L.L. lines, remove cap (2) and add refined
water (Example: Commercially available battery fluid) to the U.L. line immediately.
3. After adding the refined water, tighten the cap securely.
a If you have added refined water above the U.L. line, take some of it out by using a syringe or similar
tool. Neutralize the liquid that has been taken out with sodium bicarbonate or other suitable liquid, and
run it off with a large amount of water.
• When electrolyte level cannot be checked through the side face of the battery
1. Remove the cap on the top of battery. (described previously)
2. Look into electrolyte level check opening (3) to check the electrolyte level. If the electrolyte level is below
sleeve (4), be sure to add refined water (Example: Commercially available battery fluid) up to the sleeve
bottom (U.L. line).
• (A) Correct level: Since the electrolyte level reaches to the sleeve bottom, the shape of the electrode
plates will appear distorted due to the surface tension.
• (B) Low: Since the electrolyte level does not reach the sleeve bottom, the shape of the electrode plates
will appear straight.
3. After adding the refined water, tighten the cap.
a If you have added refined water above the U.L. line, take some of it out by using a syringe or similar
tool. Neutralize the liquid that has been taken out with sodium bicarbonate or other suitable liquid, and
run it off with a large amount of water.
c6. Check of wiring harness for discoloration, burn and cover peeling
• Check the wiring harness and cables for discoloration and burn.
a Discoloration and burn indicate that short circuit or ground fault may be in the circuit.
• Check the wiring harnesses and cables for damage and peeling of the covers.
• If any fault is discovered, repair or replace the wiring harness or cable.
c7. Check for removal of wiring harness clamps and sagging of wiring harness
• Check the wiring harnesses for sagging and play caused by removal of a clamp.
a In particular, carefully check the wiring harness around the hot and movable parts.
40-16 D65EX,PX,WX-17
40 Troubleshooting
• If any part is off the clamp, resecure it with the clamp.
c8. Check of grounding

a Check the ground terminal for looseness and rusting in particular.
• Open left engine hood.
• Remove receiver drier (1).
• Check connection of the ground terminal (GND20) of the engine controller.
D65EX,PX,WX-17 40-17
40 Troubleshooting
• Check the connection of ground cable (2) of the engine controller.
• Open the right engine hood.

• Check the connection of (GND3) in portion P and that of (GND03) in portion Q.
a ENGMB: Engine mounting bolt.

• Check the connection of ground strap (3) of the engine.
40-18 D65EX,PX,WX-17
40 Troubleshooting
• Cab ground
a (GND11) and (GND12) are located on the bottom at left rear in the operator's cab.
• Remove cover (4).
• Check the connection of (GNDC5).
c9. Check of connectors for loose and locks for damage
D65EX,PX,WX-17 40-19
40 Troubleshooting
• Pull the male and female parts of the connector with hand to check the condition of their connection.
• If the connecting condition is unusual, connect it securely.
• Check the connector to see whether it is unlocked and check its lock portion and housing for cracks.
• Check the lock screws of the engine controller and power train controller for looseness.
a Use a hexagonal wrench with 4 mm width across flats.
c10. Check of connector pin for corrosion, bend and deformation
• Disconnect the connector and check the pins for corrosion, bending and retraction. Check the female pins
for expansion.
• If any pin is found to be damaged, repair or replace it.
a If the pins are not shiny, apply contact restorer to them and connect and disconnect several times to shine
them. (If the pins do not become shiny, connect and disconnect the connector 10 times)
c11. Check of the connector for water and foreign matter getting in
• Disconnect the connector and check whether there is water, dirt, sand, etc. in it.
a If there is water or foreign matter in the connector, check the seal for damage.
• If the seal is defective, repair or replace it.
• Dry the connector off the moisture by using a drier.
40-20 D65EX,PX,WX-17
40 Troubleshooting
• Remove foreign matter in the connector with a cloth or other material, and blow compressed air against
the inside of the connector.
c12. Check of wiring harness for open and short circuit

• Check the connections (crimped parts) between each connector pin and the wiring harness.
• If there is any open circuit in the wiring harness or connector as illustrated in (A), repair or replace them.
• Check whether any pins are touching any adjacent pins due to peeling of the wire cover, defective
crimping of the pin, etc.
c13. Check of fuse for breakage and corrosion
a When replacing a fuse, be sure to turn off the power (turn the starting switch to OFF position) and turn the
battery disconnect switch to OFF position.
• A fusible link is a large-capacity fuse.
• If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse holder,
replace the fuse.
• Replace each fuse with the one of the same capacity.
Remove the cover at the left bottom of the operator seat, and the fuse box is seen.
• Open cover (1).
D65EX,PX,WX-17 40-21
40 Troubleshooting
Fusible links (FL1) and (FL2) are located there.
c14. Check of alternator voltage (when engine speed is medium or higher)

1. Open the engine hood.
2. Connect the positive (+) lead of the multimatter to alternator terminal (B) and connect the negative (-) lead
to the chassis ground.
3. Start and warm up the engine and measure the voltage while running the engine at a medium or a higher
speed.
• If the voltage is out of the normal range, repair or replace the alternator.
c15. Check of battery relay operation sound
1. Open the battery cover.
2. Check whether the battery relay operation sound is heard when the starting switch is turned to ON/OFF
position.
• If the operation sound is not heard, check the related circuits, referring to E-1 described in the E mode
troubleshooting.
• If the related circuits are free from a failure, replace the battery relay.
40-22 D65EX,PX,WX-17
40 Troubleshooting
Classification and procedure for troubleshooting

Classification of troubleshooting troubleshooting corresponding to that
Description phenomenon in the "E-mode", "H-mode", or
Mode
"S-mode".
Dis-
play 3. Action to take after failure is eliminated
Troubleshooting by failure code Clear all the failure codes in the electrical
of
code system abnormality record, referring to the next
E- page.
Troubleshooting of electrical system
mode [*1], [*2]
H- Troubleshooting of hydraulic and 1. While pressing numerical key [4] on the panel
mode mechanical systems switch at the normal screen, press [1], [2] and [3]
S- Troubleshooting of engine in order.
mode
Procedure for troubleshooting

If a phenomenon which appears a source of a
trouble occurs on the machine, go to the
corresponding troubleshooting section according to
the following procedure.
1. Procedure for troubleshooting when user
code and failure code are displayed on
machine monitor:
If a user code and a failure code are displayed
on the standard screen of the machine monitor,
perform the troubleshooting for the
corresponding "Display of code" according to
the displayed failure 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 user
code and 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
2. On the service menu screen, press switch [F3]
"Display of code" according to the failure
(R) twice in the panel switch section, and select
code.
"03 Abnormality Record".
a If an electrical system failure code is 3. Press [F6] switch (
displayed delete all the codes once and
reproduce them, and then see if the ) on the panel switch to enter and go to
failure is still detected. (See [*2].) "Abnormality Record" screen.
a A failure code of the mechanical system
cannot be deleted.
2) If no failure code is found in the abnormality
record, a failure 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 the failure again and select
the same phenomenon from the table of
“Phenomenon to be assumed a failure and
troubleshooting number”, and then perform
D65EX,PX,WX-17 40-23
40 Troubleshooting
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
sure to note it down.
9. While pressing numerical key [4] on the panel
switch, press [1], [2] and [3] in this order to go to
the "Clear mode". (Same as 1)
10.Press [F2] switch (CLEAR) on the panel switch.
4. Press [F6] switch (
) on the panel switch to enter and go to

"Mechanical system Abnormality Record"
screen.
11.Press [F6] switch (
) on the panel switch to clear all the failure codes

temporarily.
12.Press [F5] switch (RETURN) on the panel
switch to return to the "Electrical system
abnormality record" screen. See if any failure
code is still displayed and note down the
displayed ones.
5. Press [F3] switch (R) on the panel switch to see
13.Press [F5] switch (RETURN) on the panel
if the next failure code is displayed and note
switch to return to the "abnormality record"
down all of the failure codes.
screen.
a A failure code of the mechanical system
cannot be deleted.
6. Press [F5] switch (RETURN) on the panel switch
to return to the "abnormality record" screen.
7. Go to 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
40-24 D65EX,PX,WX-17
40 Troubleshooting
Classification and procedures for troubleshooting numbers

Troubleshooting
No. Phenomena supposed to show troubles
Index
User code and failure code
Action level is displayed on the machine monitor. Press function switch [F5] to
1 display the "Occurred error list". Follow the
troubleshooting
Failure code is displayed on the mechanical system abnormality record
2 procedure for the
screen
failure code
3 Failure code is displayed on the electrical system abnormality record screen
Troubleshooting
No. Symptom of failure
Index
Check items related to engine
4 Engine does not start E-1, S-1
When starting switch is turned to the "START" position, the engine is not
5 E-1, S-1
cranked, or started
6 Engine cranks but no exhaust smoke comes out S-2
7 Fuel is being injected but engine does not start S-3
8 Engine starting performance becomes deteriorated S-4
9 Engine does not pick up smoothly S-5
10 Engine stops during operation S-6 , H-2
11 Engine runs rough or is unstable S-7
12 Engine lacks power S-8
13 Exhaust smoke is black (KDPF gets clogged in a short time) S-9
14 Oil is consumed much S-10
15 Oil becomes contaminated quickly S-11
16 Fuel consumption is excessive S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Oil pressure drops S-14
19 Fuel is in oil S-15
20 Coolant is in oil (milky) S-16
21 Coolant temperature rises too high (overheating) S-17
22 Unusual noise is heard S-18
23 Vibration is excessive S-19
24 Air cannot be bled from fuel circuit S-20
25 Automatic regeneration is frequent S-21
26 Active regeneration is long S-22
27 White smoke is exhausted during active regeneration S-23
28 Manual preheater does not operate E-2
29 Automatic preheater does not operate E-3
30 While preheater is operating, preheating monitor does not light up E-4
Symptom related to to power train
31 Machine lacks power (or drawbar pull) H-1
32 Machine cannot travel (at 2nd or 3rd speed) H-2
33 Machine cannot travel at any gear speed H-3
34 Machine travels only in one direction, forward or reverse H-4
35 Large time lag at gear shifting or directional selection H-5
36 Machine cannot be steered (machine does not turn leftward or rightward) H-6
37 Steering lacks speed or power H-7
38 Brake does not work H-8
39 Torque converter does not lock up H-9
40 Power train oil overheats H-10
Unusual noise is heard from work equipment pump or from around HSS
41 H-11
motor
Symptom related to work equipment
D65EX,PX,WX-17 40-25
40 Troubleshooting
Troubleshooting
Index
42 Speed of all work equipments is slow H-12
43 None of the work equipment moves H-13
44 Blade lift lacks speed or power H-14
45 Blade tilt lacks speed or power H-15
46 Speed or power of blade angle is low H-16
47 Ripper is slow to raise, or lifting force is not enough H-17
48 Excessive hydraulic drift of blade lift cylinder H-18
49 Excessive hydraulic drift of blade tilt cylinder H-19
50 Excessive hydraulic drift of ripper cylinder H-20
Symptom is related to machine monitor
When starting switch is turned to ON position, machine monitor displays
51 nothing E-5
When starting switch is turned to ON position (with engine stopped), basic
52 check monitor lights up E-6
53 Air cleaner clogging monitor lights up yellow while engine is running E-7
54 Charge level monitor lights up while engine is running E-8
55 Engine coolant temperature monitor lights up while engine is running E-9
56 Engine oil pressure monitor lights up while engine is running E-10
57 Power train oil temperature monitor lights up while engine is running E-11
58 Hydraulic oil temperature monitor lights up while engine is running E-12
59 Engine coolant temperature gauge does not indicate normally E-13
60 Fuel level gauge does not indicate normally E-14
The power train oil temperature gauge (multi-gauge) does not indicate
61 properly E-15
62 Hydraulic oil temperature gauge (multi-gauge) does not indicate properly E-16
63 Operation mode does not change E-17
64 Gear shift mode does not change E-18
65 When customize switch is operated, customize screen is not displayed E-19
When setting is changed on customize screen, setting of machine is not
66 changed E-20
67 Reverse slow mode does not operate properly E-21
68 Alarm buzzer does not sound or does not stop sounding E-22
69 When starting switch is turned to OFF position, service meter is not displayed E-23
70 Machine monitor cannot be set in service mode E-24
"Testing and
Air conditioner does not operate normally (including failure codes related to troubleshooting
71 air conditioner) procedure" in Chapter
80
Others
72 Horn does not sound E-25
73 Horn does not stop sounding E-26
74 Backup alarm does not sound E-27
75 Back-up alarm does not stop sounding E-28
76 Head lamp does not light up E-29
77 Rear lamp does not light up E-30
78 None of the wipers operate continuously nor intermittently E-31
Front windshield wiper does not operate (continuous or intermittent operation
79 is defective) E-32
Rear windshield wiper does not operate (continuous or intermittent operation
80 is defective) E-33
Left door wiper does not operate (continuous or intermittent operation is
81 defective) E-34
40-26 D65EX,PX,WX-17
40 Troubleshooting
Troubleshooting
Index
Right door wiper does not operate (continuous or intermittent operation is
82 defective) E-35
83 KOMTRAX system does not operate properly E-36
84 Fans speed is unusual (excessively high or low, or fan stops) H-21
85 Unusual noise is heard from around fan H-22
D65EX,PX,WX-17 40-27
40 Troubleshooting
Information mentioned in troubleshooting table

(Rev. 2011/01)
a The following information is summarized in the troubleshooting table and the related circuit diagram.
Before performing troubleshooting, understand that information fully.
Action level Failure code
Failure name displayed on the Abnormality Record
Display on Display on Failure
screen of the machine monitor
machine monitor machine monitor
Detail of failure Description of the failure detected by the machine monitor or controller
Action of machine
Action to be taken to protect the system and equipment when the machine monitor or
monitor or
controller detects a trouble
controller
Problem on Problem that appears on machine as result of action (above) taken by machine monitor or
machine controller
Related Information related to the detected failure or troubleshooting
information
Probable cause Procedure, measuring location, criteria and remarks
<Contents of description>
• Procedure
• Measuring location
1 Defective component a "Between A – B" means “Measure voltage or resistance and so on
between A and B".
• Criteria to judge probable causes (normal value)
• Remarks required for judgment
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
Open circuit or short circuit in • If the check result shows no abnormality, and unless otherwise
2 wiring harness
specified, proceed to the next step (next cause item).
• Check that the failure is fixed after a failure was found and repaired.
<Failures in wiring harness>
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not connected to ground circuit contacts the ground wiring
Breaking of harness or machine.
3 (Wire breakage or defective • Hot short circuit
contact of connectors) A harness not connected to the power circuit (24 V) contacts with the
power circuit.
• Short circuit
An independent wire in the harness contacts with other wire.
(poor insulation at connector and others)
Ground fault in harness

4
(Contact with GND circuit)
Hot short circuit

5
(Contact with 24 V circuit)
40-28 D65EX,PX,WX-17
40 Troubleshooting

<Precautions for troubleshooting>
1. Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless
otherwise specified.
6 Short-circuiting of harness • When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
• When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter only to either
male or female connector.
2. Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads
7 Defective controller as shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.
Circuit diagram related
This is the excerpted circuit diagram related to

troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
• NO: Normally Open
• NC: Normally Closed
D65EX,PX,WX-17 40-29
40 Troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure

sensor system
a Since the pressure sensors consist of not only resistor but also electronic circuit components such as
amplifiers they have variation in measured value and their own polarities. So troubleshooting must be
performed carefully.
Failure codes applicable to this diagnosis
• CA123: Charge air pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If the polarities of multimeter probes to apply are reversed, measured values may change.
Therefore, when measuring the resistances in steps 1 and 2, apply the multimeter probes to the
pressure sensor connector so that their polarities match those of the sensor.
a If the measured value is infinite, take measurements by applying the probes of the opposite
polarities and record the finite value obtained as a measured value.
a Since the measured values may be dispersed, take several measurements.
The cause of this dispersion appears to be an electric charge in a sensor. Take measurements
several times in steps 1 and 2. Consider this dispersion when judging whether or not the wiring
harness is open in step 3.
2. Measure and record the resistance of the wiring harness between the pressure sensor and engine
controller connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on the engine controller
side, and connect T-adapter (4) to the wiring harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit
If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, the "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.
40-30 D65EX,PX,WX-17
40 Troubleshooting
List of pressure sensor measuring locations and reference values
Measuring location at Measured internal

Sensor sensor pin resistance of sensor Remarks
(reference)
Charge pressure R2: between (2) and (4) Approx. 100 z Sensor is common to engine
sensor R1: between (1) and (4) Approx. 200 z models 107 and 114
*: When measuring R2', disconnect the following: (See the circuit diagram related to each failure code)
• When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit (Measuring location on
Sensor (Measuring location on Measured value wiring harness side Measured value
sensor pin side connetor) connector of engine
controller)
R2': Between (37) and
R2: between (2) and (4)
Charge pressure (47) (*)
sensor R1': Between (44) and
R1: between (1) and (4)
(47)
D65EX,PX,WX-17 40-31
40 Troubleshooting
Connector list and layout

D65EX-17, D65PX-17
Number Layout
Connector No. Connector type Location
of pins address
1 SOL DT 2 1st clutch ECMV solenoid AN-6
1 SW DT 2 1st clutch ECMV fill switch AN-6
2 SOL DT 2 2nd clutch ECMV solenoid AP-4
2 SW DT 2 2nd clutch ECMV fill switch AP-4
3 SOL DT 2 3rd clutch ECMV solenoid AM-6
3 SW DT 2 3rd clutch ECMV fill switch AN-6
3DCN DT-12B 12 Intermediate connector S-9
3DSG DT 6 Intermediate connector S-9
A/C DT 2 Air conditioner compressor I-1
AC01 SUMITOMO 10 Intermediate connector X-6
AC02 YAZAKI 4 Intermediate connector X-6
AC04 SUMITOMO 5 Compressor relay U-1
AC05 S090 2 Air conditioner refrigerant pressure switch W-3
AC06 DT 2 Intermediate connector B-6
ACB1 JAE 7 Defuser (mode) motor 1 (air conditioner unit) –
ACBM SUMITOMO 2 Blower motor (air conditioner unit) –
ACECU AMP 32 Air conditioner controller –
ACFS YAZAKI 2 Frost sensor (air conditioner unit) –
FRESH/RECIRC air changeover servomotor (air
ACIS JAE 7 –
conditioner unit)
ACPS YAZAKI 2 Inner sensor (air conditioner unit) –
ACPT SUMITOMO 4 Power transistor (air conditioner unit) –
ACS DT 2 Surge killer H-1
ACSM JAE 7 A/M servo motor –
AF1 DT 2 Air cleaner clogging sensor H-9
AFS DT 6 Intermediate connector G-9
AGA1 1 GPS controller W-8
AGA2 1 Intermediate connector N-1
AGA3 1 Intermediate connector E-7
AL/B Terminal 1 Alternator B terminal C-4
AL/E Terminal 1 Alternator E terminal C-5
AL/R Terminal 1 Alternator R terminal C-3
AMB AIR Ambient pressure sensor
FRAMATOME 3 AJ-6
PRESSURE
ASUS DT 2 Air suspension seat X-4
AUX1 DTHD 1 Optional power supply outlet C-8
BCV DT-12A 12 Intermediate connector K-8
BKAL DT 2 Backup alarm K-8
BNSW DT-12A 12 Intermediate connector Q-9
BOOST Boost pressure and intake manifold temperature
SUMITOMO 4 AJ-5
PRESS. & IMT sensor
BRB Terminal 1 Battery relay terminal B C-7
BRC Terminal 1 Battery relay terminal M A-7
BRE Terminal 1 Battery relay terminal E B-6
BRK DT 3 Brake potentiometer R-1
BRSW Terminal 1 Battery relay terminal BR B-6
BVRV DT 2 Transmission output shaft speed sensor AP-5
CAM SENSOR FRAMATOME 3 CAM sensor (Bkup) AE-3
CB01 DT 4 Intermediate connector AC-7
CB02 M 2 Rear speaker (left) AC-7
40-32 D65EX,PX,WX-17
40 Troubleshooting
Number Layout
of pins address
CB04 M 2 Rear speaker (right) AA-8
CB07 PA 9 Radio Z-7
CB08 M 3 Accessory (12V power supply) Z-7
CB10 SWP 6 Additional light switch Z-9
CB11 SWP 6 Wiper intermittent switch Z-9
CB12 SWP 6 Rear wiper switch Z-9
CB13 SWP 6 Right wiper switch Y-8
CB14 SWP 6 Front wiper switch Y-8
CB15 SWP 6 Left wiper switch Y-8
CB16 KES-1 2 Room lamp Y-3
CB17 DT 4 Right door wiper motor Y-2
CB18 DT 4 Intermediate connector Y-3
CB23 DT 6 Front wiper motor Y-4
CB24 DT 4 Left door wiper motor AC-1
CB25 YAZAKI 4 Relay for light AD-5
CB26 YAZAKI 11 Front wiper and rear wiper intermittent unit AD-4
CB27 YAZAKI 11 Left wiper and right wiper intermittent unit AD-5
CB34 SWP 6 Revolving warning lamp switch Z-9
CB35 DT 2 Intermediate connector Y-4
CB37 DT 6 Rear wiper motor AC-7
CBACC1 DT 2 Accessory socket X-5
CBACC2 DT 2 Accessory socket 2 X-5
CBBCN DT 2 Rotary lamp Y-5
CBCIG – 2 Cigarette lighter X-6
CBCV1 DT 6 DC converter AD-5
CBFB1 Terminal 1 Fuse box AA-9
CBFL DT 2 Additional front light (left) AC-1
CBFR DT 2 Additional front light (right) Y-6
CBRL DT 2 Additional rear light (left) AD-6
CBRR DT 2 Additional rear light (right) AB-7
CK01 070 18 KOMTRAX terminal T-9
CK02 070 12 KOMTRAX terminal T-9
CLP – 6 Revolving warning lamp relay T-1
CM01 070 18 Machine monitor N-9
CM02 070 12 Machine monitor O-7
CM04 070 8 Machine monitor N-9
CMR1 DT 4 Rear view camera –
CMR2 DT 3 Intermediate connector AD-6
COOLANT Engine coolant temperature sensor
DELPHI 2 AE-6
TEMP
CRANK Crankshaft sensor (Ne)
FRAMATOME 3 AJ-4
SENSOR
CTE DT 3 CAN terminating resistor 120 z AH-2
DCL DT 3 Decelerator pedal potentiometer Q-1
DIA2 DT 3 Fuel control dial V-8
DIAL DT 3 Intermediate connector U-1
DPNL DT 2 Diode (emergency switch) AO-9
DSH DRC-40A 40 Intermediate connector P-1
ECM J1 DRC 60 Engine controller AI-2
ECM J2 DRC 60 Engine controller AJ-3
D65EX,PX,WX-17 40-33
40 Troubleshooting
Number Layout
of pins address
EG1 DTP 2 Intermediate connector I-1
EG2 DT-12B 12 Intermediate connector G-1
EGC3 DRC26-60 60 Engine controller AJ-4
EGPW DTP 2 Intermediate connector C-8
EGR-SOL DT 2 EGR solenoid AH-7
EXHAUST GAS
TEMPERE- FRAMATOME 2 EGR gas temperature sensor AF-8
TURE
EXHAUST Exhaust gas pressure sensor
FRAMATOME 3 AE-4
PRESSURE
F SOL DT 2 F clutch ECMV solenoid AP-3
F SW DT 2 F clutch ECMV fill switch AP-2
F105 DTDH 1 Intermediate connector C-8
F30 DTDH 1 Intermediate connector C-7
FAC DT 2 Fan pump control valve AK-2
FAR DT 2 Fan reverse solenoid C-2
FD1 DRC16-70B 70 Intermediate connector A-9
FL1_2 Terminal 1 Fusible link B-9
FL1_4 Terminal 1 Fusible link C-9
FL2_1 Terminal 1 Fusible link A-8
FL2_3 Terminal 1 Fusible link A-7
FLP1 SUMITOMO 5 Headlamp relay U-1
FLSW SWP 6 Front lamp switch M-7
FLV DT 2 Fuel level sensor L-7
FRS DT 2 Fan speed sensor D-2
FS11 – – Fuse box S-1
FTK DT 4 Intermediate connector J-9
FUEL LIFT Lift pump
DT 2 AE-4
PUMP
FUEL RAIL Common rail pressure sensor
BOSCH 3 AJ-5
PRESS
GND Terminal 1 Ground (ROPS) K-9
GND03 Terminal 1 Ground (right frame) C-5
GND09 Terminal 1 Ground (engine body) G-1
GND11 Terminal 1 Ground (floor) X-5
GND12 Terminal 1 Ground (floor) X-5
GND20 Terminal 1 Ground (engine body) AH-2
GND3 Terminal 1 Ground (engine body) E-1
GNDC1 Terminal 1 Ground (cab) AA-7
GNDC2 Terminal 1 Ground (cab) AA-7
GNDC3 Terminal 1 Ground (cab) AD-6
GNDC4 Terminal 1 Ground (cab) AB-7
GNDC5 Terminal 1 Ground (cab) X-5
GPARA D-SUB 9 GPS radio antenna X-7
GPSB DT-12B 12 Intermediate connector N-2
GPSB1 DRC26-40A 40 GPS controller X-7
GPSB2 DRC26-40B 40 GPS controller W-8
GPSPW DT 2 GPS radio antenna X-6
40-34 D65EX,PX,WX-17
40 Troubleshooting
Number Layout
of pins address
HDT DT 2 Hydraulic oil temperature sensor AL-7
HEAT DT 2 Intermediate connector V-8
HEAT2 DT 2 Seat heater U-9
HHP AMP 3 Hydraulic oil pressure sensor AL-5
HNSW DT 2 Horn switch Q-9
HRN Terminal 1 Horn C-3
HSL DT 2 HSS EPC (left) AK-6
HSR DT 2 HSS EPC (right) AL-6
Terminal A of electrical intake air heater (ribbon
HT/A Terminal 1 heater) relay J-2
Terminal B of electrical intake air heater (ribbon
HT/B Terminal 1 heater) relay I-9
Terminal C of electrical intake air heater (ribbon
HT/C Terminal 1 heater) relay H-9
Diode (electrical intake air heater (ribbon
HTD DT 2 heater)) G-9
INJECTOR #1 DT 2 Injector #1 AE-5
INJECTOR #2 DT 2 Injector #2 AE-6
INJECTOR #3 DT 2 Injector #3 AF-8
INJECTOR #4 DT 2 Injector #4 AG-8
INJECTOR #5 DT 2 Injector #5 AG-8
INJECTOR #6 DT 2 Injector #6 AI-7
INJECTOR
DT 4 Intermediate connector AE-5
CYL. 1&2
INJECTOR
DT 4 Intermediate connector AF-8
CYL. 3&4
INJECTOR
DT 4 Intermediate connector AJ-6
CYL. 5&6
INLET
METERING BOSCH 2 Fuel supply pump AE-7
VALVE
INTER-
DT 12 Intermediate connector AH-8
CONNECT
KEY DT 6 Starting switch O-8
L SOL DT 2 Lockup clutch ECMV solenoid AL-5
L SW DT 2 Lockup clutch ECMV fill switch AL-5
LBU DT 2 System operation lamp L-6
LDNE DT 2 Lift LOWER EPC P-8
LHD DT 2 Intermediate connector C-4
LHDL DT 2 Headlamp (left) C-6
LHDR DT 2 Headlamp (right) C-6
LMD SWP 8 Diode (console box) M-6
LREL DT 2 Rear lamp L-8
LRSE DT 2 Lift RAISE EPC P-5
MAF FRAMATOME 4 MAF sensor G-9
MC2 DTM 8 Intermediate connector D-7
MC2C DT 6 Intermediate connector N-2
MGA1 1 GPS controller W-7
MGA2 1 Intermediate connector N-1
MGA3 1 Intermediate connector E-7
MM1 DT-8A 8 Intermediate connector D-7
MONI 19 Monitor panel P-6
NSF SUMITOMO 5 Neutral safety relay T-1
D65EX,PX,WX-17 40-35
40 Troubleshooting
Number Layout
of pins address
OEM
CONNECTION FRAMATOME 24 Intermediate connector AI-2
(OEM)
OEM(OEM
CONNECTION) FRAMATOME 24 Intermediate connector AH-2
OIL
PRESSURE FRAMATOME 1 Engine oil pressure switch AJ-3
SWICH
OPPW DT 2 Power supply for device X-3
PAC DT 6 Intermediate connector S-1
PCCV FRAMATONE 3 Crankcase pressure sensor J-9
PDPF FRAMATOME 4 KDPF pressure sensor E-8
PHR SUMITOMO 5 Preheater relay T-1
PKSW DT 3 Parking lock switch X-4
PL1 DRC16-70A 70 Intermediate connector A-9
PL1F DRC-70A 70 Intermediate connector AO-9
PL1M DRC-70A 70 Intermediate connector AP-9
PNL 21-31 31 Intermediate connector AN-8
PRT DT-12A 12 Intermediate connector C-5
PRTR DT-8A 8 Intermediate connector I-1
PSL SUMITOMO 5 Personal lock relay U-1
PT1 DT 3 Pitch angle sensor D-1
PTL DT 2 Blade angle EPC (left) AK-7
PTP DT 2 Blade pitch selector solenoid –
PTR DT 2 Blade angle EPC (right) AK-7
R SOL DT 2 R clutch ECMV solenoid AM-5
R SW DT 2 R clutch ECMV solenoid (fill switch) AL-5
RFD DT-12A 12 Intermediate connector AK-5
RFD2 DT 4 Intermediate connector AK-5
RHT Terminal 1 Electrical intake air heater (ribbon heater) I-2
RLP SUMITOMO 5 Back-up lamp relay U-1
RLSW SWP 6 Rear lamp switch M-7
RSD DT 2 Diode X-3
RSR 5 Reverse signal relay X-6
SBC DT 2 Seat belt alarm switch X-4
SEGR DT 3 EGR valve lift sensor AI-7
SESW SWP 6 Engine shutdown secondary switch O-9
SFTD YAZAKI 3 Shift down switch U-8
SFTU YAZAKI 3 Shift up switch V-8
SLS 050 2 Sunlight sensor M-8
SRV DT-12A 12 Intermediate connector (attachment) X-4
SSJ DT 4 Intermediate connector D-7
ST DT 2 Starting motor J-2
ST/B Terminal 1 Terminal B for starting motor G-1
STC1 DRC26-24 24 Power train controller V-2
STC2 DRC26-40A 40 Power train controller V-2
STC3 DRC26-40B 40 Power train controller V-2
SVGT DT 3 KVGT position AH-8
TCT DT 2 Torque converter oil temperature sensor AO-1
TDPF FRAMATOME 4 Intermediate connector F-8
TEMP1 FRAMATOME 2 KDOC inlet temperature sensor F-8
TEMP2 FRAMATOME 2 KDOC outlet temperature sensor E-8
TEMP3 FRAMATOME 2 KDPF outlet temperature sensor F-9
40-36 D65EX,PX,WX-17
40 Troubleshooting
Number Layout
of pins address
TERMINATOR CAN terminating resistor
DT 3 AI-3
PORT
TIP AMP 3 Torque converter pressure sensor AN-1
TLHE DT 2 Tilt LEFT EPC P-6
TLV1 DT-8B 8 Lever assembly X-4
TLV2 DT 6 Intermediate connector V-2
TOA YAZAKI 2 Outside air temperature sensor C-8
TOOL PORT DT 3 CAN AE-2
TRHE DT 2 Tilt RIGHT EPC P-8
TVC DT 2 Pump TVC solenoid AK-3
VGT REV AMP 3 KVGT speed sensor AH-8
VGT-SOL DT 2 KVGT solenoid AI-7
WELK DT 3 Work equipment lock switch Q-9
WIF1 DT 2 Water-in-fuel sensor I-9
WLK DT 2 Work equipment lock solenoid AK-6
WSFR YAZAKI 2 Washer motor (front) L-5
WSLH YAZAKI 2 Washer motor (left) L-6
WSRH YAZAKI 2 Washer motor (right) L-6
WSRR YAZAKI 2 Washer motor (rear) L-5
D65EX,PX,WX-17 40-37
40 Troubleshooting
Layout of connector (1/7)
40-38 D65EX,PX,WX-17
40 Troubleshooting
(2/7)
D65EX,PX,WX-17 40-39
40 Troubleshooting
(3/7)
40-40 D65EX,PX,WX-17
40 Troubleshooting
(4/7)
D65EX,PX,WX-17 40-41
40 Troubleshooting
(5/7)
40-42 D65EX,PX,WX-17
40 Troubleshooting
(6/7)
D65EX,PX,WX-17 40-43
40 Troubleshooting
(7/7)
40-44 D65EX,PX,WX-17
40 Troubleshooting
Connector contact identification
(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.
D65EX,PX,WX-17 40-45
40 Troubleshooting
40-46 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-47
40 Troubleshooting
40-48 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-49
40 Troubleshooting
40-50 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-51
40 Troubleshooting
40-52 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-53
40 Troubleshooting
40-54 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-55
40 Troubleshooting
40-56 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-57
40 Troubleshooting
40-58 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-59
40 Troubleshooting
40-60 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-61
40 Troubleshooting
40-62 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-63
40 Troubleshooting
40-64 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-65
40 Troubleshooting
40-66 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-67
40 Troubleshooting
40-68 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-69
40 Troubleshooting
40-70 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-71
40 Troubleshooting
40-72 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-73
40 Troubleshooting
40-74 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-75
40 Troubleshooting
40-76 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-77
40 Troubleshooting
40-78 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-79
40 Troubleshooting
40-80 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-81
40 Troubleshooting
T-branch box and T-branch adapter table

(Rev. 2009. 03)
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
Identification symbol
Number of pins
Out of kit
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
Part number Part name
799-601- T-box (for ECONO) 21 q q q q q

2600
799-601- T-box (for MS) 37 q
3100
799-601- T-box (for MS) 37 q
3200
799-601- Plate for MS (14-pin) q
3380
799-601- Adapter for BENDIX (MS) 24 MS-24P q
3410
3420
3430
3440
3450
3460
3510
3520
3530
2910
799-601-
Case q
3470
799-601- Adapter for MIC 5 MIC-5P q q q
2710
799-601- Adapter for MIC MIC-
13 q q q
2720 13P
17 q q q q q q
2730 17P
21 q q q q q q
2740 21P
799-601- Adapter for MIC 9 MIC-9P q q q q
2950
799-601- Adapter for ECONO ECONO
2 q q
2750 2P
3 q q
2760 3P
4 q q
2770 4P
40-82 D65EX,PX,WX-17
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
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

8 q q
2780 8P
12 q q
2790 12P
799-601- Adapter for DLI 8 DLI-8P q q
2810
2820
2830
799-601- Extension cable (ECONO type) ECONO
12 q q q
2840 12P
799-601-
Case q
2850
799-601- q
T-box (for DRC60, ECONO) 60
4350
799-601- q
Case
4360
799-601- Adapter for X (T-adapter) 1 q q
7010
799-601- Adapter for X 2 X2P q q q q
7020
7030
7040
799-601- Adapter for SWP 6 SW6P q q q
7050
799-601- Adapter for SWP 8 SW8P q q q
7060
799-601- Adapter for SWP 12 SW12P q
7310
799-601- Adapter for SWP 14 SW14P q q
7070
799-601- Adapter for SWP 16 SW16P q
7320
799-601- Adapter for M (T-adapter) 1 q q
7080
799-601- Adapter for M 2 M2P q q q q
7090
7110
7120
7130
799-601- Adapter for M 8 M8P q
7340
799-601- Adapter for S 8 S8P q q q q
7140
799-601- Adapter for S (White) 10 S10P q q q q
7150
D65EX,PX,WX-17 40-83
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
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
799-601- Adapter for S (Blue) 12 S12P q q q

7160
799-601- Adapter for S (Blue) 16 S16P q q q q
7170
799-601- Adapter for S (White) 16 S16PW q
7330
799-601- Adapter for S (White) 12 S12PW q
7350
799-601- Adapter for AMP040 8 A8P q
7180
799-601- Adapter for AMP040 12 A12P q q
7190
799-601- Adapter for AMP040 16 A16P q q q q
7210
799-601- Adapter for AMP040 20 A20P q q q q
7220
799-601-
Short connector for X 2 q q q q
7230
799-601-
Case q q
7240
799-601-
Case q
7270
799-601- Adapter for 070 10 07-10 q
7510
799-601- Adapter for 070 12 07-12 q
7520
799-601- Adapter for 070 14 07-14 q
7530
799-601- Adapter for 070 18 07-18 q
7540
799-601- Adapter for 070 20 07-20 q
7550
799-601- Adapter for relay 5 REL-5P q
7360
799-601- Adapter for relay 6 REL-6P q
7370
799-601- Adapter for JFC 2 q
7380
799-601- q
Adapter for DTM 2 DTM2 q
9010
799-601- q q q
Adapter for DT 2 DT2 q
9020
799-601- q
9030
799-601- q q q
9040
799-601- q
9050
799-601- q
Adapter for DT (gray) 8 DT8GR q
9060
799-601- q
Adapter for DT (black) 8 DT8B q
9070
40-84 D65EX,PX,WX-17
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
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
799-601- q
Adapter for DT (green) 8 DT8G q
9080
799-601- q
Adapter for DT (Brown) 8 DT8BR q
9090
799-601- DT12G- q
Adapter for DT (gray) 12 q
9110 R
799-601- q
Adapter for DT (black) 12 DT12B q
9120
799-601- q
Adapter for DT (green) 12 DT12G q
9130
799-601- q
Adapter for DT (Brown) 12 DT12BR q
9140
799-601- Adapter for HD30-18 8 D18-8 q q
9210
9220
9230
9240
9250
9260
9270
9280
9290
799-601- q
Plate for HD30 (24-pin) q q
9310
799-601- q
T-box (for ECONO) 24 q q
9320
799-601-
Case q
9330
799-601-
Case q
9340
799-601- q
Adapter for DRC 40 DRC-40
9350
799-601- q
Adapter for DRC 24 DRC-24
9360
799-601- Socket for engine (CRI-T2) 2 G q
9410*
Adapter for engine (CRI-T2) q q
799-601- Adapter for engine (CRI-T3)
PFUEL 3 A3
9420
Oil pressure sensor
799-601- Socket for engine (CRI-T2) q q
2 P
9430* Socket for engine(CRI-T3) PCV
799-601- Socket for engine (CRI-T2) 1, 2, 3
3 q
9440*
D65EX,PX,WX-17 40-85
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
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
795-799- Socket for engine (HPI-T2) 2 S q

5520*
Socket for engine (HPI-T2) q q
795-799- Socket for engine (CRI-T3) 2 C
5530*
Temperature sensor
795-799- Socket for engine (HPI-T2) q q
2 A
5540* Socket for engine(CRI-T3) TIM
795-799- Cable for engine (HPI-T2) 3 q
5460
5470
5480
799-601- q q
Adapter for engine (140-T3) PIM 4 ITT3N
4110
799-601- Adapter for engine (CRI-T3) NE, q q
3 FCIN
4130 CAM
799-601- Adapter for engine (CRI-T3) q q
3 FCIG
4140 Ambient pressure
3 FCIB
4150 POIL
2 4160
4160 Oil pressure switch
3 4180
4180 PEVA
3 1, 2, 3L
4190* Rail pressure
799-601- Socket for engine (CRI-T3) 1, 2, 3, q q
4
4230* Air intake pressure/temperature 4C
3 1, 2, 3A
4240* PAMB
799-601- q q
Socket for engine (CRI-T3) PIM 3 1, 2, 3B
4250*
799-601- 1, 2, 3, q q
Socket for engine (CRI-T3) G 3
4330* G
2 2, PA
4340* Pump actuator
799-601- Socket for engine (CRI-T3)(95) 1, 2, 3,
4 q
4380* Air intake pressure/temperature 4T
799-601- q q
Adapter for controller (ENG) 4 DTP4
4260
799-601- q
Adapter for controller (ENG) 50 DRC50
4211
799-601- q
Adapter for controller (ENG) 60 DRC60
4220
799-601- Socket for controller (95 ENG) 60 q
4390*
799-601- Box for controller (PUMP) 1-
q
4280* 21
40-86 D65EX,PX,WX-17
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
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
799-601- Adapter for controller (HST) 16 HST16A q

9720
799-601- Adapter for controller (HST) 16 HST16B q
9710
799-601- Adapter for controller (HST) 26 HST26A q
9730
2,
799-601- Multi-adapter for pins DT2 to 4
3, q
9890 and DTM2
4
*: Shows not T-adapter but socket.
D65EX,PX,WX-17 40-87
40 Troubleshooting
Fuse locations table

Connection table of fusible links and fuse boxes
a This connection table shows the devices to which each power supply of the fusible links and fuse boxes
supplies power.
a The switched power supply is the power (battery relay output) which is supplied while the stating switch is
in ON position and the continuous power supply is the power (battery direct output) which is supplied while
the starting switch is in OFF and ON positions.
a When performing the troubleshooting related to the electrical system, check the fusible links and fuses to
see if the power is supplied properly.
Fuse box (FS12)
Fusible link Fuse

Power
supply Fuse No. capacity Destination of power
(Connector No.) (A)
1 15 Monitor (ACC power supply)
Continu- 3 5 Air conditioner controller (ACC power supply)
FL1[30 A] ous 4 5 Engine controller (ACC power supply)
(FL1-4) power 5 20 Starting switch B
supply 6 20 Air conditioner controller (continuous power supply)
7 15 iB continuous power supply
FL2[120 A] Switched 8 5 Horn
power
(FL2-4) supply 9 30 Cab switched power supply
Continu- 10 20 Cab continuous power supply
FL1[30 A] ous
(FL1-4) power 13 5 System operating lamp
supply
FL2[120 A] Switched 14 20 Headlamp
power
(FL2-4) supply 15 20 Rear lamp
Fuse box (FS22)
Fusible link Fuse

Power
supply Fuse No. capacity Destination of power
(Connector No.) (A)
FL2[120 A] Switched 1 20 Power train controller power supply
power
(FL2-4) supply 2 20 Air conditioner power supply
Continu- Monitor, power train controller, KOMTRAX continuous
3 20 power supply
FL1[30 A] ous
(FL1-4) power 4 30 Engine controller
supply 5 – Engine controller
FL2[120 A] Switched
power 6 20 Optional device
(FL2-4) supply
40-88 D65EX,PX,WX-17
40 Troubleshooting
Fuse box (B) (operator's cab)
Fusible link Fuse

Power
Fuse No. capacity Destination of power
(Connector No.) supply
(A)
FL1[30 A] FS12
1 10 Radio memory
(FL1-4) No.10
2 20 Additional light, revolving warning lamp
3 20 12 V converter
FL2[120 A]
FS12 No.9 4 20 Radio, room lamp, cigarette lighter, intermittent wiper
(FL2-4)
5 10 Front wiper, rear wiper
6 10 Right and left door wipers
Locations of fusible links (FL1, FL2)
Location of fuse box and fuse numbers
D65EX,PX,WX-17 40-89
40 Troubleshooting
40-90 D65EX,PX,WX-17
40 Troubleshooting
Precautions for cleaning and replacing KDPF (KCSF, KDOC)

1. Related information 2] On machine monitor, check history of
output of “CA2639: Stationary
k Use care not to burn yourself since KDPF regeneration request“ and “CA1921:
and KDOC are heated to 500°C or above. KDPF soot load high error 1“, and
“CA1922: KDPF soot load high error 2“.
• Soot load in KCSF in KDPF is classified into
[Case 1: When replacing KCSF after
eight levels. You can confirm the current soot
removing KDPF]
load by displaying "Diagnostic Tests" from
the machine monitor service menu and then a Since existence of the following condition
selecting "02 Regeneration for service" indicates that the soot load is beyond the
screen from there. regenerable level, you must remove KDPF
2. When cleaning or replacing KCSF and replace KCSF.
1) In periodic cleaning for every 4,500 hours • The time from output of “CA2639: Stationary
1] Check the level of soot load. If the soot regeneration request (L01)“ to output of
load level is displayed, turn on and “CA1921: KDPF soot load high error 1 (L03)“
continue active regeneration for service is >= 300 sec.
until the load becomes zero. and
2] Stop the engine and wait until the • the time from output of “CA1921: KDPF soot
temperature of piping around engine load high error (L03)“ to output of “CA1922:
drops, then remove KDPF and remove KDPF soot load high error 2 (L04)“ is >= 300
KCSF, too. sec.““
3] Clean KCSF using the ash cleaning [Contents of work]
system, which is used at the specified Case 1-1 Stop the engine and wait until the
maintenance shops and the like. (When temperature of piping around engine drops,
reusing a removed KCSF after cleaning then remove KCSF.
it) Case 1-2 Install another KDPF (new or used
4] Install the cleaned KCSF to the machine. one).
(When reusing a removed KCSF after Case 1-3 Turn starting switch to ON position
cleaning it) and perform KDPF cleaning reset from the
5] Install another KCSF to the machine. KDPF reset screen.
(When replacing a KCSF with new one) If you perform cleaning reset of KDPF, the
6] Turn starting switch to ON position and changes provided in ( ) are reflected.
perform KDPF cleaning reset from the (Soot level: 9 g/l o 8.1 g/l, action level: L04
KDPF reset screen. o L03, failure code: CA1922 o CA1921)
7] Start the engine and warm it up at low Case 1-4 Perform KDPF Change reset from
idle. the KDPF reset screen.
8] Perform active regeneration for service. Case 1-5 Start the engine and warm it up at
2) If cracks or damages are detected low idle.
Case 1-6 Perform active regeneration for
1] Stop the engine and wait until the
service.
temperature of piping around engine
(This active regeneration for service ends
drops, then remove KDPF and remove
when soot load becomes 2 g/l. Therefore,
KCSF, too.
this regeneration may last for two hours or
2] Install another KCSF (new or used
so.))
KCSF) to the machine.
Case 1-7 After the active regeneration for
3] Turn starting switch to ON position and
service is finished, confirm that the failure
perform KDPF cleaning reset from the
code (CA1922, CA1921 and/or CA2639) is
KDPF reset screen.
not output.
4] Perform KDPF Change reset from the
[Case 2: When active regeneration for
KDPF reset screen.
service is performed (removal of KDPF is
5] Start the engine and warm it up at low
unnecessary]
idle.
6] Perform active regeneration for service. a When the following condition exists, soot is
3) KDPF soot load high error 2 (CA1922) is not actually accumulated (9 g/l or
output equivalent). It results from increase in
1] Stop the machine and confirm from the differential pressure being caused by
machine monitor that the failure code troubles such as plugging due to non-uniform
(CA1922) is output. accumulation of soot. Since actual soot load
D65EX,PX,WX-17 40-91
40 Troubleshooting
is not so large as to cause abnormal Case 1-2 Perform KDOC reset from the
combustion when active regeneration is KDPF reset screen.
executed, you do not have to replace KCSF. [Case 2] When cracks or damages are not
If you reduce the soot load by active detected on KDOC
regeneration for service, you can use KCSF Case 2-1 Clean KDOC and install it again.
continuously. Case 2-2 Perform KDOC reset from the
• After making sure through troubleshooting KDPF reset screen.
that a sensor system failure is not present, Case 2-3 Perform 40-minute long active
execute the active regeneration for service regeneration for service two times. (Fuel is
when any of the followings exists. injected during regeneration.)
• The time from output of “CA2639: Stationary a When performing regeneration for service
regeneration request (L01)“ to output of consecutively, stop the engine once.
“CA1921: KDPF soot load high error 1 (L03)“ Case 2-4 Output of CA2637 (KDOC face
is < 300 sec. plugging) after the active regeneration for
or service indicates that efficiency of KDOC is
• the time from output of “CA1921: KDPF soot degraded. In this case, KDOC must be
load high error (L03)“ to output of “CA1922: replaced.
KDPF soot load high error 2 (L04)“ is < 300
sec.
[Contents of work]
Case 2-1 Start the engine, warm it up at low
idle, then perform KDPF cleaning reset from
the KDPF reset screen.
Case 2-2 Perform active regeneration for
service.
(This active regeneration for service ends
when soot load becomes 2g/l. Therefore,
this regeneration may last for two hours or
so.))
Case 2-3 After the active regeneration for
service is finished, confirm that the failure
code (CA1922, CA1921 and/or CA2639) is
not output.
3. When cleaning or replacing KDOC
1) If cracks or damages are detected
1] If cracks or damages are detected on
KDOC, replace KDOC.
2] Perform KDOC reset from the KDPF
reset screen.
2) When regeneration ineffective (CA1691) is
output
1] Stop the machine and confirm from the
machine monitor that the failure code
(CA1691) is output.
(CA2637 is sometimes output at the
same time.)
2] Check the engine gas color.
3] While CA1691 is output, perform the
active regeneration for service for 40
minutes. (KDOC drying operation: Fuel is
not injected during regeneration.)
4] Stop the engine and wait until the
temperature of piping around engine
drops, then remove KDOC and check it
for cracks and damages.
[Case 1] When cracks or damages are
detected on KDOC
Case 1-1 Replace KDOC.
40-92 D65EX,PX,WX-17
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure codes table
Failure Component Action Category
Failure (Displayed on screen) Remarks
code in charge level of record
Electrical
1500L0 Transmission clutch: Abnormal PT L03 system
Electrical
15SAL1 Forward clutch: Fill High PT L03 system
Electrical
15SALH Forward clutch: Fill Low PT L03 system
Electrical
15SBL1 Reverse clutch: Fill High PT L03 system
Electrical
15SBLH Reverse clutch: Fill Low PT L03 system
Electrical
15SEL1 Speed 1st clutch: Fill High PT L03 system
Electrical
15SELH Speed 1st clutch: Fill Low PT L03 system
Electrical
15SFL1 Speed 2nd clutch: Fill High PT L03 system
Electrical
15SFLH Speed 2nd clutch: Fill Low PT L03 system
Electrical
15SGL1 Speed 3rd clutch: Fill High PT L03 system
Electrical
15SGLH Speed 3rd clutch: Fill Low PT L03 system
Electrical
15SJL1 L/U : Fill High PT L03 system
Electrical
15SJLH L/U : Fill low PT L03 system
Electrical
1800MW P/T clutch: Slip PT L03 system
See
Electrical Chapter
879AKA A/C Inner Sensor Open Circuit MON –
system 80, Other
items
See
Electrical Chapter
879AKB A/C Inner Sensor Short Circuit MON –
system 80, Other
items
See
Electrical Chapter
879BKA A/C Outer Sensor Open Circuit MON –
system 80, Other
items
See
Electrical Chapter
879BKB A/C Outer Sensor Short Circuit MON –
system 80, Other
items
See
Electrical Chapter
879CKA Ventilating Sensor Open Circuit MON –
system 80, Other
items
See
Electrical Chapter
879CKB Ventilating Sensor Short Circuit MON –
system 80, Other
items
See
Electrical Chapter
879DKZ Sunlight Sensor Open or Short Circuit MON –
system 80, Other
items
D65EX,PX,WX-17 40-93
40 Troubleshooting

See
Electrical Chapter
879EMC Ventilation Dumper Abnormality MON L01 system 80, Other
items
See
Electrical Chapter
879FMC Air Mix Dumper Abnormality MON L01 system 80, Other
items
See
Electrical Chapter
879GKX Refrigerant Abnormality MON L01 system 80, Other
items
Electrical
989L00 Engine Controller Lock Caution1 MON –
system
Electrical
989M00 Engine Controller Lock Caution2 MON –
system
Electrical
989N00 Engine Controller Lock Caution3 MON –
system
Electrical
A1U0N3 HC desorb request 1 ENG L01 system
Electrical
A1U0N4 HC desorb request 2 ENG L03 system
Mechanical
AA10NX Air Cleaner Clogging MON L01 system
Mechanical
AB00KE Charge Voltage Low MON L03 system
Mechanical
B@BAZG Eng Oil Press Low ENG L03 system
Mechanical
B@BCNS Eng Water Overheat ENG L02 system
Mechanical
B@CENS P/L Oil Overheat PT L02 system
Mechanical
B@HANS Hyd Oil Overheat PT L02 system
Electrical
CA115 Eng Ne and Bkup Speed Sens Error ENG L04 system
Electrical
CA122 Chg Air Press Sensor High Error ENG L03 system
Electrical
CA123 Chg Air Press Sensor Low Error ENG L03 system
Electrical
CA131 Throttle Sensor High Error ENG L03 system
Electrical
CA132 Throttle Sensor Low Error ENG L03 system
Electrical
CA144 Coolant Temp Sens High Error ENG L01 system
Electrical
CA145 Coolant Temp Sens Low Error ENG L01 system
Electrical
CA153 Chg Air Temp Sensor High Error ENG L03 system
Electrical
CA154 Chg Air Temp Sensor Low Error ENG L03 system
Electrical
CA187 Sensor 2 Supply Volt Low Error ENG L03 system
Electrical
CA221 Ambient Press Sensor High Error ENG L03 system
40-94 D65EX,PX,WX-17
40 Troubleshooting

Electrical
CA222 Ambient Press Sensor Low Error ENG L03 system
Electrical
CA227 Sensor 2 Supply Volt High Error ENG L03 system
Mechanical
CA234 Eng Overspeed ENG L02 system
Electrical
CA238 Ne Speed Sensor Supply Volt Error ENG L01 system
Electrical
CA239 Ne Speed Sens Supply Volt High Error ENG L01 system
Electrical
CA271 IMV/PCV1 Short Error ENG L03 system
Electrical
CA272 IMV/PCV1 Open Error ENG L03 system
Electrical
CA281 Pump Press Balance Error ENG L03 system
Electrical
CA295 Ambient Press Sens In Range Error ENG L03 system
Electrical
CA322 Inj #1(L#1) Open/Short Error ENG L03 system
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
CA343 ECM Critical Internal Failure ENG L04 system
Electrical
CA351 Injectors Drive Circuit Error ENG L03 system
Electrical
Electrical
CA356 Mass Air Flow Sensor High Error ENG L03 system
Electrical
CA357 Mass Air Flow Sensor Low Error ENG L03 system
Electrical
Electrical
CA428 Water in Fuel Sensor High Error ENG L01 system
Electrical
CA429 Water in Fuel Sensor Low Error ENG L01 system
Electrical
CA435 Eng Oil Press SW Error ENG L01 system
Electrical
CA441 Battery Voltage Low Error ENG L04 system
Electrical
CA442 Battery Voltage High Error ENG L04 system
Electrical
CA449 Rail Press Very High Error ENG L03 system
Electrical
CA451 Rail Press Sensor High Error ENG L03 system
D65EX,PX,WX-17 40-95
40 Troubleshooting

Electrical
CA452 Rail Press Sensor Low Error ENG L03 system
Electrical
CA488 Chg Air Temp High Torque Derate ENG L03 system
Electrical
CA515 Rail Press Sens Sup Volt High Error ENG L03 system
Electrical
CA516 Rail Press Sens Sup Volt Low Error ENG L03 system
Electrical
CA553 Rail Press High Error ENG L01 system
Electrical
CA555 Crankcase Press High Error 2 ENG L01 system
Electrical
CA556 Crankcase Press High Error 3 ENG L03 system
Electrical
CA559 Rail Press Low Error ENG L01 system
Electrical
CA595 Turbo Speed High Error 2 ENG L01 system
Electrical
CA687 Turbo Speed Low Error ENG L01 system
Electrical
CA689 Eng Ne Speed Sensor Error ENG L01 system
Electrical
CA691 Intake Air Temp Sens High Error ENG L01 system
Electrical
CA692 Intake Air Temp Sens Low Error ENG L01 system
Electrical
CA697 ECM Int Temp Sensor High Error ENG L01 system
Electrical
CA698 ECM Int Temp Sensor Low Error ENG L01 system
Electrical
CA731 Eng Bkup Speed Sens Phase Error ENG L01 system
Electrical
CA778 Eng Bkup Speed Sensor Error ENG L01 system
Electrical
CA1117 Persistent Data Lost Error ENG L04 system
Electrical
CA1663 KDOC Temp Reversed Error ENG L03 system
Electrical
CA1664 KDOC Malfunction ENG L03 system
Electrical
CA1691 Regeneration Ineffective ENG L03 system
Electrical
Electrical
Electrical
CA1843 Crankcase Press Sens High Error ENG L01 system
Electrical
CA1844 Crankcase Press Sens Low Error ENG L01 system
Electrical
CA1879 KDPF Delta P Sensor High Error ENG L03 system
Electrical
CA1881 KDPF Delta P Sensor Low Error ENG L03 system
Electrical
CA1883 KDPF Delta P Sens In Range Error ENG L03 system
40-96 D65EX,PX,WX-17
40 Troubleshooting

Electrical
CA1911 Rail Press Valve Trip Error ENG L03 system
Electrical
CA1921 KDPF Soot Load High Error 1 ENG L03 system
Electrical
CA1922 KDPF Soot Load High Error 2 ENG L04 system
Electrical
CA1942 Crankcase Press Sens In Range Error ENG L01 system
Electrical
CA1981 KDPF Delta Press High Error ENG L03 system
Electrical
CA1993 KDPF Delta Pressure Low Error ENG L03 system
Electrical
CA2185 Throt Sensor Sup Volt High Error ENG L03 system
Electrical
CA2186 Throt Sensor Sup Volt Low Error ENG L03 system
Electrical
CA2249 Rail Press Very Low Error ENG L03 system
Electrical
CA2265 Fuel Feed Pump Open Error ENG L01 system
Electrical
CA2266 Fuel Feed Pump Short Error ENG L01 system
Electrical
CA2271 EGR Valve Pos Sens High Error ENG L03 system
Electrical
CA2272 EGR Valve Pos Sens Low Error ENG L03 system
Electrical
CA2288 Turbo Speed High Error 1 ENG L01 system
Electrical
CA2311 IMV Solenoid Error ENG L03 system
Electrical
CA2349 EGR Valve Solenoid Open Error ENG L03 system
Electrical
CA2353 EGR Valve Solenoid Short Error ENG L03 system
Electrical
CA2357 EGR Valve Servo Error ENG L03 system
Electrical
CA2373 Exhaust Manifold Press Sens High error ENG L03 system
Electrical
CA2374 Exhaust Manifold Press Sens Low error ENG L03 system
Electrical
CA2375 EGR Orifice Temp Sens High Error ENG L03 system
Electrical
CA2376 EGR Orifice Temp Sens Low Error ENG L03 system
Electrical
CA2381 KVGT Pos Sens High Error ENG L03 system
Electrical
CA2382 KVGT Pos Sens Low Error ENG L03 system
Electrical
CA2383 KVGT Solenoid Open Error ENG L03 system
Electrical
CA2386 KVGT Solenoid Short Error ENG L03 system
Electrical
CA2387 KVGT Servo Error ENG L03 system
Electrical
CA2554 Exh Manifold Press Sens In Range error ENG L03 system
D65EX,PX,WX-17 40-97
40 Troubleshooting

Electrical
CA2555 Grid Htr Relay Volt Low Error ENG L01 system
Electrical
CA2556 Grid Htr Relay Volt High Error ENG L01 system
Electrical
CA2637 KDOC Face Plugging ENG L01 system
Electrical
CA2639 Manual Stationary Regeneration Request ENG L01 system
Electrical
CA2961 EGR Orifice Temp High Error 1 ENG L03 system
Electrical
CA2973 Chg Air Press Sensor In Range Error ENG L03 system
Electrical
CA3133 KDPF Outlet Press Sens High Error ENG L03 system
Electrical
CA3134 KDPF Outlet Press Sens Low Error ENG L03 system
Electrical
CA3135 KDPF Outlet Press Sens In Range Error ENG L03 system
Electrical
CA3251 KDOC Inlet Temp High Error ENG L03 system
Electrical
CA3253 KDOC Temp Error - Non Regeneration ENG L03 system
Electrical
CA3254 KDOC Outlet Temp High Error 1 ENG L01 system
Electrical
CA3255 KDPF Temp Error - Non Regeneration ENG L03 system
Electrical
CA3256 KDPF Outlet Temp High Error 1 ENG L01 system
Electrical
CA3311 KDOC Outlet Temp High Error 2 ENG L03 system
Electrical
CA3312 KDPF Outlet Temp High Error 2 ENG L03 system
Electrical
CA3313 KDOC Inlet Temp Sensor Low Error ENG L03 system
Electrical
CA3314 KDOC Inlet Temp Sens High Error ENG L03 system
Electrical
CA3315 KDOC Inlet Temp Sens In Range Error ENG L03 system
Electrical
CA3316 KDOC Outlet Temp Sens Low Error ENG L03 system
Electrical
CA3317 KDOC Outlet Temp Sens High Error ENG L03 system
Electrical
CA3318 KDOC Outlet Temp Sens In Range Error ENG L03 system
Electrical
CA3319 KDPF Outlet Temp Sens High Error ENG L03 system
Electrical
CA3321 KDPF Outlet Temp Sens Low Error ENG L03 system
Electrical
CA3322 KDPF Outlet Temp Sens In Range Error ENG L03 system
Electrical
CA3419 Mass Air Flow Sensor Sup Volt High Error ENG L03 system
Electrical
CA3421 Mass Air Flow Sensor Sup Volt Low Error ENG L03 system
Electrical
CA3741 Rail Press Valve Trip Error ENG L03 system
40-98 D65EX,PX,WX-17
40 Troubleshooting

Electrical
D130KA Neutral relay: Open PT L01 system
Electrical
D130KB Neutral relay: Short circuit PT L01 system
Electrical
D19DKA Amber light relay: Open PT L01 system
Electrical
D19DKB Amber light relay: Short circuit PT L01 system
Electrical
D19JKZ Personal Code Relay Abnormality MON L03 system
Electrical
D811MC KOMTRAX Error KOMTRAX –
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX –
system
Electrical
D8ALKA Operating Lamp Open Circuit (KOMTRAX) KOMTRAX –
system
Electrical
D8ALKB Operating Lamp Short Circuit (KOMTRAX) KOMTRAX –
system
Electrical
D8AQKR CAN2 Discon (KOMTRAX) MON –
system
Electrical
DAF0MB Monitor ROM Abnormality MON –
system
Electrical
DAF0MC Monitor Error MON –
system
Electrical
DAF8KB Camera Power Supply Short Circuit MON L03 system
Electrical
DAF9KQ Model Selection Abnormality MON L03 system
Electrical
DAFGMC GPS Module Error MON –
system
Electrical
DAFLKA Operating Lamp Open Circuit (Monitor) MON –
system
Electrical
DAFLKB Operating Lamp Short Circuit (Monitor) MON –
system
Electrical
DAFQKR CAN2 Discon (Monitor) KOMTRAX –
system
Electrical
DAZ9KQ A/C Model Selection Abnormality MON –
system
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01 system
Electrical
DB2QKR CAN2 Discon (Engine Con) MON L03 system
Electrical
DB2RKR CAN1 Discon (Engine Con) MON L03 system
Electrical
DBE0KT PT controller: Abnormality in controller PT L01 system
Electrical
DBE1KK PT controller: Source voltage low PT L04 system
Electrical
DBE2KK PT controller: Output voltage low PT L04 system
Electrical
DBE5KK PT: Sensor volt 5 V (0) Out of normal range PT L03 system
Electrical
DBE6KK PT: Sensor volt 24 V Out of normal range PT L03 system
Electrical
DBE7KK PT: Sensor volt 5 V (1) Out of normal range PT L01 system
D65EX,PX,WX-17 40-99
40 Troubleshooting

Electrical
DBE9KQ PT controller: Type select signal PT L04 system
Electrical
DBELKA Operating Lamp Open Circuit(PT Con) PT –
system
Electrical
DBELKB Operating Lamp Short Circuit(PT Con) PT –
system
Electrical
DBEQKR CAN2 Discon (PT Con) MON L03 system
Electrical
DBERKR CAN1 Discon (PT Con) MON L03 system
Electrical
DD12KA Shift up Sw: Open PT L03 system
Electrical
DD12KB Shift up Sw: Short circuit PT L03 system
Electrical
DD13KA Shift down Sw: Open PT L03 system
Electrical
DD13KB Shift down Sw: Short circuit PT L03 system
Electrical
DD14KA Parking lever Sw: Open PT L03 system
Electrical
DD14KB Parking lever Sw: Short circuit PT L03 system
Electrical
DDKFL4 Left Angle Sw: Signal mismatch PT L01 system
Electrical
DDKGL4 Right Angle Sw: Signal mismatch PT L01 system
Electrical
DDKHKA iB Sw: Open PT L01 system
Electrical
DDKHKB iB Sw: Short circuit PT L01 system
Electrical
DDN7KA Weq pitch Sw: Open PT L01 system
Electrical
DDN7KB Weq pitch Sw: Short circuit PT L01 system
Electrical
DDNLKA Weq lock Sw: Open PT L03 system
Electrical
DDNLKB Weq lock Sw: Short circuit PT L03 system
Electrical
DGS1KA Hyd oil temp sensor: Open PT L01 system
Electrical
DGS1KX Hyd oil temp: Out of normal range PT L01 system
Electrical
DGT1KA T/C oil temp sensor: Open PT L01 system
Electrical
DGT1KX T/C oil temp sensor: Out of normal range PT L01 system
Electrical
DH21KA Weq pressure sensor: Open PT L01 system
Electrical
DH21KB Weq pressure sensor: Hot Short PT L01 system
Electrical
DHA4KA Air Cleaner Clog Sensor Open Circuit MON L01 system
Electrical
DHTDKA T/C pressure sensor: Open PT L03 system
Electrical
DHTDKB T/C pressure sensor: Hot Short PT L03 system
40-100 D65EX,PX,WX-17
40 Troubleshooting

Electrical
DK10KA Fuel control Dial: Open PT L03 system
Electrical
DK10KB Fuel control Dial: Short circuit PT L03 system
Electrical
DK30KA ST lever1: Open PT L03 system
Electrical
DK30KB ST lever1: Hot Short PT L03 system
Electrical
DK30KX ST lever: Main and Sub Error PT L04 system
Electrical
DK30KZ ST lever: Main and Sub Error PT L04 system
Electrical
DK30L8 ST lever: Signal mismatch PT L03 system
Electrical
DK31KA ST lever2: Open PT L03 system
Electrical
DK31KB ST lever2: Hot Short PT L03 system
Electrical
DK40KA Brake potentiometer: Open PT L01 system
Electrical
DK40KB Brake potentiometer: Hot Short PT L01 system
Electrical
DK55KX FR lever: Main and Sub Error PT L04 system
Electrical
DK55KZ FR lever: Main and Sub Error PT L04 system
Electrical
DK55L8 FR lever: Signal mismatch PT L03 system
Electrical
DK56KA FR lever1: Open PT L03 system
Electrical
DK56KB FR lever1: Hot Short PT L03 system
Electrical
DK57KA FR lever2: Open PT L03 system
Electrical
DK57KB FR lever2: Hot Short PT L03 system
Electrical
DKH1KA Pitch angle sensor: Open PT L03 system
Electrical
DKH1KB Pitch angle sensor: Hot Short PT L03 system
Electrical
DLM3KA Fan rev. sensor: Open PT L01 system
Electrical
DLM3MB Fan control: Mismatch PT L01 system
Electrical
DLT3KA T/M out-speed sensor: Open PT L03 system
Electrical
DLT3KB T/M out-speed sensor: Short circuit PT L03 system
Electrical
DR21KX Camera 2 Picture Rev. Drive Abnormality MON L01 system
Electrical
DR31KX Camera 3 Picture Rev. Drive Abnormality MON L01 system
Electrical
DV20KB Back-up alarm : Short circuit PT L01 system
Electrical
DW5AKA Pitch select solenoid: Disconnection PT L01 system
D65EX,PX,WX-17 40-101
40 Troubleshooting

Electrical
DW5AKB Pitch select solenoid: Short circuit PT L01 system
Electrical
DW5AKY Pitch select solenoid: Hot short PT L01 system
Electrical
DW7BKA Fan reverse solenoid: Open PT L01 system
Electrical
DW7BKB Fan reverse solenoid: Short circuit PT L01 system
Electrical
DWN1KA Hss EPC RH: Open PT L03 system
Electrical
DWN1KB Hss EPC RH: Short circuit PT L03 system
Electrical
DWN1KY Hss EPC RH: Hot short PT L04 system
Electrical
DWN2KA Hss EPC LH: Open PT L03 system
Electrical
DWN2KB Hss EPC LH: Short circuit PT L03 system
Electrical
DWN2KY Hss EPC LH: Hot short PT L04 system
Electrical
DWN5KA Fan pump solenoid 1: Open PT L03 system
Electrical
DWN5KB Fan pump solenoid 1: Short circuit PT L03 system
Electrical
DWN5KY Fan pump solenoid 1: Hot Short PT L01 system
Electrical
DXA2KA TVC solenoid1: Open PT L01 system
Electrical
DXA2KB TVC solenoid1: Short circuit PT L01 system
Electrical
DXA2KY TVC solenoid1: Hot short PT L01 system
Electrical
DXH1KA Lock-up ECMV: Open PT L03 system
Electrical
DXH1KB Lock-up ECMV: Short circuit PT L03 system
Electrical
DXH1KY Lock-up ECMV: Hot short PT L03 system
Electrical
DXH4KA 1st clutch ECMV: Open PT L03 system
Electrical
DXH4KB 1st clutch ECMV: Short circuit PT L03 system
Electrical
DXH4KY 1st clutch ECMV: Hot short PT L03 system
Electrical
DXH5KA 2nd clutch ECMV: Open PT L03 system
Electrical
DXH5KB 2nd clutch ECMV: Short circuit PT L03 system
Electrical
DXH5KY 2nd clutch ECMV: Hot short PT L03 system
Electrical
DXH6KA 3rd clutch ECMV: Open PT L03 system
Electrical
DXH6KB 3rd clutch ECMV: Short circuit PT L03 system
Electrical
DXH6KY 3rd clutch ECMV: Hot short PT L03 system
40-102 D65EX,PX,WX-17
40 Troubleshooting

Electrical
DXH7KA R clutch ECMV: Open PT L03 system
Electrical
DXH7KB R clutch ECMV: Short circuit PT L03 system
Electrical
DXH7KY R clutch ECMV: Hot short PT L04 system
Electrical
DXH8KA F clutch ECMV: Open PT L03 system
Electrical
DXH8KB F clutch ECMV: Short circuit PT L03 system
Electrical
DXH8KY F clutch ECMV: Hot short PT L04 system
Electrical
DXJ4KA Weq lock Sol.: Open PT L03 system
Electrical
DXJ4KB Weq lock Sol.: Short circuit PT L03 system
Electrical
DXJCKA Blade angle left EPC: Open PT L01 system
Electrical
DXJCKB Blade angle left EPC: Short circuit PT L01 system
Electrical
DXJCKY Blade angle left EPC: Hot short PT L03 system
Electrical
DXJDKA Blade angle right EPC: Open PT L01 system
Electrical
DXJDKB Blade angle right EPC: Short circuit PT L01 system
Electrical
DXJDKY Blade angle right EPC: Hot short PT L03 system
a In this table, failure codes are arranged in the order of characters from numeric to alphabelic character.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PT: Power train controller
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action code columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The history classification column shows in which system each failure is classified, the electrical equipment
system or mechanical equipment system, when it is recorded in the abnormality record.
For details, see "Troubleshooting by failure code (Display of code)".
D65EX,PX,WX-17 40-103
40 Troubleshooting
Failure code [1500L0] Transmission clutch:Abnormal

Action
Failure code Dual failures in transmission and clutch systems
level Failure
(Power train controller system)
L03 1500L0
• Among failure codes related to transmission clutch, following codes appeared at the
same time (Gear speed limit).
(1) Either one of codes [DXH4KA] or [DXH4KB], and either one of codes [DXH5KA] or
[DXH5KB]
• Among failure codes related to transmission clutch, following codes appeared at the
same time (travel failure).
Detail of (2) Either one of [DXH8KA] or [DXH8KB], and either one of [DXH7KA] or [DXH7KB]
failure (3) Either one of [DXH6KA] or [DXH6KB], and (1) above
(4)[15SALH] and [15SBLH]
(5) Either one of [15SAL1] or [DXH8KY], and either one of [15SBL1] or [DXH7KY]
(6) [15SELH] and [15SFLH] and [15SGLH]
(7) Either one of [15SEL1] or [DXH4KY], and either one of [15SFL1] or [DXH5KY]
(8) Either one of [15SEL1] or [DXH4KY], and either one of [15SGL1] or [DXH6KY]
(9) Either one of [15SFL1] or [DXH5KY], and either one of [15SGL1] or [DXH6KY]
Action of • Restricts operation of engine and transmission.
controller
• Auto shift down function does not start.
Problem on • Once machine is stopped, engine speed is limited to medium (half) speed.
machine • Once machine is stopped, travel is restricted to specific gear speed.
• Machine cannot travel.
Related • Method of reproducing failure code: Start engine and travel.
information
Cause Procedure, measuring location, criteria and remarks
Check the failure being displayed at the same time, and perform troubleshootings for those 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]
40-104 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SAL1] Forward clutch:Fill High

Action level Failure code Transmission forward travel clutch fill ON failure
Failure
L03 15SAL1 (Power train controller system)
Detail of • Nevertheless controller does not output command current to transmission F clutch ECMV
failure solenoid circuit, fill switch signal is turned ON.
• Sets transmission to neutral when operator sets it to reverse position (Prevention of
Action of double engagement).
controller • Restricts operation of engine and transmission.
machine • Once machine is stopped, travel is limited to F1.
• The signal condition of forward travel clutch ECMV fill switch can be checked with
monitoring function.
Related • Method of reproducing failure code: Start engine and travel in N (Neutral).
information • Remove seat (approx. 50 kg) and seat bottom cover.
• First, check power train oil filter for clogging etc.
• Then, check that clutch pressure is normal by referring to Step "H-1" of troubleshooting (H
mode).
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector F SW, and connect T-adapter to male side.
Defective F clutch ECMV fill
1 switch (internal short circuit) Between fill switch connector (female) (1) and
Resis- ground
Min. 1 Mz
tance
(Fill switch turned OFF)
2. Disconnect connector F SW.
Ground fault of wiring 3. Start engine.
2 harness or defective power
If failure code [15SAL1] is still displayed, wiring harness may be
train controller
grounded or power train controller is defective.
(If failure code [15SAL1] disappears, F clutch fill switch is defective.)
a If cause 2 is not cause for failure, this check is not required.
Ground fault of wiring 1. Turn starting switch to OFF position.
3 harness 2. Disconnect connectors STC2 and F SW, and connect T-adapters to
(contact with ground circuit) either female side.
Resis- Between ground and STC2 (female) (35) or F
SW (female) (1) Min. 1 Mz
tance
If "check result of cause 2 is abnormal" and "check result of cause 3 is
normal", power train controller is defective.
• Reference
2. Insert T-adapter into connector STC2.
3. Start engine.
Defective power train a Keep PCCS lever in N position.
4
controller
Voltage Between STC2 (35) and ground 7 to 11 V
Descriptions for 1 to 3 are the same as above.
4. While depressing brake pedal, operate PCCS lever (to select gear
speed) and perform troubleshooting.
Between STC2 (35)
Voltage F1/F2/F3 Max. 1 V
and ground
D65EX,PX,WX-17 40-105
40 Troubleshooting
Circuit diagram related to forward clutch ECMV
40-106 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SALH] Forward clutch:Fill Low

Action level Failure code Transmission forward travel clutch fill OFF failure
Failure
L03 15SALH (Power train controller system)
Detail of • Nevertheless controller outputs command current to transmission F clutch ECMV
failure solenoid circuit, fill switch signal is turned OFF.
• Sets transmission to neutral when operator sets it to forward position (Prevention of
Action of defective engagement).
machine • Once machine is stopped, travel is limited to R1.
• The signal condition of forward travel clutch ECMV fill switch can be checked with
Related • Method of reproducing failure code: Start engine and travel forward.
mode).
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 Resis- Between F SW (male) (1) and ground
1 Min. 1 Mz
switch (It does not turn ON) tance
Resis- Between F SW (male)
(1) and ground F1/F2/F3 Max. 1 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC2 and F SW, and connect T-adapters to
2 (open circuit or defective each female side.
contact) Resis- Between STC2 (female) (35) and F SW
(female) (1) Max. 1 z
tance
3. Start engine.
Defective power train Voltage Between STC2 (35) and ground 7 to 11 V
3
controller Descriptions for 1 to 3 are the same as above.
Between STC2 (35)
Voltage F1/F2/F3 Max. 1 V
and ground
D65EX,PX,WX-17 40-107
40 Troubleshooting
Circuit diagram related to forward clutch ECMV
40-108 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SBL1] Reverse clutch:Fill High

Action level Failure code Transmission reverse clutch fill ON failure
Failure
L03 15SBL1 (Power train controller system)
Detail of • Nevertheless controller does not output command current to transmission R clutch ECMV
failure solenoid circuit, fill switch signal is turned ON.
• Sets transmission to neutral when operator sets it to forward position (Prevention of
Action of double engagement).
machine • Once machine is stopped, travel is limited to R1.
• The signal condition of reverse gear clutch ECMV fill switch can be checked with
Related • Method of reproducing failure code: Start engine and travel in N (Neutral).
mode).
Defective R clutch ECMV fill 2. Disconnect connector R SW, and connect T-adapter to male side.
1 switch (internal short circuit) Resis- Between R SW (female) (1) and ground
Min. 1 Mz
tance (Fill switch turned OFF)
2. Disconnect connector R SW.
Ground fault of wiring 3. Start engine
2 harness or defective power
If failure code [15SBL1] is still displayed, wiring harness is grounded or
train controller
power train controller is defective.
(If failure code [15SBL1] disappears, R clutch fill switch is defective.)
3 harness 2. Disconnect connectors STC2 and R SW, and connect T-adapters to
Resis- Between ground and STC2 (female) (25) or R
tance
• Reference
3. Start engine.
4
controller
Between STC2 (25)
Voltage R1/R2/R3 Max. 1 V
and ground
D65EX,PX,WX-17 40-109
40 Troubleshooting
Circuit diagram related to R clutch ECMV solenoid
40-110 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SBLH] Reverse clutch:Fill Low

Action level Failure code Transmission reverse clutch fill switch OFF failure
Failure
L03 15SBLH (Power train controller system)
Detail of • Nevertheless controller outputs command current to transmission R clutch ECMV
• Sets transmission to neutral when operator sets it to reverse position (Prevention of
Action of defective engagement).
machine • Once machine is stopped, travel speed is limited to F1.
• The signal condition of reverse gear clutch ECMV fill switch can be checked with
Related • Method of reproducing failure code: Start engine and travel in reverse.
mode).
2. Disconnect connector R SW, and connect T-adapter to male side.
3. Start engine.
Defective R clutch ECMV fill Resis- Between R SW (male) (1) and ground
1 Min. 1 Mz
switch (It does not turn ON) tance
Resis- Between R SW (male)
(1) and ground R1/R2/R3 Max. 1 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC2 and R SW, and connect T-adapters to
2 (open circuit or defective female side of each connector.
contact) Resis- Between STC2 (female) (25) and R SW
tance
3. Start engine.
Defective power train Voltage Between STC2 (25) and ground 7–11 V
3
Between STC2 (25)
Voltage R1/R2/R3 Max. 1 V
and ground
D65EX,PX,WX-17 40-111
40 Troubleshooting
40-112 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SEL1] Speed 1st clutch:Fill High

Action level Failure code Transmission 1st gear clutch fill switch ON failure
Failure
L03 15SEL1 (Power train controller system)
Detail of • Nevertheless controller does not output command current to transmission 1st clutch
failure ECMV solenoid circuit, fill switch signal is turned ON.
controller
machine • Once machine is stopped, travel speed is restricted to F1 and R1.
• The signal condition of 1st gear speed clutch ECMV fill switch can be checked with
Related • Method of reproducing failure code: Start engine and travel lever in N (Neutral).
mode).
Defective 1st clutch ECMV fill 2. Disconnect connector 1 SW, and connect T-adapter to male side.
1 switch (internal short circuit) Resis- Between 1 SW (female) (1) and ground
Min. 1 Mz
2. Disconnect connector 1 SW.
2 harness or defective power If failure code [15SEL1] is still displayed, wiring harness is grounded or
train controller power train controller is defective.
(If failure code [15SEL1] disappears, 1st gear speed clutch fill switch is
defective.)
3 harness 2. Disconnect connectors STC3 and 1 SW, and connect T-adapters to
(contact with ground circuit) female side of either connector.
Resis- Between ground and STC3 (female) (19) or 1
tance
• Reference
3. Start engine.
4
controller
Between STC3 (19)
Voltage F1/R1 Max. 1 V
and ground
D65EX,PX,WX-17 40-113
40 Troubleshooting
Circuit diagram related to 1st clutch ECMV
40-114 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SELH] Speed 1st clutch:Fill Low

Action level Failure code Transmission 1st gear speed clutch fill switch OFF failure
Failure
L03 15SELH (Power train controller system)
Detail of • Nevertheless controller outputs command current to transmission 1st clutch ECMV
controller
machine • Once machine stops, travel speed is limited to F2 and R2.
• The signal condition of 1st gear speed clutch ECMV fill switch can be checked with
Related • Method of reproducing failure code: Start engine and travel in F1 or R1.
mode).
2. Disconnect connector 1 SW, and connect T-adapter to male side of
connector.
3. Start engine.
Defective 1st clutch ECMV fill Resis- Between 1 SW (male) (1) and ground
1 switch (It does not turn ON.) Min. 1 Mz
tance
Resis- Between 1 SW (male)
(1) and ground F1/F2/F3 Max. 1 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and 1 SW, and connect T-adapters to
2 (open circuit or defective female sides of both connectors.
contact) Resis- Between STC3 (female) (19) and 1 SW
tance
3. Start engine.
3
Between STC3 (19)
and ground
D65EX,PX,WX-17 40-115
40 Troubleshooting
40-116 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SFL1] Speed 2nd clutch:Fill High

Action level Failure code Transmission 2nd gear speed clutch fill switch ON failure
Failure
L03 15SFL1 (Power train controller system)
Detail of • Nevertheless controller does not output command current to transmission 2nd clutch
controller
machine • Once machine stops, travel speed is limited to F2 and R2.
• The signal condition of 2nd clutch ECMV fill switch can be checked with monitoring
function.
mode).
Defective 2nd clutch ECMV 2. Disconnect connector 2 SW, and connect T-adapter to male side of
1 fill switch (internal short connector.
circuit) Resis- Between 2 SW (female) (1) and ground
Min. 1 Mz
2 harness or defective power If failure code [15SFL1] is still displayed, wiring harness is grounded or
train controller the power train controller is defective.
(If failure code [15SFL1] disappears, the 2nd clutch fill switch is
defective.)
tance
• Reference
3. Start engine.
4
controller
Between STC3 (29)
and ground
D65EX,PX,WX-17 40-117
40 Troubleshooting
Circuit diagram related to 2nd clutch ECMV
40-118 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SFLH] Speed 2nd clutch:Fill Low

Action level Failure code Transmission 2nd gear speed clutch fill switch OFF failure
Failure
L03 15SFLH (Power train controller system)
Detail of • Nevertheless controller outputs command current to transmission 2nd clutch ECMV
controller
• The signal condition of 2nd clutch ECMV fill switch can be checked with monitoring
function.
mode).
connector.
3. Start engine.
Defective 2nd clutch ECMV a Keep PCCS lever in N position.

1 fill switch (It does not turn Resis- Between 2 SW (male) (1) and ground
Min. 1 Mz
ON.) tance
(1) and ground F2/R2 Max. 1 z
tance
Open circuit of wiring harness 2. Disconnect connectors STC3 and 2 SW, and connect T-adapters to
tance
3. Start engine.
3
Between STC3 (29)
and ground
D65EX,PX,WX-17 40-119
40 Troubleshooting
40-120 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SGL1] Speed 3rd clutch:Fill High

Action level Failure code Transmission 3rd gear speed clutch fill switch ON failure
Failure
L03 15SGL1 (Power train controller system)
Detail of • Nevertheless controller does not output command current to transmission 3rd clutch
controller
• The signal condition of 3rd clutch ECMV fill switch can be checked with monitoring
function.
• Then, check that clutch oil pressure is normal by referring to Step "H-1" of troubleshooting
(H mode).
3rd clutch ECMV fill switch is 2. Disconnect connector 3 SW, and connect T-adapter to male side of
1 defective (internal short connector.
circuit). Resis- Between 3 SW (female) (1) and ground
Min. 1 Mz
2 harness or defective power If failure code [15SGL1] is still displayed, wiring harness is grounded or
(If failure code [15SGL1] disappears, 3rd gear clutch fill switch is
defective.)
tance
• Reference
3. Start engine.
4
controller
Between STC3 (39)
and ground
D65EX,PX,WX-17 40-121
40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV solenoid
40-122 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SGLH] Speed 3rd clutch:Fill Low

Action level Failure code Transmission 3rd gear speed clutch fill switch OFF failure
Failure
L03 15SGLH (Power train controller system)
Detail of • Nevertheless controller outputs command current to transmission 3rd clutch ECMV
controller
• The signal condition of 3rd clutch ECMV fill switch can be checked with monitoring
function.
(H mode).
connector.
3. Start engine
3rd gear clutch ECMV fill a Keep PCCS lever in N position.

1 switch is defective (it does not Resis- Between 3 SW (male) (1) and ground
Min. 1 Mz
turn ON.) tance
(1) and ground F3/R3 Max. 1 z
tance
Open circuit of wiring harness 2. Disconnect connectors STC3 and 3 SW, and connect T-adapters to
2 (open circuit or defective each female side of each connector.
tance
3. Start engine.
3
Between STC3 (39)
and ground
D65EX,PX,WX-17 40-123
40 Troubleshooting
Circuit diagram related to 3rd clutch ECMV solenoid
40-124 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SJL1] L/U :Fill Hihg

Action level Failure code Lockup clutch fill switch ON failure
Failure
L03 15SJL1 (Power train controller system)
Detail of • Nevertheless controller does not output command current to torque converter lockup
failure clutch ECMV solenoid circuit, fill switch signal is turned ON.
Action of • Prohibits lockup.
controller
Problem on • Engine may stall during travel.
machine
• Condition of lockup clutch ECMV fill switch signal can be checked with monitoring
function.
• Method of reproducing failure code: Start engine and travel in F2 (forward) (auto gearshift
Related mode).
(H mode).
Defective lockup clutch 2. Disconnect connector L SW, and connect T-adapter to male side of
1 ECMV fill switch (internal connector.
short circuit) Resis- Between L SW (male) (1) and ground
Min. 1 Mz
2. Disconnect connector L SW.
Ground fault of wiring 3. Start engine
2 harness or defective power If failure code [15SJL1] is still displayed, wiring harness is grounded or
(If failure code [15SJL1] disappears, lockup clutch fill switch is
defective.)
3 harness 2. Disconnect connectors STC2 and L SW, and connect T-adapters to
Resis- Between ground and STC2 (female) (36) or L
tance
• Reference
3. Start engine.
Defective power train Descriptions for 1 to 3 are the same as above.
4
controller
4. Raise tracks off the ground.
5. Travel in F2 (forward) (automatic gearshift mode) and perform
troubleshooting with clutch locked up.
a See Item (6) "Measuring torque converter lockup (LU) clutch
pressure" of Testing and Adjusting, "Testing power train oil
pressure".
Between STC2 (36)
Voltage R1 Max. 1 V
and ground
D65EX,PX,WX-17 40-125
40 Troubleshooting
Circuit diagram related to lockup clutch ECMV solenoid
40-126 D65EX,PX,WX-17
40 Troubleshooting
Failure code [15SJLH] L/U :Fill low

Action level Failure code Lockup clutch fill switch OFF failure
Failure
L03 15SJLH (Power train controller system)
Detail of • Nevertheless controller outputs command current to torque converter lockup clutch
failure ECMV solenoid circuit, fill switch signal is turned OFF.
Action of • Prohibits lockup.
controller
Problem on • It is impossible to lockup.
machine
• Condition of lockup clutch ECMV fill switch signal can be checked with monitoring
function.
• Method of reproducing failure code: Start engine and travel in F2 (forward) (auto gearshift
Related mode).
mode).
2. Disconnect connector L SW, and connect T-adapter to male side of
connector.
3. Start engine.
Defective lockup clutch 4. Raise tracks off ground.
ECMV fill switch (It does not 5. Travel in F2 (automatic gearshift mode), and perform
1
turn ON.) troubleshooting with lockup in operation.
pressure" of Testing Adjusting, "Testing power train oil pressure".
Resis- Between L SW (male) (1) and ground
Max. 1 z
tance (Fill switch: ON)
Open circuit in wiring harness 2. Disconnect connectors STC2 and L SW, and connect T-adapters to
contact) Resis- Between STC2 (female) (36) and L SW
tance
If cause is not found by above checks, power train controller is
defective.
• Reference
3. Start engine.
Voltage Between STC2 (36) and ground 7–11 V
Defective power train Descriptions for 1 to 3 are the same as above.
3
controller
4. Raise tracks off ground.
5. Travel in F2 (automatic gearshift mode), and perform troubleshooting
with lockup in operation.
pressure" of Testing and Adjusting, "Testing power train oil
pressure".
Between STC2 (36)
Voltage R1 Max. 1 V
and ground
D65EX,PX,WX-17 40-127
40 Troubleshooting
40-128 D65EX,PX,WX-17
40 Troubleshooting
Failure code [1800MW] P/L clutch:Slip

Action level Failure code Power train clutch slipping
Failure
L03 1800MW (Power train controller system)
Detail of • When torque converter is locked up, engine speed does not match sensed transmission
failure output shaft speed.
Action of • Restricts operations of engine and transmission.
controller
machine • Once machine is stopped, travel is restricted to F1 and R1.
• Engine condition (speed) and torque converter condition (speed) can be checked with
monitoring funtion.
Related Code 01002: Engine speed; code 31400: Transmission output shaft speed (torque
information converter speed)
• Method of reproducing failure code: start engine, turn lockup switch ON and drive
machine.
Power train clutch slip (When a Clutch slip is detected; check cause of slip and condition of machine
1 the system is normal) damage, then repair machine.
Defective engine speed Check whether failure codes [CA689] and [CA778] are displayed. If
2 they are displayed, perform troubleshooting.
sensor
Defective transmission speed Check whether failure codes [DLT3KA] and [DLT3KB] are displayed. If
3 they are displayed, perform troubleshooting.
sensor
Defective power train Since this is internal failure, troubleshooting cannot be performed.
4
controller
D65EX,PX,WX-17 40-129
40 Troubleshooting
Failure code [879AKA] Air Conditioner Inner Sensor Disconnection

See "Failure code [879AKA] Air Conditioner Inner Sensor Disconnection" in chapter 80 "Others".
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
40-130 D65EX,PX,WX-17
40 Troubleshooting
Failure code [879AKB] Air Conditioner Inner Sensor Disconnection

See chapter 80 Others "Failure code [879AKB] Air Conditioner Inner Sensor Disconnection".
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
D65EX,PX,WX-17 40-131
40 Troubleshooting
Failure code [879BKA] Air Conditioner Outside Air Sensor Disconnection

See chapter 80 Others "Failure code [879BKA] Air Conditioner Outside Sensor Disconnection".
40-132 D65EX,PX,WX-17
40 Troubleshooting
Failure code [879BKB] Air Conditioner Outside Air Sensor Disconnection

See chapter 80 Others "Failure code [879BKB] Air Conditioner Outside Temperature Sensor Short Circuit".
D65EX,PX,WX-17 40-133
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Disconnection

See "Failure code [879CKA] Ventilating Sensor Disconnection" in chapter 80 "Others".
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
40-134 D65EX,PX,WX-17
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit

See chapter 80 Others "Failure code [879CKB] Ventilating Sensor Short Circuit".
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
D65EX,PX,WX-17 40-135
40 Troubleshooting
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit

See chapter 80 Others "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit".
40-136 D65EX,PX,WX-17
40 Troubleshooting
Failure code [879EMC] Ventilation Abnormal

See chapter 80 Others "Failure code [879EMC] Ventilation Abnormal".
a Since the vent select servo motor cannot be disconnected on the machine, the air conditioner controller or
air conditioner unit must be replaced.
D65EX,PX,WX-17 40-137
40 Troubleshooting
Failure code [879FMC] A/M Damper Abnormal

See chapter 80 Others "Failure code [879FMC] A/M Damper Abnormal".
a Since the air mix servo motor connector cannot be disconnected on the machine, the air conditioner
controller or air conditioner unit must be replaced.
40-138 D65EX,PX,WX-17
40 Troubleshooting
Failure code [879GKX] Refrigerant Abnormality

See chapter 80 Others "Failure code [879GKX] Refrigerant Abnormality".
D65EX,PX,WX-17 40-139
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution 1

Action level Failure code Engine controller lock caution 1
Failure
– 989L00 (Machine monitor system)
Detail of • Engine controller lock up is detected (Factor 1).
failure
Action of • None in particular
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to one before replacement.
information • Method of reproducing failure code: Turn starting switch to ON position.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
40-140 D65EX,PX,WX-17
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution 2

Failure
– 989M00 (Machine monitor system)
failure
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to one before replacement.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
If this failure code is displayed while machine monitor is not replaced,
2 Defective machine monitor machine monitor may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
D65EX,PX,WX-17 40-141
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution 3

Failure
– 989N00 (Machine monitor system)
failure
Action of • Tries automatic recovery.
monitor
Problem on
machine
Related • Method of reproducing failure code: Failure code cannot be reproduced since machine
information recovers when cause of failure disappears.
If this failure code is generated repeatedly, engine controller may be
1 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
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40 Troubleshooting
Failure code [A1U0N3]: KDPF Dry Request (HC Release)

Action level Failure code KDPF dry request (HC release)
Failure
L01 A1U0N3 (Engine controller system)
Detail of • Unburned fuel remains in KCSF due to long operation of engine at low idle.
failure
Action of Requests manual stationary regeneration (fuel drying) to operator.
controller Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)
k Since the temperature of the KDPF and KDOC will become higher than 500 °C , take
care not to get burn injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301(V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C ))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
Related function. (Code: 47200 (°C ))
information • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
engine running at idle (without regenerating KDPF) are all approx. 100 to 250 °C and
temperature differences among them are approx. 10 °C (KDOC inlet temperature>KDOC
outlet temperature>KDPF outlet temperature).
• When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approx. 250 to 400 °C , and KDOC outlet temperature and KDPF outlet
temperature reach to approx. 450 to 550 °C .
• If there is a significant difference between KDOC inlet temperature and KDOC outlet
temperature when KDPF is completely cool or engine is running at idle (without
regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet temperature
sensor, whichever is suspected to be defective, judging from KDPF outlet temperature.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
• Method of reproducing failure code: Turn starting switch to ON position.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
2 temperature sensor troubleshooting for it.
D65EX,PX,WX-17 40-143
40 Troubleshooting

1. Turn starting switch to ON position.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor, and note down the temperature
values of each sensor at their initial condition and during manual
stationary regeneration (see "Related information").
3. Make sure that machine is in safe condition.
4. From service menu of machine monitor, select "Diagnostic Tests"
screen, open "0 Regeneration for Service", and then execute
Soot accumulation in KCSF "Manual Statonary Regeneration" (manual stationary regeneration
3
inside KDPF. will be completed in approx. 40 minutes).
If this failure code is not displayed after manual stationary regeneration
is completed, cause is soot accumulation.
a If another failure code is displayed during manual stationary
regeneration, perform troubleshooting for it.
a If failure code [CA2639] is displayed after manual stationary
regeneration is completed, perform troubleshooting for it.
4 Defective engine controller If this failure code is displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
a Turn starting switch to ON position and check that failure code [CA2639] is not displayed.
40-144 D65EX,PX,WX-17
40 Troubleshooting
Failure code [A1U0N4] KDPF Dry Request (HC Release)

Action level Failure code KDPF dry request 2 (HC release)
Failure
L03 A1U0N4 (Engine controller system)
Detail of • Unburned fuel remains in KCSF because engine has been run at low idle or low load for a
failure long time.
Action of Requests manual stationary regeneration (fuel drying) to operator.
controller Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
Related temperature differences among them are approx. 10 °C (KDOC inlet temperature>KDOC
information outlet temperature>KDPF outlet temperature).
• When manual stationary regeneration is performed as an action taken for A1U0N3 or
A1U0N4, dosing fuel is not injected. Therefore, KDOC inlet, KDOC outlet, and KDPF
outlet temperatures will be around 250–400 °C .
• In other cases than the above, when active regeneration (manual stationary regeneration)
is in progress, the KDOC inlet temperature will be approx. 250–400 °C , and the KDOC
outlet temperature and KDPF outlet temperature will both be approx. 450–550 °C .
• It takes about 40 minutes to perform active regeneration (manual stationary
regeneration).
• If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
"TEMP3").
1. Perform manual stationary regeneration by following the instructions
Performing manual stationary on the monitor.
1
regeneration (to dry KCSF) If this failure code is cleared after regeneration is performed, repair is
complete.
connector
D65EX,PX,WX-17 40-145
40 Troubleshooting

Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
4 Defective engine controller If this failure code appears and no failure is found by above checks,
a Turn the starting switch ON and make sure that this failure code and code [A1U0N3] are not displayed.
40-146 D65EX,PX,WX-17
40 Troubleshooting
Failure code [AA10NX] Air Cleaner Clogging

Action level Failure code Air cleaner clogging
Failure
L01 AA10NX (Machine monitor system)
Detail of • Air cleaner clogging switch signal voltage is not 1 V or less while engine is running, and
failure machine monitor detects clogging of air cleaner (open of sensor contacts).
Action of • Displays air cleaner clogging monitor in yellow on machine monitor.
controller
Problem on • If machine is operated under such a condition, engine may be damaged.
machine
• Input condition (ON/OFF) from air cleaner clogging switch can be checked with
Related monitoring function.
information (Code 04501: Monitor Input 2)
• Method of reproducing failure code: Start engine.
Clogged air cleaner Air cleaner may be clogged. Check it for clogging and then clean or
1 replace if clogged.
(when system is normal)
2. Disconnect connector AF1 and connect T-adapter to male side of
connector.
Defective air cleaner clogging 3. Start engine.
2 switch (internal When air cleaner
disconnection) Max. 1 z
Resis- Between AF1 (male) works properly *1
tance (1) and (2) When air cleaner
Min. 1 Mz
is clogged *2
Open circuit in wiring harness 2. Disconnect connectors CM02 and AF1, and connect T-adapters to
female side of each connector.
3 (wire breakage or defective Between CM02 (female) (4) and AF1 (female)
contact of connector) Resis- (1) Max. 1 z
tance
Between AF1 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine
4 Defective machine monitor When air cleaner
Max. 1 V
Between CM02 (4) and works properly
Voltage
CM01 (3) When air cleaner
7 to 11 V
is clogged
• Air cleaner suction resistance
*1: -3,430 Pa Max. {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
Circuit diagram related to air cleaner clogging
D65EX,PX,WX-17 40-147
40 Troubleshooting
Failure code [AB00KE] Battery Charge Voltage Low

Action level Failure code Charging voltage is low.
Failure
L03 AB00KE (Machine monitor system)
Detail of • While engine is running, voltage from alternator lowers, and machine monitor detects that
failure battery charge voltage is low.
Action of
machine • Displays the charge level monitor in red on machine monitor.
monitor
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. Connect T-adapter to connector CM01.
alternator 3. Start engine and perform troubleshooting while running engine at
1
medium speed or higher.
(When system is normal)
Voltage Between CM01 (16) and (3) 26 to 30.5
V
If no failure is found by check on cause 1, charging level monitor system
Defective charge level
2 may be defective. Perform troubleshooting for "E-8 Charge level monitor
monitor system
lights up while engine is running" in E mode.
40-148 D65EX,PX,WX-17
40 Troubleshooting
Electrical diagram related to charging circuit
D65EX,PX,WX-17 40-149
40 Troubleshooting
Failure code [B@BAZG] Engine Oil Pressure Low

Action level Failure code Drop of engine oil pressure
Failure
L03 B@BAZG (Engine controller system)
Detail of • Engine controller detects abnormal drop of engine oil pressure when voltage from engine
failure oil pressure switch drops to ground level while engine is running.
Action of
machine • Displays engine oil pressure monitor in red on machine monitor.
monitor
Problem on • If machine is used as it is, engine may be seized.
machine
• Engine oil pressure switch signal is input to engine controller that transmits information to
machine monitor through CAN communication system.
Related • For troubleshooting of engine oil pressure switch while engine is not running, see failure
information code [CA435].
Drop of engine oil pressure
1 Engine oil pressure may be low. Check it and remove cause if it is low.
If no failure is found by check on cause 1, engine oil pressure sensor
Defective engine oil pressure
2 system may be defective. Perform troubleshooting for failure code
sensor system
[CA435].
40-150 D65EX,PX,WX-17
40 Troubleshooting
Failure code [B@BCNS] Eng Water Overheat

Action level Failure code Engine coolant overheat
Failure
L02 B@BCNS (Engine controller system)
Detail of • While engine is running, voltage from engine coolant temperature sensor drops, so engine
failure controller determines that engine coolant is overheated.
Action of • Displays engine coolant temperature monitor red on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function
information (Code: 04107 Engine coolant temperature)
Overheating of engine
1 coolant Engine coolant may overheat. Check it and remove cause if it overheats.
If no failure is found by checks on cause 1, engine coolant temperature
Defective engine coolant
2 sensor system may be defective. Carry out troubleshooting for failure
temperature sensor system
codes [CA144] and [CA145].
D65EX,PX,WX-17 40-151
40 Troubleshooting
Failure code [B@CENS] P/L Oil Overheat

Action level Failure code Power train oil overheating
Failure
L02 B@CENS (Power train controller system)
Detail of • While engine is running, voltage from torque converter oil temperature sensor drops, and
failure power train controller detects overheated power train oil.
Action of
machine • Displays power train oil temperature monitor in red on machine monitor.
monitor
Problem on • If machine is used as it is, power train components may be damaged.
machine
• Signal voltage of torque converter oil temperature sensor is input to power train controller
that transmits information to machine monitor through CAN communication system.
Related • Torque converter oil temperature can be checked with monitoring function.
information (Code: 30100 T/C oil temperature)
• Torque converter oil temperature is considered to be power train oil temperature.
Overheating of torque
converter (power train) oil Overheating of torque converter (power train) oil is considered. If oil is
1 overheated, remove cause for failure.
If cause 1 is not detected, torque converter oil temperature sensor
Defective torque converter oil
[DGT1KA] or [DGT1KX] .
40-152 D65EX,PX,WX-17
40 Troubleshooting
Failure code [B@HANS] Hyd Oil Overheat

Action level Failure code Hydraulic oil overheating
Failure
L02 B@HANS (Power train controller system)
Detail of • While engine is running, voltage of hydraulic oil temperature sensor drops and
failure transmission controller detects overheating of hydraulic oil temperature.
Action of
machine • Displays hydraulic oil temperature monitor in red on machine monitor.
monitor
Problem on • If machine is operated as it is, work equipment and HSS circuit devices may be damaged.
machine
• Signal voltage of hydraulic oil temperature sensor is input to the power train controller that
transmits information to machine monitor through CAN communication system.
Related • Hydraulic oil temperature can be checked with monitoring function
information (Code: 04401 Hyd Oil Temperature)
Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it is
1 overheating.
If no failure is found by check on cause 1, hydraulic oil temperature
Defective hydraulic oil gauge system may be defective. Perform troubleshooting for failure
2 temperature gauge system code [DGS1KX] or for "E-6 Hydraulic oil temperature gauge (multi-
gauge) does not display normally" in E-mode.
D65EX,PX,WX-17 40-153
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action level Failure code Engine Ne and Bkup speed sensor error
Failure
L04 CA115 (Engine controller system)
Detail of • Abnormality is detected in signal circuits of Ne and Bkup speed sensors at the same time.
failure
Action of • Stops engine.
controller
Problem on • Engine does not start (if engine is stopped).
machine • Engine stops (if engine is running).
Related • Method of reproducing failure code: Start engine.
information
Defective Ne speed sensor
1 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
system
If no failure is found by above checks, engine controller is defective.
3 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
40-154 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error

Action
Failure code Charge pressure sensor high error
level Failure
(Engine controller system)
L03 CA122
Detail of • High voltage is detected in pressure signal circuit of charge (boost) pressure &
failure temperature sensor.
• Takes it that charge pressure is at calculated value and allows engine to run.
Action of • Restricts engine output and allows engine to run.
controller • Closes EGR valve.
• Stops regeneration control by KDPF.
Problem on • Engine output lowers.
machine
• Input voltage from charge (boost) pressure sensor can be checked with monitoring
function.
(Code: 36501 (V))
• Charge (boost) pressure sensed by charge (boost) pressure sensor can be checked with
Related
information
(Code: 36500 (kPa))
• If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in
normal condition.
information on troubleshooting", and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code does not appear, wiring harness connector is
defective.
Defective sensor power If failure code [CA187] or [ CA227] is also displayed, perform
2 troubleshooting for it first.
source 2 circuit
2. Disconnect connector BOOST PRESS & IMT.
If failure code changes from [CA122] to [CA123] ,boost pressure sensor
Defective boost pressure & is defective.
3 temperature sensor
a Failure code [CA153] for temperature sensor is displayed at the
same time.
Ignore this failure code since it appears because of disconnection of
sensor.
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
4 Short circuit in wiring harness connect T-adapter to female side of ECM J1.
Resis- Between ECM J1 (female) (15) and (60) Min. 100
tance Kz
Hot short circuit in wiring 2. Disconnect connector BOOST PRESS & IMT, and connect T-
harness adapter to connector ECM J1.
5 3. Turn starting switch to ON position (with connector BOOST PRESS
(contact with 24 V circuit) & IMT disconnected).
Voltage Between ECM J1 (15) and (59) Max. 1 V
(Since this is internal defect, troubleshooting cannot be performed.)
D65EX,PX,WX-17 40-155
40 Troubleshooting
Circuit diagram related to charge pressure sensor
40-156 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error

Action
Failure code Charge air pressure sensor low error
level Failure
L03 CA123
Detail of • Low voltage is detected in pressure signal circuit of charge (boost) pressure &
failure temperature sensor.
• Takes it that charge pressure is at calculated value and allows engine to run.
Problem on
• Engine output lowers.
machine
• Input voltage from charge (boost) pressure sensor can be checked with monitoring
function.
(Code: 36501 (V))
• Charge (boost) pressure sensed by charge (boost) pressure sensor can be checked with
Related (Code: 36500 (kPa))
• Since troubleshooting "socket" for this sensor features female connector only, it is not
usable for checking open circuit in wiring harness and voltage at sensor connector (not
designed for T-adapter).
• If sensor connector is disconnected, this failure code is displayed.
connector
Defective power supply
system of charge pressure If failure code [CA187] or [CA227] is also displayed, perform
2 sensor (boost pressure troubleshooting for it first.
sensor)
2. Disconnect connectors CAM SENSOR, AMB. AIR PRESSURE,
BOOST PRESS & IMT, and ECM J1.
Short circuit in wiring harness 3. Connect T-adapter to female side of ECM J1.
3
Between ECM J1 (female) (15) and (59) Min. 100
Resis- Kz
tance Between ECM J1 (female) (15) and (60) Min. 100
Kz
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
Ground fault of wiring connect T-adapter to female side of ECM J1.
4 harness (contact with ground Min. 100
circuit) Between ECM J1 (female) (15) and ground
Resis- Kz
tance Between ECM J1 (female) (60) and ground Min. 100
Kz
If no failure is found by the above checks, there may be open circuit in
5 Open circuit in wiring harness
wiring harness. (*)
a If causes 1 to 5 are not cause for failure and check result of cause 6
is abnormal, sensor is defective.
Defective boost pressure and
temperature sensor 1. Turn starting switch to OFF position.
6 (improper input voltage to 2. Insert T-adapter in connector ECM J1.
engine controller) 3. Turn starting switch to ON position.
Sensor
Voltage Between ECM J1 (15) and (59) 0.3 to 4.7 V
output
D65EX,PX,WX-17 40-157
40 Troubleshooting

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
Circuit diagram related to charge pressure sensor
40-158 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error

Action
Failure code Throttle sensor high error
level Failure
L03 CA131
Detail of • High voltage is detected decelerator pedal (throttle sensor) signal circuit. .
failure
Action of • Sets decelerator pedal (throttle sensor) position to fixed value and allows engine to run.
controller
Problem on • Engine speed cannot be controlled by decelerator pedal (throttle sensor).
machine
• Signal voltage from 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 operate
decelerator.
1
defective.
a If this failure code appears, perform following.
Defective throttle sensor If failure code [CA2185] is also displayed, perform troubleshooting for it
2 power supply system first.
2. Disconnect connector DCL and connect T-adapter to male side of
connector.
Defective decelerator pedal
3 Between DCL (male) (B) and (C) Approx. 2
(throttle sensor)
Resis- Kz
tance Between DCL (male) (A) and (C) 0.2 to 1.8 Kz
Between DCL (male) (B) and (A) 0.2 to 1.8 Kz
2. Disconnect connectors EGC3 and connect T-adapter to female side
Open or short circuit in wiring of connector.
4
harness Approx. 2
Resis- Between EGC3 (female) (42) and (41) Kz
tance Between EGC3 (female) (51) and (41) 0.2 to 1.8 Kz
a If no failure is found in checks on cause 4, this check is not required.
5 Short circuit in wiring harness 2. Disconnect connectors EGC3 and DCL, and connect T-adapters to
female side of either connector.
Resis- Between EGC3 (female) (42) and (51), or
between DCL (female) (A) and (B) Min. 1 Mz
tance
Hot short circuit in wiring 2. Disconnect connector DCL and connect T-adapter to female side of
6 harness connector.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between DCL (female) (A) and ground Max. 1 V
D65EX,PX,WX-17 40-159
40 Troubleshooting

• Reference
2. Insert T-adapter in EGC3.
7 Defective engine controller 4. Operate decelerator pedal, and perform troubleshooting.
Between EGC3 (42) 4.75 to 5.25
Power supply
and (41) V
Depress decelerator Approx. 3.5
Voltage
Between EGC3 (51) pedal. V
and (41) Release decelerator
Approx. 2 V
pedal.
Circuit diagram related to throttle sensor
40-160 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error

Action
Failure code Throttle sensor low error
level Failure
L03 CA132
Detail of • Low voltage is detected decelerator pedal (throttle sensor) signal circuit.
failure
Action of • Sets decelerator pedal (throttle sensor) position to fixed value and allows engine to run.
controller
Problem on • Engine speed cannot be controlled by decelerator pedal (throttle sensor).
machine
• Signal voltage from decelerator pedal (throttle sensor) can be checked with monitoring
function.
Related
(Code: 31703 Decelerator pedal sensor voltage)
information
decelerator.
1
defective.
Defective throttle sensor If failure code [CA2186] is also displayed, perform troubleshooting for it
2 power supply system first.
2. Disconnect connector DCL and connect T-adapter to male side of
Defective decelerator pedal connector.
3 (throttle sensor) Between DCL (male) (B) and (C) Approx. 2 Kz
Resis- Between DCL (male) (A) and (C)
0.2 to 1.8 Kz
tance
Between DCL (male) (B) and (A) 0.2 to 1.8 Kz
4
harness
Resis- Between EGC3 (female) (42) and (41) Approx. 2 Kz
tance Between EGC3 (female) (51) and (41) 0.2 to 1.8 Kz
2. Disconnect connectors EGC3 and DCL and connect T-adapters to
Open circuit in wiring harness female side of connector.
5 (wire breakage or defective Between EGC3 (female) (42) and DCL
(female) (B) Max. 1 z
contact of connector)
Resis- Between EGC3 (female) (51) and DCL
(female) (A) Max. 1 z
tance
Between EGC3 (female) (41) and DCL
(female) (C) Max. 1 z
a If no failure is found in check on cause 4, this check is not required.

6 Short circuit in wiring harness 2. Disconnect connectors EGC3 and DCL, and connect T-adapters to
female side of either connector.
Resis- Between EGC3 (female) (41) and (51), or
between DCL (female) (A) and (C) Min. 1 Mz
tance
D65EX,PX,WX-17 40-161
40 Troubleshooting

Ground fault in wiring 2. Disconnect connectors EGC3 and DCL, and connect T-adapters to
7 harness (contact with ground female side of either connector.
circuit) Resis- Between ground and EGC3 (female) (51) or
DCL (female) (A) Min. 1 Mz
tance
If no failure is found in above checks, engine controller is defective.
• Reference
8 Defective engine controller 4. Operate decelerator pedal, and troubleshoot.
Between EGC3 (42)
Power supply 4.75 to 5.25 V
and (41)
Depress decelerator
Voltage Approx. 3.5 V
Between EGC3 (51) pedal.
and (41) Release decelerator
Approx. 2 V
pedal.
40-162 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error

Action level Failure code Coolant temperature sensor high error
Failure
Detail of • High voltage is detected in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed temperature (90 °C ),and allows engine to run.
controller
Problem on • Engine does not start easily at low temperature.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function (Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • This failure code is displayed if temperature sensor connector is disconnected.
• Because troubleshooting "socket" for this sensor features female connector only, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed for T-adapter).
1
defective.
2. Disconnect connector COOLANT TEMP, and connect socket to male
side.
a If coolant temperature sensor has resistance of 700 z to 37 Kz with
coolant temperature above 0 °C , regard coolant temperature sensor
Defective coolant as normal.
2 temperature sensor 0 °C 30 to 37 Kz
Between COOLANT TEMP (male) 9.3 to 10.7
25 °C
Resis- (A) and (B) Kz
tance a Coolant temperature 50 °C 3.2 to 3.8 Kz
-Resistance characteristics 80 °C 1.0 to 1.3 Kz
95 °C 700 to 800 z
2. Disconnect connector ECM J1 and connect T-adapter to female side
of connector.
Open or short circuit in wiring Between ECM J1 (female) (14) and (13)
3 (coolant temperature: Min. 0 °C )
harness
Resis- 700 z to 37
tance a Resistance is the same as that shown in Kz
resistance characteristics table of coolant
temperature sensor of cause 2.
D65EX,PX,WX-17 40-163
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-164 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error

Action level Failure code Coolant temperature sensor low error
Failure
Detail of • Low voltage is detected in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed temperature (90 °C ),and allows engine to run.
controller
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
Related monitoring function. (Code: 04107 (°C))
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA144] for "High Error" is displayed.
1
defective.
2. Disconnect connector COOLANT TEMP, and connect socket to male
side of connector.
a If coolant temperature sensor has resistance of 700 z to 37 Kz with
coolant temperature above 0 °C , regard coolant temperature sensor
as normal.
0 °C 30 to 37 Kz
Defective coolant 9.3 to 10.7
2 Between COOLANT TEMP (male) 25 °C
temperature sensor Kz
(A) and (B) 3.2 to 3.8
50 °C
Kz
Resis- a Coolant temperature 1.0 to 1.3
tance -Resistance characteristics 80 °C
Kz
95 °C 700 to 800 z
All coolant
Between (B) and ground tempera- Min. 100 Kz
ture range
of connector.
Short circuit in wiring Between ECM J1 (female) (14) and (13)
3 (coolant temperature: Min. 0 °C )
harness
Resis- 700 z to 37
tance a Resistance is the same as that shown in Kz
resistance characteristics table of coolant
temperature sensor of cause 2.
Ground fault in wiring 2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect
4 harness (contact with ground T-adapters to female side of ECM J1.
circuit) Resis- Between ECM J1 (female) (14) and ground
Min. 100 Kz
tance
D65EX,PX,WX-17 40-165
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-166 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error

Action level Failure code Charge (Boost) temperature sensor signal voltage is too
Failure high.
L03 CA153
Detail of • High voltage is detected in charge (boost) temperature sensor signal circuit.
failure
• Takes it that charge temperature (boost temperature) is at calculated value and allows
engine to run.
Action of • Closes EGR valve.
controller • Restricls engine output and allows engine to run.
• Stops KDPF regeneration control.
machine • Engine output lowers.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 ( °C ))
information • Because troubleshooting "socket" for this sensor features female connector only, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
• This failure code is displayed if temperature sensor connector is disconnected.
1
defective.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to
male side of connector.
a If temperature sensor has resistance of 80 z to 48 Kz , regard
charge temperature sensor as normal.
-40 °C 41 to 48 Kz
Defective charge -20 °C 14 to 16 Kz
2 temperature sensor 5.4 to 6.1
Between BOOST PRESS & IMT 0 °C
Kz
Resis- (male) (3) and (4) 1.6 to 1.8
30 °C
tance a Charge temperature Kz
-Resistance characteristics 560 to 600
60 °C
z
90 °C 230 to 250 z
130 °C 80 to 90 z
of connector.
3
harness
Resis- a Use Temperature-Resistance 80 z to 48
tance characteristics table for troubleshooting on Kz
cause 2.
D65EX,PX,WX-17 40-167
40 Troubleshooting
Circuit diagram related to charge temperature sensor
40-168 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error

Action level Failure code Charge (boost) temperature sensor signal voltage is too low.
Failure
Detail of • Low voltage is detected in charge (boost) temperature sensor signal circuit.
failure
• Takes it that charge temperature (boost temperature) is at calculated value and allows
engine to run.
controller • Restricts engine output and allows engine to run.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
Related checked with monitoring function. (Code: 18500 ( °C ))
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA153] for "High Error" is displayed.
1
defective.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to
male side of connector.
a If charge temperature sensor has resistance of 80 z to 48 Kz ,
regard charge temperature sensor as normal.
-40 °C 41 to 48 Kz
Defective charge -20 °C 14 to 16 Kz
2 temperature sensor Between BOOST PRESS & IMT 0 °C 5.4 to 6.1 Kz
(male) (3) and (4) 30 °C 1.6 to 1.8 Kz
Resis- a Charge temperature 560 to 600
tance 60 °C
-Resistance characteristics z
90 °C 230 to 250 z
130 °C 80 to 90 z
Between BOOST PRESS & IMT Whole
(male) (3) and ground range Min. 100 Kz

of connector.
3
harness
Resis- a Use Temperature-Resistance 80 z to 48
tance characteristics table for troubleshooting on Kz
cause 2.
Ground fault in wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
4 harness (contact with ground connect T-adapter to female side of ECM J1.
circuit) Resis- Between ECM J1 (female) (5) and ground
Min. 100 Kz
tance
D65EX,PX,WX-17 40-169
40 Troubleshooting
Circuit diagram related to charge temperature sensor
40-170 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Volt Low Error

Action level Failure code Sensor power supply 2 voltage is too low.
Failure
Detail of • Low voltage appears in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor, and fixes ambient pressure (52.44 kPa
{0.53 kg/cm2 }) and allows engine to run.
• Ignores signals from charge (boost) pressure sensor, takes it that charge (boost) pressure
Action of is at calculated value, and allows engine to run.
controller • Ignores signals from crankcase pressure sensor, fixes crankcase pressure (0 kPa) and
allows engine to run.
• Closes EGR valve.
• Restricts engine output and allows engine to run.
machine
information
1
defective.
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. After each troubleshooting, turn starting swith to OFF position.
If this failure code is not displayed when connector is disconnected, that
sensor or engine wiring harness is defective.
Defective sensor or wiring a Other failure codes are displayed as well. This is because connector
2
harness is disconnected. Ignore failure codes other than [CA187].
Cam (Bkup speed) sensor CAM SENSOR
Charge (boost) pressure sensor BOOST PRESS & IMT
Connector Ambient pressure sensor AMB. AIR. PRESSURE
Crankcase pressure sensor PCCV
Engine wiring harness ECM J1
3 Defect in related system If another failure code is displayed, perform troubleshooting for it.
2. Disconnect connector ECM J1 and connect T-adapter to male side of
connector.
4 Defective engine controller 3. Turn starting switch to ON position with connector ECM J1
disconnected.
Voltage Between ECM J1 (male) (60) and (59) 4.75 to 5.25
V
D65EX,PX,WX-17 40-171
40 Troubleshooting
Circuit diagram related to sensor power supply 2
40-172 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA234] Eng Overspeed

Action level Failure code Engine overspeed
Failure
L02 CA234 (Engine controller defective)
Detail of • Engine speed is above operating range.
failure
Action of • Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem on • Engine speed fluctuates.
machine
Related • Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
information • Method of reproducing failure code: Run engine at full speed.
1 Use of improper fuel Fuel used may be improper. Check it directly
Improper use Usage of machine may be improper. Instruct operator on proper use of
3
machine.
If no problem is found by checks on causes 1 and 2, engine controller is
4 Defective engine controller defective.
D65EX,PX,WX-17 40-173
40 Troubleshooting
Failure code [CA221] Ambient Press Sens High Error

Action
Failure code Ambient pressure sensor voltage is too high.
level Failure
L03 CA221
Detail of • High voltage is detected in ambient pressure sensor signal circuit .
failure
• Fixes ambient pressure to 52.44 kPa (0.53 kg/cm2 ) and allows engine to run.
machine
• Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
1
defective.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform
2 supply 1 system troubleshooting for it first.
Defective ambient pressure 2. Disconnect connector AMB. AIR PRESSURE.
3
sensor 3. Turn starting switch to ON position.
If failure code [CA221] changes to [CA222], sensor is defective.
2. Disconnect connectors ECM J1 and AMB AIR PRESSURE, and
4 Short circuit in wiring harness connect T-adapters to female side of either of them.
Resis- Between ECM J1 (60) and (16), or between Min. 100
tance AMB. AIR PRESSURE (female) (1) and (3) Kz
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapter to female side of connector AMB. AIR
Hot short in wiring harness PRESSURE or insert T-adapter in connector ECM J1.
5 (contact with 24 V circuit) 4. Turn starting switch to ON position with connector AMB AIR
PRESSURE disconnected.
Between ECM J1 (16) and (59), or between
Voltage Max. 1 V
AMB. AIR PRESSURE (female) (3) and (2)
40-174 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to ambient pressure sensor
D65EX,PX,WX-17 40-175
40 Troubleshooting
Failure code [CA222] Ambient Press Sens Low Error

Action
Failure code Ambient pressure sensor voltage is too low.
level Failure
L03 CA222
Detail of • Low voltage is detected in ambient pressure sensor signal circuit .
failure
machine
• Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
Related function.
information (Code: 37400 (kPa))
• If sensor connector is disconnected, this failure code is displayed.
1
defective.
If failure code [CA187] or [CA227] is also displayed, perform
troubleshooting for it first.
Defective power supply 2. Disconnect connector AMB. AIR PRESSURE and connect T-
2 system for ambient pressure adapter to female side of connector.
Power
Between AMB. AIR PRESSURE 4.75 to
Voltage supply
(female) (1) and (2) 5.25 V
input
2. Disconnect connectors AMB AIR PRESSURE and ECM J1, and
connect T-adapters to female side of either of them.
a If no failure is found by check on power
supply input of cause 2, this check is not Max. 10 z
Open circuit in wiring harness required. Between ECM J1 (female) (60)
3 (wire breakage or defective and AMB. AIR PRESSURE (female) (1)
contact of connector) Resis-
a If no failure is found by check on power
tance
supply input of cause 2, this check is not Max. 10 z
required. Between ECM J1 (female) (59)
and AMB. AIR PRESSURE (female) (2)
Between ECM J1 (female) (16) and AMB. AIR
PRESSURE (female) (3) (sensor output) Max. 10 z
40-176 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and
Ground fault in wiring harness Between ECM J1 (female) (16) and ground, or
4 between AMB. AIR PRESSURE (female) (3) Min. 100
(contact with ground circuit) Kz
Resis- and ground
tance Between ECM J1 (female) (60) and ground, or
between AMB. AIR PRESSURE (female) (1) Min. 100
and ground Kz

2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and
5 Short circuit in wiring harness connect T-adapters to female side of either of them.
Resis- Between ECM J1 (16) and (60), or between Min. 100
tance AMB. AIR PRESSURE (female) (2) and (3) Kz
a If above troubleshooting detects failure, sensor is defective.
Defective ambient pressure 2. Insert T-adapter in connector ECM J1.
6
Sensor 0.5 to 4.5
Voltage Between ECM J1 (16) and (60)
output V
Circuit diagram related to ambient pressure sensor
D65EX,PX,WX-17 40-177
40 Troubleshooting
Failure code [CA227] Sens Supply 2 Volt High Error

Action
Failure code Sens Supply 2 Volt High Error
level Failure
L03 CA227
Detail of • High voltage is detected in sensor power supply 2 circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor, and fixes ambient pressure (52.44 kPa
{0.53 kg/cm2 }) and allows engine to run.
• Ignores signals from charge (boost) pressure sensor, takes it that charge (boost) pressure
Action of is at calculated value, and allows engine to run.
controller • Ignores signals from crankcase pressure sensor, fixes crankcase pressure (0 kPa) and
allows engine to run.
machine
information
1 Sens Supply 2 Volt High Error Perform troubleshooting for failure code [CA187].
40-178 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA238] Ne Speed Sens Supply Volt Error

Action
Failure code Ne Speed sensor supply voltage is unusual
level Failure
L01 CA238
Detail of • Low voltage appears in power supply circuit of engine Ne speed sensor.
failure
Action of • Controls engine with signal from engine Bkup speed sensor.
controller
• Running engine stops (when Bkup (CAM) speed sensor is also defective).
Problem on • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
machine • Starting performance is poor.
• Engine hunts.
information
1
defective.
2. Disconnect connector CRANK SENSOR, and turn starting switch to
ON position.
2 Defective sensor If this failure code is not displayed, crank sensor is defective.
a Other failure codes are also displayed. This is because of
disconnection of connector. Ignore failure codes other than [CA238].
2. Disconnect wiring harness ECM J1 and turn starting switch to ON
position.
3 Defective wiring harness If this failure code is not displayed, engine wiring harness is defective.
a Other failure codes are also displayed. This is because of
disconnection of connector. Ignore failure codes other than [CA238].
2. Disconnect connector ECM J1 and connect T-adapter to male side
of connector.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
V
Circuit diagram related to Ne speed sensor
D65EX,PX,WX-17 40-179
40 Troubleshooting
Failure code [CA239] Ne Speed Sens Supply Volt High Error

Action level Failure code Ne speed sensor supply voltage high error
Failure
Detail of • Failure occurs in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from Bkup speed sensor.
controller
machine • Engine starting performance is poor
• Engine hunts.
information
1
defective.
2. Disconnect connector CRANK SENSOR.
If this failure code is not displayed, sensor disconnected or engine wiring
2 Defective NE speed sensor
harness is defective.
a Other failure codes are displayed at the same time. This is because
of connector being disconnected. So ignore other codes than this
failure code [CA239].
2. Disconnect connector ECM J1.
3 Defective wiring harness If this failure code does not appear anymore, wiring harness is defective.
of connector being disconnected. So ignore other codes than this
failure code [CA239].
connector.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
V
40-180 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to Ne speed sensor
D65EX,PX,WX-17 40-181
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error

D65EX-17,PX-17,WX-17
Action
Failure code Short circuit in IMV/PCV1
level Failure
L03 CA271
Detail of • Short circuit is detected in drive circuit of supply pump actuator (IMV).
failure
controller
• Engine speed does not increase from low idle.
machine • Common rail fuel pressure rises above command value.
information
1
defective.
Defective supply pump 2. Disconnect connector INLET METERING VALVE.
actuator
If failure code changes from [CA271] to [CA272] , supply pump actuator
is defective.
Short circuit or ground fault in of connector.
3 wiring harness Between ECM J1 (female) (30) and (40) 1 to 5 z
Resis-
Kz
4 Short circuit in wiring harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
connect T-adapter to female side of ECM J1.
tance Kz
2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
Ground fault in wiring harness connect T-adapter to female side of ECM J1.
5 (contact with ground circuit)
Between ECM J1 (female) (30) and ground Min. 100
Resis- Kz
Kz
40-182 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to IMV/PCV1
D65EX,PX,WX-17 40-183
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error

Action
Failure code Open circuit in IMV/PCV1
level Failure
L03 CA272
Detail of • Open circuit is detected in drive circuit of supply pump actuator.
failure
Action of None in particular
controller
Problem on • Engine runs but its speed does not stabilize.
machine • Common rail fuel pressure rises above command value.
Related • Because troubleshooting "socket" for this sensor features female connector only, it is not
information connectable to female connector of sensor wiring harness, and thus not usable for
1
defective.
2. Disconnect connector INLET METERING VALVE.
Defective supply pump Between INLET METERING VALVE (male) (1)
2 1–Max. 5 z
actuator Resis- and (2)
tance Between INLET METERING VALVE (male) (1)
and ground Min. 100 Kz

Open or short circuit in wiring 2. Disconnect connector ECM J1 and connect T-adapter to female side
3 of connector.
harness
Resis- Between ECM J1 (female) (30) and (40)
1–Max. 5 z
tance
Ground fault in wiring 1. Turn starting switch to OFF position.
4 harness (contact with ground 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
circuit) connect T-adapter to female side of ECM J1.
Resis- Between ECM J1 (female) (30) and ground Min. 100 Kz
tance Between ECM J1 (female) (40) and ground Min. 100 Kz
2. Disconnect connector INLET METERING VALVE.
3. Insert T-adapter in connector ECM J1.
Hot short circuit in wiring 4. Turn starting switch to ON position (with connector INLET
5 harness METERING VALVE connected) and start measurement after at least
(contact with 24 V circuit) one minute.
a Average voltage is displayed because of PWM.
Voltage Between ECM J1 (30) and (40) Max. 3 V
40-184 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to IMV/PCV1
D65EX,PX,WX-17 40-185
40 Troubleshooting
Failure code [CA281] Pump Press Balance Error

Action
Failure code Supply pump pressure balance error
level Failure
L03 CA281
Detail of • Response of fuel force feed is poor due to high pressure pump mechanical system error.
failure
controller
Problem on • Engine does not start.Engine runs but its speed does not stabilize.
machine • The pressure of high-pressure fuel differs between front and rear side of supply pump.
information
Bleed air from the fuel circuit. For detail, see Testing and adjusting,
1 Mixing of air in fuel circuit
"Bleeding air from fuel circuit".
See descriptions of wiring harness and connectors in "c: Electrical
2 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check them directly.
If no problem is found in checks on causes 1 to 2, engine controller may
3 Defective engine controller be defective.
40-186 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA295] Ambient Pressure Sensor In Range Error

Action
Failure code Ambient Pressure Sensor In Range Error
level Failure
L03 CA295
Detail of • Ambient pressure sensor output value displayed is out of normal range.
failure
machine
• Input voltage from ambient pressure sensor can be checked by using the monitoring
function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function.
(Code: 37400 (kPa))
Defective ambient pressure
1 Perform troubleshooting for failure codes [CA221] and [CA222].
sensor system
D65EX,PX,WX-17 40-187
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error

Action
Failure code Injector #1 open or short circuit
level Failure
L03 CA322
Detail of • Open or short circuit occurs in drive circuit of No. 1 injector.
failure
controller
Problem on • Poor combustions or hunting occurs.
Related • While engine is running normally, pulse voltage of approx. 65 V is supplied to injector (+)
information side but cannot be measured by using multimeter because it cannot measure pulse
voltages.
1
defective.
2. Disconnect connector INJECTOR CYL 1 & 2, and connect T-adapter
to male side of connector.
2 Defective No. 1 injector Between INJECTOR CYL 1 & 2 (male) (3)
Max. 2 z
Resis- and (4)
tance Between INJECTOR CYL 1 & 2 (male) (3)

Open circuit or ground fault of
3 of connector.
wiring harness
Resis- Between ECM J1 (female) (48) and (58) Max. 2 z
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
4 (wire breakage or defective connect T-adapters to female side of each connector.
contact of connector) Between ECM J1 (female) (48) and
Max. 2 z
Resis- INJECTOR CYL 1 & 2 (female) (3)
tance Between ECM J1 (female) (58) and
INJECTOR CYL 1 & 2 (female) (4) Max. 2 z

5 harness (contact with ground 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
circuit) connect T-adapters to female side of either connector.
Resis- Between ground and ECM J1 (female) (48)
or INJECTOR CYL 1 & 2 (female) (3) Min. 100 Kz
tance
40-188 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
a Check with circuit tester in continuity mode.
Short circuit in wiring harness No continuity
6 Between ECM J1 (female) (48) and each pin
other than (48) (No sound is
heard)
Continuity
No continuity
Between ECM J1 (female) (58) and each pin
other than (58) (No sound is
heard)
Defective injectors of other If different failure codes are displayed, perform troubleshootings for
7 cylinders them on ahead.
Defective injector system
wiring harness on other If failure codes of other injectors are displayed, perform troubleshootings
8
cylinder for them on ahead.
Circuit diagram related to injector #1
D65EX,PX,WX-17 40-189
40 Troubleshooting
Failure code [CA323] Inj #5 (L#5) Open/Short Error

Action
Failure code Injector #5 open or short circuit error
level Failure
L03 CA323
failure
controller
voltages.
1
defective.
Max. 2 z
Resis- and (4)

3 of connector.
wiring harness
4 (wire breakage or defective connect T-adapters to female side of either connector.
Max. 2 z

tance
40-190 D65EX,PX,WX-17
40 Troubleshooting

a Check with multimeter in continuity mode.
6 Between ECM J1 (female) (44) and every
pin other than (44) (No sound is
heard)
Continuity
No continuity
Between ECM J1 (female) (54) and every
heard)
Defective injector of other If failure codes for other injectors are displayed, perform
7 cylinder troubleshootings for them on ahead.
If failure codes for other injectors are displayed, perform
8 wiring harness on other
troubleshootings for them on ahead.
cylinder
D65EX,PX,WX-17 40-191
40 Troubleshooting

Action
level Failure
L03 CA324
failure
controller
voltages.
1
defective.
Max. 2 z
Resis- and (4)

3 of connector.
wiring harness
Max. 2 z

5 harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and
(contact with ground circuit) connect T-adapters to female side of either connector.
tance
40-192 D65EX,PX,WX-17
40 Troubleshooting

heard)
Continuity
No continuity
heard)
cylinder
D65EX,PX,WX-17 40-193
40 Troubleshooting

Action
level Failure
L03 CA325
failure
controller
Related • While engine is running normally, pulse voltage of apporx. 65 V is supplied to injector (+)
information side but cannot be measured with multimeter because it cannot measure pulse voltages.
1
defective.
Max. 2 z
Resis- and (2)

3 of connector.
wiring harness
Max. 2 z

tance
40-194 D65EX,PX,WX-17
40 Troubleshooting

heard)
Continuity
No continuity
heard)
cylinder
D65EX,PX,WX-17 40-195
40 Troubleshooting

Action
Failure code Injector #2 (L#2) Open or short circuit
level Failure
L03 CA331
failure
controller
Related • While engine is running normally, approximately 65 V of pulse voltage is supplied to
information injector (+) side. But it is pulse voltage and cannot be measured with multimeter.
1
defective.
Max. 2 z
Resis- and (2)

3 of connector.
wiring harness
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
Max. 2 z

tance
40-196 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
connect T-adapters to ECM J1 female side.
heard)
Continuity
No continuity
heard)
cylinder
D65EX,PX,WX-17 40-197
40 Troubleshooting

Action
Failure code Injector #4 (L#4) open or short circuit
level Failure
L03 CA332
failure
controller
Related • While engine is running normally, approximately 65 V of pulse voltage is supplied to
information injector (+) side. But it is pulse voltage and cannot be measured with multimeter.
1
defective.
Max. 2 z
Resis- and (2)

3 of connector.
wiring harness
Max. 2 z

tance
40-198 D65EX,PX,WX-17
40 Troubleshooting

heard)
Continuity
No continuity
heard)
cylinder
D65EX,PX,WX-17 40-199
40 Troubleshooting
Failure code [CA343] ECM Critical Internal Failure

Action level Failure code Engine controller internal failure
Failure
Detail of • Engine controller has internal defect.
failure
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine start if it is stopped.
• Power supply voltage of engine controller can be checked with moniitoring funtion.
Related (Code: 03203 Battery voltage)
information • Method of reproducing failure code: Turn starting switch to ON position
Defective engine controller
system
40-200 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error

Action level Failure code Injectors drive circuit error
Failure
Detail of • Injector drive circuit is defective.
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
machine
information
Check failure code (injector system failure code) that is displayed at the
1 Defect in related system
same time. If another code is displayed, perform troubleshooting for it.
system
D65EX,PX,WX-17 40-201
40 Troubleshooting

Action level Failure code Sensor power supply 1 voltage is low.
Failure
Detail of • Low voltage appears in sensor power supply 1 (5 V) circuit.
failure
• Signals from exhaust manifold pressure sensor are ignored and engine controller closes
Action of EGR valve and restricts engine output.
controller • Signals from EGR valve lift sensor and KVGT position sensor are ignored and engine
controller continues operation with signals fixed to values before failure is detected.
machine
information
1
defective.
3. After each troubleshooting, return to step 1.
If this failure code is not displayed when a connector is disconnected,
that sensor or engine wiring harness is defective.
Defective sensor or wiring
2
harness a Other failure codes are also displayed. This is because connector is
disconnected. Ignore all failure codes except for [CA352].
Exhaust manifold pressure sensor EXHAUST PRESSURE
EGR valve lift sensor SEGR
Connector
KVGT position sensor SVGT
Engine wiring harness ECM J2
connector.
4 Defective engine controller 3. Turn starting switch to ON position with connector ECM J2
disconnected.
V
40-202 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to sensor power supply 1
D65EX,PX,WX-17 40-203
40 Troubleshooting
Failure code [CA356] Mass Air Flow Sensor High Error

Action level Failure code Mass air flow sensor high error
Failure
Detail of • High frequency input appears in mass air flow sensor signal circuit.
failure
• Sets mass air flow to fixed value (10 kg/min) and allows engine to run.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured with multimeter.
Related • Mass air flow sensor and intake temperature sensor are integrated.
1
defective.
2 supply system troubleshooting for it first.
Defective mass air flow 2. Disconnect connector MAF
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code changes to [CA357], mass air flow sensor is
defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connector MAF and connect T-adapter to female side of
Defective sensor power connector.
4 supply system 3. Turn starting switch to ON position.
Power Approx. 12
Voltage Between MAF (female) (2) and (3)
supply V
a If no failure is found by check on cause 4, this check is not required.
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and MAF, and connect T-adapter to
5 (wire breakage or defective female side of each connector.
contact of connector) a Open circuit in ground circuit
Resis- Between ECM J1 (female) (22) and MAF
tance
2. Disconnect connectors ECM J1 and MAF, and connect T-adapter to
female side of ECM J1.
6 Short circuit in wiring harness
Resis- Between ECM J1 (female) (23) and every pin Min. 100
tance other than (23) Kz
40-204 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to mass air flow sensor
D65EX,PX,WX-17 40-205
40 Troubleshooting
Failure code [CA357] Mass Air Flow Sensor Low Error

Action level Failure code Mass air flow sensor low error
Failure
Detail of • Input of low frequency voltage to mass air flow signal circuit is detected.
failure
• Sets mass air flow to fixed value (10 kg/min) and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured with multimeter.
• Mass air flow sensor and intake temperature sensor are integrated.
Related • If sensor connector is disconnected, this failure code and failure code [CA691] are
information displayed at the same time.
1
defective.
Defective mass air flow 2. Replace mass air flow sensor.
(internal defect) If this failure code does not appear, original mass air flow sensor is
defective.
Defective sensor power connector.
4 supply system 3. Turn starting switch to ON position.
Power Approx. 12
Voltage Between MAF (female) (2) and (3)
supply V
a If no failure is found in check on cause 4,
this check is not required. Max. 10 z
Open circuit in wiring harness Between ECM J1 (female) (21) and MAF
5 (wire breakage or defective (female) (2)
tance
Between ECM J1 (female) (22) and MAF
(female) (3)
Between ECM J1 (female) (23) and MAF

Ground fault in wiring harness 2. Disconnect connectors ECM J1 and MAF, and connect T-adapter to
6 female side of either connector.
(contact with ground circuit)
Resis- Between ground and ECM J1 (female) (23) or Min. 100
tance MAF (female) (1) Kz
40-206 D65EX,PX,WX-17
40 Troubleshooting

Resis- Between ECM J1 (female) (23) and every pin Min. 100
tance other than (23) Kz
Hot short circuit in wiring connector.
8 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit)
a Ignore displayed failure codes.
Voltage Between MAF (female) (1) and (3) Max. 1 V
D65EX,PX,WX-17 40-207
40 Troubleshooting
Failure code [CA386] Sens Supply 1 Volt High Error

Action
Failure code Sens Supply 1 Volt High Error
level Failure
L03 CA386
Detail of • High voltage is detected in sensor power supply 1 circuit.
failure
• Signals from exhaust manifold pressure sensor are ignored and engine controller closes
Action of EGR valve and restricts engine output.
controller • Signals from EGR valve lift sensor and KVGT position sensor are ignored and engine
controller continues operation with signals fixed to values before failure is detected.
machine
information
Sensor power supply high Perform troubleshooting for failure code[CA352]
1
error
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40 Troubleshooting
Failure code [CA428] Water in Fuel Sensor High Error

D65EX-17,PX-17,WX-17
Action
Failure code Water-in-fuel sensor high error
level Failure
L01 CA428
Detail of • High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function.
Related (Code: 18800 WIF sensor condition)
1
defective.
2. Disconnect connector WIF1 and connect T-adapter to female side of
Defective water-in-fuel sensor connector.
2 installed to fuel pre-filter
a If water is in water separator, drain it.
Resistance Between WIF1 (female) (1) and (2) 10 to100 Kz
Short circuit or ground fault in 2. Disconnect connector ECM J1 and connect T-adapter to female
3 wiring harness side of connector.
Between ECM J1 (female) (24) and (32)
Resistance (Water sensor resistance) 10 to100 Kz

Open circuit in wiring harness 2. Disconnect connectors ECM J1 and WIF1, and connect T-adapters
4 (wire breakage or defective to ECM J1 (female) and WIF1 (male).
contact of connector) Between ECM J1 (female) (32) and WIF1
(male) (1) Max. 10 z
Resistance
Between ECM J1 (female) (24) and WIF1

2. Disconnect connectors ECM J1 and WIF1, and connect T-adapters
to female side of ECM J1.
5 Short circuit in wiring harness a Check with multimeter in continuity mode.
No continuity
Continuity (no sound is
pin other than (24)
heard.)
D65EX,PX,WX-17 40-209
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-210 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA429] Water in Fuel Sensor Low Error

Action
Failure code Water-in-fuel sensor low error
level Failure
L01 CA429
Detail of • Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function.
Related (Code: 18800 WIF sensor condition)
1
defective.
2. Disconnect connector WIF1 and connect T-adapter to female side of
connector.
Defective water-in-fuel
2 sensor installed to fuel pre- a If water is in water separator, drain it.
filter Between WIF1 (female) (1) and (2) 10 to100
Resis- Kz
tance Between WIF1 (female) (1) and ground Min. 100
Kz
Short circuit or ground fault in of connector.
3 wiring harness Between ECM J1 (female) (24) and (32) 10 to100
Resis- (water-in-fuel sensor resistance) Kz
tance Min. 100
Between ECM J1 (female) (24) and ground
Kz
2. Disconnect connectors ECM J1 and WIF1, and connect T-adapters
to female side of ECM J1.
4 Short circuit in wiring harness a Check with circuit tester in continuity mode.
No
Between ECM J1 (female) (24) and every pin continuity
Continuity
other than (24) (no sound
is heard.)
5 harness (contact with ground 2. Disconnect connectors ECM J1 and WIF1, and connect T-adapters
circuit) to either connector of ECM J1 (female) or WIF1 (male).
tance WIF1 (male) 2 Kz
D65EX,PX,WX-17 40-211
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-212 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA435] Eng Oil Press SW Error

Action
Failure code Engine oil pressure switch failure
level Failure
L01 CA435
Detail of • Failure occurs in engine oil pressure switch signal circuit.
failure
controller
Problem on • Protection function by engine oil pressure does not operate.
machine • Engine oil pressure monitor is not displayed normally.
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is
stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running).
Related • To display this failure code, engine controller checks if engine oil pressure switch is in
information CLOSED (ON), that is, if signal voltage is zero or not, only when engine is stopped.
• Failure of engine oil pressure switch with engine running is shown by failure code
[B@BAZG].
1
defective.
2. Disconnect connector OIL PRESSURE SWITCH and connect T-
Defective engine oil
2 adapter to male side of connector.
pressure switch
Resis- Between OIL PRESSURE SWITCH (male) (1)
and ground Max. 10 z
tance
3 of connector.
harness
Resis- Between ECM J1 (female) (31) and ground
Max. 10 z
tance
Circuit diagram related to engine oil pressure switch
D65EX,PX,WX-17 40-213
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error

Action level Failure code Battery voltage is low.
Failure
Detail of • Low voltage appears in controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues running ordinarily, but it may stop during operation or may not restart
machine once it is stoped.
• Power supply voltage of engine controller can be checked with monitoring function.
Related (Code: 03204 Battery voltage)
information • Method of reproducing failure code: Turn starting switch to ON position
Loose connection or corroded
1 Battery cable terminal may be loose or corroded. Check it directly.
battery terminal
Loosened terminal or 1. Turn starting switch to OFF position.
2 incomplete disconnection at Check terminals of alternator, battery relay, ground (GND20) etc. for
terminal looseness.
3
defective.
1. Turn starting switch to OFF position, then perform troubleshooting.
4 Improper battery voltage 2. Perform troubleshooting when engine is cranked.
Voltage Between battery terminals (+) and (-). 20 to 30 V
2. Insert T-adapter into connector PRTR.
5 Defective alternator 3. Start engine (Engine speed: Medium or faster).
Voltage Between PRTR (2) and ground 26 to 30.5
V
• Reference
1. Turn starting switch to OFF position, and turn battery disconnect
switch to OFF position.
6 Defective engine controller 3. Turn battery disconnect switch to ON position.
4. Measure voltage with starting switch at OFF position and when
starting engine.
Between EGC3 (1) and (21) 20 to 30 V
Voltage
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40 Troubleshooting
Circuit diagram related to engine controller power supply
D65EX,PX,WX-17 40-215
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error

Action
Failure code Battery voltage high error
level Failure
L04 CA442
Detail of • High voltage (36 V or higher) appears in controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues running ordinarily, but it may stop during operation or may not restart
machine once it is stoped.
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03204(V))
1 Battery voltage too high Perform troubleshooting for the failure code [CA441].
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40 Troubleshooting
Failure code [CA449] Rail Press Very High Error

Action
Failure code Rail pressure is very high
level Failure
L03 CA449
Detail of • Excessively high pressure failure (2) occurs in common rail circuit.
failure
controller
machine
• Common rail pressure can be checked with monitoring function.
Related (Code 36400: Common rail pressure)
Since air mixed in low-pressure circuit is suspected, so inspect directly
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
Air in low pressure circuit 3. Check pressure pickup plug for fuel and air leakage.
2
• If this error occurs during the air bleeding operation after fuel filter
replacement, air is possibly remaining in fuel circuit, so continue to
run engine at low idle for approximately 3 minutes. When air
bleeding is completed, engine speed becomes stable and error
display disappears.
a For check of pressure in fuel low-pressure circuit, see "Testing fuel
pressure" in Testing and adjusting.
• Measure pressure on fuel filter outlet side.
At high idle
Fuel pressure in low- Min. 0.48 MPa
pressure circuit (When engine can be
{Min. 4.9 kg/cm2 }
started)
• Measure pressure on fuel filter inlet and outlet sides.
• Pressure drop in fuel low-pressure circuit is calculated by deducting
pressure at fuel filter outlet from pressure at fuel filter intlet.
Fuel low pressure Max. 0.08 MPa
Defective fuel low pressure At high idle
3 circuit pressure drop {Max. 1.4 kg/cm2 }
circuit devices
• Measure fuel low pressure on inlet side of gear pump of supply
pump.
Fuel suction circuit Min. -33.9 kPa
pressure (gear pump At high idle
side) {Min. 254 mmHg }

pressure (fuel At high idle
connector side) {Min. 203 mmHg }
4 Defective fuel cooler a Directly check for fuel leakage from fuel tube of fuel cooler, O-ring
and seal washer damages, and check valve clogging or damage.
D65EX,PX,WX-17 40-217
40 Troubleshooting

2. Monitoring code: 36400 is displayed with monitoring function of
Defective common rail
5 machine monitor.
pressure sensor
Common rail pressure While engine is 0 ± 0.39 MPa
36400 stopped {0 ± 4 kg/cm2 }
Defective wiring harness equipment" in "Checks before troubleshooting" of "General information
6
connector on troubleshooting", and check it.
Defective engine controller of connector.
7 ground wiring harness a Check terminal GND20 for looseness and rusting.
Resis- Between ground and each of EGC3 (female)
(31) and (32) Max. 10 z
tance
8 Defective supply pump Supply pump is possibly defective if no failure is found in causes 1 to 9.
Circuit diagram related to GND of engine controller
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40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error

Action level Failure code Rail pressure sensor high error
Failure
Detail of • High voltage is detected in signal circuit of common rail pressure sensor.
failure
Action of • Restricts engine output (restricts common rail pressure) and allows engine to run.
controller
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function (Code: 36400 (MPa)).
• This failure code is displayed if common rail pressure sensor connector is disconnected.
1
defective.
a If failure code [CA515] or [ CA516] is also displayed, perform
Defective common rail 2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to
2 pressure sensor power female side of connector.
supply system 3. Turn starting switch to ON position.
Power
Between FUEL RAIL PRESS 4.75 to
Voltage supply
(female) (A) and (B) 5.25 V
input
2. Disconnect connectors FUEL RAIL PRESS and ECM J2, and
connect T-adapter to female side each connector.
a If power supply input in checks on cause 2
is normal, this check is not required. Max. 10 z
Open circuit in wiring harness Between ECM J2 (female) (31) and FUEL RAIL
3 (wire breakage or defective PRESS (female) (A)
a If power supply input in checks on cause 2
tance
is normal, this check is not required. Max. 10 z
Between ECM J2 (female) (21) and FUEL RAIL
PRESS (female) (B)
Between ECM J2 (female) (44) and FUEL RAIL
PRESS (female) (C) (sensor output) Max. 10 z

2. Disconnect connectors FUEL RAIL PRESS and ECM J2.
4 Short circuit in wiring harness 3. Connect T-adapter to female side of ECM J2.
tance Kz
D65EX,PX,WX-17 40-219
40 Troubleshooting

2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to
connector ECM J2.
Hot short circuit in wiring 3. Turn starting switch to ON position (with connector FUEL RAIL
5 harness PRESS disconnected).
(contact with 24 V circuit) a Pin (44) of ECM J2 is connected to 5 V circuit via resistor inside
engine controller.
Voltage Between ECM J2 (44) and (21) Approx. 5
V
a If causes 1 to 5 are not cause for failure and check result of cause 6
is abnormal, sensor is defective.
pressure sensor (defective 1. Turn starting switch to OFF position.
6 input voltage to engine 2. Insert T-adapter in connector ECM J2.
controller) 3. Turn starting switch to ON position.
Sensor 0.2 to 4.6
Voltage Between ECM J2 (55) and (21)
output V
Circuit diagram related to common rail pressure sensor
40-220 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error

Action level Failure code Rail pressure sensor low error
Failure
Detail of • Low voltage is detected in signal circuit of common rail pressure sensor.
failure
controller
machine
• Signal voltage from the common rail pressure sensor can be checked with monitoring
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function (Code: 36400 (MPa)).
• If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
1
defective.
a If failure code [CA515] or [CA516] is also displayed, perform
Defective common rail 2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to
2 pressure sensor power female side of connector.
supply system 3. Turn starting switch to ON position.
Power
Between FUEL RAIL PRESS 4.75 to 5.25
Voltage supply
(female) (A) and (B) V
input
Defective common rail 2. Disconnect connector FUEL RAIL PRESS.
3 pressure sensor 3. Turn starting switch to ON position.
If failure code changes from [CA452] to [CA451], sensor is defective.
2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
Open circuit in wiring harness connect T-adapter to female side of each connector.
4 (wire breakage or defective
contact of connector) a Open circuit of 5 V circuit
Resis- Between ECM J2 (female) (31) and FUEL
RAIL PRESS (female) (A) Max. 10 z
tance
Ground fault in wiring harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
5 (contact with ground circuit) connect T-adapter to female side of ECM J2.
Resis- Between ECM J2 (female) (44) and ground
Min. 100 Kz
tance
2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
6 Short circuit in wiring harness connect T-adapter to female side of ECM J2.
Resis- Between ECM J2 (44) and (21)
Min. 100 Kz
tance
D65EX,PX,WX-17 40-221
40 Troubleshooting
40-222 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA488] Chg Air Temp High Torque Derate

Action level Failure code Chg Air Temp High Torque Derate
Failure
Detail of • Temperature signal from boost pressure & temperature sensor exceeds upper limit of
failure control temperature.
controller
machine
• Boost temperature can be checked with monitoring function.
Related (Code: 18500 Boost temperature)
Aftercooler cooling performance may be degraded. Check for following
points:
Drop of cooling performance
1 • Defective fan rotation
of aftercooler
• Insufficient cooling air
• Clogged aftercooler fins
Unusual rise of turbocharger Outlet temperature of turbocharger may be unusually high. Check
2 outlet temperature related parts.
Defective boost temperature
3 Perform troubleshooting for failure codes [CA153] and [CA154].
sensor system
D65EX,PX,WX-17 40-223
40 Troubleshooting
Failure code [CA515] Rail Press Sens Sup Volt High Error
Action level Failure code Common rail pressure sensor supply voltage high error
Failure
Detail of • High voltage is detected in common rail pressure sensor power supply (5 V).
failure
controller
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring function.
(Code: 36401(V))
Related • Pressure measured by common rail pressure sensor can be checked with monitoring
information function. (Code: 36400 (MPa))
1
defective.
2. Disconnect connector FUEL RAIL PRESS.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code does not appear anymore, sensor is defective.
(internal defect)
a Other failure codes are displayed at the same time. This happens
because connector is disconnected. So ignore other than this failure
code.
Defective wiring harness If this failure code does not appear any more, wiring harness may have
3
failure. Perform following troubleshooting.
because connector is disconnected. So ignore other than this failure
code.
Hot short circuit in wiring 2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to
4 harness female side of connector.
Between FUEL RAIL PRESS (female) (A) and 4.75 to 5.25
Voltage
(B) V
2. Disconnect connector ECM J2 and connect T-adapter.
Voltage Between ECM J2 (male) (31) and (21) 4.7 to 5.25 V
40-224 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-225
40 Troubleshooting
Failure code [CA516] Rail Press Sens Sup Volt Low Error
Action level Failure code Common rail pressure sensor supply voltage low error
Failure
Detail of • Low voltage is detected in common rail pressure sensor power supply (5 V).
failure
controller
Problem on
machine
information
1
defective.
2. Disconnect connector FUEL RAIL PRESS.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code does not appear anymore, sensor is defective.
(internal defect)
because connector is disconnected. So ignore other codes than this
failure code.
Defective wiring harness If this failure code does not appear any more, wiring harness may be
3
defective. Perform following troubleshooting.
failure code.
4 harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
(contact with ground circuit) connect T-adapter to female side of either of them.
tance FUEL RAIL PRESS (female) (A) Kz
a If no failrure is found in checks on cause 3, this check is not required.
Between ECM J2 (female) (21) and (31), or
Resis- between FUEL RAIL PRESS (female) (A) and Min. 100
tance (B) Kz

2. Disconnect connector ECM J2 and connect T-adapter.
6 Defective engine controller 4.7 to 5.25
Voltage Between ECM J2 (male) (31) and (21)
V
40-226 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-227
40 Troubleshooting
Failure code [CA553] Rail Press High Error

Action
Failure code Rail Press High Error
level Failure
L01 CA553
Detail of • Excessively high pressure trouble (1) has occurred in the common rail circuit.
failure
controller
Problem on • Engine noise becomes louder at no or light load.
Connection of ground terminals may be defective. Check the following
terminals.
Defective connection of • Ground terminal of machine ((–) terminal of battery)
2 ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
3 Perform troubleshooting for failure code [CA451], [CA452]
pressure sensor system
40-228 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA555] Crankcase Press High Error 2

Action level Failure code Crankcase pressure high error 1
Failure
Detail of • High pressure error (level 1) in crankcase pressure is detected.
failure
Action of • None in particular.
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
1 Clogged KCCV filter Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
Blocked KCCV gas piping emulsion is found inside KCCV, KCCV blowby gas piping may be
2
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
3 troubleshooting for failure codes [CA1843] and [CA1844].
sensor
D65EX,PX,WX-17 40-229
40 Troubleshooting
Failure code [CA556] Crankcase Pressure High Error 3

Action level Failure code Crankcase pressure high error 2
Failure
Detail of • Crankcase pressure high error (level 2) has occurred.
failure
Action of • Limits engine output and allows engine to run.
controller
machine
(Code: 48401(V))
Related • The pressure sensed by the crankcase pressure sensor can be checked by using
information monitoring function. (Code: 48400 (MPa))
2
leaks.
Crankcase pressure sensor Crankcase pressure sensor system may be defective. Perform
defective
When the error is not cleared after the KCCV filter is replaced and
crankcase pressure high error 2 occurs in a short time, the engine may
4 Blow-by gas increases
be seized or the turbocharger may be defective. Carry out
troubleshooting for the mechanical system.
40-230 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA559] Rail Pump Press Low Error

Action
Failure code Supply pump pressure low error 1
level Failure
E02 CA559
Detail of • Supply pump pressure low error 1 occurs in common rail circuit.
failure
controller
• Engine does not start or engine is hard to start.
Problem on • Exhaust gas color becomes black.
1 No fuel Check fuel level.
2 Defective fuel tank breather Check fuel tank breather for clogging.
Check fuel for leakage outside. (Check visually while running engine at
3 Fuel leakage to outside
low idle).
• Measure pressure on fuel filter inlet side.
• Cranking speed: Min. 150 rpm
Fuel pressure in low- Min.0.105 MPa
During cranking
pressure circuit {Min.1.4 kg/cm2 }
• Measure pressure on fuel filter outlet side.
Fuel pressure in low- Min. 0.48 MPa
At high idle
pressure circuit {Min. 4.9 kg/cm2 }
• Measure pressure on fuel filter inlet and outlet sides.
Defective low pressure circuit
4 • Pressure drop in fuel low-pressure circuit is calculated by deducting
device (Note 1)
the pressure at fuel filter outlet from pressure at fuel filter intlet.
Fuel low pressure Max. 0.08 MPa
At high idle
circuit pressure drop {Max. 1.4 kg/cm2 }
• Measure pressure on inlet side of gear pump of supply pump.
pressure (gear pump At high idle
side) {Min. 254 mmHg }

• Measure pressure on fuel connector side.
pressure (fuel At high idle
connector side) {Min. 203 mmHg }
D65EX,PX,WX-17 40-231
40 Troubleshooting

a For check of return rate from injector, see “Checking fuel return rate
and leakage” in Testing and adjusting.
During cranking
Fuel leakage from high (When engine does not Few drops/30 sec.
5 pressure connections (inside Return rate from start)
cylinder head) injector At low idle
(When engine can be Max. 70 cc/60 sec.
started)
If fuel return is excessive, check the tightening of high pressure pipe
connections by referring to "Reference".
a For check of return rate from injector, see “Checking fuel return rate
and leakage” in Testing and adjusting.
During cranking
6 Defective injector (When engine does not Few drops/30 sec.
Return rate from start)
injector At low idle
(When engine is Max. 70 cc/60 sec.
started)
a For check of fuel return rate from supply pump, see "Checking fuel
return rate and leakage" in Testing and adjusting.
During cranking
7 Defective supply pump (When engine does not Max. 320 cc/30 sec.
Fuel return rate from start)
supply pump At low idle
(When engine is Max. 350 cc/30 sec.
started)
a For check of fuel leakage from pressure limiter, see “Checking fuel
8 Defective pressure limiter return rate and leakage” in Testing and adjusting.
Leakage from pressure Max. 30 drops/min
At low idle
limiter
Air may be in low-pressure circuit. Check it according to 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 fuel and air from pressure pickup plug for leakage level.
• If this error occurs during air bleeding after fuel filter is replaced, air
may remain in fuel circuit. Keep running engine at low idle for about
three minutes. As air is bled from fuel circuit, engine speed will be
stabilized, and error display disappears.
Note 1: To determine defective low-pressure circuit parts, perform checks for following items.
1.
1) Clogging of fuel tank breather
2) Sticking of check valve (3) installed to cooling plate (2) of engine controller (1)
3) Leakage or clogging of low-pressure fuel piping
4) Clogging of fuel pre-filter
5) Clogging of fuel main filter
6) Replace fuel filter when problem is not removed even if no clogging is found.
Reference
40-232 D65EX,PX,WX-17
40 Troubleshooting
The high pressure pipes from the common rail are connected to the injectors via high pressure connections
provided inside the cylinder head.
Since the high pressure connections are tightened with nuts (1), retighten nuts (1).
3 : 50 ± 4 Nm {5 ± 0.4 kgm}
Width across flats: 24 mm
D65EX,PX,WX-17 40-233
40 Troubleshooting
40-234 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA595] Turbocharger Speed High Error 2

Action level Failure code Turbocharger Speed High Error 2
Failure
Detail of • Turbocharger high speed error is detected.
failure
controller
machine
• The speed sensed by the turbocharger speed sensor can be checked by using monitoring
Related function (Code: 48100 (rpm)).
Increased turbocharger
1 Turbocharger speed may increase abnormally high. Check it.
speed
2 Defective turbocharger Check turbocharger for defect.
If no failure is found in check on cause 1, turbocharger speed sensor
Defective turbocharger speed system may be defective. Perform troubleshooting for failure code
3
sensor [CA687].
D65EX,PX,WX-17 40-235
40 Troubleshooting
Failure code [CA687] Turbo Speed Low Error

Action
Failure code Turbocharger speed low error
level Failure
L01 CA687
Detail of • Turbocharger speed low error is detected.
failure
Action of • Set turbocharger speed to calculated speed and run engine.
controller
Problem on
machine
• Turbocharger speed detected by turbocharger speed sensor can be checked with
information (Code: 48100 (rpm))
1 Defective turbocharger Check turbocharger for defect.
2
defective.
Defective turbocharger speed 2. Disconnect connector VGT_REV and connect T-adapter to female
3 sensor side of connector.
(internal defect) Resis- Between VGT_REV (female) (1) and (2) 600 to 1600
tance z
Open or short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector ECM J2 and connect T-adapter to female side
4 (short circuit, wire breakage of connector.
and defective contact of Resis- Between ECM J2 (female) (32) and (33) 600 to1600
connector) tance z
2. Disconnect connectors ECM J2 and VGT_REV, and connect T-
Ground fault in wiring harness adapters to female side of either of them.
5 Resis- Between ground and ECM J2 (female) (32)
(contact with ground circuit) Min. 100 Kz
tance or VGT_REV (female) (1)
or VGT_REV (female) (2) Min. 100 Kz
tance
Short circuit in wiring harness 2. Disconnect connectors ECM J2 and VGT_REV, and connect T-
6 adapters to female side of either of them.
Resis- Between ECM J2 (female) (32) and (33), or
between VGT_REV (female) (1) and (2) Min. 100 Kz
tance
As turbocharger speed sensor may be mounted incorrectly (loose
Defective mount of sensor or
7 fitting) or speed sensor parts (internal KVGT parts) may be defective
defective speed sensing part
(due to thermal deformation), check them closely.
40-236 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to turbocharger speed sensor
D65EX,PX,WX-17 40-237
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error

Action
Failure code Engine Ne speed sensor error
level Failure
E03 CA689
Detail of • Abnormal signal appear in engine Ne speed sensor circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
machine • Engine is hunting.
• Starting performance is poor
• Since inside of speed sensor is not composed of coil but hall sensor and electronic circuit,
speed sensor cannot be determined to be normal by measuring its resistance with
Related multimeter.
information • Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be
measured with multimeter.
• Speed sensor detects a portion of speed sensing ring where no tooth is located mounted
on camshaft by the rotation of crankshaft.
1
defective.
Defective Ne speed sensor If failure code [CA238] or [CA239] is displayed at the same time,
2 power supply system perform troubleshooting for it first.
Breakage or improper
Engine Ne speed sensor may be broken or may have improper
3 installation (looseness) of
installation (looseness). Check it.
engine Ne speed sensor
2. Disconnect connector CRANK SENSOR and connect T-adapter to
female side of connector.
Defective Ne speed sensor
power supply input
Power
Between CRANK SENSOR
Voltage supply 4.75 to 5.25
(female) (1) and (2) V
input
2. Disconnect connectors ECM J1 and CRANK SENSOR.
a If no failure is found in checks on cause 4,
Open circuit in wiring harness Between ECM J1 (female) (36) and CRANK
SENSOR (female) (1)
tance
Between ECM J1 (female) (37) and CRANK
SENSOR (female) (2)
Between ECM J1 (female) (26) and CRANK
SENSOR (female) (3) Max. 10 z
40-238 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect connectors ECM J1 and CRANK SENSOR.
Short circuit in wiring harness Between ECM J1 (female) (36) and (26) or
6 Min. 100 Kz
Resis- CRANK SENSOR (female) (1) and (3)
tance Between ECM J1 (female) (26) and (37) or
CRANK SENSOR (female) (2) and (3) Min. 100 Kz

Ground fault in harness 2. Disconnect connectors ECM J1 and CRANK SENSOR.
7
(contact with ground circuit) Resis- Between ground and ECM J1 (female) (26)or
CRANK SENSOR (female) (3) Min. 100 Kz
tance
Hot short circuit in wiring 2. Disconnect connector CRANK SENSOR.
(contact with 24 V circuit) Between CRANK SENSOR (female) (3) and
Voltage Max. 1 V
ground
1. Remove Ne speed sensor (crank sensor).
2. Check speed sensor ring (R) through sensor mounting hole.
Damage or loose mounting of a A portion (A) of speed sensing ring (R) has no tooth for purpose of
9 speed sensing wheel detecting speed.
a If speed sensing ring (R) is loosened, correct it following instructions
given in "Reference".
If no failure is found in above checks, Ne speed sensor is defective.
10 Defective Ne speed sensor
Circuit diagram related to engine Ne speed sensor
Reference Check of crankshaft speed sensing ring for looseness (114 Engine)
Remove damper, flywheel, flywheel housing and outside main cap, and check crankshaft speed sensing ring
for looseness.
D65EX,PX,WX-17 40-239
40 Troubleshooting
a When replacing crankshaft speed sensing ring, you must remove crankshaft.
a Keep rear seal, gasket and liquid gasket LG-6 and LG-7 on hand.
Removal
1. Remove engine assembly. For details, see "Removal and installation of engine assembly" in Disassembly
and assembly.
2. Remove the followings. For details, see "Removal and installation of engine rear seal" in Disassembly and
assembly.
1) Damper
2) Flywheel
3) Flywheel housing
4) Rear seal housing
3. Remove oil pan.
4. Remove mounting bolt (2) of main cap (1).
5. Insert bolt (2) into the bolt hole of main cap (1), and shake and remove main cap (1).
a Check that the embossed letters of "BACK" on side face (A) of main cap (1) are facing the rear of
cylinder block.
(3): Speed sensing ring
6. Check mounting bolt (4) of Ne speed (crankshaft) sensing ring (3) for looseness.
a If the bolts are loosened, replace them with new bolts.
a Tighten each bolt evenly.
3 Mounting bolt (4):
8 ± 2 Nm {0.8 ± 0.2 kgm}
(5): Crankshaft
Installation
a See the figures in "Removal" for installation.
1. Install main cap (1) with the embossed letters "BACK" facing to the rear side of cylinder block.
40-240 D65EX,PX,WX-17
40 Troubleshooting
2 Crankshaft journal surface:

Engine oil (E015W-40)
a Push in by hitting it lightly with a plastic hammer or rubber hammer.
2. Install main cap (1) with mounting bolt (2).
2 Mounting bolt:
Engine oil (E015W-40)
3 Main cap mounting bolt:
1]: 167 ± 8 Nm {17.0 ± 0.8 kgm}
2]: Loosen 360 deg.
3]: 30.4 ± 3.0 Nm {3.1 ± 0.3 kgm}
4]: 50 ± 4.9 Nm {5.1 ± 0.5 kgm}
5]: 120deg. ± 5deg.
3. Install oil pan.
Tighten mounting bolts [1] to [32] sequentially.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
4. Reinstall engine rear seal and engine assembly. For details, see "Removal and installation of engine rear
seal" and "Removal and installation of engine assembly" in Disassembly and assembly.
D65EX,PX,WX-17 40-241
40 Troubleshooting
Failure code [CA691] Intake Air Temp Sens High Error

Action level Failure code Intake air temperature sensor high error
Failure
Detail of • High voltage is detected in signal circuit of intake air temperature sensor.
failure
Action of • Sets intake temperature to fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake temperature sensor are integrated.
Related • If sensor connector is disconnected, this failure code is displayed together with failure
information code [CA357].
1
defective.
2. Disconnect connector MAF and connect T-adapter to male side of
connector.
-30 °C 25 to 28 Kz
Defective intake temperature
Between MAF (male) (3) and (4) 0 °C 5.5 to 6.1 Kz
2 sensor
25 °C 1.9 to 2.1 Kz
(internal defect) Resis- a Intake temperature - resistance
tance characteristics 40 °C 1.1 to 1.2 Kz
100 °C 180 to 185 z
Between MAF (male) (3) and Whole
ground (sensor body) range Min. 100 Kz
harness of connector.
3 (short circuit, wire breakage Resis- Between ECM J1 (female) (6) and (22) 180 z to 28
or defective contact of tance Kz
connector) a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Hot short circuit in wiring 2. Disconnect connector MAF
harness 3. Connect T-adapter in connector ECM J1 or to female side of
4
connector MAF.
Between ECM J1 (female) (6) and (22) or
Voltage Max. 5.25 V
MAF (female) (1) and (3)
Resis- Between ECM J1 (female) (6) and each pin
other than (6) Min. 100 Kz
tance
40-242 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to intake air temperature sensor
D65EX,PX,WX-17 40-243
40 Troubleshooting
Failure code [CA692] Intake Air Temp Sens Low Error

Action level Failure code Intake air temperature sensor low error
Failure
Detail of • Low voltage error is detected in signal circuit of intake air temperature sensor.
failure
Action of • Sets intake temperature to fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
Related • Mass air flow sensor and intake temperature sensor are integrated.
1
defective.
2. Disconnect connector MAF.
If this failure code changes to failure code [CA691], intake air
temperature sensor is defective.
• Reference
Defective intake temperature
2. Disconnect connector MAF and connect T-adapter to male side of
2 sensor
connector.
(internal defect) -30 °C 25 to 28 Kz
Between MAF (male) (3) and (4) 0 °C 5.5 to 6.1 Kz
25 °C 1.9 to 2.1 Kz
Resis- a Intake temperature - resistance
tance characteristics 40 °C 1.1 to 1.2 Kz
100 °C 180 to 185 z
Between MAF (male) (3) and Whole
ground (sensor body) range Min. 100 Kz
3 (short circuit, wire breakage Resis- Between ECM J1 (female) (6) and (22) 180 z to 28
or defective contact of tance Kz
connector) a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Ground fault in wiring harness 2. Disconnect connectors ECM J1 and MAF, and connect T-adapter to
Resis- Between ground and ECM J1 (female) (6) or
MAF (female) (4) Min. 100 Kz
tance
Resis- Between ECM J1 (female) (6) and every pin
tance
40-244 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to intake air temperature sensor
D65EX,PX,WX-17 40-245
40 Troubleshooting
Failure code [CA697] ECM Internal Temp Sensor High Error

Action level Failure code ECM Int Temp Sensor High Error
Failure
Detail of • High voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by
Related using monitoring function (Code: 18900(°C)).
1 Improper usage of controller Check if the controller has been used in high temperature environments.
40-246 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA698] ECM Internal Temp Sensor Low Error

Action level Failure code ECM Int Temp Sensor Low Error
Failure
Detail of • Low voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by

Related using monitoring function (Code: 18900(°C)).

1 Improper usage of controller Check if the controller has been used in low temperature environments.
D65EX,PX,WX-17 40-247
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action
Failure code Engine Bkup speed sensor phase error
level Failure
L03 CA731
Detail of • Phase error is detected in signals from engine Ne speed sensor and engine Bkup speed
failure sensor.
Action of • Continues control by using engine Ne speed sensor signal.
controller
• Engine stops during operation (when Ne speed sensor is also defective at the same
time).
Problem on • Engine can not start or engine is hard to start.
machine • Idle speed is untable.
• Exhaust gas color becomes black.
information
Damaged engine Ne speed Check engine Ne speed sensor (crankshaft sensor) directly as it may be
1 (crankshaft) sensor damaged.
Damaged engine Bkup speed Check engine Bkup speed sensor (camshaft sensor) directly as it may
2 (camshaft) sensor be damaged.
Since defective mounting or damage of speed detection ring on
crankshaft side is suspected, perform inspection according to the
Defective mounting or
3 damage of speed detection 1. Set No. 1 piston to compression top dead center (align stamping
ring on crankshaft side mark).
2. Remove Ne speed sensor (crankshaft sensor).
3. If portion (A) (portion without tooth) of speed sensing ring is visible
through sensor mounting hole, installation is correctly done.
Camshaft gear (CAMG) is used as speed sensing ring on camshaft
side. Since its inappropriate installation or damage can be the cause of
failure, check it according to the following procedure.
Defective installation or 1. Set No. 1 piston to compression top dead center (align stamping
4 breakage of camshaft gear mark).
2. Remove Bkup speed sensor.
3. If two ribs (B) of camshaft gear (CAMG) are visible through sensor
mounting hole, it is mounted normally.
Defective timing adjustment Since defective timing adjustment of crankshaft and camshaft is
5 suspected, check it directly.
of crankshaft and camshaft
Defective connection of ground terminal is suspected. Check following
terminals directly:
Defective connection of • Ground terminal of machine ((–) terminal of battery)
6 ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
40-248 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-249
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error

Action
Failure code Engine Bkup speed sensor error
level Failure
L03 CA778
Detail of • Abnormality is detected in engine Bkup speed sensor signals.
failure
Action of • Continues control by using engine Ne speed sensor signal.
controller
Problem on • Engine does not start.
• Since inside of speed sensor is not composed of coil but hall sensor and electronic circuit,
speed sensor cannot be determined to be normal by measuring its resistance with
Related multimeter.
information • Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be
measured with multimeter.
• Speed sensor detects two ribs on side face of camshaft gear.
Defective wiring harness equipment" in "Checks before troubleshooting" of "General information on
1
connector troubleshooting", and check it.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply 2 circuit for it first.
Damage or incorrect
(loose) installation of Check engine Bkup speed (cam) sensor as it may be damaged or incorrectly
3 engine Bkup speed (loosely) installed.
(cam) sensor
2. Disconnect connector CAM SENSOR , and connect T-adapter to female
Defective engine Bkup
side of connector.
4 speed sensor power
supply input
Power Between CAM SENSOR (female) (1) Power 4.75 to 5.25
supply and (2) supply V
2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
Open circuit in wiring adapters to female side of each connector.
harness Between ECM J1 (female) (60) and CAM SENSOR
5 (wire breakage or
defective contact of Resis- Between ECM J1 (female) (59) and CAM SENSOR
connector) Max. 10 z
tance (female) (2)
Between ECM J1 (female) (9) and CAM SENSOR

2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
adapter to female side of either connector.
Short circuit in wiring
6 Between ECM J1 (female) (9) and (60) or CAM
harness Min. 100 Kz
Resis- SENSOR (female) (1) and (3)
tance Between ECM J1 (female) (9) and (59) or CAM
SENSOR (female) (2) and (3) Min. 100 Kz

Ground fault in wiring 2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
7 harness (contact with adapter to female side of either connector.
ground circuit) Resis- Between ground and ECM J1 (female) (9) or CAM
Min. 100 Kz
tance SENSOR (female) (3)
40-250 D65EX,PX,WX-17
40 Troubleshooting

Hot short circuit in wiring 2. Disconnect connector CAM SENSOR , and connect T-adapter to female
8 harness side of connector.
Voltage Between CAM SENSOR (female) (3) and ground Max. 1 V
Remove engine Bkup speed (CAM) sensor, and check camshaft gear
Loosening on camshaft through hole.
9 gear
a If camshaft gear (CAMG) is loosened, correct it following instructions
given in "Reference".
If no failure is found by above checks, engine Bkup speed (CAM) sensor is
Defective engine Bkup defective.
10 speed (cam) sensor
Defective engine If no failure is found by above checks, engine controller is defective. (Since
11 this is internal defect, troubleshooting cannot be performed.)
controller
D65EX,PX,WX-17 40-251
40 Troubleshooting
Circuit diagram related to engine Bkup speed sensor
Reference: Check of camshaft gear for looseness (114 Engine)

Remove pulley, damper, front seal, front cover and housing, and check camshaft gear for looseness.
a Keep the front seal, gasket, liquid gasket LG-7 and front seal tool (795-799-8120) on hand.
Removal
1. Remove the followings. For details, see "Removal and installation of engine front seal" in Disassembly
and assembly.
1) Remove fan and fan belt.
2) Remove pulley (1).
3) Remove damper (2).
(DP): Dowel pin
40-252 D65EX,PX,WX-17
40 Troubleshooting
4) Remove carrier assembly (3).

5) Remove dust seal (4) and front seal (5) from carrier assembly (3).
2. Remove front cover (6).
3. Remove housing (7).
(8): Gasket
4. Check mounting bolt (10) of gear (9) of camshaft (11) for looseness.
24 ± 4 Nm
Installation
a See the figures in "Removal" for installation.
1. Install gasket (8) to housing (7) and install front cover (6).
2 Housing:
Liquid gasket (LG-7)
2. Install front seal (5) and dust seal (4) to carrier (3). For details, see "Removal and installation of engine
front seal" in Disassembly and assembly.
1) Install front seal (5) and dust seal (4) to carrier (3).
2) Install carrier assembly to front cover (6).
D65EX,PX,WX-17 40-253
40 Troubleshooting
3) Install dowel pin (DP), and install damper (2).

4) Install pulley (1).
5) Install fan belt, and install the fan.
6) Install the cooling system assembly.
40-254 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA1117] Engine Controller Partial Data Lost Error

Action level Failure code Persistent Data Lost Error
Failure
Detail of
• Internal defect occurred in controller.
failure
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on start if it is stopped.
machine • Engine controller cannot store internal data correctly
Related • Since the engine controller internal data (KDPF related, etc.) may be lost, appropriate
information actions must be taken after the system recovers from the error.
Since the power supply circuit may be defective, carry out
1 Defective power supply circuit
troubleshooting for failure code [CA441].
Improper operation of battery Battery disconnect switch may have been operated improperly.
2
disconnect switch
Actions to be
taken after See "How to perform regeneration for service" section.
recovery from
error
D65EX,PX,WX-17 40-255
40 Troubleshooting
Failure code [CA1664] KDOC Malfunction

Action
Failure code Defective KDOC function
level Failure
L03 CA1664
• During KDPF regeneration, KDOC inlet temperature sensor and KDOC outlet
Detail of temperature sensor indicate almost the same values (difference within approximately 10 °
failure C ).
controller • Stops regeneration control by KDPF.
machine
function. (Code: 47300 (℃ °C ))
engine running at idle (without regenerating KDPF) are approx. 100 to 250 °C and
temperature differences among them are approx. 10 °C (KDOC inlet temperature >
KDOC outlet temperature> KDPF outlet temperature).
Related
information
temperature are approx. 450 to 550 °C .
• It takes approximately 40 seconds to complete active regeneration (manual stationary
regeneration).
• KDOC inlet temperature sensor connector label "TEMP1" is seen on KDPF temperature
sensor consolidating box with black embossed letters (same for KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3").
<Clearing failure code>
Start the engine and run at high idle for approximately 15 minutes.
a Automatic regeneration starts, and after 10 to 15 minutes, the engine controller checks
the KDOC inlet temperature and outlet temperature.
a It is necessary to run the engine at high idle to generate sufficient amount of exhaust gas
and cause a temperature difference between the KDOC inlet and outlet, to clear this
failure code.
• Method of reproducing failure code:
Start engine and turn manual stationary regeneration switch ON (when this failure code is
not displayed).
Start the engine and run at high idle for 15 minutes. Then check that the failure code is
not displayed.
(Same as <Clearing failure codes>) (when this failure code is displayed)
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] appears, perform
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
3 Defective KDOC 1. Check that KDPF is installed to exhaust system.

2. Check that KDOC is installed to KDPF.
40-256 D65EX,PX,WX-17
40 Troubleshooting

1. Perform checks and repair referring to harness and connecter
related descriptions in "c: Electrical equipment" of "Checks before
troubleshooting" in "General information on troubleshooting".
Defective wiring harness 2. When repair is completed, perform <Clearing failure codes> in
4 "Related information".
connector
If this failure code does not appear, wiring harness connector is
defective.
KDPF outlet temperature sensor, and record signal voltages from
respective temperature sensors in initial condition (see relevant
information).
4. Disconnect either connector TEMP1 or TEMP2.
KDPF outlet temperature sensor, and record the second signal
voltages from respective temperature sensors (see relevant
information).
If there is no substantial difference in signal voltages sensed by KDOC
inlet temperature sensor and KDPF outlet temperature sensor in the
second time (almost the same as the first time), check wiring harness
for short circuit (failure codes [CA3315] and [CA3322]).
a If this failure code is still displayed, even after <Clearing failure codes> in "Related information" is
performed, perform troubleshooting again.
Circuit diagram related to KDOC temperature sensor
D65EX,PX,WX-17 40-257
40 Troubleshooting
Failure code [CA1691] Regeneration Ineffective

Action
Failure code Regeneration ineffective
level Failure
L01, L03 CA1691
• KDOC efficiency (catalyst action) is degraded (soot trapped in KCSF does not burn
Detail of sufficiently because the KDOC outlet temperature does not rise enough. During
failure regeneration, KDOC inlet temperature is normally approx. 250 to 400 °C , and KDOC
outlet temperature is normally approx. 450 to 550 °C .)
controller • Stops KDPF regeneration control.
machine
function. (Code: 47300 (°C °C ))
temperature differences among them are approx. 10 °C (KDOC inlet temperature >
KDOC outlet temperature> KDPF outlet temperature).
• When manual stationary regeneration (normal) is in progress, KDOC inlet temperature is
approx. 250 to 400 °C , and KDOC outlet temperature and KDPF outlet temperature
reach to approx. 450 to 550 °C .
Related • When manual stationary regeneration without injecting dosing fuel (KDOC drying) is in
information progress, KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature are all approx. 250 to 400 °C .
"TEMP3").
a When the KDOC in the KDPF is changed, perform KDOC change resetting to finish repair
work.
• Performing manual stationary regeneration from "Regeneration for Service" menu.
a When soot accumulation is at level 3 or lower, manual stationary regeneration can be
performed only from "Regeneration for Service" menu.
1. Start engine.
2. Check that machine is in safe condition.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then execute "Manual Statonary Regeneration" (manual stationary
regeneration will be completed in approx. 40 minutes).
a Failure code [CA2637] can be issued simultaneously, however, carry out troubleshooting
for this failure code.
• Method of reproducing failure code:
When KDOC is changed, repair complete verification is unnecessary.
If KDOC is not changed, start the engine and turn the manual stationary regeneration
switch ON (see Cause 6.)
40-258 D65EX,PX,WX-17
40 Troubleshooting

• If there is a significant difference between temperatures at
Defective KDOC outlet KDOC outlet, KDOC inlet and KDPF outlet when the KDPF is
1 temperature sensor completely cool or engine running at idle (not regenerating),
replace the KDOC outlet temperature sensor.
1. Rapidly accelerate engine from low idle to high idle two times,
and then keep engine running at high idle for five seconds.
• If excessive black smoke is exhausted when accelerating
engine or running it at high idle, perform troubleshooting for "S-
2 Unusual exhaust gas color 9 KDPF gets clogged in a short time".
a It does not matter that black smoke particles are exhausted
during engine acceleration but are not exhausted during
running at high idle.
a To dry KDOC
2. Monitor signal voltages from KDOC inlet temperature sensor
and KDPF outlet temperature sensor, note temperature values
Defective KDOC from each sensor with KDPF under initial condition and during
3 manual stationary regeneration, and check that KDOC outlet
(KDOC drying needed)
temperature sensor is normal (see "Related information").
3. Perform manual stationary regeneration (see "Related
information".)
a Since this is for drying KDOC, dosing fuel is not injected during
regeneration.
k Perform after the KDPF and KDOC are sufficiently cooled.
1. Remove KDPF.
2. Remove KDOC.
Defective KDOC 3. Blow air from KDOC outlet side to clean ceramic surfaces
4
or damaged KDOC surfaces) inside KDOC.
4. Check ceramic inside KDOC for cracks.
If cracks are found in KDOC, KDOC is defective (replace KDOC).
a Perform the following regardless whether KDOC is replaced or
not.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, select "Diagnostic
Tests", open "03 KDPF Memory Rest", and then execute "03
KDOC Change" (reset after KDOC change).
a When KDOC change reset is performed, failure codes
[CA1691] and [CA2637] will no longer be displayed.At this
5 Reset after KDOC change
time, dosing fuel injection that has been disabled by the active
failure code will also be enabled.
a Check that reset after KDOC change is completed
successfully (by reset count). If not, perform troubleshooting
again.
a When the KDOC is changed, finish troubleshooting without
performing manual stationary regeneration.
D65EX,PX,WX-17 40-259
40 Troubleshooting

a Perform this troubleshooting when KDOC is not changed.
2. Monitor signal voltages from KDOC inlet temperature sensor
and KDPF outlet temperature sensor, note temperature values
from each sensor with KDPF under initial condition and during
manual stationary regeneration, and check that KDOC outlet
temperature sensor is normal (see "Related information").
3. Perform manual stationary regeneration (see "Related
information".)
Defective KDOC 4. Turn starting switch to OFF position.
6 5. Start the engine and perform manual stationary regeneration
KDOC catalyst action) again (to make sure failure code [CA2637] is not issued
again).
a Check that failure code is not displayed to finish
troubleshooting.
regeneration is completed, KDOC is defective (catalyst action
of KDOC is degraded. Change KDOC.)
a Perform troubleshooting for cause 5 when the KDOC is
changed.
40-260 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA1695] Sensor 5 Supply Volt High Error

Action
Failure code Sensor power supply 5 high error
level Failure
L03 CA1695
Detail of • High voltage error is detected in 5 V power supply for KDPF differential pressure sensor
failure and KDPF outlet pressure sensor.
• Sets KDPF outlet pressure to fixed value (0 kPa{0 kg/cm2 }) and allows engine to run.
• Sets KDPF differential pressure to presumptive value and allows engine to run (uses
Action of differential pressure of 0 kPa in some cases).
controller • Closes EGR valve and opens KVGT fully.
machine
Related • KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated.
1
defective.
Defective KDPF differential 2. Disconnect connector PDPF.
pressure (outlet pressure) 3. Turn starting switch to ON position.
2 sensor a Ignore displayed failure codes other than this code.
(internal defect) If this failure code is not displayed, KDPF differential pressure (outlet
pressure) sensor is defective.
2. Disconnect connectors EGC3 and PDPF, and connect T-adapter to
3 female side of EGC3.
harness
Resis- Between EGC3 (female) (52) and every pin
tance
2. Disconnect connector PDPF.
3. Connect T-adapter in connector EGC3 or to female side of connector
4 Defective engine controller PDPF.
Between EGC3 (female) (52) and (43) or
Voltage 4.75 to 5.25 V
PDPF (female) (4) and (1)
Circuit diagram related to sensor power supply 5 circuit
D65EX,PX,WX-17 40-261
40 Troubleshooting

Action
Failure code Sensor power supply 5 low error
level Failure
L03 CA1696
Detail of • Low voltage appears in 5 V power supply circuit for KDPF differential pressure sensor and
failure KDPF outlet pressure sensor.
• Sets KDPF outlet pressure to fixed value (0 kPa{0 kg/cm2 }) and allows engine to run.
• Sets KDPF differential pressure to presumptive value and allows engine to run (uses
Action of differential pressure of 0 kPa in some cases).
machine
Related • KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated.
1
defective.
Defective KDPF differential 2. Disconnect connector PDPF.
pressure (outlet pressure) 3. Turn starting switch to ON position.
2 sensor a Ignore displayed failure codes other than this code.
(internal defect) If this failure code is not displayed, KDPF differential pressure (outlet
pressure) sensor is defective.
Ground fault in wiring 2. Disconnect connectors EGC3 and PDPF and connect T-adapter to
3 harness female side of either connector.
(contact with ground circuit) Resis- Between ground and EGC3 (female) (52) or
PDPF (female) (4) Min. 100 Kz
tance
4 female side of EGC3.
harness
tance
3. Connect T-adapter in connector EGC3 or to female side of connector
5 Defective engine controller PDPF.
Between EGC3 (female) (52) and (43) or
PDPF (female) (4) and (1)
40-262 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to sensor power supply 5 circuit
D65EX,PX,WX-17 40-263
40 Troubleshooting
Failure code [CA1843] Crankcase Press Sens High Error

Action level Failure code Crankcase pressure sensor high error
Failure
Detail of • High voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approx. 0 kPa), and runs engine.
controller
Problem on
machine
(Code: 48401(V))
1
defective.
Defective crankcase 2. Disconnect connector PCCV.
3 pressure sensor 3. Turn starting switch to ON position.
(internal defect) If failure code changes from [CA1843] to [CA1844], crankcase pressure
sensor is defective.
2. Disconnect connectors ECM J1 and PCCV, and connect T-adapters
Open circuit in wiring harness to female side of each connector.
contact of connector) a To check for open circuit in GND circuit.
Resis- Between ECM J1 (female) (59) and PCCV
tance
5 Short circuit in wiring harness to female side of either connector.
between PCCV (female) (1) and (3) Min. 100 Kz
tance
Hot short circuit in wiring 2. Disconnect connector PCCV and connect T-adapter to female side of
Voltage Between PCCV (female) (3) and (2) Max. 1 V
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
Sensor
output
40-264 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to crankcase pressure sensor
D65EX,PX,WX-17 40-265
40 Troubleshooting
Failure code [CA1844] Crankcase Press Sens Low Error

Action level Failure code Crankcase pressure sensor low error
Failure
Detail of • Low voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approx. 0 kPa), and runs engine.
controller
Problem on
machine
(Code: 48401(V))
1
defective.
Defective sensor power 2. Disconnect connector PCCV and connect T-adapter to female side of
2 supply system connector.
Between PCCV (female) (1) and Power 4.75 to 5.25
Voltage
(2) supply V
to female side of each connector.
a If a failure is found in wiring harness, disconnect connector OEM
CONNECTION/OEM as well and check likewise to determine which
is responsible for failure, namely engine side wiring harness or
chassis side wiring harness.
Open circuit in wiring harness a If cause 2 is not cause for failure, this
3 (wire breakage or defective Resis- check is not required.
Max. 10 z
contact of connector) tance Between ECM J1 (female) (60) and PCCV
(female) (1)
a If cause 2 is not cause for failure, this
Resis- check is not required.
Max. 10 z
tance Between ECM J1 (female) (59) and PCCV
(female) (2)
Resis- Between ECM J1 (female) (3) and PCCV
tance
40-266 D65EX,PX,WX-17
40 Troubleshooting

to female side of either connector.
Ground fault in wiring a If failure is found in wiring harness, disconnect connector OEM
4 harness CONNECTION/OEM as well and check likewise to determine which
(contact with ground circuit) is responsible for failure, namely engine side wiring harness or
chassis side wiring harness.
Resis- Between ground and ECM J1 (female) (3) or
PCCV (female) (3) Min. 100 Kz
tance
5 Short circuit in wiring harness to female side of either connector.
between PCCV (female) (2) and (3) Min. 100 Kz
tance
Defective crankcase 2. Insert T-adapter into connector PCCV.
6 pressure 3. Turn starting switch to ON position.
sensor (internal defect) Between PCCV (female) (3) and Sensor
(2) output
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
Sensor
output
Circuit diagram related to crankcase pressure sensor
D65EX,PX,WX-17 40-267
40 Troubleshooting
Failure code [CA1879] KDPF Delta P Sensor High Error

Action
Failure code KDPF delta pressure sensor high error
level Failure
L03 CA1879
Detail of • High voltage appears in KDPF delta pressure sensor signal circuit.
failure
• Sets KDPF differential pressure to presumptive value and allows engine to run.
(If another failure code is also generated, controller may run engine using differential
Action of pressure of 0 kPa.)
machine
k Since the temperature of the KDPF will become higher than 500 °C , take care not to
get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
Related • If failure code [CA1695] is not displayed but failure code [CA3133] is displayed, GND
information circuit may have open circuit (defective connection of connector).
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47100(V))
• Differential pressure sensed by KDPF delta pressure sensor can be checked with
monitoring function. (Code: 47101 (MPa))
connector
If failure code [CA1695] or [CA1696] is displayed, perform
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector PDPF and connect T-adapter to female side.
Voltage Between PDPF (female) (4) and (1) 4.75 to 5.25 V
Defective KDPF delta If failure code changes to [CA1881], KDPF delta pressure sensor is
3 pressure sensor defective.
a If this failure code is still displayed, wiring harness or engine
controller is defective.
a Ignore other displayed failure codes.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EGC3 and PDPF, and connect T-adapters to
4 female side of each connector.
(wire breakage or defective
Resis- Between EGC3 (female) (43) and PDPF
tance
40-268 D65EX,PX,WX-17
40 Troubleshooting

female side of EGC3.
5 a Check with multimeter in continuity mode.
harness
No continuity
Between EGC3 (female) (55) and every pin
Continuity (No sound is
other than (55)
heard)
6 Defective engine controller If this failure code appears and no failure is found in above checks,
engine controller is defective. (Since this is internal defect,
Circuit diagram related to KDPF delta pressure sensor
D65EX,PX,WX-17 40-269
40 Troubleshooting
Failure code [CA1881] KDPF Delta P Sensor Low Error

Action
Failure code KDPF delta pressure sensor low error
level Failure
L03 CA1881
Detail of • Low voltage error appears in KDPF delta pressure sensor signal circuit.
failure
machine
get burn injury.
• If failure code [CA1696] is not displayed but failure code [CA3134] is on screen, sensor
Related connector is disconnected or open circuit of 5 V circuit (defective contact of connector)
information can be suspected.
• This failure code is generated if sensor connector is disconnected.
(Code: 47100(V))
1
defective.
Defective sensor power supply 1. Turn starting switch to OFF position.

2 system 2. Disconnect connector PDPF and connect T-adapter to female side
of connector.
2. Disconnect connectors EGC3 and PDPF, and connect T-adapters
check is not required. Max. 10 z
Open circuit in wiring harness Between EGC3 (female) (43) and PDPF
tance
Between EGC3 (female) (52) and PDPF
(female) (4)
40-270 D65EX,PX,WX-17
40 Troubleshooting

Ground fault in wiring harness 2. Disconnect connectors EGC3 and PDPF and connect T-adapter to
Resis- Between ground and EGC3 (female) (55) or
Min. 100 Kz
tance PDPF (female) (2)
No continuity
Continu- Between EGC3 (female) (55) and every pin
ity other than (55) (No sound is
heard)
Defective KDPF delta 2. Insert T-adapter into connector PDPF.
6 pressure 3. Turn starting switch to ON position.
Voltage Between PDPF (2) and (1) 0.5 to 4.5 V
D65EX,PX,WX-17 40-271
40 Troubleshooting
Failure code [CA1883] KDPF Delta P Sens In Range Error

Action
Failure code KDPF delta pressure sensor in range error
level Failure
L03 CA1883
Detail of • Signal voltage from KDPF delta pressure sensor does not indicate correct value. (Signal
failure voltage is within "normal" or "operating" range.)
machine
get burn injury.
(Code: 47100(V))
Related monitoring function. (Code: 47101 (MPa))
information • Method of reproducing failure code: Turn starting switch to ON position (wait and see for 1
minute)
• <Clearing failure code>
1. Turn starting switch ON from OFF position to start engine.
2. When the engine is warmed up, set the fuel dial to Full and run the engine for about 30
seconds at torque converter stall.
• Repeat 1) and 2) operations several times. If this failure code is cancelled, repair is
complete.
1. Remove KDPF delta pressure sensor tube.
2. Clean KDPF delta pressure sensor tube to clear any clog.
3. Check KDPF delta pressure sensor tube for cracking and damage.
4. Connect both ends of tube securely to install KDPF delta pressure
sensor.
Defective KDPF delta • Reference
1 pressure sensor tube How to check KDPF delta pressure sensor tube for clogging
2. Monitor differential pressure sensed by KDPF delta pressure sensor
on monitoring screen of machine monitor.
Code 47101(MPa) 0 ± 0.003(MPa)
connector
defective.

of connector.
40-272 D65EX,PX,WX-17
40 Troubleshooting

If failure code [CA1881] is not displayed, wiring harness or engine
a Check cause 2 again.
Defective wiring harness or 1. Turn starting switch to OFF position.

4 engine controller 2. Disconnect connector PDPF and connect short circuit connector to
a Connect 5 V to signal circuit (short-circuit connector PDPF (4)
pin and (2) pin).
Defective KDPF delta a If no failure is found in check on cause 4, KDPF delta pressure
5 pressure sensor sensor is defective.
tance
(female) (4)

Ground fault in wiring harness 2. Disconnect connectors EGC3 and PDPF, and connect T-adapters
7 to female side of either connector.
Min. 100 Kz
No continuity
heard)
1. Turn starting switch to ON position and wait for approximately 1
minute (recheck of error with key turned to ON position).
2. If this failure code appears, perform procedure for <Clearing failure
9 Defective engine controller code> in "Related information".
If this failure code is still displayed and no failure is found in above
checks, engine controller is defective. (Since this is internal defect,
a If this failure code still appears and does not disappear even after performing "How to clear the failure
code" in the related information, repeat the troubleshooting.
D65EX,PX,WX-17 40-273
40 Troubleshooting
40-274 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA1921] KDPF Soot Level High Error 1

Action level Failure code Soot level high error 1
Failure
• Soot level in the KDPF has reached level 6 or 7. Regeneration is required for removing
Detail of the soot (operator is requested to perform regeneration).
failure (If the soot sedimentation reaches level 8, the KDPF must be changed.)
controller • Disables active regeneration and allows only, manual stationary regeneration for service.
machine
a Time required for manual stationary regeneration depends on the amount of soot in the
KCSF, however, about two or three hours is required for levels 6 and 7. (One or two hours
needed for soot level 5.)
• Soot sedimentation in the KDPF is classified into 8 levels. The current soot level can be
checked on the machine monitor by selecting the "02 Regeneration for service" screen.
• Manual stationary regeneration to remove soot is allowed if soot accumulation is at level 7
or lower level.
• If the soot sedimentation reaches level 8, code [CA1922] is displayed. The KDPF is
completely clogged with soot, and inspection, cleaning, or replacement must be carried
out.
Probable causes for soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• Excessive soot may accumulate if temperature of exhaust gas entering after treatment
system (KDPF) is low.
• To avoid soot accumulation, engine must be operated with high loads.
2. Engine has failure that lead to excessive black smoke.
• If "error 2777" is displayed while failure code [CA1921] is displayed, soot sedimentation is
Related at level 4 or higher. Automatic regeneration will be disabled in this state.
information
a Enabling automatic regeneration
From the service screen of the machine monitor, select the "Diagnostic Tests" screen,
open "02 Regeneration for service", and then cancel "Regeneration Disable" (automatic
regeneration inhibition). (When cancelled, regeneration is performed automatically when
engine load becomes high.)
• Since the temperature of the KDOC and KDPF will become higher than 500 °C , take care
not to get burn injury.
D65EX,PX,WX-17 40-275
40 Troubleshooting
temperature differences among them are approx. 10 °C (KDOC inlet temperature>KDOC
outlet temperature>KDPF outlet temperature).
Related temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
information "TEMP3").
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
a If "error 2777" is displayed while failure code [CA1921] is displayed, automatic
regeneration is disabled.
a If failure code [CA1922] has been displayed and it changes to [CA1921] during the
troubleshooting process, refer to failure code [CA1922].
• Performing manual stationary
1.Start engine.
2.Make sure that machine is in safe condition.
3.Perform manual stationary regeneration. (Manual stationary
regeneration can also be performed from the user mode of the
machine monitor.)
• Failure code [CA2639] appears machine monitor during manual
KDPF (KCSF) soot level error stationary regeneration, however, this is normal (manual stationary
1
regeneration is completed in about two or three hours and then
failure code [CA2639] disappears).
a If failure code [CA2639] is still displayed on machine monitor after
three hours has passed, perform troubleshooting for failure code
[CA2639].
a Check that the failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform the following.
1. Rapidly accelerate engine from low idle to high idle two times, and
then keep engine running at high idle for five seconds.
• If excessive black smoke is exhausted when accelerating engine or
2 Unusual exhaust gas color running it at high idle, perform troubleshooting for "S-9 KDPF gets
clogged in a short time".
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
a Check that no failure code appears.
40-276 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA1922] KDPF Soot Level High Error 2

Action
Failure code Amount of soot sediment high 2
level Failure
L04 CA1922
• Soot level in the KDPF is excessive, and the machine must be stopped immediately for
Detail of inspection.
failure • Soot accumulation reaches level 8 (KDPF is completely clogged with soot).
controller • Automatic or active regeneration is impossible, manual stationary regeneration is
impossible.
machine
• Soot accumulation is classified into eight levels. To check current soot accumulation level
machine monitor, select "Diagnostic Tests" from service menu, and then display "02
Regeneration for Service" screen.
• This failure code appears when soot accumulation reaches level 8 (at level 8, KDPF is
completely clogged with soot and needs to be inspected, cleaned, or changed).
• Manual stationary regeneration to remove soot is allowed if soot accumulation is at level 7
or lower level.
a Time required for completing manual stationary regeneration depends on KCSF soot
accumulation level. About two to three hours of regeneration is required if soot
accumulation is at level 6 or 7.
system (KDPF) is low. To avoid excessive soot accumulation, engine must be operated
with high loads.
Related • If failure code [CA1921] and error code 2777 remains active in abnormality record and
information failure code [CA1922] is displayed, automatic regeneration is disabled. So it must be
enabled.
a Enabling automatic regeneration
From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then cancel "Regeneration Disable" (automatic regeneration inhibition).
(Automatic, regeneration is performed automatically when engine load becomes high.)
Probable causes for soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
system (KDPF) is low.
• To avoid soot accumulation, engine must be operated with high loads.
2. Engine has failure that lead to excessive black smoke.
D65EX,PX,WX-17 40-277
40 Troubleshooting
k Since the temperature of the KDOC and KDPF will become higher than 500 °C , take
function. (Code: 47300 ( °C ))
temperature differences among them are approx. 10 °C (KDOC inlet temperature > KDOC
outlet temperature> KDPF outlet temperature).
Related temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
information "TEMP3").
(Code: 47100(V))
• Performing the manual stationary regeneration from "Regeneration for Service"
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
1. Start engine.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02
Regeneration for Service", and then execute "Manual Statonary Regeneration".
a Executing reset procedure KDPF cleaning
From service menu of machine monitor, select "Diagnostic Tests", open "03 KDPF
Memory Rest", and then execute "02 KDPF Cleaning" (reset after KDPF cleaning).
a Executing reset procedure KDPF change
From service menu of machine monitor, select "Diagnostic Tests", open "03 KDPF
Memory Rest", and then execute "01 KDPF Change" (reset after KDPF change).
a When the KCSF in the KDPF is changed, always perform the resetting procedures for
KDPF cleaning and KDPF change, and then perform manual stationary regeneration from
"Regeneration for service" to eliminate moist and impurities from the KCSF.
40-278 D65EX,PX,WX-17
40 Troubleshooting

• Checking record of failure code appearances.
2. Check generation records of failure codes CA2639, CA1921, and
CA1922 on abnormality record screen of machine monitor.
Time interval between appearances of CA2639 and CA1921 is equal to
or
X300 sec
and
Defective KDPF (KCSF) Time interval between appearances of CA1921 and CA1922 is equal to
1 or
(KCSF change required)
X300 sec
If above condition holds, excessive soot is accumulated. Remove KDPF,
change KCSF with a new one, and perform troubleshooting for causes 3
to 8.
a If above condition does not hold, actual soot accumulation level is
lower than that indicated. After checking that sensors are normal,
perform troubleshooting for cause 2. If failure code [CA1922]
changes to [CA1921], manual stationary regeneration can be
performed.
• Executing reset procedure for KDPF cleaning
2. Perform reset procedure for KDPF cleaning (see "Related
information").
3. If failure code changes from [CA1922] to [CA1921], make sure that
machine is in safe condition and then perform manual stationary
regeneration.
(Manual stationary regeneration can also be performed from user
mode of machine monitor.)
a If failure code [CA1922] remains unchanged, remove KDPF, change
Defective KDPF (KCSF) KCSF, and perform troubleshooting for causes 3 and subsequent
causes.
(manual stationary • Failure code [CA2639] appears on machine monitor during manual
2
regeneration required due to stationary regeneration, however, this is normal (manual stationary
excessive soot accumulation) regeneration is completed in about two or three hours and then
failure code [CA2639] disappears).
three hours passes, perform troubleshooting for failure code
[CA2639].
a Check that no failure code appears after manual stationary
regeneration is completed.
a If failure code [CA1922], [CA1921], or [CA2639] appears after
manual stationary regeneration is completed, perform
troubleshooting for cause 9.
• Executing reset procedure for KDPF cleaning
2. Perform reset procedure for KDPF cleaning (see "Related
information").
a Check that failure code is changed from [CA1922] to [CA1921].
3 Fail in reset of KDPF (KCSF) a If failure code [CA1922] remains unchanged, perform reset
procedure for KDPF cleaning again.
• Executing reset procedure for KDPF change
3. Perform reset procedure for KDPF change (see "Related
information").
a Perform troubleshooting for cause 4 and subsequent causes.
D65EX,PX,WX-17 40-279
40 Troubleshooting

Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] appears, perform
Defective KDPF outlet If failure code [CA3319], [CA3321], or [CA3322] appears, perform
2. Monitor differential pressure sensed by KDPF delta pressure sensor
on monitoring screen of machine monitor.
Code 47101(MPa) 0 ± 0.003(MPa)
Defective KDPF delta a Perform the following when delta pressure does not fall in above
pressure sensor range.
7 1. Remove KDPF delta pressure sensor tube.
sensor (including sensor
tube) 2. Clean KDPF delta pressure sensor tube to clear any clog.
a Perform following step if KDPF delta pressure sensor tube is not
clogged.
3. Perform troubleshooting for cause "Short circuit in harness" of failure
code [CA1881] or [CA1883] (if no short circuit is found, replace
KDPF delta pressure sensor).
1. Perform manual stationary regeneration from "Regeneration for
Service" (see "Related information").
• Failure code [CA2639] appears on machine monitor during manual
Performing manual stationary stationary regeneration, however, this is normal (manual stationary
8 regeneration is completed in about two or three hours and then
regeneration (to dry KCSF) failure code [CA2639] disappears).
three hours passes, perform troubleshooting for failure code
[CA2639].
a If failure code [CA1922], [CA1921], or [CA2639] appears after
manual stationary regeneration is completed, perform the following.
9 Unusual exhaust gas color • If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
idle.
40-280 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA1942] Crankcase Press Sensor In Range Error

Action level Failure code Crankcase pressure sensor in-range error
Failure
Detail of • Crankcase pressure sensor output value displayed is out of normal range.
failure
controller
Problem on
machine
(Code: 48401(V))
Related • Crankcase pressure sensed by crankcase pressure sensor can be checked with
information monitoring function. (Code: 48400 (MPa))
Crankcase pressure sensor Crankcase pressure sensor system may be defective. Perform
defective
3
leaks.
When the error is not cleared after the KCCV filter is replaced and
crankcase pressure high error 2 occurs in a short time, the engine may
4 Blow-by gas increases
be seized or the turbocharger may be defective. Carry out
troubleshooting for the mechanical system.
D65EX,PX,WX-17 40-281
40 Troubleshooting
Failure code [CA1993] KDPF Delta Pressure Low Error

Action level Failure code KDPF delta pressure low error
Failure
Detail of • Signals from KDPF delta pressure sensor indicate a value lower than the threshold.
failure
machine
get burn injury.
(Code: 47100(V))
Related
information
Since there is a possibility of error occurring during operation, start the engine, warm it up,
and run at work equipment pump relief for 30 seconds. Repeat this several times. If this
failure code is cleared, repair is complete.
Defective KDPF delta If failure code [CA1879], [CA1881], or [CA1883] is displayed, perform
1 pressure troubleshooting for it.
Check that KDPF is attached to the exhaust system, and no foreign
2 KDPF error
material exists in the KDPF.
Check the following.
1. Check if the KDPF delta pressure sensor tube exists
Defective KDPF delta 2. Check if the KDPF delta pressure sensor tube is connected correctly
3 pressure sensor tube 3. Remove KDPF delta pressure sensor tube and check for clogging,
cracks, and damages
4. Check the connection of KDPF delta pressure sensor tube at both
ends for looseness
1. Turn the starting switch ON, and leave the machine for about one
minute (to reexecute initial diagnostics).
4 Defective engine controller code>in "Related information".
If this failure code is still displayed and no failure is found by above
checks, engine controller is defective. (Since this is an internal defect,
a If this failure code is still displayed, even after <Clearing failure codes>in "Related information" is carried
out, redo troubleshooting.
40-282 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2185] Throt Sensor Sup Volt High Error

Action level Failure code Throttle sensor supply voltage high error
Failure
Detail of • High voltage is detected in throttle sensor power supply circuit.
failure
Action of • Ignores signals from decelerator pedal (throttle sensor), and takes it that decelerator
controller pedal position is at fixed value, and allows engine to run.
Problem on • Engine speed cannot be controlled by decelerator pedal.
machine
information
1
2. Disconnect connectors EGC3 and DCL, and connect T-adapter to
2 Short circuit in wiring harness female side of EGC3.
other than EGC3 (female) (42) Min. 100 Kz
tance
Hot short circuit in wiring 2. Disconnect connector DCL and connect T-adapter to female side of
harness connector.
3
Voltage Between DCL (female) (B) and ground 4.75 to 5.25
V
2. Disconnect connectors EGC3 and connect T-adapter to male side of
connector.
4 Defective engine controller 3. Turn starting switch to ON position with wiring harness
disconnected.
Voltage Between EGC3 (male) (42) and (41) 4.75 to 5.25
V
D65EX,PX,WX-17 40-283
40 Troubleshooting
40-284 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2186] Throt Sensor Sup Volt Low Error

Action level Failure code Throttle sensor supply voltage low error
Failure
Detail of • Low voltage appears in throttle sensor power supply circuit.
failure
Action of • Ignores signals from decelerator pedal (throttle sensor), and takes it that decelerator
controller pedal position is at fixed value, and allows engine to run.
Problem on • Engine speed cannot be controlled by decelerator pedal.
machine
information
1
2. Disconnect connector DCL and turn starting switch to ON position.
If this failure code is not displayed, throttle sensor is defective.
2 Defective throttle sensor
a Other failure code is displayed together. This is because that sensor
connector is disconnected. Ignore failure codes other than
[CA2186].
Ground fault in wiring harness 2. Disconnect connectors EGC3 and DCL and connect T-adapter to
3 (contact with ground circuit) female side of either connector.
DCL (female) (B) Min. 100 Kz
tance
2. Disconnect connectors EGC3 and DCL, and connect T-adapter to
other than EGC3 (female) (42) Min. 100 Kz
tance
2. Disconnect connectors EGC3 and connect T-adapter to male side of
connector.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness
disconnected.
Voltage Between EGC3 (male) (42) and (41) 4.75 to 5.25
V
D65EX,PX,WX-17 40-285
40 Troubleshooting
40-286 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error

Action level Failure code Common rail pressure very low error
Failure
Detail of • Supply pump does not feed fuel (level 2).
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked by using
information monitoring function. (Code:36400(MPa))
Supply pump no pressure Perform troubleshooting for failure code[CA559].
1
error
D65EX,PX,WX-17 40-287
40 Troubleshooting
Failure code [CA2265] Fuel Feed Pump Open Error
Action level Failure code Fuel feed pump open circuit error
Failure
Detail of • Open circuit is detected in the fuel feed pump drive signal circuit.
failure
controller
Problem on • Engine starting performance is poor
machine
information
1
defective.
Defective fuel feed pump 2. Disconnect connector FUEL LIFT PUMP.
2
(internal open circuit in wiring) Resis- Between FUEL LIFT PUMP (male) (1) and
(2) Max. 20 z
tance
3 of connector.
harness
Max. 20 z
tance
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and FUEL LIFT PUMP and connect
4 (wire breakage or defective T-adapters to female side of each connector.
contact of connector) Between ECM J1 (female) (1) and FUEL
Max. 1 z
Resis- LIFT PUMP (1)
tance Between ECM J1 (female) (11) and FUEL
LIFT PUMP (2) Max. 1 z

2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect
T-adapter to female side of ECM J1.
Between ECM J1 (female) (1) and every pin No continuity
other than (1) (No sound is heard)
2. Disconnect connector FUEL LIFT PUMP.
3. Insert T-adapter in connector ECM J1 or connect to female side of
Hot short circuit in wiring connector FUEL LIFT PUMP.
6 harness 4. Turn starting switch to ON position (with connector FUEL LIFT
(contact with 24 V circuit) PUMP as connected) and start measurement after one minute.
a Average voltage is displayed because of PWM.
Between ECM J1 (1) and (11), or between
Voltage Max. 6 V
FUEL LIFT PUMP (female) (1) and (2)
40-288 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to fuel feed pump
D65EX,PX,WX-17 40-289
40 Troubleshooting
Failure code [CA2266] Fuel Feed Pump Short Error

Action level Failure code Fuel feed pump short circuit error
Failure
Detail of • Short circuit is detected in fuel feed pump actuator drive circuit.
failure
controller
Problem on • Engine starting performance is poor
machine
information
1
defective.
Defective fuel feed pump 2. Disconnect connector FUEL LIFT PUMP.
(internal open circuit in wiring)
If failure code changes from [CA2266] to [CA2265], fuel feed pump is
defective.
3
harness
Resis- Between ECM J1 (female) (1) and (11) 1 to 20 z
2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect
4 Short circuit in wiring harness T-adapter to female side of ECM J1 or FUEL LIFT PUMP.
Resis- between FUEL LIFT PUMP (female) (1) and
Min. 100 Kz
tance (2)
Ground fault in wiring harness 2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect
5 T-adapter to female side of ECM J1 or FUEL LIFT PUMP.
Between ECM J1 (female) (1) and ground, or
Resis- between FUEL LIFT PUMP (female) (1) and
Min. 100 Kz
tance ground
40-290 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to fuel feed pump
D65EX,PX,WX-17 40-291
40 Troubleshooting
Failure code [CA2271] EGR Valve Pos Sens High Error

Action
Failure code EGR valve lift sensor high error
level Failure
L03 CA2271
Detail of • High voltage is detected in EGR valve lift sensor signal circuit.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 (V))
Related • Position sensed by EGR valve lift sensor can be checked with monitoring function.
information (Code: 18100 (mm))
1
defective.
2 supply system troubleshooting for failure code [CA352] or [CA386] first.
Defective EGR valve lift 2. Disconnect connector SEGR.
(internal defect) If failure code [CA2271] changes to [CA2272], the EGR valve lift sensor
is defective.
2. Disconnect connector INTER-CONNECT.
If failure code [CA2271] changes to [CA2272], the connector box is
Defective connector box defective.
4
(internal short circuit) a EGR solenoid failure code [CA2349], KVGT sensor failure code
[CA2382], and KVGT solenoid failure code [CA2383] are also
displayed together. Ignore those failure codes since they are
displayed because of disconnection of connector INTER-
CONNECT.
2. Disconnect connector INTER-CONNECT and SEGR, and connect T-
Open circuit in connector box adapter.
5 (open circuit or defective
Resis- Between INTER-CONNECT (male) (4) and
SEGR (female) (B) Max. 10 z
tance
2. Disconnect connectors ECM J2 and INTER-CONNECT, and
Open circuit in wiring harness connect T-adapters to female side of each connector.
6 (wire breakage or defective a To check for open circuit in GND circuit.
contact of connector) a If cause 2 is not cause for failure, this check is not required.
Resis- Between ECM J2 (female) (47) and INTER-
CONNECT (female) (4) Max. 10 z
tance
40-292 D65EX,PX,WX-17
40 Troubleshooting

Resis- between INTER-CONNECT (female) (3) and Min. 100
tance (5) Kz

Hot short circuit in wiring 2. Disconnect connectors INTER-CONNECT and connect T-adapter to
8 harness female side of connector.
Voltage Between SEGR (female) (C) and (B) Max. 1 V
• Reference
2. Insert T-adapter into connector ECM J2.
Between ECM J2 (female) (59) and Sensor 1.0 to 4.0
Voltage
(47) output V
Circuit diagram related to EGR valve lift sensor
D65EX,PX,WX-17 40-293
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error

Action
Failure code EGR valve lift sensor low error
level Failure
L03 CA2272
Detail of • Low voltage is detected in signal circuit of EGR valve lift sensor.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 (V))
Related • Position sensed by EGR valve lift sensor can be checked with monitoring function.
1
defective.
troubleshooting for failure code [CA352] or [CA386] first.
Defective sensor power 2. Disconnect connector SEGR and connect T-adapter to female side of
2 supply system connector.
Between SEGR (female) (A) and Sensor 4.75 to 5.25
Voltage
(B) output V
adapter.
this check is not required.
Max. 10 z
Open circuit in connector box Between INTER-CONNECT (male) (3) and
3 (open circuit or defective SEGR (female) (A).
tance
this check is not required.
Max. 10 z
Between INTER-CONNECT (male) (4) and
SEGR (female) (B).
SEGR (female) (C) Max. 10 z

Ground fault in connector adapter.
4 box Between ground and INTER-CONNECT
Min. 100 Kz
(contact with ground circuit) Resis- (male) (5), and SEGR (female) (C)
tance Between ground and INTER-CONNECT
(male) (3), and SEGR (female) (A) Min. 100 Kz
40-294 D65EX,PX,WX-17
40 Troubleshooting

Short circuit in connector box adapter.
5 Between INTER-CONNECT (male) (4) and
(internal short circuit) Min. 100 Kz
Resis- (5), or between SEGR (female) (B) and (C)
tance Between INTER-CONNECT (male) (3) and
(4), or between SEGR (female) (A) and (B) Min. 100 Kz

2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
T-adapters to female side of each connector.
check is not required.
Open circuit in wiring Max. 10 z
harness Between ECM J2 (female) (30) and
6 INTER-CONNECT (female) (3)
tance
check is not required.
Max. 10 z
Between ECM J2 (female) (47) and
INTER-CONNECT (female) (4)
Between ECM J2 (female) (59) and INTER-

Ground fault in wiring T-adapters to female side of each connector.
7 harness (contact with ground Between ECM J2 (female) (59) and INTER-
circuit) Min. 100 Kz
Resis- CONNECT (female) (5), and ground
tance Between ECM J2 (female) (30) and INTER-
CONNECT (female) (3), and ground Min. 100 Kz

T-adapters to female side of each connector.
8 between INTER-CONNECT (female) (4) and Min. 100 Kz
harness
Resis- (5)
tance Between ECM J2 (female) (30) and (47), or
between INTER-CONNECT (female) (3) and Min. 100 Kz
(4)
2. Insert T-adapter into connector SEGR.
Defective EGR valve lift
9 sensor a Sensor voltage is measured with wiring harness connected.
(internal defect) Accordingly, if voltage is abnormal, check wiring harness controller
for another failure, and then judge.
Between SEGR (female) (C) and Sensor
(B) output
10 Defective engine controller (Since this is internal defect, troubleshooting cannot be performed.)
D65EX,PX,WX-17 40-295
40 Troubleshooting
Circuit diagram related to EGR valve lift sensor
40-296 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2288] Turbo Speed High Error 1

Action
Failure code Turbocharger speed high error 1
level Failure
L01 CA2288
Detail of • Turbocharger high speed error is detected.
failure
Action of
controller
machine
• Speed detected by turbocharger speed sensor can be checked with monitoring function.
Related (Code: 48100 (rpm))
Increased turbocharger
1 Turbocharger speed may increase abnormally high. Check it.
speed
2 Defective turbocharger Turbocharger may be defective. Check it.
If no failure is found in check on cause 1, turbocharger speed sensor
Defective turbocharger speed system may be defective. Perform troubleshooting for failure code
3
sensor [CA687].
D65EX,PX,WX-17 40-297
40 Troubleshooting
Failure code [CA2311] lMV Solenoid Error
Action
Failure code IMV solenoid error
level Failure
L03 CA2311
Detail of • Resistance value of supply pump actuator circuit is unusually high or low.
failure
controller
machine
information
1 IMV solenoid error Perform troubleshooting for failure codes [CA271] and [CA272].
40-298 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Error

Action
Failure code EGR valve solenoid open error
level Failure
L03 CA2349
Detail of • Open circuit is detected in EGR valve solenoid drive circuit.
failure
machine
• Signal current to EGR valve lift solenoid can be checked with monitoring function.
Related (Code: 48600 (mA))
1. See descriptions of wiring harness and connectors in "c:
Electrical equipment" in "Checks before troubleshooting" of
"General information on troubleshooting", and check it.
1 Defective wiring harness connector 2. Turn starting switch to ON position.
defective.
Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to
2 male side of connector.
(internal open circuit)
Between EGR-SOL (male) (1) and
Resistance (2) 5 to 10 z

2. Disconnect connector ECM J2 and connect T-adapter to
Open circuit or short circuit in female side of connector.
3 wiring harness a Resistance of EGR valve solenoid
Resistance (16) 5 to 10 z

2. Disconnect connectors ECM J2 and EGR-SOL, and connect
Ground fault in wiring harness T-adapters to female side of either connector.
4
(contact with ground circuit) Between ground and ECM J2
Resistance (female) (6) or EGR-SOL (female) Min. 100 Kz
(1)
a If no failure is found in checks on cause3, this check is not
required.
Open circuit in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT,
5 (open circuit or defective contact of and connect T-adapter.
connector) Between INTER-CONNECT (male)
(1) and EGR-SOL (female) (1) Max. 10 z
Resistance
Between INTER-CONNECT (male)
(2) and EGR-SOL (female) (2) Max. 10 z
a If no failure is found in checks on cause 4, this check is not

required.
Ground fault in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT,
6
(contact with ground circuit) and connect T-adapter.
Between ground and INTER-
Resistance CONNECT (male) (1) or EGR-SOL Min. 100 Kz
(female) (1)
D65EX,PX,WX-17 40-299
40 Troubleshooting

required.
Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
7 (wire breakage or defective contact connect T-adapter to female side of connector.
of connector) Between ECM J2 (female) (6) and
INTER-CONNECT (female) (1) Max. 10 z
Resistance
INTER-CONNECT (female) (2) Max. 10 z

required.
Ground fault in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
8 (contact with ground circuit) connect T-adapters to female side of each connector.
Between ground and ECM J2
Resistance (female) (6) or INTER-CONNECT Min. 100 Kz
(female) (1)
2. Disconnect connector EGR-SOR and connect T-adapter to
Hot short circuit in wiring harness
9 (contact with 24 V circuit) a Turn starting switch to ON position.
No continuity
Between EGR-SOL (female) (1)
and (2)
heard)
If no failure is found in above checks, engine controller is
10 Defective engine controller defective. (Since this is internal defect, troubleshooting cannot be
performed.)
Circuit diagram related to EGR valve solenoid
40-300 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Error

Action
Failure code EGR valve solenoid short circuit
level Failure
L03 CA2353
Detail of
• Short circuit occurs in EGR valve solenoid drive circuit.
failure
machine
• Signal current to EGR valve lift solenoid can be checked with monitoring function.
1
defective.
Defective EGR valve 2. Disconnect connector EGR-SOL and connect T-adapter to male side
2 solenoid of connector.
(internal open circuit) Resis- Between EGR-SOL (male) (1) and (2)
5 to 10 z
tance
Open circuit or short circuit in of connector.
3 wiring harness
a Resistance of EGR valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and EGR-SOL, and connect T-
4 harness adapters to female side of either connector.
(contact with ground circuit) Resis- Between ground and ECM J2 (female) (6) or Min. 100
tance EGR-SOL (female) (1) Kz
Ground fault in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT, and
5
(contact with ground circuit) connect T-adapter.
Resis- Between ground and INTER-CONNECT Min. 100
tance (male) (1) or EGR-SOL (female) (1) Kz
6 harness (contact with ground 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
circuit) T-adapters to female side of each connector.
tance INTER-CONNECT (female) (1) Kz
D65EX,PX,WX-17 40-301
40 Troubleshooting

2. Disconnect connector EGR-SOR and connect T-adapter to female
side of connector.
Hot short circuit in wiring
7 harness (contact with 24 V a Turn starting switch to ON position.
circuit) No
continuity
Continuity Between EGR-SOL (female) (1) and (2)
(No sound
is heard)
Circuit diagram related to EGR valve solenoid
40-302 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2357] EGR Valve Servo Error

Action level Failure code EGR valve servo error
Failure
Detail of • Servo error of EGR valve is detected.
failure (Response from EGR lift sensor differs for EGR valve opening command value.)
Action of • Stops current to EGR valve (closes EGR valve).
machine
• EGR valve position can be checked with the monitoring function (Code: 18100 EGR valve
Related position (mm)).
Improper EGR valve drive a For measurement of EGR valve drive pressure, see Testing and
2 pressure adjusting, " Measuring EGR valve and bypass valve drive pressure".
If EGR valve drive pressure is not normal, check items 3 and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine hydraulic engine oil pressure".
3 system (main circuit) If engine oil pressure is not normal, preform troubleshooting (S mode)
for mechanical system. (S-12 Oil pressure lowers.)
Defective oil pipe for EGR Oil pump or relief valve for EGR valve circuit may be defective. Check
4
valve them.
Defective oil pipe for EGR Oil piping for EGR valve circuit may be defective. Check it.
5
valve
Defective oil return pipe for Oil return piping for EGR valve circuit may be defective. Check it.
6
EGR valve
7 Defective EGR valve EGR valve may be defective. Check it.
Defective EGR valve lift Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
sensor
If no problem is found by checks on causes 1 to 8, engine controller is
9 Defective engine controller defective.
D65EX,PX,WX-17 40-303
40 Troubleshooting
Failure code [CA2373] Exhaust Manifold Press Sens High error
Action High pressure detected by exhaust manifold pressure

Failure code sensor
level Failure
Detail of • High voltage error is detected in signal circuit of exhaust manifold pressure sensor.
failure
• Runs engine by setting exhaust manifold pressure to calculated value.
machine
• Signal voltage from exhaust manifold pressure sensor can be checked with monitoring
function.
(Code: 48301 (V))
Related • Pressure sensed by exhaust manifold pressure sensor can be checked with monitoring
(Code: 48300 (MPa))
1
defective.
Defective charge pressure 2. Disconnect connector EXHAUST PRESSURE.
(internal defect) If failure code [CA2373] changes to [CA2374], exhaust manifold
pressure sensor is defective.
Short circuit in wiring harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
connect T-adapter to female side of connector.
4 (short circuit between
harnesses) Between ECM J2 (female) (34) and (30), or
Resis- between EXHAUST PRESSURE (female) (3) Min. 100
tance and (1) Kz

Hot short circuit in wiring 2. Disconnect connector EXHAUST PRESSURE and connect T-
harness adapter to female side of connector.
5
Between EXHAUST PRESSURE (female) (3)
Voltage Max. 1 V
and (2)
• Reference
2. Insert T-adapter to connector ECM J2.
Voltage
(47) output V
40-304 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to exhaust manifold pressure sensor
D65EX,PX,WX-17 40-305
40 Troubleshooting
Failure code [CA2374] Exhaust Manifold Press Sens Low error

Action Low pressure detected by exhaust manifold pressure
Failure code sensor
level Failure
Detail of • Low voltage error is detected in signal circuit of exhaust manifold pressure sensor.
failure
machine
function.
(Code: 48301 (V))
(Code: 48300 (MPa))
1
defective.
Defective sensor power 2. Disconnect connector EXHAUST PRESSURE and connect T-
2 supply system adapter to female side of connector.
Between EXHAUST PRESSURE Power 4.75 to 5.25
Voltage
(female) (1) and (2) supply V
2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
Open circuit in wiring harness Between ECM J2 (female) (30) and EXHAUST
PRESSURE (female) (1) Max. 10 z
contact of connector) Resis- Between ECM J2 (female) (47) and EXHAUST
tance
Between ECM J2 (female) (34) and EXHAUST

2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
Ground fault in wiring connect T-adapters to female side of either connector.
4 harness (contact with ground Between ECM J2 (female) (34) and EXHAUST Min. 100
circuit) Resis- PRESSURE (female) (3), and ground. Kz
tance Between ECM J2 (female) (30) and EXHAUST Min. 100
PRESSURE (female) (1), and ground. Kz
Short circuit in wiring harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
connect T-adapters to female side of connector.
5 (short circuit between wiring
Resis- between EXHAUST PRESSURE (female) (2)
Max. 100 z
tance and (3)
40-306 D65EX,PX,WX-17
40 Troubleshooting

Defective exhaust manifold 2. Disconnect connector ECM J2 and connect T-adapter to female side
pressure sensor of connector.
(internal defect)
Between EXHAUST PRESSURE (female) (3)
and (2)
If no abnormality is found by above checks, engine controller is
7 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
Circuit diagram related to exhaust manifold pressure sensor
D65EX,PX,WX-17 40-307
40 Troubleshooting
Failure code [CA2375] EGR Orifice Temp Sens High Error

Action High temperature detected by EGR orifice temperature
Failure code sensor
level Failure
Detail of • High voltage error is detected in EGR orifice temperature sensor signal circuit.
failure
machine
• Voltage sensed by EGR orifice temperature sensor can be checked with monitoring
function.
(Code: 48501 (V))
Related • Temperature sensed by EGR orifice temperature sensor can be checked with monitoring
(Code: 48500( °C ))
1
defective.
2. Disconnect connector EXHAUST GAS TEMPERATURE and
connect T-adapter to male side of connector.
760 to 880
-30 °C
Kz
380 to 515
0 °C
Kz
155 to 225
25 °C
Kz
Defective EGR orifice
temperature sensor (internal Between EXHAUST GAS 21 to 29
2 80 °C
defect) TEMPERATURE (male) (1) and (2) Kz
Resis- 900 to
tance 200 °C
1050 z
150 to 200
300 °C
z
400 °C 40 to 56 z
500 °C 15 to 22 z
Between EXHAUST GAS
Whole Min. 100
TEMPERATURE (male) (2) and
range Kz
ground (sensor body)
Open or short circuit of wiring 2. Disconnect connector ECM J2 and connect T-adapter to female side
3 (open or short circuit, or a Resistance is the same as that given in temperature-resistance
defective contact of characteristics table of EGR orifice temperature sensor that is used
connector) to check cause 2.
Resis- Between ECM J2 (female) (18) and (48) 15 z to
tance 880 Kz
40-308 D65EX,PX,WX-17
40 Troubleshooting

Hot short circuit in wiring 2. Disconnect connector EXHAUST GAS TEMPERATURE and
harness connect T-adapter to female side of connector.
Between EXHAUST GAS TEMPERATURE Max. 5.25
Voltage
Circuit diagram related to EGR orifice temperature sensor
D65EX,PX,WX-17 40-309
40 Troubleshooting
Failure code [CA2376] EGR Orifice Temp Sens Low Error
Action
Failure code EGR orifice temperature sensor low error
level Failure
L03 CA2376
Detail of • Low voltage is detected in EGR orifice temperature sensor signal circuit.
failure
machine
function.
(Code: 48501 (V))
(Code: 48500 (°C))
1
defective.
Defective EGR orifice 2. Disconnect connector EXHAUST GAS TEMPERATURE.
2 temperature sensor (internal 3. Turn starting switch to ON position.
defect) If this failure code changes to [CA2375], the EGR orifice temperature
• Reference
2. Disconnect connector EXHAUST GAS TEMPERATURE and
connect T-adapter to male side of connector.
760 to 880
-30 °C
Kz
380 to 515
0 °C
Kz
155 to 225
25 °C
Defective EGR orifice Kz
3 temperature sensor (internal Between EXHAUST GAS 21 to 29
80 °C
defect) TEMPERATURE (male) (1) and (2) Kz
Resis- 900 to
tance 200 °C
1050 z
150 to 200
300 °C
z
400 °C 40 to 56 z
500 °C 15 to 22 z
Between EXHAUST GAS
Whole Min. 100
TEMPERATURE (male) (2) and
range Kz
ground (sensor body)
40-310 D65EX,PX,WX-17
40 Troubleshooting

Open or short circuit of wiring 2. Disconnect connector ECM J2 and connect T-adapter to female side
4 (open or short circuit, or a Resistance is the same as that given in temperature-resistance
defective contact of characteristics table of EGR orifice temperature sensor that is used
connector) to check cause 2.
Resis- Between ECM J2 (female) (18) and (48) 15 z to
tance 880 Kz
2. Disconnect connectors ECM J2 and EXHAUST GAS
Ground fault in wiring harness TEMPERATURE, and connect T-adapters to female side of either
5 (contact with ground circuit) connector.
tance EXHAUST GAS TEMPERATURE (female) (2) Kz
Circuit diagram related to EGR orifice temperature sensor
D65EX,PX,WX-17 40-311
40 Troubleshooting
Failure code [CA2381] KVGT Pos Sens High Error

Action
Failure code KVGT position sensor high error
level Failure
L03 CA2381
Detail of • High voltage is detected in signal circuit of KVGT position sensor.
failure
• Closes EGR valve and opens KVGT fully.
machine
• The signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • The position sensed by KVGT position sensor can be checked with monitoring function.
1
defective.
Defective KVGT position 2. Disconnect connector SVGT.
(internal defect) a If failure code [CA2381] changes to [CA2382], the KVGT position
2. Disconnect connector INTER-CONNECT.
Defective connector box If failure code [CA2381] changes to [CA2382], connector box is
4 defective.
(internal short circuit)
a EGR solenoid failure code [CA2349], EGR sensor failure code
[CA2272], and KVGT solenoid failure code [CA2383] are displayed
together. Ignore these failure codes since they appear because of
disconnection of INTER-CONNECT connector.
2. Disconnect connectors INTER-CONNECT and SVGT, and connect
Open circuit in connector box T-adapter.
5 (open circuit or defective
contact of connector) a To check for open circuit in GND circuit
SVGT (female) (B) Max. 10 z
tance
Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
contact of connector) a To check for open circuit in GND line
tance
40-312 D65EX,PX,WX-17
40 Troubleshooting

Short circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
7 (short circuit between
Resis- between INTER-CONNECT (female) (8) and Min. 100
tance (10) Kz

Hot short circuit in wiring 2. Disconnect connector SVGT and connect T-adapters to female side
8 harness of connector.
Voltage Between SVGT (female) (C) and (B) Max. 1 V
• Reference
2. Insert T-adapter to connector ECM J2.
Voltage
(47) output V
Circuit diagram related to KVGT position sensor
D65EX,PX,WX-17 40-313
40 Troubleshooting
Failure code [CA2382] KVGT Pos Sens Low Error

Action
Failure code KVGT position sensor low error
level Failure
L03 CA2382
Detail of • Low voltage is detected in signal circuit of KVGT position sensor.
failure
machine
• The signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • The position sensed by KVGT position sensor can be checked with monitoring function.
1
defective.
Defective sensor power 2. Disconnect connector SVGT and connect T-adapters to female side
2 supply system of connector.
Between SVGT (female) (A) and Power 4.75 to
Voltage
(B) supply 5.25 V
Open circuit in connector box T-adapter.
3 (open circuit or defective Between INTER-CONNECT (male) (8) and
SVGT (female) (A) Max. 10 z
SVGT (female) (B) Max. 10 z
tance
SVGT (female) (C) Max. 10 z

Ground fault in connector box T-adapter.
4 Between ground and INTER-CONNECT (male) Min. 100
Resis- (10), and SVGT (female) (C) Kz
tance Between ground and INTER-CONNECT (male) Min. 100
(8), and SVGT (female) (A) Kz
40-314 D65EX,PX,WX-17
40 Troubleshooting

Short circuit in connector box T-adapter.
5 Between INTER-CONNECT (male) (9) and Min. 100
Resis- (10), or between SVGT (female) (B) and (C) Kz
tance Between INTER-CONNECT (male) (8) and (9), Min. 100
or between SVGT (female) (A) and (B) Kz
Open circuit in wiring harness connect T-adapters to female side of each connector.
6 (wire breakage or defective Between ECM J2 (female) (30) and INTER-
tance
Between ECM J2 (female) (38) and INTER-

connect T-adapters to female side of each connector.
Ground fault in wiring harness
7 (contact with ground circuit) Between ground and ECM J2 (female) (38), Min. 100
Resis- and INTER-CONNECT (female) (10) Kz
tance Between ground and ECM J2 (female) (30), Min. 100
and INTER-CONNECT (female) (8) Kz
Short circuit in wiring harness Between ECM J2 (female) (47) and (38), or
8 (short circuit between between INTER-CONNECT (female) (9) and Min. 100
Kz
harnesses) Resis- (10)
tance Between ECM J2 (female) (30) and (47), or
between INTER-CONNECT (female) (8) and Min. 100
(9) Kz

2. Insert T-adapter into connector SVGT.
Defective KVGT position
9 sensor a Sensor voltage is measured with wiring harness connected.
(internal defect) Accordingly, if voltage is abnormal, check wiring harness controller
for another failure, and then judge.
Between SVGT (female) (C) and Sensor 1.0 to 4.0
Voltage
(B) output V
D65EX,PX,WX-17 40-315
40 Troubleshooting
Failure code [CA2383] KVGT Solenoid Open Error

Action
Failure code KVGT solenoid drive open error
level Failure
L03 CA2383
Detail of • Open error is detected in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked with monitoring function (Code: 48800
Related (mA)).
1
defective.
Defective KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapters to male
2 side of connector.
Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
3 wiring harness
a Resistance of KVGT valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-
(contact with ground circuit) Resis- Between ECM J2 (female) (10) and ground, or Min. 100
tance between VGT-SOL (female) (1) and ground Kz
Open circuit in connector box 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
5 (open circuit or defective connect T-adapter.
contact of connector) Between INTER-CONNECT (male) (6) and
Max. 10 z
Resis- VGT-SOL (female) (1)
tance Between INTER-CONNECT (male) (7) and
VGT-SOL (female) (2) Max. 10 z

Ground fault in connector box 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
6
tance (male) (6) and VGT-SOL (female) (1) Kz
40-316 D65EX,PX,WX-17
40 Troubleshooting

Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
7 (wire breakage or defective T-adapter to female side of connector.
contact of connector) Between ECM J2 (female) (10) and INTER-
Max. 10 z
Resis- CONNECT (female) (6)
tance Between ECM J2 (female) (20) and INTER-

2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-
adapter to female side of ECM J2.
circuit) No
Between ECM J2 (female) (10) and each other continuity
Continuity
pin (No sound
is heard)
Circuit diagram related to KVGT solenoid
D65EX,PX,WX-17 40-317
40 Troubleshooting
Failure code [CA2386] KVGT Solenoid Short Error

Action
Failure code KVGT solenoid short error
level Failure
L03 CA2386
Detail of
• Short circuit is detected in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked with monitoring function.
1
defective.
Defective KVGT valve 2. Disconnect connector VGT-SOL and connect T-adapters to male
2 solenoid side of connector.
(internal short circuit) Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
3 wiring harness
a Resistance of KVGT valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-
(contact with ground circuit) Resis- Between ECM J2 (female) (10) and ground, or Min. 100
tance between VGT-SOL (female) (1) and ground Kz
Ground fault in connector box 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
5
tance (male) (6), and VGT-SOL (female) (1) Kz
40-318 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-
adapter to female side of ECM J2.
circuit) No
Between ECM J2 (female) (10) and each other continuity
Continuity
pin (No sound
is heard)
Circuit diagram related to KVGT solenoid
D65EX,PX,WX-17 40-319
40 Troubleshooting
Failure code [CA2387] KVGT Valve Servo Error

Action level Failure code KVGT servo error
Failure
Detail of • KVGT servo error has occurred
failure (Response from KVGT position sensor differs from KVGT opening command.)
machine
information
1 Defect in related system If another failure code is indicated, carry out troubleshooting for it.
a For testing of KVGT drive pressure, see Testing and adjusting,
KVGT drive oil pressure "Testing EGR and KVGT oil pressure".
2
abnormal
a If the KVGT drive pressure is abnormal, check causes 3 and 4.
Defective engine oil pressure a For check of engine oil pressure, see Testing and adjusting, "Testing
3 system engine oil pressure".
(main circuit) If engine oil pressure is not normal, perform troubleshooting (S
mode) for mechanical system. (S-12 Oil pressure lowers.)
4 Defective oil pump for KVGT Oil pump or relief valve for KVGT circuit may be defective. Check them.
Defective oil supply pipe for Oil supply pipe for the KVGT circuit may be defective. Check it.
5
KVGT
Defective oil return pipe for Oil return pipe for KVGT circuit may be defective. Check it.
6
KVGT
7 Defective KVGT KVGT may be defective. Check it.
Defective KVGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
8
sensor
9 Defective engine controller If no failure is found by above checks, engine controller is defective.
40-320 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2554] Exh Manifold Press Sens In Range error
Action
Failure code Exhaust manifold pressure sensor in-range error
level Failure
L03 CA2554
Failure • Output from exhaust manifold pressure sensor indicates value outside normal range.
machine
function.
(Code: 48301 (V))
(Code: 48300 (MPa))
Blocking of exhaust manifold As exhaust manifold pressure sensor pipe may be blocked, perform
1 pressure sensor pipe troubleshooting for it.
Defective exhaust manifold As exhaust manifold pressure sensor system may be defective, perform
2 pressure sensor troubleshooting for failure codes [CA2373] and [CA2374].
D65EX,PX,WX-17 40-321
40 Troubleshooting
Failure code [CA2555] Grid Htr Relay Volt Low Error
Action level Failure code Intake air heater relay open circuit
Failure
Failure • Open circuit is detected in drive circuit (primary circuit) of preheat relay.
controller
Problem on • Intake air heater does not work in auto-preheating (deteriorated starting performance at
machine low temperature and emission of white smokes)
• Method of reproducing failure code: Turn starting switch to ON position (Coolant
Related temperature: Max. -5 °C )
information • Troubleshooting of this failure code covers circuits from engine controller to primary (coil)
circuit of preheating relay PHR.
• For troubleshooting of secondary circuit of heater relay and preheating relay PHR, see E-
2 in E-mode.
1
defective.
2. Disconnect relay PHR and connect T-adapter to male side.
Resis- Between PHR (male) (1) and (2)
200 to 400 z
tance
Defective preheating relay
2 1. Turn starting switch to OFF position.
PHR
2. Replace relay PHR with another one.
If this failure code disappears, original preheating relay PHR is
defective.
3
harness
Resis- Between EGC3 (female) (4) and (13)
200 to 400 z
tance a Relay PHR coil resistance
2. Disconnect connector EGC3 and relay PHR, and connect T-
4 Open circuit in wiring harness adapters to female side of each of them.
Between EGC3 (female) (4) and PHR
Max. 10 z
Resis- (female) (1)
tance Between EGC3 (female) (13) and PHR
40-322 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to intake air heater relay
D65EX,PX,WX-17 40-323
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Volt High Error
Action level Failure code Intake air heater relay short circuit
Failure
Failure • Short circuit is detected in drive circuit (primary circuit) of preheater relay.
controller
Problem on • Intake air heater does not work in auto-preheating (deteriorated starting performance at
machine low temperature and emission of white smokes)
• Temperature sensed by engine coolant temperature sensor can be checked by using
• Method of reproducing failure code: Turn starting switch to ON position (Coolant
Related temperature: Max. -5 °C )
information • Troubleshooting of this failure code covers circuits from engine controller to primary (coil)
circuit of preheating relay PHR.
• For troubleshooting of secondary circuit of heater relay and preheating relay PHR, see E-
2 in E-mode.
1
defective.
2. Disconnect relay PHR and connect T-adapter to male side.
Resis- Between PHR (male) (1) and (2) 200 to 400
tance z
Defective preheating relay
PHR
2. Replace relay PHR with another one.
If this failure code disappears, original preheating relay PHR is
defective.
2. Disconnect connector EGC3 and relay PHR, and connect T-
3 Ground fault in wiring harness adapters to female side of either of them.
Resis- Between ground and EGC3 (female) (4) or Min. 100
tance PHR (female) (1) Kz
2. Disconnect connector EGC3 and relay PHR, and connect T-adapter
to female side of EGC3.

No
Between EGC3 (female) (4) and every pin continuity
Continuity
other than (4) (No sound
is heard)
40-324 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to intake air heater relay
D65EX,PX,WX-17 40-325
40 Troubleshooting
Failure code [CA2637] KDOC Blocked

Action
Failure code KDOC face plugging
level Failure
L01 CA2637
• KDOC face is plugged.
1. Due to operating conditions, KDOC face became dirty and efficiency of catalyst is
Detail of degraded (KDOC needs cleaning)
failure 2. KDOC deteriorates due to high temperatures, or reduces its efficiency due to adhesion of
foreign matter or breakage (KDOC must be replaced with a new one or a remanufactured
one)
machine
k Since the temperature of the exhaust connector, KDOC, and KDPF will become
higher than 500 °C , take care not to get burn injury.
a When the KDOC in the KDPF is changed, perform KDOC change resetting to finish repair
work.
• Performing manual stationary regeneration from "Regeneration for Service" menu.
a When soot accumulation is at level 3 or lower, manual stationary regeneration can be
performed only from "Regeneration for Service" menu.
Related
information 1. Start engine.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02
Regeneration for Service", and then execute "Manual Statonary Regeneration".
• If a KDOC efficiency degraded condition continues, this failure code [CA2637] may be
repeatedly issued, and then failure code [CA1691] (regeneration ineffective) may be
issued.
• Start engine. After warm-up operation, operate machine normally for about three hours.
(Higher exhaust temperature allows failure code to be cleared faster.)
1 Defective KVGT If failure code [CA238*] appears, perform troubleshooting for it first.
If failure codes such as [CA227*], [CA23**] appear, perform
2 Defective EGR valve troubleshooting for them first.
1. Remove turbocharger exhaust connector.
Defective turbocharger 2. Check inside of turbocharger exhaust connector for oil and fuel.
3
exhaust connector • If oil or fuel is found, perform troubleshooting for failure codes such
as [CA227*], [CA23**], etc.
Defective exhaust connector Check exhaust system between turbocharger and KDPF for damage or
4 or duct leading to KDPF loose connections of connectors or ducts.
• If excessive black smoke is exhausted when running engine at high
idle, perform troubleshooting for "S-9 KDPF gets clogged in a short
5 Unusual exhaust gas color
time".
idle.
40-326 D65EX,PX,WX-17
40 Troubleshooting

1. Remove KDPF.
2. Remove KDOC.
• Check KDOC for cracks (replace KDOC if cracks are found).
• Check if more than 50% of KDOC inlet surface is clogged with soot
6 Defective KDOC or not.
(KDOC cleaning)
a Perform troubleshooting for cause 7 when the KDOC is changed,
and perform troubleshooting for cause 8 when the KDOC is
cleaned.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, select "Diagnostic Tests",
open "03 KDPF Memory Rest", and then execute "03 KDOC
Change" (reset after KDOC change).
7 Reset after KDOC change
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When the KDOC is changed, finish troubleshooting without
performing manual stationary regeneration.
1. Perform manual stationary regeneration from "Regeneration for
service" (see "Related information") (to dry the KCSF).
a Failure code [CA2639] may be displayed on the machine
monitor during manual stationary regeneration, however, this is
normal (manual stationary regeneration is completed in about 40
Performing manual stationary minutes then failure code [CA2639] disappears).
regeneration (to dry KCSF)
3. Perform Regeneration for service (to make sure repair is
completed).
a If failure code [CA2637] is displayed after Regeneration for service
is performed, the efficiency of the KDOC is degraded. Change the
KDOC and perform KDOC change resetting. (See cause 7.)
a Operate machine for about three hours and check that no failure code appears.
D65EX,PX,WX-17 40-327
40 Troubleshooting
Failure code [CA2639] Manual Stationary Regeneration Request

Action level Failure code Manual stationary regeneration request
Failure
The manual stationary regeneration request prompts the operator to "forcibly" perform
stationary regeneration, which is more effective to remove soot, because the soot
Detail of sedimentation in the KCSF of KDPF has exceeded the level for automatic regeneration.
failure • Soot level at 4 or 5
• During manual stationary regeneration process, this failure code is displayed on machine
monitor, but this is normal.
Action of
• Normal control
controller
Problem on • None in particular
machine
40-328 D65EX,PX,WX-17
40 Troubleshooting
k Since the temperature of the KDOC and KDPF will become higher than 500 °C , take
a If manual stationary regeneration is started when KDOC inlet temperature is below approx.
250 °C , fuel dosing will be disabled, so actually regeneration will not start.
• KVGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
• The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature at
idle (not regenerating) will all be approx. 100 – 250 °C and the difference between these
temperatures will be approx. 10 °C (KDOC inlet temperature>KDOC outlet
temperature>KDPF outlet temperature).
Related temperature is approx. 250 to 400 °C , and KDOC outlet temperature and KDPF outlet
information temperature are approx. 450 to 550 °C .
"TEMP3").
• How to perform stationary manual regeneration
1. Start engine.
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then execute "Manual Statonary Regeneration".
a Time required for manual stationary regeneration depends on the amount of soot in the
KCSF, however, it will be estimated as follows.
• Soot level 4: approx. 40 minutes to 1 hour
• Soot level 5: approx. 1 to 2 hours
a If the soot sedimentation reaches level 6 or 7, failure code [CA1921] is displayed.
a If the soot sedimentation reaches level 8, failure code [CA1922] is displayed.
a If this failure code is still displayed after several hours have passed after manual
stationary regeneration, perform the following troubleshooting procedures.
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
• If there is a significant difference between the KDOC inlet
Defective KDOC inlet temperature and KDOC outlet temperature when the KDPF is
1 temperature sensor completely cool or engine running at idle (not regenerating), replace
the KDOC inlet temperature sensor.
During manual stationary regeneration, if KDOC inlet temperature is
below approx. 250 °C , and KVGT solenoid current stays at approx.
2 Defective KVGT 1000 mA for several hours and the regeneration is not completed for a
long time, the KVGT is defective.
Defective KDPF (KDOC, 1. Perform troubleshooting for S mode, "S-22".
3 KCSF) 2. Remove KDOC and KCSF from inside KDPF and clean KDOC and
KCSF.
D65EX,PX,WX-17 40-329
40 Troubleshooting

regeneration is completed, perform the following.
• If excessive black smoke is exhausted when accelerating engine or
4 Unusual exhaust gas color running it at high idle, perform troubleshooting for "S-9 KDPF gets
idle.
5 Defective engine controller If this failure code appears and no failure is found by above checks,
40-330 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA2961] EGR Orifice Temp High Error 1
Action
Failure code EGR orifice temperature high error 1
level Failure
L03 CA2961
• Output signal from EGR temperature sensor exceeds control limit or it indicates value
Failure outside normal range.
controller
machine
function.
(Code: 48501(V))
(Code: 48500 (°C))
1 Defect in related system If another failure code is indicated, perform troubleshooting for it.
Increasing of EGR gas As EGR gas temperature may increase excessively, perform
2 temperature troubleshooting for it.
Defective EGR orifice EGR orifice temperature sensor system may be defective. Perform
3 temperature sensor troubleshooting for failure codes [CA2375] and [CA2376].
D65EX,PX,WX-17 40-331
40 Troubleshooting
Failure code [CA2973] Chg Air Press Sensor In Range Error
Action
Failure code Charge pressure sensor in-range error
level Failure
L03 CA2973
Failure • Charge pressure (boost pressure) sensor output indicates value outside of normal range.
• Takes it that charge pressure (boost pressure) is at calculated value and allows engine to
run.
machine
• The signal voltage from charge pressure (boost pressure) sensor can be checked with
(Code: 36501 (V))
Related • Pressure of charge pressure (boost pressure) sensor can be checked with monitoring
(Code: 36500 (MPa))
Defective charge pressure Charge pressure sensor system may be defective. Perform
sensor
40-332 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3133] KDPF Outlet Press Sens High Error

Action
Failure code KDPF outlet pressure sensor high error
level Failure
L03 CA3133
Failure • High voltage is detected in KDPF outlet pressure sensor signal circuit.
• Controller continues operation based on estimated KDPF delta pressure sensor value
Action of (gauge pressure).
controller (If another failure code is displayed at the same time, operation may be continued at 0
kPa (gauge pressure).)
Problem on
• None
machine
get burn injury.
Related • If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, open
information circuit of GND circuit (defective contact of connector) can be suspected.
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring function
(Code: 3004 (V))
• Differential pressure from KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 3003 (MPa))
1
defective.
Defective sensor power 1. Turn starting switch to OFF position.

2 supply 2. Disconnect connector PDPF and connect T-adapter to female side of
connector.
Defective KDPF outlet If this failure code changes to [CA3134], KDPF outlet pressure sensor is
3 pressure sensor defective.
harness 2. Disconnect connectors EGC3 and PDPF, and connect T-adapters to
contact of connector) a To check for open circuit in GND line
Resis- Between EGC3 (female) (43) and PDPF
tance
D65EX,PX,WX-17 40-333
40 Troubleshooting

harness
No continuity
other than (58)
heard)
Circuit diagram related to KDPF outlet pressure sensor
40-334 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3134] KDPF Outlet Press Sens Low Error

Action
Failure code KDPF outlet pressure sensor low error
level Failure
L03 CA3134
Failure • Low voltage is detected in KDPF outlet pressure sensor signal circuit.
• Controller continues operation based on estimated KDPF outlet pressure sensor value
Problem on
• None
machine
get burn injury.
• If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
Related connector is disconnected or open circuit of 5 V circuit (defective contact of connector)
information can be suspected.
(Code: 3004 (V))
function. (Code: 3003 (MPa))
N- Procedure, measuring location, criteria and remarks
Cause
o.
1
defective.
2 Defective sensor power supply 2. Disconnect connector PDPF and connect T-adapter to female side
of connector.
a If cause 2 is not cause for trouble, this
tance
(female) (4)
D65EX,PX,WX-17 40-335
40 Troubleshooting

Cause
o.
Ground fault in wiring harness 2. Disconnect connectors EGC3 and PDPF and connect T-adapter to
Min. 100 Kz
No continuity
heard)
Defective KDPF outlet pressure 2. Insert T-adapter into connector PDPF.
sensor
Voltage Between PDPF (3) and (1) 0.5 to 4.5 V
40-336 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Action
Failure code KDPF outlet pressure sensor in-range error
level Failure
L03 CA3135
• KDPF outlet pressure sensor indicates pressure higher than the normal value. (Signal
Failure voltage is within "normal" or "operating" range.)
• Controller continues operation based on estimated KDPF outlet pressure sensor value
Problem on
• None
machine
get burn injury.
(Code: 3004 (V))
Related function. (Code: 3003 (MPa))
information • Method of reproducing failure code: Turn starting switch to ON position (wait and see for 1
minute)
• <Clearing failure code>
1. Turn starting switch ON from OFF position to start engine.
2. When the engine is warmed up, set the fuel dial to Full and run the engine for about 30
seconds at torque converter stall.
• Repeat 1) and 2) operations several times. If this failure code is cancelled, repair is
complete.

Cause
o.
1. Remove KDPF delta pressure sensor tube.
2. Clean KDPF delta pressure sensor tube to clear any clog.
3. Check KDPF delta pressure sensor tube for cracking and damage.
4. Connect both ends of tube securely and install KDPF delta pressure
sensor tube.
Defective KDPF differential • Reference
1 pressure sensor tube
How to check KDPF delta pressure sensor tube for clogging
2. Monitor outlet pressure sensed by KDPF outlet pressure sensor
that is displayed on monitoring screen of machine monitor.
Code 3003(MPa) 0 ± 0.0015 (MPa)
connector
defective.

of connector.
D65EX,PX,WX-17 40-337
40 Troubleshooting

Cause
o.

4 engine controller 2. Disconnect connector PDPF and connect short-circuit connector to
female side.
a Connect 5 V circuit to signal circuit (short-circuit connector
PDPF (4) pin and (3) pin).
Defective KDPF outlet pressure a If no failure is found in check on cause 4, KDPF outlet pressure
5
sensor sensor is defective.
tance
(female) (4)

Ground fault in wiring harness 2. Disconnect connectors EGC3 and PDPF, and connect T-adapters
7 to female side of either connector.
Min. 100 Kz
8 Short circuit in wiring harness a Check with circuit tester in continuity mode.
No continuity
heard)
1. Turn starting switch to ON position and wait for approximately 1
minute (recheck of error with key turned to ON position).
9 Defective engine controller code> in "Related information".
If this failure code appears and no failure is found in above checks,
40-338 D65EX,PX,WX-17
40 Troubleshooting
a If this failure code still appears and does not disappear even after performing "How to clear the failure
code" in the related information, repeat the troubleshooting.
D65EX,PX,WX-17 40-339
40 Troubleshooting
Failure code [CA3251] KDOC Inlet Temp High Error
Action
Failure code KDOC inlet temperature high error
level Failure
L03 CA3251
Failure • KDOC inlet temperature is maintained at high level.
controller • Controller regards KDOC inlet temperature as default value ((250 °C ).
machine
Related function. (Code: 47201(V))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature at idle
are approximately 100 to 250 °C . Temperature difference among them is approximately
10 °C (KDOC inlet temperature> KDOC outlet temperature > KDPF outlet temperature).
• Misfire on injector can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection amount in order
to compensate torque drop, causing high exhaust temperature.
• Start engine and run at low idle for approximately 10 minutes.
• If display of failure code remains, controller runs engine for two minutes further at high
idle.
Cause
o.
connector
defective.
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform
2 temperature sensor troubleshooting for [CA3313], [CA3314] or [CA3315] first.
2. Disconnect connectors EGC3 and TEMP1 (KDOC inlet temperature
sensor), and connect T-adapter to female side of EGC3.
No continuity
heard)
40-340 D65EX,PX,WX-17
40 Troubleshooting

2. With monitoring function, display signal voltages and temperatures
from KDOC inlet temperature sensor, KDOC outlet temperature
sensor, and KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note down temperature values (after checking that they are
stabilized)
Defective KDOC inlet 5. Monitor temperature of each sensor.
If any of temperature sensor values changes by more than 24 °C ,
regard temperature sensor as defective.
a If none of temperature sensor values changes by more than 24 °C ,
no failure is in sensors. Perform troubleshooting for cause 5 and
subsequent causes.
a If another failure code appears during running engine at idle,
perform troubleshooting for it first.
Check intake system hoses, clamps, and tubes for damages and loose
5 Malfunction of intake system connection. Repair as necessary. (Repair intake air leaks)
When a certain cylinder is cut out, engine speed does not change (see
6 Defective injector "Handling of cylinder cut-out operation in Testing and adjusting)
2. Check inside of turbocharger exhaust connector for oil and fuel.
Oil leak into turbocharger • If oil or fuel is found, visually check for oil leaks from EGR valve and
7
exhaust connector turbocharger. Repair any failure.
a Wipe off oil and fuel on piping thoroughly.
Check exhaust system between turbocharger and KDPF for oil leak or
fuel leak.
Oil leak into exhaust connector • Wipe off oil or fuel if found.
8 and ducts leading to KDPF
a If any trace of oil or fuel leakage into KDPF is found, check KDPF.
Clean or replace KDPF as necessary.
code> in "Related information".
D65EX,PX,WX-17 40-341
40 Troubleshooting
Circuit diagram related to KDOC inlet temperature sensor
40-342 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3253] KDOC Temp Error - Non Regeneration

Action
Failure code KDPF temperature error in non regeneration state
level Failure
L03 CA3253
Detail of • The KDOC outlet temperature is continuously extremely high when active regeneration is
failure not performed.

machine
• Temperature sensed by the KDOC outlet temperature sensor can be checked by using
monitoring function. (Code: 47400 ℃ °C )
Related • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201(V))
• If misfire occurs at the injector,
2. When there is a problem in any of the cylinders, fuel injection at other cylinders may
be increased to compensate for the torque drop, causing a KDOC inlet temperature
high error.
• If an error code is displayed, run the engine at high idle for three more minutes.
KDOC inlet temperature Perform troubleshooting for failure code [CA3251]
1
sensor error
KDOC outlet temperature Perform troubleshooting for cause 5 of failure code [CA3254]
2
sensor error
1. Remove KDPF.
2. Remove KDOC.
a When KDOC in KDPF is changed, always perform reset procedure
3 Defective KDOC (degraded) for KDOC change, and then perform manual stationary regeneration
from "Regeneration for Service" to eliminate moist from KDOC. (See
troubleshooting for causes 7 and 8 of failure code [CA2637].)
• Check if more than 50% of the KDOC inlet face is plugged with soot
or not.
(KDOC cleaning)
Defective engine controller code> in "Related information".
4
D65EX,PX,WX-17 40-343
40 Troubleshooting
Failure code [CA3254] KDOC Outlet Temp High Error 1

Action
Failure code KDOC outlet temperature high error 1
level Failure
L01 CA3254
Failure • KDOC inlet temperature is maintained at high level.
controller
machine
Related • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (℃ °C ))
• If injector misfires
• If display of failure code remains, controller runs engine for two minutes further at high
idle.
1
defective.
2 temperature sensor troubleshooting for it first.
2. Disconnect connectors EGC3 and TEMP2 (KDOC outlet
temperature sensor), and connect T-adapter to female side of
EGC3.
No continuity
heard)
40-344 D65EX,PX,WX-17
40 Troubleshooting

stabilized)
Defective KDOC outlet 5. Monitor temperature of each sensor.
If any of temperature sensor values changes by more than 24 °C ,
subsequent causes.
5 Malfunction of intake system connection. Repair them as necessary. (Repair intake air leaks)
Run engine in cylinder cut-out mode to identify disabled cylinder that
6 Defective injector causes no change in engine speed. (See Testing and adjusting
"Cylinder cut-out test mode".)
2. Check inside of turbocharger exhaust connector for oil and fuel
Oil leak into turbocharger attached.
7 • If oil or fuel is found, visually check for oil leaks from EGR valve and
exhaust connector
turbocharger. Repair any failure.
fuel leak.
Oil leak into exhaust connector • Wipe off oil or fuel if found.
8 and ducts leading to KDPF
a If any trace of oil or fuel leakage into KDPF is found, check KDPF.
1. Remove KDPF.
2. Remove KDOC.
a When the KDOC of KDPF is changed, perform KDOC change
9 Defective KDOC resetting and then finish troubleshooting without performing manual
stationary regeneration. (See cause 7 of failure code [CA2637].)
• Check if more than 50% of KDOC inlet surface is clogged with soot
or not.
(KDOC cleaning)
If this failure code appears and no failure is found in above checks,
D65EX,PX,WX-17 40-345
40 Troubleshooting
Circuit diagram related to KDOC outlet temperature sensor
40-346 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3255] KDPF Temp Error - Non Regeneration

Action
Failure code KDPF temperature error in non regeneration state
level Failure
L03 CA3255
Detail of • The KDPF outlet temperature is continuously extremely high when active regeneration is
failure not performed.
machine
Related
• If an error code is displayed, run the engine at high idle for three more minutes.
1 KDPF system error Perform troubleshooting for failure code [CA3312]
D65EX,PX,WX-17 40-347
40 Troubleshooting
Failure code [CA3256] KDPF Outlet Temp High Error 1

Action
Failure code KDPF outlet temperature high error 1
level Failure
L01 CA3256
Detail of • The KDPF outlet temperature is continuously high.
failure
controller
machine
Related
• Start the engine and run at low idle for approximately 1 minute.
1 Defective KDPF system Perform troubleshooting for failure code [CA3312]
40-348 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3311] KDOC Outlet Temp High Error 2

Action
Failure code KDOC outlet temperature high error 2
level Failure
L03 CA3311
Detail of • The KDOC outlet temperature compared to the KDOC inlet temperature is continuously
failure extremely high.
machine
Related care not to get burn injury.
information
• Start the engine and run at low idle for approximately 1 minute.
1 KDOC system error Perform troubleshooting for failure code [CA3254]
D65EX,PX,WX-17 40-349
40 Troubleshooting
Failure code [CA3312] KDPF Outlet Temp High Error 2

Action
Failure code KDPF outlet temperature high error 2
level Failure
L03 CA3312
Failure • KDPF outlet temperature is maintained at a very high level.
machine
• If injector misfires
• Start engine and run it at low idle for approximately 1 minute.
1
defective.
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform
2 temperature sensor troubleshooting for [CA3319], [CA3321] or [CA3322] first.
2. Disconnect connectors EGC3 and TEMP3 (KDPF outlet
temperature sensor), and connect T-adapter to female side of
EGC3.
No continuity
heard)
40-350 D65EX,PX,WX-17
40 Troubleshooting

stabilized)
Defective KDPF outlet 5. Monitor temperature of each sensor.
4 temperature sensor If any of temperature sensor values changes by more than 24 °C ,
subsequent causes.
5 Malfunction of intake system
connection. Repair them as necessary. (Repair intake air leaks)
When a certain cylinder is cut out, engine speed does not change (see
6 Defective injector
"Handling of cylinder cut-out operation in Testing and adjusting)
2. Check inside of turbocharger exhaust connector for oil and fuel
Oil leak into turbocharger attached.
7 • If oil or fuel is found, visually check for oil leaks from EGR valve and
exhaust connector
turbocharger. Repair any failure.
fuel leak.
Oil leak into exhaust
8 connector and ducts leading to • Wipe off oil or fuel if found.
KDPF a If any trace of oil or fuel leakage into KDPF is found, check KDPF.
1. Remove KDPF.
2. Remove KDOC.
a When KDOC in KDPF is replaced, always perform reset procedure
9 Defective KDOC for KDOC change, and then perform manual stationary
regeneration from "Regeneration for Service" to eliminate moisture
from KDOC. (See troubleshooting for causes 7 and 8 of failure code
[CA2637].)
• Check whether 50% or more of KDOC inlet surface is clogged with
soot (clean KDOC).
D65EX,PX,WX-17 40-351
40 Troubleshooting
Circuit diagram related to KDPF outlet temperature sensor
40-352 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error

Action
Failure code KDOC inlet temperature sensor low error
level Failure
L03 CA3313
Failure • Low voltage is detected in KDOC inlet temperature sensor circuit.
• Substitutes KDOC outlet temperature for KDOC inlet temperature to run engine.
(Sets KDOC inlet temperature to default value (250 °C ) if KDOC outlet temperature
Action of sensor is also abnormal and allows engine to run.)
machine
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3314] for "High Error" appears.
• KDOC inlet temperature sensor connecter label "TEMP1" is seen on KDPF temperature
sensor consolidating box in black embossed letters (same for KDOC outlet temperature
Since error may occur during operation, start engine and run it at low idle for approximately
one minute. If this failure code disappears, repair is complete.
1
defective.
D65EX,PX,WX-17 40-353
40 Troubleshooting

2. Disconnect TEMP1 (KDOC inlet temperature sensor).
If this failure code changes to [CA3314], KDOC inlet temperature
a If display of this failure code still remains, wiring harness or engine
• Reference
Defective KDOC inlet 1. Turn starting switch to OFF position.
2 temperature sensor 2. Disconnect connector TEMP1 and connect T-adapter to female side
of connector.
-10 °C 33 to 65 Kz
Between TEMP1 (female) 0 °C 25 to 47 Kz
(1) and (2) 50 °C 7.8 to 12.2 Kz
Resis-
a Temperature-Resistance 100 °C 3.2 to 4.5 Kz
tance
characteristics 400 °C 200 to 240 z
700 °C 64 to 69 z
Between TEMP1 (female) (1) and ground Min. 100 Kz
Ground fault in wiring harness 1. Turn starting switch to OFF position.
(contact with ground circuit) 2. Disconnect connectors EGC3 and TEMP1 and then connect T-
3 (including inside of KDPF adapter to female side of EGC3 or male side of TEMP1.
temperature sensor Resis- Between ground and EGC3 (female) (45) or
Min. 100 Kz
consolidating box) tance TEMP1 (male) (1)
2. Disconnect connectors EGC3 and TEMP1, and connect T-adapter
Short circuit in wiring harness to female side of EGC3.
(including inside of KDPF
temperature sensor
consolidating box) No continuity
heard)
a If no failure is found in checks on causes 3 and 4, this check is not
required.
2. Disconnect connector TDPF and connect T-adapter to male side of
connector.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
5 Defective KDPF temperature
sensor consolidating box a If no failure is found in checks on cause 3,
this check is not required. Min. 100 Kz
Between TDPF (male) (3) and ground
Resis-
tance a If no failure is found in checks on cause 4,
Between TDPF (male) (3) and every pin
other than (3)
6 2. Disconnect connectors EGC3 and TDPF, and connect T-adapter to
Min. 100 Kz
tance TDPF (female) (3)
40-354 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect connectors EGC3 and TDPF, and connect T-adapter to
No continuity
heard)
8
D65EX,PX,WX-17 40-355
40 Troubleshooting
Failure code [CA3314] KDOC Inlet Temp Sens High Error

Action
Failure code KDOC inlet temperature sensor high error
level Failure
L03 CA3314
Failure • High voltage is detected in KDOC inlet temperature sensor circuit.
• Substitutes KDOC outlet temperature for KDOC inlet temperature to run engine.
((If a failure is detected in KDOC outlet temperature sensor also controller continues
Action of operation regarding KDOC inlet temperature as default value (250 °C ).)
machine
function. (Code: 47301 (V))
• This failure code appears if sensor connector is disconnected.
• If failure codes [CA3317] and [CA3319] are also displayed, disconnection of connector of
KDPF temperature sensor integration box or open circuit of ground circuit (defective
contact of connector) can be suspected.
1
defective.
40-356 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect connector TEMP1 (KDOC inlet temperature sensor)
and connect T-adapter to male side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box
with jumper cable.
a Connect ground to signal circuit.
If this failure code changes to [CA3313] , KDOC inlet temperature
Defective KDOC inlet a If this failure code is still displayed, wiring harness or engine
2 temperature sensor controller is defective.
• Reference
2. Disconnect connector TEMP1 and connect T-adapter to female side
of connector.
-10 °C 33 to 65 Kz
Resis- (1) and (2) 50 °C 7.8 to 12.2 Kz
tance a Temperature-Resistance 100 °C 3.2 to 4.5 Kz
700 °C 64 to 69 z
Open circuit or short circuit in 2. Disconnect connectors EGC3 and connect T-adapter to female side
wiring harness of connector.
3 (including inside of KDPF Between EGC3 (female) (45) and (19)
temperature sensor Resis- a Resistance is the same as that listed in
consolidating box) 64 z to 65 Kz
tance the above temperature-resistance
characteristics.
Open circuit in wiring harness
(wire breakage or defective 2. Disconnect connectors EGC3 and TEMP1 and connect T-adapter
contact of connector) to female side of EGC3 and male side of TEMP1.
4
(including inside of KDPF Between EGC3 (female) (45) and TEMP1
temperature sensor Max. 10 z
Resis- (male) (1)
consolidating box) tance Between EGC3 (female) (19) and TEMP1

5 (including inside of KDPF
temperature sensor
heard)
D65EX,PX,WX-17 40-357
40 Troubleshooting

a If no failure is found in check on causes 3 to 5, this check is not
required.
connector.
3. Disconnect connectors TEMP1, TEMP2 and TEMP3, and connect
T-adapter to male side of TEMP1.
a If no failure is found in check on cause 3
or 4, this check is not required. Max. 10 z
Defective KDPF temperature
6 Between TDPF (male) (2) and TEMP1
sensor consolidating box
(male) (2)
a If no failure is found in check on cause 3
Resis- or 4, this check is not required. Max. 10 z
tance Between TDPF (male) (3) and TEMP1
(male) (1)
check is not required. Min. 100 Kz
Between TDPF (male) (3) and every pin
other than (3)
a If no failure is found in check on cause 3 or 4, this check is not
required.
Open circuit in wiring harness 2. Disconnect connectors EGC3 and TDPF, and connect T-adapters to
7 (wire breakage or defective each female side of each connector.
contact of connector) Between EGC3 (female) (45) and TDPF
Max. 10 z
Resis- (female) (3)
tance Between EGC3 (female) (19) and TDPF

No continuity
heard)
9
40-358 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to KDOC and KDPF temperature sensors
D65EX,PX,WX-17 40-359
40 Troubleshooting
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error

Action
Failure code KDOC inlet temperature sensor in range error
level Failure
L03 CA3315
• The actual difference between the temperatures sensed by KDOC inlet temperature
Failure sensor and KDOC outlet temperature sensor disagrees with the forecasted value.
(The signal voltage is within the input range, though.)
• KDOC outlet temperature is substituted for KDOC inlet temperature to continue operation.
(If KDOC outlet temperature sensor is also abnormal, takes it that KDOC inlet
Action of temperature is default value (250 °C ) and allows engine to run.)
• Limits engine output and allows engine to run.
machine
"TEMP3").
1. Turn the starting switch to OFF position once, then start engine.
2. After warming up, run the engine under a heavy load for 10 minutes or longer in total.
(Above operation may be replaced with an approximately 30-minute long actual operation
under a heavy load with fuel control dial being set to the maximum.)
Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform
1 temperature sensor troubleshooting for the displayed code first.
2
connector "Related information".
40-360 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect TEMP1 (KDOC inlet temperature sensor).

3 engine controller 2. Disconnect connector TEMP1 and connect T-adapter to male side.
using jumper line.
a Connect ground to signal line.
a If no failure is found by check on cause 3, KDOC inlet temperature
• Reference
2. Disconnect connector TEMP1 and connect T-adapter to female
Defective KDOC inlet side.
4 temperature sensor -10 °C 33 to 65 Kz
Resis- (1) and (2) 50 °C 7.8 to 12.2 Kz
characteristics 400 °C 200 – 240 z
700 °C 64 to 69 z
Open circuit or short circuit in
2. Disconnect connector EGC3 and connect T-adapter to female side.
wiring harness
Between EGC3 (female) (45) and (19)
temperature sensor Resis- a The resistance is the same as that listed
64 z – 65 Kz
consolidating box) tance in the above temperature-resistance
characteristics.
Open circuit in wiring harness a If cause 5 is not the cause for the trouble, this check is not required.
system 1. Turn starting switch to OFF position.
(wire breakage or defective 2. Disconnect connectors EGC3 and TEMP1 and connect T-adapter
6 contact of connector) to female side of EGC3 and male side of TEMP1.
Between EGC3 (female) (45) and TEMP1
(including inside of KDPF Max. 10 z
temperature sensor Resis- (male) (1)
(contact with ground circuit) 2. Disconnect connectors EGC3 and TEMP1 and then connect T-
7 (including inside of KDPF adapter to female side of EGC3 or male side of TEMP1.
Min. 100 Kz
D65EX,PX,WX-17 40-361
40 Troubleshooting

temperature sensor
Continu- Between EGC3 (female) (45) and each pin
heard)
a If no failure is found by check on causes 3 to 5, this check is not
required.
2. Disconnect connector TDPF and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2 and TEMP3 and connect
T-adapter to male side of TEMP1.
a If no failure is found by check on cause 5
Between TDPF (male) (2) and TEMP1
(male) (2)
9 sensor consolidating box a If no failure is found by check on cause 5
Between TDPF (male) (3) and TEMP1
Resis- (male) (1)
tance
a If cause 7 is not the cause for the trouble,
a If no failure is found by check on cause 8,
Between TDPF (male) (3) and each pin
other than (3)
a If no failure is found by check on cause 5 or 6, this check is not
required.
Open circuit in wiring harness 2. Disconnect connectors EGC3 and TDPF and connect T-adapters to
10 (wire breakage or defective each female side.
Max. 10 z
Resis- (female) (3)
a If cause 7 is not the cause for the trouble, this check is not required.
11 2. Disconnect connectors EGC3 and TDPF and connect T-adapter to
Min. 100 Kz
No continuity
Continu- Between EGC3 (female) (45) and each pin
heard)
40-362 D65EX,PX,WX-17
40 Troubleshooting

1. Remove KDPF.
2. Remove KDOC.
13 Defective KDOC (degraded
• Check if more than 50% of KDOC inlet surface is plugged with soot
or not.
(KDOC cleaning)
D65EX,PX,WX-17 40-363
40 Troubleshooting
Failure code [CA3316] KDOC Outlet Temp Sens Low Error

Action
Failure code KDOC outlet temperature sensor low error
level Failure
L03 CA3316
Failure • Low voltage is detected in KDOC outlet temperature sensor circuit.
• Substitute KDOC inlet temperature for KDOC outlet temperature to run engine.
(Sets KDOC outlet temperature to default value (250 °C ) to run engine. If a failure is
Action of detected in KDOC inlet temperature sensor.)
machine
• If sensor connector is disconnected or its open circuit is detected, high error code
[CA3317] is displayed in stead of this failure code.
<How to clear failure code>
In order to prevent error during operation, run engine at idle for one minute after starting it. If
this failure code is cancelled after above operation, repair is complete.
1
defective.
40-364 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).
If this failure code changes to [CA3317] , KDOC outlet temperature
• Reference
Defective KDOC outlet 2. Disconnect connector TEMP2 and connect T-adapter to female side
2 temperature sensor of connector.
-10 °C 33 to 65 Kz
0 °C 25 to 47 Kz
Between TEMP2 (female) (1) and 7.8 to 12.2
(2) 50 °C
Kz
Resis- 3.2 to 4.5
tance a Temperature-Resistance 100 °C
Kz
characteristics
400 °C 200 to 240 z
700 °C 64 to 69 z
Between TEMP2 (female) (1) and ground Min. 100 Kz
(contact with ground circuit) 2. Disconnect connectors EGC3 and TEMP2 and connect T-adapter to
3 (including inside of KDPF female side of EGC3 or male side of TEMP2.
Min. 100 Kz
(including inside of KDPF
temperature sensor
heard)
required.
connector.
5 sensor consolidating box a If no failure is found in checks on cause 3,
Resis-
Between TDPF (male) (1) and every pin other
than (1)
6 2. Disconnect connectors EGC3 and TDPF, and connect T-adapter to
(contact with ground circuit) female side either connector.
Min. 100 Kz
D65EX,PX,WX-17 40-365
40 Troubleshooting

a Check with in continuity mode.
No continuity
heard)
If this failure code appears, perform procedure described in related
Defective engine controller information "How to clear the failure code".
8
40-366 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3317] KDOC Outlet Temp Sens High Error

Action
Failure code KDOC outlet temperature sensor high error
level Failure
L03 CA3317
Failure • High voltage is detected in KDOC outlet temperature sensor circuit.
• Substitutes KDOC inlet temperature for KDOC outlet temperature to run engine.
(Sets KDOC outlet temperature to default value (250 °C ) to run engine, if a failure is
Action of detected in KDOC inlet temperature sensor.)
machine
• This failure code is displayed if sensor connector is disconnected.
• If failure codes [CA3314] and [CA3319] are also displayed, disconnection of KDPF
temperature sensor consolidation box or open circuit in GND circuit (defective contact of
connector) can be suspected.
sensor consolidation box in black embossed letters (same for KDOC outlet temperature
1
defective.
D65EX,PX,WX-17 40-367
40 Troubleshooting

2. Disconnect KDOC outlet temperature sensor (connector TEMP2)
and connect T-adapter to female side of connector.
with jumper cable.
a Connect ground to signal circuit.
If this failure code changes to [CA3316], KDOC outlet temperature
Defective KDOC outlet controller is defective.
2 temperature sensor • Reference
of connector.
-10 °C 33 to 65 Kz
Between TEMP2 (female) (1) and 0 °C 25 to 47 Kz
7.8 to 12.2
Resis- (2) 50 °C
Kz
700 °C 64 to 69 z
temperature sensor Resis- a Resistance is the same as that listed in 64 z to 65
consolidation box) tance above temperature-resistance Kz
characteristics.
Open circuit in wiring harness a If no failure is found in checks on cause 3, this check is not required.
system 1. Turn starting switch to OFF position.
(wire breakage or defective 2. Disconnect connectors EGC3 and TEMP2, and connect T-adapters
Resis- (male) (1)
temperature sensor
consolidation box) tance Between EGC3 (female) (19) and TEMP2

2. Disconnect connectors EGC3 and TEMP2, and connect T-adapter to
Short circuit in wiring harness female side of EGC3.
temperature sensor
consolidation box) No continuity
other than (48)
heard)
40-368 D65EX,PX,WX-17
40 Troubleshooting

required.
connector.
3. Disconnect connectors TEMP1, TEMP2 and TEMP3 and connect T-
adapter to male side of TEMP2.
a If no failure is found in check on cause 3 or
4, this check is not required. Max. 10 z
Defective KDPF temperature Between TDPF (male) (2) and TEMP2 (male)
6
sensor consolidation box (2)
Resis- 4, this check is not required. Max. 10 z
tance Between TDPF (male) (1) and TEMP2 (male)
(1)
than (1)
required.
Max. 10 z
Resis- (female) (1)

No continuity
other than (48)
heard)
9 Defective engine controller If this failure code is still displayed and no failure is found in above
D65EX,PX,WX-17 40-369
40 Troubleshooting
40-370 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error

Action
Failure code KDOC outlet temperature sensor in range error
level Failure
L03 CA3318
• The actual difference between the temperatures sensed by KDOC outlet temperature
Failure sensor and KDOC inlet temperature sensor disagrees with the forecasted value.
• Controller continues operation replacing KDOC outlet temperature with KDOC inlet
temperature.
((If a failure is detected in KDOC inlet temperature sensor, too, controller continues
Action of operation regarding KDOC outlet temperature as the default value (250 °C ).)
machine
"TEMP3").
Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform
1. Perform checks and repair referring to harness and connecter related
descriptions in "c: Electrical equipment" of "Checks before
2
D65EX,PX,WX-17 40-371
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).

3 engine controller 2. Disconnect connector TEMP2 and connect T-adapter to male side.
using jumper line.
a If no failure is found by check on cause 3, KDOC outlet temperature
• Reference
2. Disconnect connector TEMP2 and connect T-adapter to female side.
Defective KDOC outlet
4 -10 °C 33–65 Kz
temperature sensor
Resis- (2) 50 °C 7.8–12.2 Kz
tance a Temperature-Resistance 100 °C 3.2 – 4.5 Kz
700 °C 64 to 69 z
2. Disconnect connectors EGC3 and connect T-adapter to female side.
wiring harness
temperature sensor Resis- a The resistance is the same as that listed in 64 z – 65
consolidating box) tance the above temperature-resistance Kz
characteristics.
Open circuit in wiring a If cause 5 is not the cause for the trouble, this check is not required.
harness system 1. Turn starting switch to OFF position.
temperature sensor Resis- (male) (1)
harness 2. Disconnect connectors EGC3 and TEMP2 and connect T-adapter to
(contact with ground circuit) female side of EGC3 or male side of TEMP2.
7
(including inside of KDPF Between ground and EGC3 (female) (48) or
Resis-
temperature sensor TEMP2 (male) (1) Min. 100 Kz
tance
consolidating box)
40-372 D65EX,PX,WX-17
40 Troubleshooting

Short circuit in wiring 2. Disconnect connectors EGC3 and TEMP2, and connect T-adapter to
harness female side of EGC3.
8 (including inside of KDPF a Check with circuit tester in continuity mode.
temperature sensor No continuity
consolidating box) Between EGC3 (female) (48) and each pin
other than (48)
heard)
required.
a If no failure is found by check on cause 5 or
Between TDPF (male) (2) and TEMP2 (male)
(2)
9 sensor consolidating box a If no failure is found by check on cause 5 or
Resis- (1)
tance
Between TDPF (male) (1) and each pin other
than (1)
required.
harness 2. Disconnect connectors EGC3 and TDPF and connect T-adapters to
10 each female side.
Max. 10 z
Resis- (female) (1)
11 harness 2. Disconnect connectors EGC3 and TDPF and connect T-adapter to
TDPF (female) (1) Min. 100 Kz
tance
Short circuit in wiring female side of EGC3.
12
harness a Check with circuit tester in continuity mode.
No continuity
Between EGC3 (female) (48) and each pin
other than (48)
heard)
D65EX,PX,WX-17 40-373
40 Troubleshooting

1. Remove KDPF.
2. Remove KDOC.
13 Defective KDOC (degraded • Check KDOC for cracks (replace KDOC if cracks are found).
• Check whether 50% or more of KDOC inlet surface is plugged with
soot (clean KDOC).
40-374 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3319] KDPF Outlet Temp Sens High Error

Action
Failure code KDPF outlet temperature sensor high error
level Failure
L03 CA3319
Failure • High voltage is detected in KDPF outlet temperature sensor circuit.
• Substitutes KDOC outlet temperature with KDPF outlet temperature to run engine.
(Sets to KDPF outlet temperature to default value (250 °C ) to run engine, if failure is
Action of detected in KDOC outlet temperature sensor.)
machine
• This failure code is displayed if sensor connector is disconnected.
• If failure codes [CA3314] and [CA3317] are also displayed, disconnection of connector of
KDPF temperature sensor consolidation box or open circuit in GND circuit (defective
contact of connector) can be suspected.
1
defective.
D65EX,PX,WX-17 40-375
40 Troubleshooting

2. Disconnect KDPF outlet temperature sensor (connector TEMP3) and
with jumper cable.
If this failure code changes to [CA3321], KDPF outlet temperature
Defective KDPF outlet controller is defective.
2 temperature sensor • Reference
of connector.
-10 °C 33 to 65 Kz
7.8 to 12.2
Resis- (2) 50 °C
Kz
700 °C 64 to 69 z
temperature sensor Resis- a Resistance is the same as that listed in 64 z to 65
consolidation box) tance above temperature-resistance Kz
characteristics.
contact of connector) to female side of EGC3 and male side of TEMP3.
4
Resis- (male) (1)
consolidation box) tance Between EGC3 (female) (19) and TEMP3

temperature sensor
consolidation box) No continuity
other than (54)
heard)
40-376 D65EX,PX,WX-17
40 Troubleshooting

required.
connector.
Defective KDPF temperature Between TDPF (male) (2) and TEMP3 (male)
6
sensor consolidation box (2)
Resis- 4, this check is not required. Max. 10 z
tance Between TDPF (male) (4) and TEMP3 (male)
(1)
than (4)
required.
Max. 10 z
Resis- (female) (4)

No continuity
other than (54)
heard)
9 Defective engine controller If this failure code is still displayed and no failure is found in above
D65EX,PX,WX-17 40-377
40 Troubleshooting
40-378 D65EX,PX,WX-17
40 Troubleshooting
Failure code [CA3321] KDPF Outlet Temp Sens Low Error

D65EX-17,PX-17,WX-17
Action
Failure code KDPF outlet temperature sensor low error
level Failure
L03 CA3321
Failure • Low voltage is detected in KDPF outlet temperature sensor circuit.
• Substitutes KDOC outlet temperature for KDPF outlet temperature to run engine.
(Sets KDPF outlet temperature to default value (250 °C ) to run engine, if failure is
Action of detected in KDOC outlet temperature sensor.)
machine
• If sensor connector is disconnected or its open circuit is detected, high error code
[CA3319] is displayed in stead of this failure code.

1
defective.
D65EX,PX,WX-17 40-379
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).
If this failure code changes to [CA3319], KDPF outlet temperature
• Reference
Defective KDPF outlet of connector.
2 temperature sensor -10 °C 33 to 65 Kz
0 °C 25 to 47 Kz
Between TEMP3 (female) (1) and 7.8 to 12.2
50 °C
(2) Kz
Resis- a Temperature-Resistance 3.2 to 4.5
100 °C
tance Kz
characteristics 200 to 240
400 °C
z
700 °C 64 to 69 z
Between TEMP3 (female) (1) and ground Min. 100
Kz
harness 2. Disconnect connectors EGC3 and TEMP3, and connect T-adapters
(contact with ground circuit) to female side of EGC3 and male side of TEMP3.
3
Resis- Min. 100
temperature sensor TEMP3 (male) (1)
tance Kz
consolidation box)
(including inside of KDPF a Check with multimeter in continuity mode.
4
temperature sensor No
consolidation box) Between EGC3 (female) (54) and every pin continuity
Continuity
is heard)
required.
connector.
5 a If no failure is found in checks on cause 3,
sensor consolidation box Min. 100
this check is not required. Kz
Resis-
this check is not required. Min. 100
Between TDPF (male) (4) and every pin other Kz
than (4)
40-380 D65EX,PX,WX-17
40 Troubleshooting

Resis- Between ground and EGC3 (female) (54) or Min. 100
tance TDPF (female) (4) Kz
No
Between EGC3 (female) (54) and every pin continuity
Continuity
is heard)
2. If this failure code appears, perform procedure described in related
Defective engine controller information "How to clear the failure code".
8
Circuit diagram related to KDPF temperature sensor
D65EX,PX,WX-17 40-381
40 Troubleshooting
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error

Action
Failure code KDPF outlet temperature sensor in range error
level Failure
L03 CA3322
• Temperature sensed by KDPF outlet temperature sensor disagrees with the forecasted
Failure value.
• Controller continues operation replacing KDPF outlet temperature with KDOC inlet
temperature.
((If a failure is detected in KDOC inlet temperature sensor, too, controller continues
Action of operation regarding KDPF outlet temperature as the default value (250 °C ).)
machine
"TEMP3").
Defective KDPF outlet If failure code [CA3319] or [CA3321] is displayed, perform
1. Perform checks and repair referring to harness and connecter related
descriptions in "c: Electrical equipment" of "Checks before
2
40-382 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).

3 engine controller 2. Disconnect TEMP3 and connect T-adapter to female side.
using jumper line.
a If no failure is found by check on cause 3, KDPF outlet temperature
• Reference
2. Disconnect connector TEMP3 and connect T-adapter to female side.
Defective KDPF outlet
4 -10 °C 33–65 Kz
temperature sensor
Resis- (2) 50 °C 7.8–12.2 Kz
tance a Temperature-Resistance 100 °C 3.2 – 4.5 Kz
700 °C 64 to 69 z
wiring harness
temperature sensor Resis- a The resistance is the same as that listed in 64 z – 65
consolidating box) tance the above temperature-resistance Kz
characteristics.
a If no abnormality is found in checks on cause 4, this check is not
Open circuit in wiring required.
harness system
Resis- (male) (1)
harness 2. Disconnect connectors EGC3 and TEMP3 and connect T-adapter to
(contact with ground circuit) female side of EGC3 or male side of TEMP3.
7
Resis-
temperature sensor TEMP3 (male) (1) Min. 100 Kz
tance
consolidating box)
D65EX,PX,WX-17 40-383
40 Troubleshooting

Short circuit in wiring 2. Disconnect connectors EGC3 and TEMP3, and connect T-adapter to
harness female side of EGC3.
8 (including inside of KDPF a Check with circuit tester in continuity mode.
temperature sensor No continuity
consolidating box) Between EGC3 (female) (54) and each pin
other than (54)
heard)
required.
a If no failure is found by check on cause 5 or
(2)
9 sensor consolidating box a If no failure is found by check on cause 5 or
Resis- (1)
tance
Between TDPF (male) (4) and each pin other
than (4)
required.
harness 2. Disconnect connectors EGC3 and TDPF and connect T-adapters to
10 each female side.
Max. 10 z
Resis- (female) (4)
TDPF (female) (4) Min. 100 Kz
tance
Short circuit in wiring female side of EGC3.
12
harness a Check with circuit tester in continuity mode.
No continuity
Between EGC3 (female) (54) and each pin
other than (54)
heard)
40-384 D65EX,PX,WX-17
40 Troubleshooting

Circuit diagram related to KDPF temperature sensor
D65EX,PX,WX-17 40-385
40 Troubleshooting
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Action level Failure code Mass air flow sensor supply voltage high error
Failure
Failure • High voltage is detected in mass air flow sensor power supply (12 V) circuit.
a If a failure is detected in signal voltage of mass air flow sensor, take the same action as
that for [CA356] and [CA357] described below.
Action of • Sets mass air flow to fixed value (10 kg/min) and allows engine to run.
machine
information
1
defective.
2. Disconnect connector MAF
Defective sensor
2 If this failure code does not appear, MAF sensor is defective.
(internal defect)
failure code.
3 Defective harness If this failure code does not appear, wiring harness is defective.
failure code.
2. Disconnect connector ECM J1 and connect T-adapter to male side
of connector.
Voltage Between ECM J1 (male) (21) and (22) Approx. 12
V
40-386 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-387
40 Troubleshooting
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Action level Failure code Mass air flow sensor supply voltage low error
Failure
Failure • Low voltage is detected in mass air flow sensor power supply (12 V) circuit.
a If failure is detected in signal voltage of mass air flow sensor, take the same action as that
for [CA356] and [CA357] described below.
Action of • Sets mass air flow to fixed value (10 kg/min) and allows engine to run.
machine
information
1
defective.
2. Disconnect connector MAF
Defective MAF sensor
2 If this failure code does not appear, MAF sensor is defective.
(internal defect)
because the connector is disconnected. So ignore other codes than
this failure code.
Defective wiring harness or
3 If this failure code does not appear, wiring harness is defective.
connector
failure code.
Ground fault in wiring 2. Disconnect connectors ECM J1 and MAF, and connect T-adapter to
(contact with ground circuit) Resis- Between ground and ECM J1 (female) (21) or Min. 100
tance MAF (female) (2) Kz
5 Short circuit in wiring harness female side of either connector.
Resis- Between ECM J1 (female) (21) and (22) or Min. 100
tance MAF (female) (2) and (3) Kz
connector.
Voltage Between ECM J1 (male) (21) and (22) Approx. 12
V
40-388 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-389
40 Troubleshooting
Failure code [CA3741] Rail Press Valve Trip Error
Action
Failure code Common rail pressure limiter valve is open.
level Failure
L03 CA3741
Failure • Engine controller determines that common rail pressure limiter valve opens.
Action of •
controller
Problem on • Engine output lowers. Engine may not start again.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function.
(Code: 36401 (V))
Related • Pressure sensed by common rail pressure sensor can be checked with monitoring
(Code: 36400 (MPa))
Common rail pressure limiter
valve is open.
40-390 D65EX,PX,WX-17
40 Troubleshooting
Failure code [D130KA] Neutral relay:Open
Action level Failure code Neutral safety relay open circuit

Failure
L01 D130KA (Power train controller system)
• No current flows when primary (coil) circuit of neutral safety relay is grounded, or no
Failure voltage is supplied when circuit is disconnected from ground terminal.
Action of
machine • Stops grounding to neutral safety relay primary circuit (coil side).
monitor
machine
• Output to primary (coil) circuit of neutral safety relay can be checked with monitoring
function. (Code 40909: P/T controller SW output)
Related parking brake lever to FREE position.
information • This failure code detects failure on primary side (coil side) of neutral safety relay, but not
on secondary side (contact side).
• When STC2 (8) pin is shorted to ground, engine starts in any gear speed including neutral
gear speed.
Defective neutral safety relay 2. Disconnect connector NSF and connect T-adapter to male side of
1 (Internal open circuit or short connector.
circuit) Resis- Between NSF (male) (1) and (2) 200 to 600
tance z
2. Disconnect connector STC2 and connect T-adapter to female side of
connector.
Open or short circuit in wiring
2 a If resistance is above 1 Mz , wiring harness has disconnection. If
harness
resistance is below 1 z , wiring harness has short circuit.
Resis- Between STC2 (female) (8) and ground 200 to 600
tance z
Open circuit in wiring harness 2. Disconnect connectors STC2 and NSF, and connect T-adapters to
contact) Between STC2 (female) (8) and NSF (female)
Resis- (1) Max. 1 z
tance
Between NSF (female) (2) and ground Max. 1 z
Ground fault in wiring harness 2. Disconnect connectors STC2 and NSF, and connect T-adapters to
Resis- Between ground and NSF (female) (1) or STC2
(female) (8) Min. 1 Mz
tance
If no failure is found in above checks, power train controller is defective.
• Reference
Defective power train 2. Insert T-adapter into connector STC2.
controller
4. Operate parking brake lever and perform troubleshooting.
Between STC2 (8) and FREE 20 to 30 V
Voltage
ground LOCK Max. 1 V
D65EX,PX,WX-17 40-391
40 Troubleshooting
Circuit diagram related to neutral safety relay
40-392 D65EX,PX,WX-17
40 Troubleshooting
Failure code [D130KB] Neutral relay:Short circuit
Action level Failure code Neutral safety relay short circuit

Failure
L01 D130KB (Power train controller system)
• Abnormal current flows in neutral safety relay primary circuit (coil side) when neutral
Failure safety relay is grounded .
Action of
machine • Stops grounding to neutral safety relay primary circuit (coil side).
monitor
machine
• Output to primary (coil) circuit of neutral safety relay can be checked with monitoring
function. (Code 40909: P/T controller SW output)
Related • Method of reproducing failure code: Turn starting switch to ON position and operate
information parking brake lever to LOCK position.
• This failure code detects failure on primary side (coil side) of neutral safety relay, but not
on secondary side (contact side).
Defective neutral gear safety 2. Disconnect connector NSF and connect T-adapter to male side of
1 relay (internal open circuit or connector.
short circuit) Resis- Between NSF (male) (1) and (2) 300 to 600
tance z
connector.
harness
tance z
Hot short circuit in wiring 2. Disconnect connectors STC2 and NSF, and connect T-adapter to
3 harness female side of STC2.
Voltage Between STC2 (female) (8) and ground Max. 1 V
• Reference
controller
4. Operate parking brake lever and perform troubleshooting.
Between STC2 (8) and FREE 20 to 30 V
Voltage
ground LOCK Max. 1 V
D65EX,PX,WX-17 40-393
40 Troubleshooting
Circuit diagram related to neutral safety relay
40-394 D65EX,PX,WX-17
40 Troubleshooting
Failure code [D19DKA] Amber light relay:Open
Action level Failure code Open circuit in yellow revolving warning lamp relay
Failure
L01 D19DKA (Power train controller system)
• No current flows when primary (coil) circuit of yellow revolving warning lamp relay is
Failure grounded, or no voltage is supplied when circuit is disconnected from ground terminal.
Action of
• Disconnects primary (coil) circuit of yellow revolving warning lamp relay from ground
machine
terminal.
monitor
Problem on
• iB switch cannot be turned on or off.
machine
• Method of reproducing failure code: Turn starting switch to ON position and turn iB switch
Related on.
information • This failure code detects failure on primary side (coil side) of yellow revolving warning
lamp relay, but does not detect failure on secondary (contact) circuit.
Yellow revolving warning 1. Turn starting switch to OFF position.
lamp relay is defective 2. Disconnect connector CLP and connect T-adapter to male side of
1 (internal open circuit or short connector.
circuit). Resis- Between CLP (male) (5) and (6) 200 to 600
tance z
connector.
harness
tance z
Open circuit in wiring harness 2. Disconnect connectors STC2 and CLP, and connect T-adapters to
contact) Between STC2 (female) (18) and CLP (female)
Resis- (5) Max. 1 z
tance
Between CLP (female) (6) and ground Max. 1 z
Hot short circuit in wiring 2. Disconnect connector CLP and connect T-adapter to female side of
Voltage Between CLP (female) (5) and ground Max. 1 V
• Reference
controller
4. Turn iB switch to ON.
Between STC2 (18) Lights up 20 to 30 V
Voltage
and ground Does not light up Max. 1 V
D65EX,PX,WX-17 40-395
40 Troubleshooting
Circuit diagram related to yellow revolving warning lamp relay
40-396 D65EX,PX,WX-17
40 Troubleshooting
Failure code [D19DKB] Amber light relay:Short circuit
Action level Failure code Short circuit in yellow revolving warning lamp relay
Failure
L01 D19DKB (Power train controller system)
• Unusual current flows in primary (coil) circuit of yellow revolving warning lamp relay when
Failure circuit is grounded.
Action of
• Disconnects primary (coil) circuit of yellow revolving warning lamp relay from ground
machine
terminal.
monitor
Problem on
• iB switch cannot be turned on or off when iB switch is in use.
machine
• Method of reproducing failure code: Turn starting switch to ON position and turn iB switch
Related ON.
information • This failure code detects failure in primary (coil) circuit of yellow revolving warning lamp
relay, but does not detects failure in secondary (contact) circuit.
Yellow revolving warning 1. Turn starting switch to OFF position.
lamp relay is defective 2. Disconnect connector CLP and connect T-adapter to male side of
circuit). Resis- Between CLP (male) (5) and (6) 200 to 600
tance z
connector.
harness
tance z
Ground fault in wiring harness 2. Disconnect connectors STC2 and CLP, and connect T-adapters to
Resis- Between ground and CLP (female) (5) or STC2
tance
• Reference
controller
4. Turn yellow revolving warning lamp ON.
Between STC2 (18) Lights up 20 to 30 V
Voltage
and ground Does not light up Max. 1 V
D65EX,PX,WX-17 40-397
40 Troubleshooting
Circuit diagram related to yellow revolving warning lamp relay
40-398 D65EX,PX,WX-17
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality

Action level Failure code Personal Code Relay defective
Failure
L03 D19JKZ (Machine monitor system)
Failure • Disconnection or short circuit is detected in primary coil circuit of personal code relay.
• None in particular (when open circuit is detected)
• Shuts off power supply to personal code relay (when short circuit is detected).
Action of • If cause of failure disappears, machine returns to normal condition by itself (when open
machine circuit is detected).
monitor • Even if cause of failure disappears, machine does not returns to normal condition until
starting switch is turned to OFF position (when short circuit is detected).
Problem on
machine
• This failure code is displayed only when engine lock function is enabled.
• Method of reproducing failure code: Turn starting switch to ON position (in disconnection).
Related Failure cannot be reproduced on machine (in short circuit).
information • Troubleshooting for this failure code covers circuit from fuse No. 1 of fuse box FS22,
through primary (coil) circuit of personal code relay PSL, to machine monitor.
Defective fuse No. 1 of fuse When fuse is blown, ground fault may have probably occurred in circuit.
1
box FS22.
2. Disconnect relay PSL, and connect T-adapter to male side.
Resis- Between PSL (male) (1) and (2)
200 to 600 z
tance
Defective personal code relay
PSL
2. Replace relay PSL with preheating relay PHR.
If this failure code disappears, original personal code relay PSL is
defective.
2. Remove fuse No. 1 in fuse box FS22.
3. Disconnect connectors CM01 and S14, and connect T-adapter to
Open circuit or short circuit or
3 female side of CM01.
ground fault in wiring harness
Between FS22-1 and CM01 (female) (6) 200 to 600 z
Resis-
Between ground and FS22-1 or CM01
tance Min. 1 Mz
(female) (6)
4 Open circuit in wiring harness 3. Disconnect connector CM01 and relay PSL, and connect T-adapters
to female side of each of them.
Between FS22-1 and PSL (female) (1) Max. 1 z
Resis-
Between PSL (female) (2) and CM01
tance Max. 1 z
(female) (6)
2. Remove fuse No. 1 of fuse box FS22.
3. Disconnect connector CM01 and relay PSL, and connect T-adapters
5 Ground fault in wiring harness to female side of each of them.
Between ground and FS22-1 or PSL (female)
Min. 1 Mz
Resis- (1)
tance Between ground and PSL (female) (2) or
CM01 (female) (6) Min. 1 Mz
D65EX,PX,WX-17 40-399
40 Troubleshooting

3. Disconnect connector CM01 and relay PSL, and connect T-adapter
to female side of connector CM01.
No continuity
Between CM01 (female) (6) and every pin
other than pin (6)
heard)
If no failure is found in above checks, machine monitor is defective.
7 Defective machine monitor (Since this is internal defect, troubleshooting cannot be performed.)
40-400 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to personal code relay
D65EX,PX,WX-17 40-401
40 Troubleshooting
Failure code [D811MC] KOMTRAX Error

Action level Failure code KOMTRAX error
Failure
– D811MC (KOMTRAX system)
Detail of
• KOMTRAX malfunctions.
failure
Action of
controller
Problem on • KOMTRAX system does not operate properly.
machine
information
KOMTRAX is defective.
1 Malfunction of KOMTRAX
40-402 D65EX,PX,WX-17
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit

Action level Failure code GPS antenna open circuit
Failure
– D862KA (KOMTRAX system)
Detail of • Open circuit is detected in GPS antenna circuit.
failure
monitor
Problem on • GPS positioning cannot work.
machine
information
Probable causes are defective GPS antenna, open circuit or short
Defective GPS antenna or circuit in antenna cable, and defective connection of antenna cable
1
antenna cable connector (GPS).
Structural illustration
D65EX,PX,WX-17 40-403
40 Troubleshooting
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX)
Action level Failure code Open circuit in system operating lamp

Failure
– D8ALKA (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit is open because voltage of
output circuit remains at about 5 V or below for about 3 seconds after starting switch is
Failure turned to ON position, during which KOMTRAX outputs no current to system operating
lamp.
controller
Problem on • While system operating lamp lights up, battery disconnect switch must not be turned OFF.
machine Turning battery disconnect switch OFF may destroy data stored in KOMTRAX memory.
• Although KOMTRAX is not able to light up system operating lamp, no trouble will result
unless battery disconnect switch is turned OFF.
Related • As long as system operating lamp light up, output circuit voltage remains at Low level.
information • No controllers output current to system operating lamp for approximately 3 seconds after
starting switch is turned to ON position. This allows KOMTRAX to detect open circuit in
system operating lamp circuit.
Blown fuse No. 5 or No. 13 in If fuse is blown, circuit probably has ground fault.
1
fuse box FS12
Open circuit in wiring harness 2. Remove fuse No. 13 of fuse box FS12.
2 (wire breakage or defective 3. Disconnect connector CK01 and connect T-adapters to female side.
contact of connector) Resis- Between CK01 (female) (15) and FS12, 13
Max. 1 z
tance
Ground fault in wiring harness 3. Disconnect connectors CM01, STC3, CK01, EGC3 and LBU, and
3 (contact with ground circuit) connect T-adapters to female side of CK01.
Resis- Between CK01 (female) (15) and ground
Min. 1 Mz
tance
Defective KOMTRAX terminal If no failure is found in above checks, KOMTRAX terminal is defective.
4
defective (Since this is internal defect, troubleshooting cannot be performed.)
40-404 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to system operating lamp
D65EX,PX,WX-17 40-405
40 Troubleshooting
Failure code [D8ALKB] Operating Lamp Short Circuit(KOMTRAX)
Action level Failure code Short circuit in system operating lamp

Failure
– D8ALKB (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit shorts because voltage of
Failure output circuit does not become Low level while KOMTRAX outputs current to system
operating lamp.
controller
Problem on • While system operating lamp lights up, battery disconnect switch must not be turned OFF.
machine Turning battery disconnect switch OFF may destroy data stored in KOMTRAX memory.
Related • Although KOMTRAX is not able to light up system operating lamp, no trouble will result
information unless battery disconnect switch is turned OFF.
• As long as system operating lamp lights up, output circuit voltage remains at Low level.
1 Short circuit in wiring harness 3. Disconnect connectors CM01, STC3, CK01, EGC3, and LBU, and
connect T-adapter to female side of LBU.
Resis- Between LBU (female) (1) and (2)
Min. 1 Mz
tance
If no failure is found in above checks, KOMTRAX terminal is defective.
2 Defective KOMTRAX terminal
40-406 D65EX,PX,WX-17
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon(KOMTRAX)
Action level Failure code Communication on KOMTRAX terminal CAN

communication 2 line impossible
Failure
– D8AQKR
(Detected by machine monitor) (Machine monitor system)
• Machine monitor cannot recognize pump controller over CAN2 communication line
Failure (KOMNET/c).
Action of
machine • None in particular
monitor
machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Four different failure codes, [DBEQKR], [DB2QKR], [D8AQKR], and [DAZQKR], are
used for defective CAN communication by CAN2 when it is detected by machine monitor.
When all of these four failure codes are displayed, ground fault, short circuit or hot short in
wiring harness (CAN communication line) can be suspected. Since air conditioner is also
operated through CAN communication, you must, in such case, check through air
Related conditioner screen whether air conditioner is operable (ON/OFF and air flow of air
information conditioner).
a Air conditioner can be operated even when failure code is displayed on machine monitor
screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or
hot short circuit in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected to continuous power supply,
they receive continuous power even while starting switch is at OFF position.
• Since CAN communication line signal is pulse voltage, it cannot be measured with
multimeter.
Blown fuse No. 1 in fuse box
1 2. Remove fuse No. 1 in fuse box FS12.
FS12
If fuse is blown, circuit probably has ground fault.
Defective power supply to Perform troubleshooting for "E-36" of E-mode.
2
KOMTRAX terminal
Defective CAN Perform checks on cause 4 to 9 in troubleshooting for failure code
3 [DB2QKR].
communication 2 line
If no failure is found in above checks, KOMTRAX terminal is defective.
4 Defective KOMTRAX terminal
5 Defective machine monitor
D65EX,PX,WX-17 40-407
40 Troubleshooting
Failure code [DAF0MB] Monitor Memory Error

Action level Failure code Monitor internal memory (ROM) error
Failure
– DAF0MB (Machine monitor system)
Detail of • Program of machine monitor is rewritten (program error).
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
40-408 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DAF0MC] Monitor Malfunction

Action level Failure code Monitor malfunction
Failure
– DAF0MC (Machine monitor system)
Detail of
• Machine monitor malfunctions.
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
D65EX,PX,WX-17 40-409
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit
Action level Failure code Short circuit in camera power supply

Failure
L03 DAF8KB (Machine monitor system)
• Output power supply voltage (rating: 8 V) from machine monitor to camera is below 6.0 V
Failure
or above 10 V.
Action of • Turns OFF output power supply voltage (rating: 8 V) to camera.
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • Camera image is not displayed on monitor screen.
machine
information
2. Disconnect camera connector CMR1, and turn starting switch to ON
Defective camera position.
1
(internal short circuit) After disconnecting camera connector and performing failure code
reproducing procedure if failure code disappears, camera has internal
defect.
2. Disconnect connector CM04.
2 Defective machine monitor 3. Connect T-adapters to male side of connector CM04.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
Ground fault in wiring harness 2. Disconnect connector CM04 and camera connector CMR1.
3 3. Connect T-adapters to female side of connector CM04.
Resis- Between CM04 (female) (1) and ground
Min. 1 Mz
tance
2. Disconnect camera connector CMR1.
Hot short circuit in wiring 3. Insert T-adapters into connector CM04.
(contact with 24 V circuit) (Disconnect camera and check that camera is not defective in
advance.)
Voltage Between CM04 (1) and (5) Max. 10 V
40-410 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to camera power supply
D65EX,PX,WX-17 40-411
40 Troubleshooting
Failure code [DAF9KQ] Model Selection Abnormality
Action level Failure code Defective model selection

Failure
L03 DAF9KQ (Machine monitor system)
• Different machine models are set by machine monitor program and by power train
Failure controller program.
(Replaced machine monitor or power train controller has a wrong part No.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Assembly part No. of power train controller program can be checked with monitoring
function. (Code: 20242)
Related • Assembly part No. of machine monitor program can be checked with monitoring function.
information (Code: 20227)
1. Display assembly number with monitoring function, and check that it
is the same as part number in Parts Catalog.
Defective machine monitor
(A wrong machine model has been programmed.)
Defective power train Defective power train controller
2
controller (A wrong machine model has been programmed.)
40-412 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DAFGMC] GPS Module Error

Action level Failure code GPS module malfunction
Failure
– DAFGMC (KOMTRAX system in machine monitor)
Detail of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX
failure communication modem in 50 seconds after KOMTRAX started.
monitor
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (wait at least 50
information seconds after starting switch is turned to ON position).
GPS module in machine monitor may be defective.
D65EX,PX,WX-17 40-413
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor)

Failure
– DAFLKA (Machine monitor system)
• Machine monitor determines that system operating lamp circuit is open because voltage
of output circuit remains at approximately 5 V or below for approximately 3 seconds after
Failure starting switch is turned to ON position, during which machine monitor outputs no current
to system operating lamp.
controller
• While system operating lamp lights up, battery disconnect switch must not be turned OFF.
Problem on Turning battery disconnect switch OFF may destroy data stored in machine monitor
machine memory.
• Although machine monitor is not able to light up system operating lamp, no trouble will
result unless battery disconnect switch is turned OFF.
Related • As long as system operating lamp lights up, output circuit voltage remains at Low level.
starting switch is turned to ON position. This allows KOMTRAX to detect open circuit in
system operating lamp circuit.
Blown fuse No. 5 or No. 13 in If fuse is blown, circuit probably has ground fault.
1
fuse box FS12
Open circuit in wiring harness 2. Remove fuse No. 13 in fuse box FS12.
2 (wire breakage or defective 3. Disconnect connector CM01 and connect T-adapter to female side
contact of connector) of connector.
Resis- Between CM01 (female) (8) and F01-16
Max. 1 z
tance
Ground fault in wiring harness 3. Disconnect connectors CM01, STC3, CK01, EGC3 and LBU, and
3 (contact with ground circuit) connect T-adapters to female side of CM01.
Min. 1 Mz
tance
40-414 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-415
40 Troubleshooting
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor)
Action level Failure code Short circuit in system operating lamp circuit
Failure
– DAFLKB (Machine monitor system)
• Machine monitor determines that system operating lamp circuit shorts because voltage of
Failure output circuit does not become Low level while machine monitor outputs current to
system operating lamp.
controller
• While system operating lamp lights up, battery disconnect switch must not be turned OFF.
Problem on Turning battery disconnect switch OFF may destroy data stored in machine monitor
machine memory.
Related • Although machine monitor is not able to light up system operating lamp, no failure will
information result unless battery disconnect switch is turned OFF.
1 Short circuit in wiring harness 3. Disconnect connectors CM01, STC3, CK01, EGC3 and LBU, and
connect T-adapters to female side of L19.
Resis- Between L19 (female) (1) and (2)
Min. 1 Mz
tance
40-416 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DAFQKR] CAN2 Discon
Action level Failure code Failed communication with machine monitor through CAN
Failurecommunication 2 line (detected by KOMTRAX terminal)
– DAFQKR
(KOMTRAX system)
• KOMTRAX terminal does not recognize machine monitor through CAN communication 2
Failure
line.
Action of
controller
Problem on • System may not operate normally.
machine
• Start of CAN communication is notified to each controller by ACC signal from starting
switch.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
Related
not displayed on machine monitor and it can be observed only through KOMTRAX
information
system.
• Since each controller and machine monitor receive power from battery directly, power
supply is kept ON even while starting switch is turned OFF.
• Since CAN communication line signal is pulse voltage, it cannot be measured with
multimeter.
Defective power supply to Perform troubleshooting for "E-5" in E mode.
1
machine monitor
Defective CAN Perform checks on causes 4 and after in troubleshooting for failure code
2 [DB2QKR]
communication
D65EX,PX,WX-17 40-417
40 Troubleshooting
Failure code [DAZ9KQ] A/C Model Selection Abnormality
Action level Failure code Air conditioner model selection mismatch

Failure
– DAZ9KQ (Machine monitor system)
• Different machine models are set by machine monitor program from that by air conditioner
Failure controller program.
(Replaced machine monitor or air conditioner controller has wrong part No.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Model code specified by air conditioner controller program cannot be checked with
• Model codes registered in machine monitor can be checked with monitoring function.
(Code: 00500)
Related • Air conditioner control data of machine monitor (machine model and series) can be
information checked with monitoring function. (Code: 55200)
• Air conditioner controller data (machine model and series) can be checked with
monitoring function. (Code: 55201) (Control data must be 09H (indicating medium size
bulldozer.)
Defective machine monitor
(Wrong machine model is programmed.)
Defective air conditioner Defective air conditioner controller
2
controller (Wrong machine model is programmed.)
40-418 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)

Action level Failure code CAN communication-2 line of air conditioner controller is
disabled
Failure
L01 DAZQKR
• Machine monitor does not recognize air conditioner controller through CAN
Failure communication 2-line (KOMNET/c).
Action of
• Holds information at time of occurrence of failure.
controller
• Information obtained from air conditioner controller is not displayed.
Problem on (Failure code or monitoring code sent by air conditioner controller)
machine • Operation of air conditioner is disabled (air does not come out)
• Air conditioner control screen is not displayed correctly on machine monitor.
switch is received.
• Four different failure codes, [DBEQKR], [DB2QKR], [D8AQKR], and [DAZQKR, are used
for defective CAN communication by CAN2, which are detected by machine monitor.
Related When all of these four failure codes are displayed, ground fault, short circuit or hot short in
information wiring harness (CAN communication circuit) can be suspected.
• Since signal on CAN communication circuit uses pulse voltage, it cannot be measured
with multimeter.
Blown fuse No. 3 in fuse box If fuse is blown, circuit may have grounding fault.
1
FS12
Improper power supply to air a Perform "Troubleshooting for electric power supply system" in
2
conditioner controller Chapter 80.
Defective CAN terminal 1. Turn starting switch to OFF position.
resistor 2. Disconnect connectors CM02 and CTE, and connect T-adapters to
3 male sides of them.
(internal open circuit or short
circuit) Resis- Between CTE (male) (A) and (B) 120 ± 12 z
tance Between CM02 (male) (7) and (9) 120 ± 12 z
• CAN communication circuit
a There is 120 z CAN terminating resistor inside machine monitor as
well. 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, there is no open circuit in wiring
harness.
Open or short circuit in wiring 1. Turn starting switch to OFF position, and turn battery disconnect
4
harness switch to OFF position.
2. Disconnect related connectors and connect T-adapters to connector
at which measurement is performed.
a If short circuit occurs (if resistance between terminals is 1 z or less),
disconnect all CAN communication connectors of each controller.
Then, check whether short circuit is in wiring harness or within
controller.
D65EX,PX,WX-17 40-419
40 Troubleshooting

Between CM02 (female) (8) and (9) Approx.
120 z
Between EGC3 (female) (17) and (18) Approx. 60
z
Between STC2 (female) (32) and (22) Approx. 60
Open or short circuit in wiring Resis- z
4
harness tance Between AC01 (female) (9) and (10) Approx. 60
z
Between CK01 (female) (10) and (11) Approx. 60
z
Between CTE (female) (A) and (B) Approx.
120 z
• ACC signal from starting switch (CAN communication start is not
recognized)
1. Turn starting switch to OFF position, and set battery disconnect
2. Disconnect connector at which measurement is performed and
insert T-adapters into it.
3. Turn battery disconnect switch to ON position, and turn starting
switch to ON position.
Between CM01 (10) and (3) 20 to 30 V
Voltage Between STC2 (14), (24) and (2) 20 to 30 V
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
2. Disconnect related connectors and connect T-adapters to female
Open circuit in wiring harness side of each connector at which measurement is performed.
5 (wire breakage or defective Between CM02 (female) (8) and STC2 (female)
(32) Max. 1 z
Between CM02 (female) (9) and STC2 (female)
(22) Max. 1 z
Between CM02 (female) (8) and EGC3 (female)
(17) Max. 1 z
(18) Max. 1 z
Between CM02 (female) (8) and AC01 (female)
Max. 1 z
Resis- (10)
tance Between CM02 (female) (9) and AC01 (female)
(9) Max. 1 z
Between CM02 (female) (8) and CK01 (female)
(10) Max. 1 z
(11) Max. 1 z
Between EGC3 (female) (17) and CTE (female)
(A) Max. 1 z
(B) Max. 1 z
40-420 D65EX,PX,WX-17
40 Troubleshooting

a If no failure is found in checks on cause 4 (no open circuit), measure
voltage at one connector.
Ground fault in wiring harness side of connector at which measurement is performed.
6
(contact with ground circuit) Between ground and either of STC2 (female)
(32), CM02 (female) (7), (8) and EGC3 (female) Min. 1 Mz
Resis- (17)
tance Between ground and either of STC2 (female)
(22), CM02 (female) (9) and EGC3 (female) Min. 1 Mz
(18)
a If no failure is found in checks on cause 4 (no open circuit), measure
voltage at one connnector for each line.
insert T-adapters into connector.
3. Turn the battery disconnect switch to ON position.
Short circuit or hot short 4. Turn starting switch to ON position.
7 circuit in wiring harness
a Since voltages of CAN H and CAN L circuits are 2.5 ± 1 V including
(contact with 24 V circuit) time during communication, regard wiring harness as normal if
voltage is between 1 and 4 V.
Between ground and either of CM02 (female)
(8), STC2 (female) (32), CK01 (female) (10), 1 to 4 V
AC01 (female) (9) and EGC3 (female) (17)
Voltage
• If all four of [DBEQKR], [DB2QKR], [D8AQKR] and [DAZQKR]
failure codes are displayed:
a Repeat following steps 1. to 3. to disconnect controllers one by one
from CAN communication and to identify defective controller.
1. Turn starting switch to OFF position and disconnect battery ground
Defective engine controller, cable.
power train controller, air 2. Disconnect CAN communication connector of engine controller
8 (connector EGC3), power train controller (connector STC2), air
conditioner unit, or
KOMTRAX terminal conditioner unit (connector AC01), and KOMTRAX terminal
(connector CK01) one by one in turn.
3. Connect battery ground cable, turn starting switch to ON position
and perform troubleshooting.
4. Return to step 1. and perform troubleshooting for next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
If no failure is found in above checks, the air conditioner controller is
Defective air conditioner defective
9
controller
D65EX,PX,WX-17 40-421
40 Troubleshooting
Circuit diagram related CAN2 communication
40-422 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con)

D65EX-17,PX-17,WX-17
Action level Failure code Communication on CAN communication 2 circuit of engine
controller is disabled.
Failure
L03 DB2QKR
• Machine monitor does not recognize engine controller through CAN communication 2
Failure circuit (KOMNET/c).
Action of
controller
• Information obtained from engine controller is not displayed and special functions to be
Problem on received do not work. Or, received data is no longer updated.
machine (failure codes and monitoring codes sent from engine controller)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
for defective CAN communication by CAN2, which are detected by machine monitor.
wiring harness (CAN communication line) can be suspected. Since air conditioner is also
Related operated through CAN communication, you must, in such case, check on air conditioner
information screen whether air conditioner is operable (ON/OFF and air flow of air conditioner).
hot short circuit in wiring harness (CAN communication circuit).
with multimeter.
Blown fuse No. 4 in fuse box
FS22, or blow fuse No. 4 in 2. Remove fuse No. 4 in fuse box FS22.
1
• When fuse is blown, engine controller may have short circuit in it.
fuse box FS12
• If fuse No. 4 of FS12 is blown, the wiring harness may be grounded.
a If the fuse is not blown, this check is not required.
2 Defective engine controller 2. Disconnect connectors EGC3 and connect T-adapter to male side of
connector.
Resis- Between EGC3 (male) (1) and (21) Max. 10 z
tance Between EGC3 (male) (11) and (31) Max. 10 z
a Check ground terminal GND20 for looseness and corrosion.
Defective power supply to 3. Turn starting switch to ON position.
3 engine controller
a If result is abnormal, perform troubleshooting for [CA441].
Between EGC3 (female) (1) and (21) 20 to 30 V
Voltage
Between EGC3 (female) (11) and (31) 20 to 30 V
Defective CAN terminating 1. Turn starting switch to OFF position.
resistor 2. Disconnect connectors CM02 and CTE, and connect T-adapters to
4 male sides of them.
circuit) Resis- Between CTE (male) (A) and (B) 120 ± 12 z
D65EX,PX,WX-17 40-423
40 Troubleshooting

harness.
1. Turn starting switch to OFF position, and turn battery disconnect
2. Disconnect related connectors and connect T-adapters to connector
at which measurement is performed.
a If short circuit occurs (if resistance between terminals is 1 z or less),
Open or short circuit in wiring disconnect all CAN communication connectors of each controller.
5 Then, check whether short circuit is in wiring harness or within
harness
controller.
120 z
Between EGC3 (female) (17) and (18) Approx. 60
z
Resis- z
tance Between AC01 (female) (9) and (10) Approx. 60
z
Between CK01 (female) (10) and (11) Approx. 60
z
Between CTE (female) (A) and (B) Approx.
120 z
recognized)
insert T-adapters into it.
Open circuit in wiring harness Between CM01 (10) and (3) 20 to 30 V
6 (wire breakage or defective Between EGC3 (3) and (21) 20 to 30 V
contact of connector) Voltage Between STC2 (14), (24) and (2) 20 to 30 V
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
side of each connector at which measurement is performed.
40-424 D65EX,PX,WX-17
40 Troubleshooting

(32) Max. 1 z
(22) Max. 1 z
(17) Max. 1 z
(18) Max. 1 z
Between CM02 (female) (8) and AC01 (female)
Open circuit in wiring harness Max. 1 z
Resis- (1)
6 (wire breakage or defective tance Between CM02 (female) (9) and AC01 (female)
contact of connector) Max. 1 z
(2)
(10) Max. 1 z
(11) Max. 1 z
(A) Max. 1 z
(B) Max. 1 z
a If no failure is found in checks on cause 5 (no open circuit),,measure

Ground fault in wiring harness side of connector at which measurement is performed.
7
(contact with ground circuit) Between ground and either of STC2 (female)
(32), CM01 (female) (7), (8) and EGC3 (female) Min. 1 Mz
Resis- (17)
(22), CM01 (female) (9) and EGC3 (female) Min. 1 Mz
(18)
a If no failure is found by checks on cause5 (no open circuit),measure
voltage at one connnector for each circuit.
insert T-adapters into connector.
3. Turn battery disconnect switch to ON position.
Short circuit or hot short 4. Turn starting switch to ON position.
a Since voltages of CAN H and CAN L circuits are 2.5 ± 1 V including
(contact with 24 V circuit) time during communication, regard wiring harness as normal if
Voltage
D65EX,PX,WX-17 40-425
40 Troubleshooting

• If all four of [DBEQKR], [DB2QKR], [D8AQKR] and [DAZQKR]
failure codes are displayed:
a Repeat following steps 1. to 3. to disconnect controllers one by one
from CAN communication and to identify defective controller.
Defective engine controller, switch to OFF position.
power train controller, air 2. Disconnect CAN communication connector of engine controller
9 conditioner unit, or (connector EGC3), power train controller (connector STC2), air
KOMTRAX terminal is conditioner unit (connector AC01), and KOMTRAX terminal
defective. (connector CK01) one by one in turn.
3. Turn battery disconnect switch to ON position, turn starting switch to
ON position, then perform troubleshooting.
4. Return to step 1. and perform troubleshooting for next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
40-426 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related CAN2 communication
D65EX,PX,WX-17 40-427
40 Troubleshooting
Failure code [DB2RKR] CAN1 Discon (Engine Con)

Action level Failure code Communication on CAN communication 1 circuit of engine
Failure controller is disabled.
L03 DB2RKR
• Machine monitor does not recognize engine controller through CAN communication 1
Failure circuit (KOMNET/r).
• Retains current working mode.
Action of
• Retains current selection of auto-deceleration.
controller
• Information obtained from engine controller is not displayed and special functions to be
recived do not work. Or, received data is no longer updated.
Problem on • Engine cannot be controlled.
machine • Engine speed and coolant temperature cannot be detected.
• Engine coolant and hydraulic oil temperature gauge needles go off on machine monitor
screen.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller may be defective (cause 1).
• Machine monitor can detects CAN1 communication failure codes of [DBERKR] and
[DB2RKR].
Related
• CAN1 terminating resister is located in machine monitor on operator's cab side and
information
connector "RES2" is located on engine side (CAN communication-1 circuit (KOMNET/r) is
not provided. It is output from connector "ECM J2".)
with multimeter.
Defective engine controller [Perform checks on causes 1 to 3 in troubleshooting for failure code
1 system [DB2QKR].
Defective CAN terminating 1. Turn starting switch to OFF position.
resistor 2. Disconnect connectors CM02 and RES2, and connect T-adapters to
2 male side of them.
circuit) Resis- Between RES2 (male) (A) and (B) 120 ± 12 z
40-428 D65EX,PX,WX-17
40 Troubleshooting

harness.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors CM02, STC2, ECM J1, ECM J2 and RES2
one by one, and connect T-adapter to female side of each
connector.
Open or short circuit in wiring a If short circuit occurs (if resistance between terminals is 1 z or less),
3 disconnect all of CAN communication connectors of each controller.
harness
Then, check whether short circuit is in wiring harness or within
controller.
120 z
z
Resis- Between RES2 (female) (A) and (B) Approx.
tance 120 z
Between ECM J1 (female) (8) and (18) Approx.
120 z
Between ECM J2 (female) (24) and (25) Approx.
120 z
recognized)
2. disconnect connectors CM01, STC3 and EGC3, and insert T-
adapter into them.
Between CM01 (10) and (3) 20 to 30 V
Voltage Between EGC3 (3) and (21) 20 to 30 V
Between STC3 (14), (24) and (2) 20 to 30 V
Open circuit in wiring harness 1. Turn starting switch to OFF position, and set battery disconnect
4 (wire breakage or defective switch to OFF position.
contact of connector) 2. Disconnect connectors CM02, STC2, ECM J1, ECM J2 and RES2,
and connect T-adapters to female side of them.
Between CM02 (female) (11) and STC2
Between CM02 (female) (12) and STC2
Between CM02 (female) (11) and ECM J1
Max. 1 z
Resis- (female) (8)
tance Between CM02 (female) (12) and ECM J1
Between ECM J2 (female) (24) and RES2
Between ECM J2 (female) (25) and RES2
D65EX,PX,WX-17 40-429
40 Troubleshooting

2. Disconnect connectors CM02, STC2, ECM J1, ECM J2 and RES2,
and connect T-adapters to female side of either connector.
Between ground and either of STC2 (female)
(33), CM02 (female) (10), (11) and ECM J1 Min. 1 Mz
Ground fault in wiring harness (female) (8)
5
(contact with ground circuit) Between ground and ECM J2 (female) (24) or
Min. 1 Mz
Resis- RES2 (female) (A)
(23), CM02 (female) (12) and ECM J1 (female) Min. 1 Mz
(18)
Between ground and either of ECM J2 (female)
(25) and RES2 (female) (B) Min. 1 Mz
a If no failure (no open circuit) is found in check on cause 3, measure

2. Disconnect either of connectors CM02, STC2 and RES2, and
3. Turn battery disconnect switch to the ON position.
Short circuit or hot short
6 circuit in wiring harness a Measurement is not performed on ECM J1 and ECM J2.
(contact with 24 V circuit) a Since voltages of CAN H and CAN L circuits are 2.5 ± 1 V including
time during communication, regard wiring harness as normal if
(33), CM02 (female) (10), (11) and RES2 1 to 4 V
(female) (A)
Voltage
(22), CM02 (female) (12) and RES2 (female) 1 to 4 V
(B)
• If failure code on [DBERKR] is also displayed:
a Locate failure in power train controller or in engine controller by
disconnecting them one by one from CAN communication circuit.
Defective power train switch to OFF position.
7 2. Disconnect power train controller (connector STC2).
controller
Does number of CAN1 communication failure
codes decrease from those on [DBERKR] and If YES, power train
[DB2RKR]? controller is defective.
• If failure code on [DBERKR] is also displayed:
a Locate failure in power train controller or in engine controller by
disconnecting them one by one from CAN communication circuit.
8 Defective engine controller 2. Disconnect engine controller (connector ECM J1).
Does number of CAN1 communication failure If YES, engine
codes decrease from those on [DABEKR] and controller is defective.
[DB2RKR]?
40-430 D65EX,PX,WX-17
40 Troubleshooting

D65EX,PX,WX-17 40-431
40 Troubleshooting
Circuit diagram related to CAN1 communication
40-432 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DBE0KT] PT controller:Abnormality in controller
Action level Failure code Defective power train controller memory value
Failure
L01 DBE0KT (Power train controller system)
Failure • Information in ROM (non-volatile memory) in power train controller is abnormal.
Action of
machine • Reset internal adjustment values to default values.
monitor
Problem on • Operator’s feeling at transmission gear shift may become uncomfortable .
machine • Adjusting function by power train controller may not operate properly.
information
Display adjustment function in service mode and perform operation of
Defective adjustment by reproducing trouble. If “E” of failure code disappears at this time, system
1 power train controller is normal.
• Adjusting code: 0002 (Power train controller initial setting)
Defective power train Since this is internal defect, troubleshooting cannot be performed. (If
2 there is no visible failure on machine, controller may be used as it is.)
controller
D65EX,PX,WX-17 40-433
40 Troubleshooting
Failure code [DBE1KK] PT controller:Source voltage low

Action level Failure code Drop of main power supply voltage for power train
Failure controller.
L04 DBE1KK
Failure • Main power supply voltage for power train controller drops to below 17 V.
controller
• Machine monitor may not display correctly.
Problem on • Relay and solenoid may not be actuated and system may not operate properly.
machine • Once machine stops, engine speed is limited to medium (half) speed afterwards.
• Once machine stops, it cannot travel at all.
• Power supply voltage of power train controller can be checked by adjusting function.
Related (Code: 2021: Power train controller voltage check mode)
If fuse FL1-4 or FS22-3 blows, circuit may be grounded. Perform
1 Blown fuse FL1-4 or FS22-3 troubleshooting for Cause 6.
Loose terminal or 1. Turn starting switch to OFF position.
2
disconnection at terminal Check terminals of battery, battery relay, etc.
1. Perform troubleshooting with starting switch at OFF position and
3 Improper battery voltage when starting engine.
Voltage Between battery terminals (+) and (-) 20 to 30 V
2. Turn battery disconnect switch to OFF position.
Open circuit or ground fault in connector.
4 wiring harness 4. Turn the battery disconnect switch to ON position.
a If voltage is 0 V, wiring harness has open-cricuit or ground fault.
Between STC3 (female) (1) and (21), (31) 20 to 30 V
Voltage
Between STC3 (female) (11) and (32), (33) 20 to 30 V
3. If fuse is blown out, replace it.
Open circuit in wiring harness 4. Disconnect connector STC3 and connect T-adapter to female side of
connector.
5 (damage of wire or defective
Between STC3 (female) (21), (31), (32) and
contact)
(33) and ground
Max. 1 z
Resis- a Check terminal GND11 for looseness and
tance rust.
Between STC3 (female) (1), (11) and battery
positive terminal Max. 1 z

Ground fault in wiring harness 3. If fuse is blown out, replace it.
6
(contact with ground circuit) 4. Disconnect connector STC3 and connect T-adapter to female side of
connector.
Resis- Between STC3 (female) (1) and (21), (31) Min. 1 Mz
tance Between STC3 (female) (11) and (32), (33) Min. 1 Mz
40-434 D65EX,PX,WX-17
40 Troubleshooting

• Reference
Defective power train 2. Turn battery disconnect switch to OFF position.
7 3. Insert T-adapter into connector STC3.
controller
Between STC3 (1) and (21), (31) 20 to 30 V
Voltage
Between STC3 (11) and (32), (33) 20 to 30 V
Circuit diagram related power train controller battery direct power supply
D65EX,PX,WX-17 40-435
40 Troubleshooting
Failure code [DBE2KK] PT controller:Output voltage low
Action level Failure code Voltage drop in power supply for load on power train
Failure controller
L04 DBE2KK
Failure • Power voltage for power train controller loads (relays and solenoids) drops below 17 V.
controller
• Relay and solenoid may not be actuated and system may not operate properly.
Problem on • Once machine stops, engine speed is limited to medium (half) speed.
machine • Once machine stops, it cannot travel at all.
• Power supply voltage of power train controller can be checked by adjusting function.
Related (Code: 2021: Power train controller voltage check mode)
information • If battery relay does not turn ON, see E-1 in E-mode.
Defective fuse (FL2-4 or If fuse FL2-4 or FS22-1 blows, circuit may be grounded. Perform
1 FS22-1) troubleshooting for Cause 6.
Loose terminal or 1. Turn starting switch to OFF position.
2
disconnection at terminal Check terminals of battery, battery relay, etc.
1. Perform troubleshooting with starting switch at OFF position and
3 Improper battery voltage when starting engine.
Voltage Between battery terminals (+) and (-) 20 to 30 V
Defective wiring harness or 4. Turn battery disconnect switch to ON position.
4 power train controller a Turn starting switch to ON position.
Between STC3 (2) and (21) 20 to 30 V
Voltage Between STC3 (12) and (31) 20 to 30 V
Between STC3 (22) and (32) 20 to 30 V
2. Turn battery disconnect switch to OFF position (to prevent short
circuit during work).
Open circuit in wiring harness 3. Disconnect connector STC3 and connect T-adapter to female side of
connector.
5 (wire damage or defective
Between STC3 (female) (21), (31), (32) and
contact)
(33) and ground
Max. 1 z
Resis- a Check terminal GND11 for looseness and
tance rust.
Between terminal STC3 (female) (2), (12) and
(22) and terminal BRC Max. 1 z

Ground fault in wiring harness 2. Turn battery disconnect switch to OFF position (to prevent short
6 circuit during work).
(contact with ground circuit) 3. If fuse is blown out, replace it.
4. Disconnect connector STC3.
Resis- Between terminal BRC and ground
Min. 1 Mz
tance
Defective power train If no failure is found in above checks, power train controller is defective.
7
controller
40-436 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related power train controller solenoid power supply
D65EX,PX,WX-17 40-437
40 Troubleshooting
Failure code [DBE5KK] PT:Sensor volt 5V (0) Out of normal range

Action level Failure code Power train controller 5 V power supply (0) error
Failure
L03 DBE5KK (Power train controller system)
• Voltage of 5 V power supply (0) from power train controller to sensors is below 4.5 V or
Failure above 5.5 V.
• Unusual current flows in 5 V power supply (0) circuit for power train controller sensor.
Action of • Stops output of 5 V power supply (0), if unusual current flows.
• System may not operate normally.
machine • Once machine stops, travel is restricted to F1 and R1.
information
3. After each troubleshooting, turn starting switch to OFF position.
• If this code is not displayed when sensor is disconnected, that
Defective fuel control dial or device related to sensor disconnected is defective.
1 PCCS lever (internal defect)
connector is disconnected. Ignore failure codes other than
[DBE5KK].
Fuel control dial DIA2
Connector
PCCS lever TLV1
2. Disconnect connector STC1 and connect T-adapter to male side of
Defective power train connector.
2
controller 3. Turn starting switch to ON position.
Voltage Between STC1 (male) (22) and (21) 4.5 to 5.5
V
Ground fault in wiring harness 2. Disconnect all of connectors STC1, DIA2 and TLV1, and connect T-
3 adapters to female side of either connector.
Resis- Between ground and STC1 (female) (22), TLV1
(female) (4) and (5), or DIA2 (female) (A) Min. 1 Mz
tance
Hot short circuit in wiring 2. Disconnect connectors DIA2 and TLV1, and connect T-adapters to
harness female side of either connector.
Between TLV1 (female) (4) and (1) or (5) and 4.5 to 5.5
Voltage
(8), or between DIA2 (female) (A) and (C) V
40-438 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to 5 V power supply (0)
D65EX,PX,WX-17 40-439
40 Troubleshooting
Failure code [DBE6KK] PT:Sensor volt 24V Out of normal range

Action level Failure code Out of 24 V power supply output voltage range for power
Failure train controller sensor
L03 DBE6KK
• Voltage of 24 V power supply from power train controller to sensors is below 17 V or
Failure above 30 V.
• Unusual current flows in 24 V power supply circuit for power train controller sensors.
Action of • Stops output of 24 V power supply if unusual voltage flows.
• System may not operate normally.
information
2. Disconnect connector PT1.
Defective pitch angle sensor 3. Turn starting switch to ON position.
1 • If this code is not displayed pitch angle sensor is defective.
(internal defect)
a Other failure codes are displayed as well. This is because connector
is disconnected. Ignore failure codes other than [DBE6KK].
2
Voltage Between STC1 (male) (16) and (21) 20 to 30 V
Ground fault in wiring harness 2. Disconnect connectors STC1 and PT1, and connect T-adapters to
Resis- Between ground and STC1 (female) (16) or
PT1 (female) (C) Min. 1 Mz
tance
2. Disconnect connector PT1 and connect T-adapter to female side of
4 Short circuit in wiring harness connector.
Voltage Between PT1 (female) (C) and (A) 20 to 30 V
40-440 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to 24 V power supply for power train controller
D65EX,PX,WX-17 40-441
40 Troubleshooting
Failure code [DBE7KK] PT:Sensor volt 5V (1) Out of normal range

Action level Failure code 5 V power supply 1 for power train controller sensor failure
Failure
L03 DBE7KK (Power train controller system)
• Voltage of 5 V power supply (1) from power train controller to sensors is below 4.5 V or
Failure above 5.5 V.
• Unusual current flows in 5 V power supply (1) circuit for power train controller sensors.
Action of • Stops output of 5 V power supply (1), if unusual current flows.
controller
information
3. After each troubleshooting, turn starting switch to OFF position.
Defective brake pedal • If this code is not displayed when sensor or device is disconnected,
potentiometer, torque that sensor or device is defective.
converter pressure sensor, or
1 work equipment pump oil a Other failure codes are displayed at the same time. This happens
pressure sensor (internal because connector is disconnected. So ignore other codes than this
defect) failure code [DBE7KK].
Brake pedal potentiometer BRK
Torque converter pressure sensor TIP
Connector
Oil pressure sensor of work
equipment pump HHP

2
Voltage Between STC2 (male) (1) and ground 4.5 to 5.5
V
2. Disconnect connectors STC2, BRK, TIP, and HHP and connect T-
Ground fault in wiring harness adapter to female side of either connector.
3
(contact with ground circuit) Between ground and STC2 (female) (1), BRK
Resis- (female) (B), TIP (female) (3) or HHP (female)
Min. 1 Mz
tance (3)
2. Disconnect connectors BRK, TIP, and HHP and connect T-adapter
Hot short circuit in wiring to female side of either connector.
(contact with 24 V circuit) Between BRK (female) (B) and (C), or between
Voltage TIP (female) (3) and (1), or between HHP 4.5 to 5.5
40-442 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to 5 V power supply (1) for power train controller sensor
D65EX,PX,WX-17 40-443
40 Troubleshooting
Failure code [DBE9KQ] PT controller:Type select signal

Action level Failure code Failure of model selection in power train controller
Failure
L04 DBE9KQ (Power train controller system)
• Specification set in power train controller does not agree with specification set in memory
Failure (Initialization of power train controller is not performed).
Action of • Stops all of outputs of power train controller.
machine • Restricts operation of engine and transmission.
monitor
• Machine does not move at all.
Problem on • Once machine stops, engine speed is restricted to medium (half) speed.
information
Display adjustment function in service mode and perform operation of
Defective adjustment of reproducing falure code. If E of failure code disappears at this time,
1 power train controller system is normal.
• Adjustment code: 0002 (Power train controller initial setting)
40-444 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DBELKA] Operating Lamp Open Circuit(PT Con)

Failure
– DBELKA (Power train controller system)
• Power train controller determines that system operating lamp circuit is open because
voltage of output of system operating lamp remains at approximately 5 V or below for
Failure approximately 3 seconds after starting switch is turned to ON position during which output
from power train controller is not made.
controller
• System operating lamp indicates period during which battery disconnect switch must not
Problem on be turned to OFF position. Turning battery disconnect switch to OFF position may destroy
machine memory data on power train controller.
• Since power train controller is not able to light system operating lamp, no problem will
result unless battery disconnect switch is turned to OFF position.
Related • As long as system operating lamp lights up, output circuit voltage remains at Low level.
starting switch is turned to ON position. This allows power train controller to detect open
circuit in system operating lamp circuit.
Defective fuses No. 5 and No. If fuse is blown, circuit many have ground fault.
1
13 in fuse box FS12
Open circuit in wiring harness 2. Remove fuse No. 5 in fuse box FS12.
2 (wire breakage or defective 3. Disconnect connector STC3 and connect T-adapter to female side of
contact of connector) connector.
Resis- Between STC3 (female) (34) and FS12-5
Max. 1 z
tance
Ground fault in wiring harness 3. Disconnect connectors CM01, STC3, CK01, EGC3, and LBU, and
3 (contact with ground circuit) connect T-adapter to female side of STC3.
Resis- Between STC3 (female) (34) and ground
Min. 1 Mz
tance
4
controller (Since this is internal defect, troubleshooting cannot be performed.)
D65EX,PX,WX-17 40-445
40 Troubleshooting
40-446 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DBELKB] Operating Lamp Short Circuit(PT Con)

Action level Failure code Short circuit in system operating lamp
Failure
– DBELKB (Power train controller system)
• Power train controller detects short circuit because output from power train controller to
Failure system operating lamp does not make output voltage low.
controller
• System operating lamp indicates period during which battery disconnect switch must not
Problem on be turned to OFF position. Turning battery disconnect switch to OFF position may destroy
machine memory data in power train controller.
Related • Since power train controller is not able to light system operating lamp, no problem will
information result unless battery disconnect switch is turned to OFF position.
1 Short circuit in wiring harness 3. Disconnect connectors CM01, STC3, CK01, EGC3, and LBU, and
connect T-adapter to female side of LBU.
Resis- Between LBU (female) (1) and (2)
Min. 1 Mz
tance
2
D65EX,PX,WX-17 40-447
40 Troubleshooting
Failure code [DBEQKR] CAN2 Discon (PT Con)
Action level Failure code CAN communication-2 circuit of power train controller is
disabled
Failure
L03 DBEQKR
• Machine monitor does not recognize power train controller over CAN communication 2
Failure circuit (KOMNET/c).
Action of
machine • Not installed
monitor
Problem on
• Not installed
machine
switch is received.
for defective CAN communication by CAN2 when it is detected by machine monitor.
wiring harness (CAN communication circuit) can be suspected. Since air conditioner is
also operated through CAN communication, you must, in such case, check on air
Related conditioner screen whether air conditioner is operable (ON/OFF and air flow of air
information conditioner).
hot short circuit in wiring harness (CAN communication circuit).
• Since CAN communication circuit signal uses pulse voltage, it cannot be measured with
multimeter.
Defective power supply to
1 Perform troubleshooting for failure codes [DBE1KK] and [DBE2KK].
power train controller
Defective CAN Perform checks on cause 4 to 9 in troubleshooting for failure code
2 communication 2 system [DB2QKR].
3
40-448 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DBERKR] CAN1 Discon (PT Con)
Action level Failure code CAN communication-1 circuit of power train controller is
Failure disabled.
L03 DBERKR
• Machine monitor does not recognize power train controller over CAN communication-1
Failure circuit (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains current setting (Hi/Lo) of travel speed.
• Holds information at the time of occurrence of failure.
• Information or special function obtained from power train controller is not displayed or
operable. Or update of received data is stopped.
• Pump control is disabled.
Problem on • Hydraulic oil temperature gauge needle goes off on machine monitor screen.
machine • Wiper operation is disabled.
• Washer operation is disabled.
• Flow control of attachment hydraulic circuit is disabled.
switch is received.
• Machine monitor indicates CAN communication error with failure code [DB2RKR]. If
failure code [DB2RKR] is also displayed, wiring harness (CAN communication circuit)
may have ground fault, short circuit, or hot short circuit.
Related
• CAN1 terminating resistor is located in machine monitor on operator's cab side and
information
connector "RES2" is located on engine side (CAN communication-1 circuit (KOMNET/r) is
not provided. It is led from connector "ECM J2").
• Since CAN communication circuit signal uses pulse voltage, it cannot be measured with
multimeter.
Defective power supply
1 system to power train Perform troubleshooting for failure codes [DBE1KK].
controller
Defective CAN Perform checks on causes 2 to 8 in troubleshooting for failure code
2 communication 1 system [DB2RKR].
Defective power train If no failure is found in above checks, power train controller is defective
3
D65EX,PX,WX-17 40-449
40 Troubleshooting
Failure code [DD12KA] Shift up Sw:Open

Action level Failure code Shift up switch disconnection
Failure
L03 DD12KA (Power train controller system)
• Both lines of NO* and NC* for shift up switch circuit are OPEN (switch: OFF) at the same
Failure
time.
Action of • Recognizes that shift up switch is not pressed.
controller
• Transmission gear cannot be shifted up.
Problem on • Auto shift-down does not function.
machine • Once machine stops, engine speed is restricted to medium (half) speed.
• Once machine stops, travel is restricted to F1 and R1.
• "NO*" line is used for detecting operation and "NC*" line is used for detecting error.
• Condition of shift up switch signal can be checked with monitoring function.
Related (Code: 40905 P/T controller SW input 1)
information • 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 of
connector.
3. Turn shift down switch to ON or OFF position and perform
Defective shift up switch troubleshooting.
1
(internal open circuit in wiring) a "Switch OFF": Release, "Switch ON": Press
Between SFTU (male) Switch: OFF Max. 1 z
Resis- (3) and (2) Switch: ON Min. 1 Mz
tance Between SFTU (male) Switch: OFF Min. 1 Mz
(1) and (2) Switch: ON Max. 1 z
2. Disconnect connector SFTU and connect T-adapter to female side
of connector.
Open circuit or hot short in a When voltage is 0V, it shows open circuit, and when voltage is 24 V,
2 wiring harness it shows hot short circuit in wiring harness.
a Voltage of approximately 9 V is applied to signal lines of "NO" and
"NC" through resistor in power train controller.
Between SFTU (female) (1) and (2) 7 to 11 V
Voltage
Between SFTU (female) (3) and (2) 7 to 11 V
a If no failure is found in checks on cause 2 this check is not required.
2. Disconnect connectors STC1 and SFTU, and connect T-adapters to
Open circuit in wiring harness female side of each connector.
3 (wire breakage or defective Between STC1 (female) (5) and SFTU (female)
(1) Max. 1 z
contact)
Resis- Between STC1 (female) (10) and SFTU
tance
Between STC1 (female) (11) and SFTU
40-450 D65EX,PX,WX-17
40 Troubleshooting

• Reference
Defective power train troubleshooting.
4
controller a Voltage of approx.9 V is applied to STC1 pin (5) and STC1 pin (11)
through resistor in power train controller.
Between STC1 (5) and Switch: OFF 7 to 11 V
(10) Switch: ON Max. 1 V
Voltage
Between STC1 (11) Switch: OFF Max. 1 V
and (10) Switch: ON 7 to 11 V
*NO: Normally Open
*NC: Normally Closed
Circuit diagram related to shift up switch
D65EX,PX,WX-17 40-451
40 Troubleshooting
Failure code [DD12KB] Shift up Sw:Short circuit

Action level Failure code Short circuit in shift up switch
Failure
L03 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.
controller
• Transmission gear cannot be shifted up.
Problem on • Auto-shift down does not function.
up switch
2. Disconnect connector SFTU and connect T-adapter to male side of
connector.
1
Between SFTU (male) Switch: OFF Max. 1 z
tance Between SFTU (male) Switch: OFF Min. 1 Mz
2. Disconnect connectors STC1, STC3 and SFTU and connect T-
Ground fault in wiring harness adapters to female side of either connector.
2 Between ground and SFTU (female) (1) or
(contact with ground circuit) Min. 1 Mz
Resis- STC1 (female) (5)
tance Between ground and SFTU (female) (3) or
STC1 (female) (11) Min. 1 Mz

2. Disconnect connectors STC1 and SFTU, and connect T-adapters to
female side of STC1.
No
3 Short circuit in wiring harness Between STC1 (female) (5) and every pin other continuity
than (5) (No sound
is heard)
Continuity
No
Between STC1 (female) (11) and every pin continuity
is heard)
40-452 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4
Between STC1 (5) and Switch: OFF 7 to 11 V
(10) Switch: ON Max. 1 V
Voltage
*NO: Normally Open
Circuit diagram related to shift up switch
D65EX,PX,WX-17 40-453
40 Troubleshooting
Failure code [DD13KA] Shift down Sw:Open

Action level Failure code Shift-down switch disconnection
Failure
L03 DD13KA (Power train controller system)
• Both linens of NO* and NC* for shift down switch circuit are OPEN (switch: OFF) at the
Failure
same time.
controller
• Shift down is not possible.
up switch.
2. Disconnect connector SFTD and connect T-adapter to male side of
connector.
3. Turn shift up switch to ON or OFF position and perform
1
Between SFTD (male) Switch: OFF Max. 1 z
tance Between SFTD (male) Switch: OFF Min. 1 Mz
2. Disconnect connector SFTD and connect T-adapter to female side
of connector.
Open circuit or hot short in a When voltage is 0 V, it shows open circuit, and when voltage is 24 V,
Between SFTD (female) (1) and (2) 7 to 11 V
Voltage
Between SFTD (female) (3) and (2) 7 to 11 V
2. Disconnect connectors STC1 and SFTD, and connect T-adapters to
3 (wire breakage or defective Between STC1 (female) (17) and SFTD
contact)
Resis- Between STC1 (female) (10) and SFTD
tance
Between STC1 (female) (23) and SFTD
40-454 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4
Between STC1 (17) Switch: OFF 7 to 11 V
and (10) Switch: ON Max. 1 V
Voltage
*NO: Normally Open
Circuit diagram related to shift down switch
D65EX,PX,WX-17 40-455
40 Troubleshooting
Failure code [DD13KB] Shift down Sw:Short circuit

Action level Failure code Short circuit in shift down switch
Failure
L03 DD13KB (Power train controller system)
• Both lines of NO* and NC* for shift down switch circuit are 0 V (switch: ON) at the same
Failure
time.
controller
• Shift down is not possible.
up switch.
2. Disconnect connector SFTD and connect T-adapter to male side of
connector.
1
Between SFTD (male) Switch: OFF Max. 1 z
tance Between SFTD (male) Switch: OFF Min. 1 Mz
Ground fault in wiring harness female side of either connector.
2 Between ground and SFTD (female) (1) or
tance Between ground and SFTD (female) (3) or

No
Short circuit in wiring harness Between STC1 (female) (17) and every pin continuity
3
is heard)
Continuity
No
is heard)
40-456 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4
and (10) Switch: ON Max. 1 V
Voltage
*NO: Normally Open
Circuit diagram related to shift down switch
D65EX,PX,WX-17 40-457
40 Troubleshooting
Failure code [DD14KA] Parking lever Sw:Open

Action level Failure code Both NO and NC lines for travel lock switch are OFF at the
Failure same time (open circuit)
L03 DD14KA
• Both lines of NO* and NC* for parking brake lever switch circuit are OPEN (switch: OFF)
Failure
at the same time.
Action of • Recognizes parking brake lever is in Free position.
• Once machine stops, engine speed is restricted to medium (half) speed.
Problem on • Once machine stops, travel is restricted to F1 and R1.
machine • Engine cannot start.
• NC* line is used for detecting operation and NO* line is used for detecting error.
• Condition of parking brake lever switch signal can be checked with monitoring function.
information • Method of reproducing failure code:Turn starting switch to ON position and operate
parking brake lever.
• When parking brake lever is in FREE, parking brake lever switch is turned off.
2. Disconnect connector PKSW and connect T-adapter to male side of
connector.
Defective parking brake lever 3. Operate parking break lever and perform troubleshooting.
1 switch (internal open circuit in
wiring) Between PKSW (male) Lever: FREE Max. 1 z
Resis- (A) and (B) Lever: LOCK Min. 1 Mz
tance Between PKSW (male) Lever: FREE Min. 1 Mz
(A) and (C) Lever: LOCK Max. 1 z
2. Disconnect connector PKSW and connect T-adapter to female side
of connector.
Open circuit or hot short a When voltage is 0 V, it shows open circuit, and when voltage is 24 V,
2 circuit in wiring harness it shows hot short circuit in wiring harness.
Between PKSW (female) (A) and (B) 7 to 11 V
Voltage
Between PKSW (female) (A) and (C) 7 to 11 V
2. Disconnect connectors STC1, STC2, and PKSW, and connect T-
Open circuit in wiring harness adapters to female side of each connector.
3 (wire breakage or defective Between STC1 (female) (10) and PKSW
contact)
Resis- Between STC2 (female) (5) and PKSW
tance
Between STC2 (female) (15) and PKSW
40-458 D65EX,PX,WX-17
40 Troubleshooting

• Reference
2. Insert T-adapter into connectors STC1 and STC2.
4. Operate parking break lever and perform troubleshooting.
Defective power train
4 a Voltage of approx.9 V is applied to STC2 pin (5) and STC2 pin (15)
controller
Between STC2 (5) and Lever: FREE Max. 1 V
STC1 (10) Lever: LOCK 7 to 11 V
Voltage
Between STC2 (15) Lever: FREE 7 to 11 V
and STC1 (10) Lever: LOCK Max. 1 V
*NO: Normally Open
Circuit diagram related to travel lock switch
D65EX,PX,WX-17 40-459
40 Troubleshooting
Failure code [DD14KB] Parking lever Sw:Short circuit

Action level Failure code Both NO and NC lines for travel lock switch are ON at the
Failure same time (short circuit)
L03 DD14KB
• Both lines of NO* and NC* in parking brake lever switch circuit are 0 V (switch: ON) at the
Failure
same time.
Action of • Recognizes parking brake lever is in Free position.
machine • Engine cannot start.
• NC* line is used for detecting operation and NO* line is used for detecting error.
• Condition of parking brake lever switch signal can be checked with monitoring function.
information • Method of reproducing failure code:Turn starting switch to ON position and operate
parking brake lever.
• When parking brake lever is in FREE, parking brake lever switch is turned off.
2. Disconnect connector PKSW and connect T-adapter to male side of
connector.
3. Operate parking brake lever to ON and OFF positions and perform
Defective parking brake lever troubleshooting.
1 switch (internal open circuit)
Between PKSW (male) Lever: FREE Max. 1 z
Resis- (A) and (B) Lever: LOCK Min. 1 Mz
tance Between PKSW (male) Lever: FREE Min. 1 Mz
(A) and (C) Lever: LOCK Max. 1 z
2. Disconnect connectors STC2 and PKSW, and connect T-adapters to
Ground fault in wiring either female side of either connector.
2 harness Between ground and PKSW (female) (B) or
Min. 1 Mz
(contact with ground circuit) Resis- STC2 (female) (5)
tance Between ground and PKSW (female) (C) or

2. Disconnect connectors STC2 and PKSW, and connect T-adapters to
No
3
is heard)
Continuity
No
is heard)
40-460 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4. Operate parking brake lever to ON and OFF positions and perform
4
Between STC2 (5) and Lever: FREE Max. 1 V
STC1 (10) Lever: LOCK 7 to 11 V
Voltage
Between STC2 (15) Lever: FREE 7 to 11 V
and STC1 (10) Lever: LOCK Max. 1 V
*NO: Normally Open
Circuit diagram related to travel lock switch
D65EX,PX,WX-17 40-461
40 Troubleshooting
Failure code [DDKFL4] Left Angle Sw:Signal mismatch

Action level Failure code Inconsistency of two lines of NO for left angle lever
Failure
L01 DDKFL4 (Power train controller system)
Failure • There is inconsistency of two lines of NO* for SW1 and SW2 in left angle lever circuit.
Action of • Recognizes that left angle lever is not pressed.
controller
Problem on • Left angle operation of work equipment is not possible.
machine
• Condition of left angle lever signal can be checked with monitoring function.
(Code: 70306 Brade knob SW input 2)
• Method of reproducing failure code: Turn starting switch to ON position and operate left
Related angle lever.
information • When left angle lever is in FREE position, both SW1 and SW2 of left angle lever are
open.
(Lever is in FREE position in illustration.)
2. Disconnect connector BNSW and connect T-adapter to male side of
connector.
Defective left angle lever 3. Operate left angle lever to ON and OFF positions, and perform
1 (wiring harness) (internal troubleshooting.
open circuit) Between BNSW (male) FREE Min. 1 Mz
Resis- (10) and (9) Left angle Max. 1 z
tance Between BNSW (male) FREE Min. 1 Mz
(11) and (9) Left angle Max. 1 z
2. Disconnect connector BNSW and connect T-adapter to female side
of connector.
Open circuit or hot short a When voltage is 0 V, it shows open circuit, and when voltage is 24 V,
2 circuit in wiring harness it shows hot short circuit in wiring harness.
a Voltage of approximately 9 V is applied to two signal lines of "NO"
Between BNSW (female) (10) and (9) 7 to 11 V
Voltage
2. Disconnect connectors STC1 and BNSW and connect T-adapters to
3 (wire breakage or defective Between STC1 (female) (10) and BNSW
contact)
Resis- Between STC1 (female) (24) and BNSW
tance
Between STC1 (female) (18) and BNSW

Ground fault in wiring harness 2. Disconnect connectors STC1 and BNSW, and connect T-adapters to
4 female side of STC1.
Resis- Between STC1 (female) (18) and ground Min. 1 Mz
tance Between STC1 (female) (24) and ground Min. 1 Mz
40-462 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4. Operate left angle lever to ON and OFF positions, and perform
5
Between STC1 (18) FREE 7 to 11 V
and STC1 (10) Left angle Max. 1 V
Voltage
and STC1 (10) Left angle Max. 1 V
*NO: Normally Open
Circuit diagram related to left and right angle levers
D65EX,PX,WX-17 40-463
40 Troubleshooting
Failure code [DDKGL4] Right Angle Sw:Signal mismatch

Action level Failure code Inconsistency of two lines of NO for right angle lever
Failure
L01 DDKGL4 (Power train controller system)
Failure • There is inconsistency of two lines of NO* for SW1 and SW2 of right angle lever circuit.
Action of • Recognizes that right angle lever is not pressed.
controller
Problem on • Right angle operation of work equipment is not possible.
machine
• Condition of right angle lever signal can be checked with monitoring function.
Related • Method of reproducing failure code: Turn starting switch to ON position and operate right
information angle lever.
• When right angle lever is in FREE position, both SW1 and SW2 of right angle lever are
open.
connector.
Defective right angle lever 3. Operate right angle lever to ON and OFF positions, and perform
1 (wiring harness) (internal troubleshooting.
open circuit) Between BNSW (male) FREE Min. 1 Mz
Resis- (7) and (9) Right angle Max. 1 z
tance Between BNSW (male) FREE Min. 1 Mz
(8) and (9) Right angle Max. 1 z
of connector.
a Voltage of approximately 9 V is applied to signal line of "NO"through
resistor in power train controller.
Voltage
2. Disconnect connectors STC1, STC3 and BNSW, and connect T-
contact)
tance

Ground fault in wiring harness connector.
4 Between STC3 (female) (30) and Resis-
Resis- ground tance
tance Between STC3 (female) (40) and Resis-
ground Min. 1 Mz
tance
40-464 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4. Turn right angle lever to ON and OFF positions, and perform
5
and STC1 (10) Right angle Max. 1 V
Voltage
and STC1 (10) Right angle Max. 1 V
*NO: Normally Open
Circuit diagram related to right and left angle levers
D65EX,PX,WX-17 40-465
40 Troubleshooting
Failure code [DDKHKA] iB Sw:Open

Action level Failure code Both NO and NC circuits for iB switch are broken off at the
Failure same time (open circuit)
L01 DDKHKA
• Both circuits of NO* and NC* for iB switch circuit are OPEN (switch: OFF) at the same
Failure
time.
Action of • Recognizes that iB switch is not pressed.
controller
Problem on
machine
• Condition of iB switch signal can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Turn starting switch to ON position and operate iB
switch.
connector.
3. Turn iB switch ON and OFF, and perform troubleshooting.
Defective iB switch (wiring
1 harness) (internal open a "Switch OFF": Release, "Switch ON": Press
circuit) Between BNSW (male) Switch: OFF Max. 1 z
tance Between BNSW (male) Switch: OFF Min. 1 Mz
of connector.
a When voltage is 0 V, it shows open circuit, and when voltage is 24 V,
Open circuit or hot short it shows hot short circuit in wiring harness.
a Ignore displayed failure codes.
Voltage
2. Disconnect connectors STC1, STC3 and BNSW, and connect T-
contact)
tance
40-466 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4. Turn iB switch ON and OFF, and perform troubleshooting.
controller
and STC1 (10) Switch: ON Max. 1 V
Voltage
and STC1 (10) Switch: ON 7 to 11 V
*NO: Normally Open
Circuit diagram related to iB switch
D65EX,PX,WX-17 40-467
40 Troubleshooting
Failure code [DDKHKB] iB Sw:Short circuit

Action level Failure code Both NO and NC circuits for iB switch are closed at the
Failure same time (short circuit)
L01 DDKHKB
Failure • Both circuits of NO* and NC* for iB switch circuit are 0 V (switch: ON) at the same time.
Action of • Recognizes that iB switch is not pressed.
controller
Problem on
machine
• "NO*" circuit is used for detecting operation and "NC*" circuit is used for detecting error.
• Condition of iB switch signal can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Turn starting switch to ON position and operate iB
switch.
connector.
3. Operate iB switch and perform troubleshooting.
Defective iB switch (wiring
1 harness) (internal open a "Switch OFF": Release, "Switch ON": Press
circuit) Between BNSW Switch: OFF Max. 1 z
Resis- (male) (1) and (3) Switch: ON Min. 1 Mz
tance Between BNSW Switch: OFF Min. 1 Mz
(male) (2) and (3) Switch: ON Max. 1 z
2. Disconnect connectors STC1, STC3 and BNSW and connect T-
Ground fault in wiring adapters to female side of either connector.
2 harness Between ground and BNSW (female) (1) or Resis-
(contact with ground circuit) STC3 (female) (20) Min. 1 Mz
tance
Between ground and BNSW (female) (2) or Resis-
tance
2. Disconnect connectors STC3 and BNSW, and connect T-adapter to
No
3
is heard)
Continuity
No
is heard)
• Reference
4. Operate iB switch and perform troubleshooting.
controller
Voltage
40-468 D65EX,PX,WX-17
40 Troubleshooting
*NO: Normally Open

Circuit diagram related to iB switch
D65EX,PX,WX-17 40-469
40 Troubleshooting
Failure code [DDN7KA] Weq pitch SW: Open

Action level Failure code Both NO and NC lines for work equipment pitch switch are
Failure OFF at the same time (open circuit)
L03 DDN7KA
• Both circuits of NO* and NC* for blade pitch switch circuit are OPEN (switch: OFF) at the
Failure
same time.
Action of • Recognizes that the blade pitch switch is not pressed.
controller
Problem on • Blade pitch switch does not work.
machine
• Condition of blade pitch switch signal can be checked with monitoring function.
Related (Code: 70300 Brade knob SW input 1)
information • Method of reproducing failure code: Turn starting switch to ON position and operate blade
pitch switch.
2. Disconnect connector BPT and connect T-adapter to female side of
connector.
3. Turn blade pitch switch to ON or OFF position and perform
Defective blade pitch switch troubleshooting.
1
Between BPT (female) Switch: OFF Max. 1 z
tance Between BPT (female) Switch: OFF Min. 1 Mz
2. Disconnect connector BPT and connect T-adapter to male side of
connector.
Between BPT (male) (1) and (2) 7 to 11 V
Voltage
Between BPT (male) (3) and (2) 7 to 11 V
2. Disconnect connectors STC1, STC2 and BPT, and connect T-
Open circuit in wiring harness adapters to female sides of STC1 and STC2, and male side of BPT.
3 (wire breakage or defective Between STC2 (female) (37) and BPT (male)
(1) Max. 1 z
contact)
Resis- Between STC1 (female) (10) and BPT (male)
(2) Max. 1 z
tance
Between STC2 (female) (27) and BPT (male)
(3) Max. 1 z
40-470 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4. Turn blade pitch switch (down) to ON or OFF position and perform
4
Voltage
*NO: Normally Open
Circuit diagram related to work equipment pitch
D65EX,PX,WX-17 40-471
40 Troubleshooting
Failure code [DDN7KB] Pitch select solenoid:Short circuit

Action level Failure code Both NO and NC circuits for work equipment pitch switch
are turned ON at the same time (short circuit)
Failure
L03 DDN7KB
• Both circuits of NO* and NC* for blade pitch switch circuit are 0 V (switch: ON) at the
Failure
same time.
Action of • Recognizes that the blade pitch switch is not pressed.
controller
Problem on • Blade pitch switch does not work.
machine
• Condition of blade pitch switch signal can be checked with monitoring function.
Related (Code: 70300 Brade knob SW input 1)
pitch switch (lower).
2. Disconnect connector BPT and connect T-adapter to female side of
connector.
3. Operate blade pitch switch and perform troubleshooting.
Defective blade pitch switch
1 a "Switch OFF": Release, "Switch ON": Press
(internal open circuit in wiring)
Between BPT (female) Switch: OFF Max. 1 z
tance Between BPT (female) Switch: OFF Min. 1 Mz
2. Disconnect connectors STC2 and BPT and then connect T-adapters
Ground fault in wiring harness to female side of STC2 or male side of BPT.
2 Between ground and BPT (male) (1) or STC2
Resis- (female) (37)
tance Between ground and BPT (male) (3) or STC2

2. Disconnect connectors STC2 and BPT, and connect T-adapters to
No
3 Short circuit in wiring harness Between STC2 (female) (27) and every pin continuity
is heard)
Continuity
No
is heard)
40-472 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4. Operate blade pitch switch and perform troubleshooting.
controller
Voltage
*NO: Normally Open
Circuit diagram related to work equipment pitch
D65EX,PX,WX-17 40-473
40 Troubleshooting
Failure code [DDNLKA] Weq lock Sw:Open

Action level Failure code Both NO and NC circuits for work equipment lock switch are
Failure turned OFF at the same time (open circuit)
L03 DDNLKA
• Both circuits of NO* and NC* for work equipment lock lever switch circuit are OPEN
Failure (switch: OFF) at the same time.
Action of • Recognizes that work equipment lock lever is in LOCk position.
machine • Work equipment operation is impossible.
• NC* circuit is used for detecting operation and NO* circuit is used for detecting error.
• Condition of work equipment lock lever switch signal can be checked with monitoring
function.
Related • Method of reproducing failure code: Turn starting switch to ON position and operate work
information equipment lock lever.
• When work equipment lock lever is in free, work equipment lock lever switch becomes
"OFF".
2. Disconnect connector WELK and connect T-adapter to male side of
connector.
Defective work equipment 3. Operate work equipment lock lever and perform troubleshooting.
1 lock lever switch (internal
open circuit) Between WELK (male) FREE Max. 1 z
Resis- (A) and (B) LOCK Min. 1 Mz
tance Between WELK (male) FREE Min. 1 Mz
(A) and (C) LOCK Max. 1 z
2. Disconnect connector WELK and connect T-adapter to female side.
a When voltage is 0 V, it shows open circuit, and when voltage is 24 V,
Open circuit or hot short in it shows hot short circuit in wiring harness.
2 wiring harness
a Voltage of approximately 9 V is applied to signal circuits of "NO" and
Between WELK (female) (A) and (B) 7 to 11 V
Voltage
Between WELK (female) (C) and (A) 7 to 11 V
2. Disconnect connectors STC1, STC2, and WELK, and connect T-
3 (wire breakage or defective Between STC1 (female) (10) and WELK
contact)
Resis- Between STC2 (female) (6) and WELK
tance
Between STC2 (female) (16) and WELK
40-474 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4. Operate work equipment lock lever switch and perform
4
Between STC2 (6) and FREE Max. 1 V
STC1 (10) LOCK 7 to 11 V
Voltage
and STC1 (10) LOCK Max. 1 V
*NO: Normally Open
Circuit diagram related to work equipment lock switch
D65EX,PX,WX-17 40-475
40 Troubleshooting
Failure code [DDNLKB] Weq lock Sw:Short circuit

Action level Failure code Both NO and NC circuits for work equipment lock switch are
Failure turned ON at the same time (short circuit)
L03 DDNLKB
• Both circuits of NO* and NC* for work equipment lock lever switch circuit are 0 V (switch:
Failure ON) at the same time.
Action of • Recognizes that work equipment lock lever is in LOCk position.
machine • Work equipment operation is impossible.
• NC* circuit is used for detecting operation and NO* circuit is used for detecting error.
• Condition of work equipment lock lever switch signal can be checked with monitoring
function.
information equipment lock lever.
• When work equipment lock lever is in free, work equipment lock lever switch becomes
"OFF".
2. Disconnect connector WELK and connect T-adapter to male side of
connector.
Defective work equipment 3. Operate work equipment lock lever and troubleshoot.
1 lock lever switch (internal
open circuit) Between WELK (male) FREE Max. 1 z
Resis- (A) and (B) LOCK Min. 1 Mz
tance Between WELK (male) FREE Min. 1 Mz
(A) and (C) LOCK Max. 1 z
2. Disconnect connectors STC2 and WELK, and connect T-adapters to
2 Between ground and WELK (female) (B) or
tance Between ground and WELK (female) (C) or

2. Disconnect connectors STC2 and WELK, and connect T-adapters to
No
Short circuit in wiring harness Between STC2 (female) (6) and every pin other continuity
3
than (6) (No sound
is heard)
Continuity
No
is heard)
40-476 D65EX,PX,WX-17
40 Troubleshooting

• Reference
4. Operate work equipment lock lever switch and perform
4
Between STC2 (6) and FREE Max. 1 V
STC1 (10) LOCK 7 to 11 V
Voltage
and STC1 (10) LOCK Max. 1 V
*NO: Normally Open
Circuit diagram related to work equipment lock switch
a The figure shows the locked work equipment.
D65EX,PX,WX-17 40-477
40 Troubleshooting
Failure code [DGS1KA] Hyd oil temp sensor:Open

Action level Failure code Hydraulic oil temperature sensor open circuit
Failure
L01 DGS1KA (Power train controller system)
Failure • Signals are not input from hydraulic temperature sensor to power train controller.
controller
Problem on • Hydraulic oil temperature on monitor panel is not displayed normally.
machine • The fan speed is restricted to a half.
• Hydraulic oil temperature can be checked with monitoring function
Related (Code: 04401 Hydraulic oil temperature)
information • Method of reproducing failure code: Turn starting switch to ON position or start engine.
Defective hydraulic oil Hydraulic oil temperature sensor system may be defective. Perform
1 temperature gauge system troubleshooting for failure codes [DGS1KX].
40-478 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DGS1KX] Hyd oil temp: signal abnormal

Action level Failure code Hydraulic oil temperature sensor: Out of input signal range
Failure
L01 DGS1KX (Power train controller system)
Detail of • Hydraulic oil temperature sensor signal is out of normal range.
failure
controller
Problem on • Hydraulic oil temperature on monitor panel is not displayed normally.
machine • Fan speed is limited to half.
• Hydraulic oil temperature can be checked in monitoring mode.
Related (Code: 04401 Hydraulic oil temperature)
information • Method of reproducing failure code: Turn starting switch to ON position or start engine.
2. Disconnect connector HDT and connect T-adapter to male side.
Approx. 90
Defective hydraulic oil 10 °C
Kz
temperature sensor
1 Between HDT (male) (1) and (2) Approx. 35
(internal open circuit or short 30 °C
Resis- Kz
circuit) tance a Temperature characteristics of Approx.
oil temperature sensor 80 °C
6.5 Kz
Approx.
100 °C
3.5 Kz
2. Disconnect connector HDT and connect T-adapter to female side.
Open circuit, short circuit, a If voltage is 0 V, wiring harness has open circuit or ground fault or
ground fault, or hot short short circuit, and if voltage is 24 V, wiring harness has hot short
2
circuit in wiring harness circuit.
a Voltage of approx.5 V is applied to temperature sensor signal circuits
Voltage Between HDT (female) (1) and (2) Approx. 5
V
connector.
Open or short circuit in wiring a Resistance accords with temperature characteristics table in cause
3 1.
harness
a If resistance is above 1 Mz , wiring harness has open circuit. If
Approx.
Resis- Between STC1 (female) (14) and (21)
3.5 to 90
tance
Kz
a If no failure is found by checks on causes 2 and 3, this check is not
required.
Open circuit in wiring harness 2. Disconnect connectors STC1 and HDT, and connect T-adapters to
contact of connector) Between STC1 (female) (14) and HDT (female)
Max. 1 z
Resis- (1)
tance Between STC1 (female) (21) and HDT (female)
(2) Max. 1 z
D65EX,PX,WX-17 40-479
40 Troubleshooting

5 2. Disconnect connectors STC1 and HDT, and connect T-adapters to
Resis- Between ground and STC1 (female) (14) or
HDT (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC1 and HDT, and connect T-adapter to
Between STC1 (female) (14) and No continuity (No
Continuity
each pin other than (14) sound is heard)
7 Power train controller system If no failure is found in above checks, power train controller is defective.
Circuit diagram related to hydraulic oil temperature sensor
40-480 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DGT1KA] T/C oil temp sensor:Open

Action level Failure code Torque converter oil temperature sensor disconnection
Failure
L01 DGT1KA (Power train controller system)
Failure • Torque converter oil temperature sensor signal is out of normal range.
controller
• Power train oil temperature gauge may not indicate normally.
Problem on • The fan speed is restricted to a half.
machine • Gear shift shock of transmission is large.
Related • Torque converter oil temperature is considered as power train oil temperature.
information
Defective torque converter oil Perform troubleshooting for causes 1 to 4 and 7 of failure code
1 temperature sensor system [DGT1KX].
D65EX,PX,WX-17 40-481
40 Troubleshooting
Failure code [DGT1KX] T/C oil temp sensor:Out of normal range

Action level Failure code Torque converter oil temperature sensor input signal is out
Failureof range
L01 DGT1KX
Failure • Torque converter oil temperature sensor signal is out of normal range.
controller
• Power train oil temperature gauge may not indicate normally.
Problem on • The fan speed is restricted to a half.
• Torque converter oil temperature is considered as power train oil temperature.
Related • Torque converter oil temperature can be checked with monitoring function.
information (Code 30100: T/C oil temperature)
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
2. Disconnect connector TCT and connect T-adapter to male side of
connector.
Defective torque converter oil Approx. 90
10 °C
temperature sensor Kz
1 Between TCT (male) (1) and (2) Approx. 35
(internal open circuit or short 30 °C
circuit) Resis- Kz
tance a Temperature characteristics of Approx.
oil temperature sensor 80 °C
6.5 Kz
Approx.
100 °C
3.5 Kz
2. Disconnect connector TCT and connect T-adapter to female side of
connector.
Open circuit or short circuit or a If voltage is 0 V, wiring harness has open circuit or ground fault or
2 ground fault or hot short short circuit, and if voltage is 24 V, wiring harness has hot short
a Voltage of approx.5 V is applied to temperature sensor signal circuits
Voltage Between TCT (female) (1) and (2) Approx. 5
V
connector.
Open or short circuit in wiring a Resistance accords with temperature characteristics table in cause
3 1.
harness
a If resistance is 1 Mz or large, wiring harness has open circuit. If
resistance is 1 z or smaller, wiring harness has short circuit.
Approx.
3.5 to 90
tance
Kz
40-482 D65EX,PX,WX-17
40 Troubleshooting

a If no failure is found in checks on causes 2 or 3 this check is not
required.
Open circuit in wiring harness 2. Disconnect connectors STC1 and TCT, and connect T-adapters to
contact) Between STC1 (female) (9) and TCT (female)
Max. 1 z
Resis- (1)
tance Between STC1 (female) (21) and TCT (female)
(2) Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors STC1 and TCT, and connect T-adapters to
Resis- Between ground and STC1 (female) (9) or TCT
tance
2. Disconnect connectors STC1 and TCT, and connect T-adapters to
each female side of STC1.
Between STC1 (female) (9) and every pin other No continuity
than (9) (No sound is heard)
7 Defective machine monitor If no failure is found in above checks, power train controller is defective
Circuit diagram related to torque converter oil temperature sensor
D65EX,PX,WX-17 40-483
40 Troubleshooting
Failure code [DH21KA] Weq pressure sensor:Open

Action level Failure code Work equipment pressure sensor open circuit
Failure
L01 DH21KA (Power train controller system)
Failure • Signal voltage of work equipment pump oil pressure sensor is 0.2 V or lower.
controller
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
information (Code: 70701 Hydraulic Pressure Sensor 1)
If failure code [DBE7KK] is also displayed, perform troubleshooting for
the failure code first.
2. Disconnect connector HHP and connect T-adapter to female side of
Defective 5 V power supply connector.
1 system for sensor 3. Turn starting switch to ON position.
a If power supply voltage is unusual, go to cause 3 or after.
Power 4.5 to 5.5
Voltage Between HHP (female) (3) and (1)
supply V
2. Insert T-adapter into connector HHP.
Defective work equipment a If power supply voltage is normal and sensor output voltage is
pump oil pressure sensor abnormal (below 0.5 V), internal open circuit and ground fault cannot
2
(internal defect) or ground be identified. In this case, go to cause 4.
fault If check result of cause 4 is normal, work equipment pump oil
pressure sensor is defective.
Sensor 0.5 to 4.5
output V
2. Disconnect connectors STC1, STC2, and HHP, and connect T-
adapters to female side of each connector.
a If power supply voltage in cause 1 is normal,
Open circuit in wiring harness Between STC2 (female) (1) and HHP (female)
3 (wire breakage or defective (3)
tance
Between STC1 (female) (21) and HHP (female)
(1)
Between STC1 (female) (1) and HHP (female)
(2) Max. 1 z

2. Disconnect connectors STC1 and HHP, and connect T-adapters to
4
(contact with ground circuit) Between STC1 (female) (1) and (21), or
Min. 1 Mz
Resis- between HHP (female) (1) and (2)
tance Between STC1 (female) (1) and ground, or
between HHP (female) (2) and ground Min. 1 Mz
40-484 D65EX,PX,WX-17
40 Troubleshooting

• Reference
controller
Voltage Between STC1 (1) and (21) 0.5 to 4.5
V
Circuit diagram related to work equipment pump oil pressure sensor
D65EX,PX,WX-17 40-485
40 Troubleshooting
Failure code [DH21KB] Work equipment pressure sensor:Hot Short

Action level Failure code Hot short of oil pressure sensor of work equipment pump
Failure
L01 DH21KB (Power train controller system)
Failure • Signal voltage of work equipment pump oil pressure sensor is above 4.8 V.
controller
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
Related (Code: 70701 Hydraulic Pressure Sensor 1)
• If sensor connector is disconnected in normal condition and starting switch is turned to
ON position, failure code [DH21KA] is displayed.
2. Disconnect connector HHP and connect T-adapter to female side of
Power 4.5 to 5.5
supply V
2. Disconnect connector HHP
Defective work equipment 3. Turn starting switch to ON position.
pump oil pressure sensor
2 If failure code [DH21KB] disappears and [DH21KA] of disconnection is
(internal defect) 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 controller is defective.)
Hot short circuit in wiring 2. Disconnect connector HHP and connect T-adapter to female side of
harness connector.
Between HHP (female) (2) and (1) or between
Voltage Max. 1 V
HHP (female) (2) and ground
2. Disconnect connectors STC1 and HHP, and connect T-adapters to
Between STC1 (female) (1) and No continuity
Continuity
every pin other than (1) (No sound is heard)
• Reference
controller
V
40-486 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to work equipment pump oil pressure sensor
D65EX,PX,WX-17 40-487
40 Troubleshooting
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit

Action level Failure code Air cleaner clogging sensor open circuit
Failure
L01 DHA4KA (Machine monitor system)
• Air cleaner clogging switch signal voltage is not 1 V or less while engine is running, and
Failure machine monitor detects clogging of air cleaner (open of sensor contacts).
Action of • Displays air cleaner clogging monitor in yellow on machine monitor.
controller
Problem on • If machine is operated under such condition, engine may be damaged.
machine
• Input condition (ON/OFF) from air cleaner clogging switch can be checked with
information (Code 04501: Monitor Input 2)
Clogged air cleaner Air cleaner may be clogged. Check it for clogging and then clean or
1 replace if clogged.
2. Disconnect connector AF1 and connect T-adapter to male side of
connector.
Defective air cleaner clogging 3. Starting the engine
2 switch (internal open circuit) When air cleaner is
Max. 1 z
Resis- Between AF1 (male) normal *1
tance (1) and (2) When air cleaner is
clogged *2 Min. 1 Mz

Open circuit in wiring harness 2. Disconnect connectors CM02 and AF1, and connect T-adapters to
contact of connector) Resis- Between CM02 (female) (4) and AF1 (female)
(1) Max. 1 z
tance
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine.
4 Defective machine monitor When air cleaner is
Between CM02 (4) and normal Max. 1 V
Voltage
CM01 (3)
Air cleaner is clogged 7 to 11 V
• Air cleaner suction resistance
*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
Circuit diagram related to air cleaner clogging
40-488 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DHTDKA] T/C pressure sensor:Open

Action level Failure code Torque converter oil pressure sensor open circuit
Failure
L03 DHTDKA (Power train controller system)
Failure • Signal voltage of torque converter oil pressure sensor is 0.2 V or lower.
controller
• Hydraulic pressure in torque converter can not be monitored.
Problem on • Gear shift shock of transmission is large.
• Signal voltage from torque converter oil pressure sensor can be checked with monitoring
Related function.
information (Code: 32605 T/C average pressure sensor voltage)
2. Disconnect connector TIP and connect T-adapter to female side of
Power 4.5 to 5.5
Voltage Between TIP (female) (3) and (1)
supply V
2. Insert T-adapter into connector TIP.
Defective torque converter a If power supply voltage is normal and sensor output voltage is
2 pressure sensor (internal abnormal (0.5 V or lower), internal disconnection and ground fault
defect) or ground fault cannot be identified. In this case, go to cause 4. If no failure is found
in check on cause 4, torque converter pressure sensor is defective.
Sensor 0.5 to 4.5
output V
2. Disconnect connectors STC1, STC2, and TIP, and connect T-
Open circuit in wiring harness Between STC2 (female) (1) and TIP (female)
3 (wire breakage or defective (3)
tance
Between STC1 (female) (21) and TIP (female)
(1)
Between STC1 (female) (20) and TIP (female)
(2) Max. 1 z
D65EX,PX,WX-17 40-489
40 Troubleshooting

2. Disconnect connectors STC1 and TIP, and connect T-adapter to
4
Min. 1 Mz
Resis- between TIP (female) (1) and (2)
between TIP (female) (2) and ground Min. 1 Mz
• Reference
controller
V
Circuit diagram related to torque converter oil pressure sensor
40-490 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DHTDKB] T/C pressure sensor:Hot Short

Action level Failure code Hot short circuit of torque converter oil pressure sensor
Failure
L03 DHTDKB (Power train controller system)
Failure • Signal voltage of torque converter pressure sensor is 4.7 V or above.
controller
Problem on • Hydraulic pressure of torque converter can not be monitored.
• Signal voltage from torque converter pressure sensor can be checked with monitoring
function.
Related (Code: 32605 T/C average pressure sensor voltage)
• If sensor connector is disconnected when system works properly and if starting switch is
turned to ON position, failure code [DHTDKA] appears.
2. Disconnect connector TIP and connect T-adapter to female side of
Power 4.5 to 5.5
supply V
2. Disconnect connector TIP.
Defective torque converter
2 pressure sensor (internal
defect) or ground fault If failure code [DHTDKB] disappears, torque converter pressure sensor
is defective. (If failure code [DHTDKB] is still displayed, it shows that
wiring harness or power train controller is defective.)
Hot short circuit in wiring 2. Disconnect connector TIP and connect T-adapter to female side of
harness connector.
Between TIP (female) (2) and (1) or between
Voltage Max. 1 V
TIP (female) (2) and ground
2. Disconnect connectors STC1 and TIP, and connect T-adapters to
Continuity
every pin other than (20) (No sound is heard)
• Reference
controller
V
D65EX,PX,WX-17 40-491
40 Troubleshooting
Circuit diagram related to torque converter oil pressure sensor
40-492 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK10KA] Fuel control Dial:Open

Action level Failure code Throttle (fuel) dial circuit open circuit
Failure
L03 DK10KA (Power train controller system)
Failure • Signal voltage of throttle (fuel) dial circuit is 0.5 V or lower.
Action of • Continues control with signal of decelerator pedal potentiometer.
• Input voltage from fuel dial circuit can be checked with monitoring function.
Related (Code 03000: Throttle Position Sensor Voltage Value)
If failure code [DBE5KK] is also displayed, perform troubleshooting for it
first.
2. Disconnect connector DIA2 and connect T-adapter to female side of
Power 4.5 to 5.5
Voltage Between DIA2 (female) (A) and (C)
supply V
2. Disconnect connector DIA2 and connect T-adapter to male side of
connector.
Defective throttle dial circuit 4. Turn fuel control dial and perform troubleshooting.
2 (internal open circuit or Between DIA2 (male) (A) and (C) Approx. 5
ground fault) Kz
0.5 to 4.5
Resis- Between DIA2 (male) (A) and (B) Kz
tance 0.5 to 4.5
Between DIA2 (male) (B) and (C)
Kz
Between DIA2 (male) (B) and ground Min. 1 Mz
2. Disconnect connectors STC1 and TLV1, and connect T-adapters to
a Resistance is same as ones shown on table in cause 2.
3 a If resistance is 1 Mz or large, wiring harness has disconnection. If
harness
Resis- Kz
tance Between STC1 (female) (6) and (21) 0.5 to 4.5
Kz
D65EX,PX,WX-17 40-493
40 Troubleshooting

2. Disconnect connectors STC1 and DIA2, and connect T-adapters to
a If power supply voltage in cause 1 or check
result of cause 3 is normal, this check is not
required. Max. 1 z
Between STC1 (female) (22) and DIA2 (female)
Open circuit in wiring harness (A)
4 (open circuit or defective a If power supply voltage in cause 1 or check
contact) Resis- result of cause 3 is normal, this check is not
tance required. Max. 1 z
(C)
a If check result of cause 3 is normal, this
(B)
a If no failure is found on cause 2 this check is not required.
5
Min. 1 Mz
Resis- between DIA2 (female) (B) and (C)
between DIA2 (female) (B) and ground Min. 1 Mz
• Reference
6
4. Turn fuel control dial and perform troubleshooting.
V
Circuit diagram related to fuel dial
40-494 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK10KB] Fuel control Dial:Short circuit

Action level Failure code Short circuit of throttle (fuel) dial circuit
Failure
L03 DK10KB (Power train controller system)
Failure • Signal voltage of throttle (fuel) dial circuit is 4.5 V or lower.
Action of • Continues control with signal of decelerator pedal potentiometer.
• Input voltage from fuel dial circuit can be checked with monitoring function.
Related (Code: 03000 Throttle Position Sensor Voltage Value)
information • Method of reproducing failure code: Starting switch
first.
2. Disconnect connector DIA2 and connect T-adapter to female side of
Power
Voltage Between DIA2 (female) (A) and (C) 4.5 to 5.5 V
supply
2. Disconnect connector DIA2 and connect T-adapter to male side of
connector.
Defective throttle dial circuit 4. Turn fuel control dial and perform troubleshooting.
2 (Internal open circuit or Approx. 5
ground fault) Between DIA2 (male) (A) and (C)
Kz
Resis- Between DIA2 (male) (A) and (B) 0.5 to 4.5
tance Kz
Between DIA2 (male) (B) and (C) 0.5 to 4.5
Kz
Hot short circuit in wiring 2. Disconnect connector DIA2 and connect T-adapter to female side of
harness connector.
Between DIA2 (female) (B) and (C) or between
Voltage Max. 1 V
DIA2 (female) (B) and ground

No
continuity
Between STC1 (female) (6) and every pin other than (6)
(No sound
is heard)
• Reference
5
4. Turn fuel control dial and performing troubleshooting.
Voltage Between STC1 (6) and (21) 0.5 to 4.5 V
D65EX,PX,WX-17 40-495
40 Troubleshooting
Circuit diagram related to fuel dial
40-496 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK30KA] ST lever1:Open

Action level Failure code Steering lever potentiometer 1 open circuit
Failure
Failure • Signal voltage of PCCS lever steering potentiometer 1 (ST lever 1) is 0.5 V or lower.
Action of • Continues control with signal of PCCS lever steering potentiometer 2 (ST lever 2).
controller • Restricts operations of engine and transmission.
• Signal voltage of PCCS lever steering potentiometer 1 can be checked with monitoring
function.
Related (Code: 50300 S/T Lever Potentiometer 1 Voltage)
information • Method of reproducing failure code: Turn starting switch to ON position and operate
PCCS lever (in steering direction))
first.
2. Disconnect connector TLV1 and connect T-adapter to female side of
Power 4.5 to 5.5
Voltage Between TLV1 (female) (5) and (8)
supply V
2. Insert T-adapter into connector TLV1.
4. Operate PCCS lever (steering) and perform troubleshooting.
Defective PCCS lever
steering potentiometer 1 a If power supply voltage is normal and sensor output voltage is
2 (internal open circuit) or abnormal (0.5 V or lower), internal open circuit and ground fault
ground fault cannot be identified. In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever steering
potentiometer 1 is defective.
Sensor 0.5 to 4.5
Voltage Between TLV1 (7) and (8)
output V
Open circuit in wiring harness Between STC1 (female) (22) and TLV1
contact) Resis-
tance
Between STC1 (female) (21) and TLV1
(female) (8)
Between STC1 (female) (2) and TLV1 (female)
(7) Max. 1 z
D65EX,PX,WX-17 40-497
40 Troubleshooting

2. Disconnect connectors STC1 and TLV1, and connect T-adapter to
4
Min. 1 Mz
Resis- between TLV1 (female) (7) and (8)
between TLV1 (female) (7) and ground Min. 1 Mz
• Reference
5
V
Circuit diagram related to steering lever
40-498 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK30KB] ST lever:Hot Short

Action level Failure code Hot short circuit of steering lever potentiometer 1
Failure
Failure • Signal voltage of PCCS lever steering potentiometer 1 (ST lever 1) is 4.5 V or higher.
function.
Defective 5 V power supply If failure code [DBE5KK] is also displayed, perform troubleshooting for it
1 system for sensor first.
2. Disconnect connector TLV1.
Defective PCCS lever 4. Operate PCCS lever (steering) and perform troubleshooting.
steering potentiometer 1
2 If failure code [DK30KB] is not displayed, PCCS lever steering
(internal open circuit) or
potentiometer is defective. (If failure code [DK30KB] is still displayed,
ground fault
a Since connector TLV1 is disconnected, many failure codes appear.
Ignore all of displayed failure codes other than [DK30KB]
connector.
3 harness (contact with 24 V
circuit)
Between TLV1 (female) (7) and (8) or between
Voltage Max. 1 V
TLV1 (female) (7) and ground

No
Continuity
is heard)
• Reference
5
D65EX,PX,WX-17 40-499
40 Troubleshooting
Circuit diagram related to steering lever potentiometer
40-500 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK30KX] ST lever:Main and Sub Error

Action level Failure code Steering lever potentiometer 2 system failure
Failure
L04 DK30KX (Power train controller system)
• In PCCS lever steering potentiometer 1 (ST lever 1) and 2 (ST lever 2), either of failure
Failure codes [DK30KA] and [DK30KB], and either of failure codes [DK31KA] and [DK31KB] are
displayed at the same time.
controller
• Signal voltages of PCCS lever steering potentiometer 1 and 2 can be checked with
information (Code: 50301 S/T Lever Potentiometer 2 Voltage)
Perform troubleshooting for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
D65EX,PX,WX-17 40-501
40 Troubleshooting
Failure code [DK30KZ] ST lever:Main and Sub Error

Action level Failure code Steering lever potentiometer 2 system failure
Failure
L04 DK30KZ (Power train controller system)
• In PCCS lever steering potentiometer 1 (ST lever 1) and 2 (ST lever 2), either of failure
Failure codes[DK30KA] and [DK30KB] and either of failure codes [DK31KA] and [DK31KB] are
controller
40-502 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK30L8] ST lever:Signal mismatch

Action level Failure code Misaligned steering lever potentiometer
Failure
L03 DK30L8 (Power train controller system)
• In PCCS lever steering potentiometer 1 (ST lever 1)and 2 (ST lever 2), total of both signal
Failure voltages is 4.41 V or lower, or 5.59 V or higher.
• Continues control with signal of normal one of PCCS lever steering potentiometer 1 (ST
Action of lever 1) or 2 (ST lever 2).
D65EX,PX,WX-17 40-503
40 Troubleshooting
Failure code [DK31KA] ST lever2:Open

Action level Failure code Steering lever potentiometer 2 open circuit
Failure
Failure • Signal voltage of PCCS lever steering potentiometer 2 (ST lever 2) is 0.5 V or lower.
function.
first.
Power 4.5 to 5.5
supply V
Defective PCCS lever
steering potentiometer 2 a If power supply voltage is normal and sensor output voltage is
2 (internal open circuit) or abnormal (0.5 V or lower), internal open circuit and ground fault
ground fault cannot be identified. In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever steering
potentiometer 2 is defective.
Sensor 0.5 to 4.5
output V
2. Disconnect connectors STC1 and TLV1 and connect T-adapters to
contact) Resis-
tance
(female) (8)
40-504 D65EX,PX,WX-17
40 Troubleshooting

4
Min. 1 Mz
• Reference
5
V
D65EX,PX,WX-17 40-505
40 Troubleshooting
Failure code [DK31KB] ST lever2:Hot Short

Action level Failure code Hot short circuit of steering lever potentiometer 2
Failure
Failure • Signal voltage of PCCS lever steering potentiometer 2 (ST lever 2) is 4.5 V or higher.
function.
Defective PCCS lever 4. Operate PCCS lever (steering) and perform troubleshooting.
steering potentiometer 2
2 If failure code [DK31KB] is not displayed, PCCS lever steering
(internal open circuit) or
potentiometer is defective. (If failure code [DK31KB] is still displayed,
ground fault
connector.
circuit)
Voltage Max. 1 V

No
Continuity
is heard)
• Reference
5
V
40-506 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-507
40 Troubleshooting
Failure code [DK40KA] Brake potentiometer:Open

Action level Failure code Brake pedal potentiometer open circuit
Failure
Failure • Signal voltage of brake pedal potentiometer is 0.5 V or lower.
Action of • Does not recognize position of brake pedal.
controller
Problem on • Auto-shift down function may not work normally.
machine • Once machine stops, engine speed shift mode is restricted to manual mode.
• Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related (Code: 50400 Brake Pedal Potentiometer Voltage)
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 of
Power 4.5 to 5.5
Voltage Between BRK (female) (B) and (C)
supply V
2. Disconnect connector BRK and connect T-adapter to male side of
connector.
4. Depress brake pedal and troubleshoot.
Defective brake pedal
2 potentiometer (internal open Between BRK (male) (B) and (C) Approx. 2
circuit or ground fault) Kz
Between BRK (male) (A) and (B) 0.2 to 1.8
Resis- Kz
tance 0.2 to 1.8
Between BRK (male) (A) and (C)
Kz
Between BRK (male) (A) and ground Min. 1 Mz
2. Disconnect connector STC1, PL1 and STC3, and connect T-adapter
a Resistance is same as shown on table in cause 2.
3 a If resistance is 1 Mz or larger, wiring harness has disconnection. If
harness
Between STC2 (female) (1) and STC1 (female) Approx. 2
Resis- (21) Kz
tance 0.2 to 1.8
Between STC1 (female) (3) and (21)
Kz
40-508 D65EX,PX,WX-17
40 Troubleshooting

2. Disconnect connectors STC1, STC2 and BRK, and connect T-
adapter to female side of each connector.
a If power supply voltage in cause 1 or check
result of cause 3 is normal, this check is not
required. Max. 1 z
Between STC2 (female) (1) and BRK (female)
Open circuit in wiring harness (B)
4 (wire breakage or defective a If power supply voltage in cause 1 or check
contact) Resis- result of cause 3 is normal, this check is not
tance required. Max. 1 z
Between STC1 (female) (21) and BRK (female)
(C)
(A)
a If no failure is found in checks on cause this check is not required.
2. Disconnect connectors STC1, STC3 and BRK and connect T-
Ground fault in wiring harness adapter to female side of either connector.
5
Min. 1 Mz
Resis- between BRK (female) (A) and (C)
between BRK (female) (A) and ground Min. 1 Mz
• Reference
6
4. Depress brake pedal and perform troubleshooting.
V
Circuit diagram related to brake pedal potentiometer
D65EX,PX,WX-17 40-509
40 Troubleshooting
Failure code [DK40KB] Brake potentiometer:Hot Short

Action level Failure code Hot short circuit of brake pedal potentiometer
Failure
Failure • Signal voltage of brake pedal potentiometer is 4.8 V or higher.
Action of • Does not recognize position of brake pedal.
controller
Problem on • Auto-shift down function may not work normally.
machine • Once machine stops, shift mode is restricted to manual mode.
• Signal voltage of brake pedal potentiometer can be checked with monitoring function.
Related (Code: 50400 Brake Pedal Potentiometer Voltage)
information • Method of reproducing failure code: Turn starting switch to ON position and operate brake
pedal.
Power
Voltage Between BRK (female) (B) and (C) 4.5 to 5.5 V
supply
2. Disconnect connector BRK and connect T-adapter to male side of
connector.
Defective brake pedal 4. Depress brake pedal and perform troubleshooting.
2 potentiometer (internal open Approx. 2
circuit or short circuit) Between BRK (male) (B) and (C)
Kz
Resis- Between BRK (male) (A) and (B) 0.2 to 1.8
tance Kz
Between BRK (male) (A) and (C) 0.2 to 1.8
Kz
Hot short in wiring harness connector.
Between BRK (female) (A) and (C) or between
Voltage Max. 1 V
BRK (female) (A) and ground
2. Disconnect connectors STC1 and BRK, and connect T-adapters to
Between STC1 (female) (3) and every pin No continuity
other than (3) (No sound is heard)
• Reference: Following shows standard values in normal condition.
5
4. Depress brake pedal and perform troubleshooting.
40-510 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to brake pedal potentiometer
D65EX,PX,WX-17 40-511
40 Troubleshooting
Failure code [DK55KX] FR lever:Main and Sub Error

Action level Failure code Travel lever potentiometer 2 system failure
Failure
L04 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
Failure codes [DK56KA] and [DK56KB], and either of failure codes [DK57KA] and [DK57KB] are
controller
• Signal voltage of PCCS lever F-R potentiometer can be checked with monitoring function.
(Code: 50200 T/M Lever 1 Potentiometer)
Related (Code: 50201 T/M Lever 2 Potentiometer)
PCCS lever (in F-R direction).
40-512 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK55KZ] FR lever:Main and Sub Error

Action level Failure code Travel lever potentiometer 2 system failure
Failure
L04 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 to ON position, only one side malfunctions and then either of failure codes
Failure [DK56KA] and [DK56KB], and either of failure codes [DK57KA] and [DK57KB] are
controller
D65EX,PX,WX-17 40-513
40 Troubleshooting
Failure code [DK55L8] FR lever:Signal mismatch

Action level Failure code Mismatched travel lever potentiometer
Failure
L03 DK55L8 (Power train controller system)
• In PCCS lever F-R potentiometer 1 (F/R lever 3) and 2 (F/R lever 4), total of both signal
Failure voltages is 4.41 V or lower or 5.59 V or higher.
• Continues control with signal of PCCS lever F-R potentiometer 1 or 2 whichever is
Action of normal.
40-514 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK56KA] FR lever1:Open

Action level Failure code Travel lever potentiometer 3 open circuit
Failure
Failure • Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is 0.5 V or lower.
Action of • Continues control with signal of PCCS lever F-R potentiometer 2 (F/R lever 4).
• Signal voltage of PCCS lever F-R potentiometer 1 can be checked with monitoring
function.
first.
Power 4.5 to 5.5
supply V
4. Operate PCCS lever (F-R) and perform troubleshooting.
Defective PCCS lever F-R a If power supply voltage is normal and sensor output voltage is
2 potentiometer 1 (internal abnormal (0.5 V or lower), internal open circuit and ground fault
open circuit) or ground fault cannot be identified. In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever F-R potentiometer 1
is defective.
Sensor 0.5 to 4.5
output V
contact) Resis-
tance
(female) (1)
D65EX,PX,WX-17 40-515
40 Troubleshooting

4
Min. 1 Mz
• Reference
5
V
Circuit diagram related to travel lever potentiometer
40-516 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK56KB] FR lever1:Hot Short

Action level Failure code Hot short circuit of travel lever potentiometer 3
Failure
Failure • Signal voltage of PCCS lever F-R potentiometer 1 (F/R lever 3) is 4.5 V or higher.
function.
Defective PCCS lever F-R 4. Operate PCCS lever (F-R) and perform troubleshooting.
2 potentiometer 1 (internal If failure code [DK56KB] is not displayed, PCCS lever F-R potentiometer
short circuit or ground fault) is defective. (This failure code is still displayed, wiring harness or power
train controller is defective.)
connector.
circuit)
Voltage Max. 1 V

No
continuity
Between STC1 (female) (13) and every pin other than (13)
(No sound
is heard)
If no failure is not found in above checks, power train controller is
defective.
• Reference
Defective power train 1. Turn starting switch to OFF position.
controller
D65EX,PX,WX-17 40-517
40 Troubleshooting
40-518 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK57KA] FR lever2:Open

Action level Failure code Travel lever potentiometer 4 open circuit
Failure
Failure • Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is 0.5 V or lower.
function.
first.
a If power supply voltage is unusual, go to cause 3 and after.
Power 4.5 to 5.5
supply V
Defective PCCS lever F-R a If power supply voltage is normal and sensor output voltage is
2 potentiometer 2 (internal abnormal (0.5 V or lower), internal open circuit and ground fault
open circuit or ground fault) cannot be identified. In this case, go to cause 4.
If check result of cause 4 is normal, PCCS lever F-R potentiometer 2
is defective.
Sensor 0.5 to 4.5
output V
contact) Resis-
tance
(female) (1)
Between STC1 (female) (7) and TLV1 (female)
(2) Max. 1 z
D65EX,PX,WX-17 40-519
40 Troubleshooting

4
Min. 1 Mz
• Reference
5
V
Related circuit diagram
40-520 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DK57KB] FR lever2:Hot Short

Action level Failure code Hot short circuit of travel lever potentiometer 4
Failure
Failure • Signal voltage of PCCS lever F-R potentiometer 2 (F/R lever 4) is 4.5 V or higher.
function.
Defective PCCS lever F-R 4. Operate PCCS lever (F-R) and perform troubleshooting.
2 potentiometer 2 (internal If failure code [DK57KB]is not displayed, PCCS lever F-R potentiometer
short circuit or ground fault) is defective. (If failure code [DK57KB] is still displayed, wiring harness or
power train controller is defective.)
connector.
circuit)
Voltage Max. 1 V

No
Continuity
is heard)
• Reference
5
D65EX,PX,WX-17 40-521
40 Troubleshooting
40-522 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DKH1KA] Pitch angle sensor:Open

Action level Failure code Pitch angle sensor open circuit
Failure
L03 DKH1KA (Power train controller system)
Failure • Signal voltage of pitch angle sensor is 0.15 V or lower.
Action of • Cannot sense pitch angle of machine.
• Gearshift shock is felt on slope or steering shock is felt on level ground.
• Condition of pitch angle sensor signal can be checked with monitoring function.
Related (Code: 60100 Pitch Angle Sensor voltage)
• If sensor connector is disconnected in normal condition, this code is displayed.
If failure code [DBE6KK] is also displayed perform, troubleshooting for it
first.
Power
Voltage Between PT1 (female) (C) and (A) 20 to 30 V
supply
2. Insert T-adapter into connector PT1.
Defective pitch angle sensor a If power supply voltage is normal and sensor output voltage is
2 (internal defect) or ground abnormal (0.5 V or lower), internal open circuit and ground fault
fault cannot be identified. In this case, go to cause 4.
If no failure is found in check on cause 4, pitch angle sensor is
defective.
Sensor
Voltage Between PT1 (female) (B) and (A) 0.2 to 4.8 V
output
2. Disconnect connectors STC1, STC3 and PT1, and connect T-
a If power supply voltage in cause 1 is
Open circuit in wiring normal, this check is not required. Max. 1 z
harness Between STC3 (female) (16) and PT1 (female)
3 (C)
a If power supply voltage in cause 1 is
tance
normal, this check is not required. Max. 1 z
Between STC1 (female) (21) and PT1 (female)
(A)
Between STC1 (female) (8) and PT1 (female)
(B) Max. 1 z
D65EX,PX,WX-17 40-523
40 Troubleshooting

a If no failure is found checks on cause 2, this check is not required.
Ground fault in wiring 2. Disconnect connectors STC1 and PT1, and connect T-adapters to
Min. 1 Mz
Resis- between PT1 (female) (B) and (A)
between PT1 (female) (B) and ground Min. 1 Mz
• Reference
5
controller 2. Insert T-adapter into connector STC1.
Circuit diagram related to pitch angle sensor
40-524 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DKH1KB] Pitch angle sensor:Hot Short

Action level Failure code Hot short circuit of pitch angle sensor
Failure
L03 DKH1KB (Power train controller system)
Failure • Signal voltage of pitch angle sensor is 4.85 V or lower.
Action of • Cannot sense pitch angle of machine.
• Gearshift shock is felt on slope or steering shock is felt on level ground.
• Condition of pitch angle sensor signal can be checked with monitoring function.
(Code: 60100 Pitch angle sensor voltage)
information • If sensor connector is disconnected in normal condition and starting switch is turned to ON
position, failure code [DKH1KA] is displayed.
If failure code [DBE6KK] is also displayed perform, troubleshooting for it
first.
Power
Voltage Between PT1 (female) (3) and (1) 20 to 30 V
supply
Defective pitch angle sensor
2 If failure code [DKH1KB] is not displayed but [DKH1KA] for open circuit
(internal defect)
is 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 circuit in wiring 2. Disconnect connector PT1 and connect T-adapter to female side of
Voltage Between PT1 (female) (B) and (A) or ground Max. 1 V
2. Disconnect connectors STC1 and PT1, and connect T-adapters to
harness
No continuity
Between STC1 (female) (8) and every pin
other than (8)
heard)
• Reference
controller
D65EX,PX,WX-17 40-525
40 Troubleshooting
Circuit diagram related to pitch angle sensor
40-526 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DLM3KA] Fan rev. sensor:Open

Action level Failure code Fan speed sensor open circuit
Failure
L01 DLM3KA (Power train controller system)
• No pulse voltage is input from fan speed sensor due to open circuit in fan speed sensor
system.
• This failure code appears under following conditions.
Failure
1. Input voltage is 3 to 4 V.
2. There is no record of pulse input.
3. Engine is running.
Action of • Does not perform PID control.
controller • Recognizes that fan speed is 0 rpm.
Problem on • Fan speed fails to accurately meet specified speed.
machine
• Fan speed input by fan speed sensor can be checked with monitoring function.
Related (Code: 10007 Fan speed)
Defective fan speed sensor 2. Disconnect connector FRS and connect T-adapter to male side of
circuit) Resis- Between FRS (male) (1) and (2) 2 to 3 Kz
tance Between FRS (male) (1) and ground Min. 1 Mz
connector.
2 a If resistance is 1 Mz or larger, wiring harness has open circuit. If
harness
2 to 3 Kz
tance
Open circuit in wiring harness 2. Disconnect connectors STC2 and FRS, and connect T-adapters to
contact) Between STC2 (female) (40) and FRS (female)
Max. 1 z
Resis- (1)
tance Between STC2 (female) (39) and FRS (female)
(2) Max. 1 z

Hot short circuit in wiring 2. Disconnect connector FRS and connect T-adapter to female side of
Voltage Between FRS (female) (1) and (2) 3 to 4 V
5
D65EX,PX,WX-17 40-527
40 Troubleshooting
Circuit diagram related to fan speed sensor
40-528 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DLM3MB] Fan control:Mismatch

Action level Failure code Fan speed do not correspond.
Failure
L01 DLM3MB (Power train controller system)
• Difference between fan speed value specified by power train controller and actual speed
Failure sensed by fan speed sensor exceeds 100 rpm.
Action of • Does not perform PID control on fan.
controller
Problem on • Fan speed control does not function normally.
machine
• Fan speed specified by power train controller can be checked with monitoring function.
(Code: 10000 Fan speed command)
• Fan speed sensed by fan speed sensor can be checked with monitoring function.
Related (Code: 10007 Fan speed)
information • This code is conditioned that fan solenoid is normal and fan speed sensor is also normal
(it means normal electrically).
Defective hydraulic circuit of Perform procedure in Testing and adjusting, "Testing fan oil pressure
1 hydraulic fan circuit".
D65EX,PX,WX-17 40-529
40 Troubleshooting
Failure code [DLT3KA] T/M out-speed sensor:Open

Action level Failure code Open circuit in transmission output shaft speed sensor
Failure
L03 DLT3KA (Power train controller system)
Failure • No signal is input from transmission bevel gear speed sensor.
Action of • Recognizes that transmission bevel gear speed is 0 rpm.
controller
• Transmission bevel gear speed cannot be monitored.
Problem on • Traction force cannot be calculated.
machine • Automatic shift down function may not operate correctly.
• Once machine stops, gear shift mode is restricted to manual gear shift mode.
• Transmission bevel gear speed can be checked with monitoring function.
Related (Code: 31400 Transmission Output Speed)
information • Method of reproducing failure code: Turn starting switch to ON position and travel (travel
machine or run tracks in the air with machine body put on stands).
Defective transmission bevel 2. Disconnect connector BVRV and connect T-adapter to male side of
gear (output) speed sensor connector.
1
(internal open or short circuit) Resis- Between BVRV (male) (1) and (2) 500 to 1,000
z
tance Between BVRV (male) (1) and ground Min. 1 Mz
connector.
harness
Resis- Between STC2 (female) (29) and (30) 500 to 1,000
tance z
Open circuit in wiring 2. Disconnect connectors STC2 and BVRV, and connect T-adapters to
harness female side of each connector.
3
(open circuit or defective Between STC2 (female) (29) and BVRV
contact) Max. 1 z
Resis- (female) (2)
tance Between STC2 (female) (30) and BVRV

Hot short circuit in wiring 2. Disconnect connector BVRV and connect T-adapter to female side of
Voltage Between BVRV (female) (1) and (2) 3 to 4 V
If no failure is found in above checks, power train controller may be
Defective power train defective. (Since this is internal defect, troubleshooting cannot be
5
controller performed.)
40-530 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to transmission output speed sensor
D65EX,PX,WX-17 40-531
40 Troubleshooting
Failure code [DLT3KB] T/M out-speed sensor:Short circuit

Action level Failure code Ground fault of transmission output shaft speed sensor
Failure
L03 DLT3KB (Power train controller system)
Failure • No signal is input from transmission bevel gear speed sensor.
Action of • Recognizes that transmission bevel gear speed is 0 rpm.
controller
• Transmission bevel gear speed cannot be monitored.
Problem on • Traction force cannot be calculated.
machine • Automatic shift down function may not operate correctly.
• Once machine stops, gear shift mode is restricted to manual gear shift mode.
• Transmission bevel gear speed can be checked with monitoring function.
Related (Code: 31400 Transmission Output Speed)
information • Method of reproducing failure code: Turn starting switch to ON position and travel (travel
machine or run tracks in the air with machine body put on stands).
Defective transmission bevel 2. Disconnect connector BVRV and connect T-adapter to male side of
gear (output) speed sensor connector.
1
(internal open or short circuit) Resis- Between BVRV (male) (1) and (2) 500 to 1,000
z
tance Between BVRV (male) (1) and ground Min. 1 Mz
connector.
2 a If resistance is 1 Mz or higher, wiring harness has disconnection. If
harness
Resis- Between STC2 (female) (29) and (30) 500 to 1,000
tance z
Short circuit in wiring 2. Disconnect connectors STC2 and BVRV, and connect T-adapters to
(contact with ground circuit) Resis- Between ground and STC2 (female) (30) or
BVRV (female) (1) Min. 1 Mz
tance
4
Circuit diagram related to transmission output speed sensor
40-532 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DV20KB] Back-up alarm :Short Circuit

Action level Failure code Backup alarm short circuit
Failure
L01 DV20KB (Power train controller system)
Failure • When a power is output to backup alarm circuit, abnormal current flows.
• Stops outputting signal voltage to backup alarm circuit.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is set to OFF position.
Problem on • Backup alarm does not sound
machine
• Operating condition of backup alarm (ON or OFF) can be checked with monitoring
function.
Related (Code: 40909 P/T controller SW output)
information • Method of reproducing failure code: Turn starting switch to ON position and set travel
lever to reverse position.
2. Disconnect connector BKAL and connect T-adapter to female side of
connector.
4. Operate travel lever to perform troubleshooting.
a If above voltages are normal and backup alarm does not operate,
Defective backup alarm backup alarm may be defective.
1
(internal defect) k Never get under the machine when travelling the machine for
measurement.
Travel lever:
Max. 1 V
NEUTRAL
Between BKAL (female) (1) and
Voltage Travel lever:
(2)
In reverse 20 to 30 V
position
connector.
harness
Resis- Between STC2 (female) (28) and ground Approx.
tance 560 z
Ground fault in wiring 2. Disconnect connectors STC2 and BKAL, and connect T-adapters to
BKAL (female) (1) Min. 1 Mz
tance
2. Insert T-adapter into connector BKAL.
4. Operate travel lever to perform troubleshooting.
Defective power train k Never get under the machine when travelling the machine for
4 measurement.
controller
Travel lever:
Max. 1 V
NEUTRAL
Voltage Between BKAL (1) and (2) Travel lever:
In reverse 20 to 30 V
position
D65EX,PX,WX-17 40-533
40 Troubleshooting
Circuit diagram related to backup alarm
40-534 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DW5AKA] Pitch select solenoid:Disconnection

Action level Failure code Work equipment pitch select solenoid open circuit
Failure
L01 DW5AKA (Power train controller system)
Failure • No current flows when power is output to work equipment pitch select solenoid circuit.
Action of • Stops output to pitch select solenoid circuit.
controller
Problem on • Work equipment pitch cannot selected.
machine
• Output condition (ON/OFF) to work equipment pitch selection solenoid can be checked
with monitoring mode.
Related
(Code: 90803 Blade ON/OFF output 1)
information
• Method of reproducing failure code: Turn starting switch to ON position and operate pitch
selection switch.
Defective work equipment 1. Turn starting switch to OFF position.

pitch selection solenoid 2. Disconnect connector PTP and connect T-adapter to male side.
1
(internal open circuit) Resis- Between PTP (male) (1) and (2)
18–28 z
tance
2. Disconnect connector STC3 and connect T-adapter to female side.
Open or short circuit in wiring a If resistance is above 1 Mz , wiring harness has disconnection. If
2
harness resistance is below 1 z , wiring harness has short circuit.
18–28 z
tance
Open circuit in wiring 2. Disconnect connectors STC3 and PTP, and connect T-adapters to
harness each female side.
3
(wire breakage or defective Between STC3 (female) (7) and PTP (female)
Resis- (1)
tance Between STC3 (female) (3) and PTP (female)
(2) Max. 1 z
If no problem is found in by above checks, power train controller may be
Defective power train defective. (Since this is an internal defect, troubleshooting cannot be
4
Circuit diagram related to work equipment pitch selection solenoid
D65EX,PX,WX-17 40-535
40 Troubleshooting
Failure code [DW5AKB] Pitch select solenoid:Short circuit

Action level Failure code Work equipment pitch selection solenoid short circuit
Failure
L01 DW5AKB (Power train controller system)
• Unusual current flows when power is output to work equipment pitch selection solenoid
Failure
circuit.
Action of • Stops output to pitch selection solenoid circuit.
controller
Problem on • Work equipment pitch cannot be selected.
machine
Related
(Code: 90803 Blade ON/OFF output 1)
information
selection switch.
Defective work equipment 2. Disconnect connector PTP and connect T-adapter to male side of
1 pitch selection solenoid connector.
(internal open or short circuit) Resis- Between PTP (male) (1) and (2) 18 to 28 z
tance Between PTP (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and PTP, and connect T-adapters to
PTP (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and PTP, and connect T-adapters to
harness
Resis- Between STC3 (female) (7) and (3), or
between PTP (female) (1) and (2) Min. 1 Mz
tance
4
40-536 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DW5AKY] Pitch select solenoid:Hot short

Action level Failure code Hot short of work equipment pitch selection solenoid
Failure
L01 DW5AKY (Power train controller system)
Failure • Current flows constantly to work equipment pitch selection solenoid circuit.
Action of • Stops output to pitch selection solenoid circuit.
controller
Problem on • Only pitch operation can be made and tilt operation cannot be made.
machine
Related
(Code 90803: Transmission controller, blade ON/OFF output 1)
information
selection switch.
Defective work equipment 2. Disconnect connector PTP and connect T-adapter to male side of
1 pitch selection solenoid connector.
(internal open circuit) Resis- Between PTP (male) (1) and (2) 18 to 28 z
tance Between PTP (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector PTP, and connect T-adapter to female side of
Voltage Between PTP (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and PTP, and connect T-adapters to
No continuity
other than (7)
heard)
Short circuit in wiring a Since T-adapter is not available for connector PL1, perform
3 troubleshooting for short circuit according to following procedure.
harness
2. Disconnect connectors STC1 to 3 and PTP, and connect T-adapters
to female sides of STC 1 to 3.
every pin of STC1 (female) (No sound is heard)
Continuity
every pin of STC2 (female) (No sound is heard)
4
D65EX,PX,WX-17 40-537
40 Troubleshooting
40-538 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DW7BKA] Fan reverse solenoid:Open

Action level Failure code Fan reverse solenoid open circuit
Failure
L01 DW7BKA (Power train controller system)
Failure • When power is output to fan reverse solenoid circuit, no current flows.
Action of • Stops output to fan reverse solenoid circuit.
controller
Problem on
• Fan reverse function cannot be used.
machine
• Output condition to fan reverse solenoid can be checked with monitoring function.
Related (Code: 40909 Transmission ON/OFF 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.
solenoid 2. Disconnect connector FAR and connect T-adapter to male side of
1 connector.
(internal open circuit in
wiring) Resis- Between FAR (male) (1) and (2)
34 to 44 z
tance
2. Disconnect connectors STC2 and STC3, and connect T-adapters to
female sides of connectors.
harness
Resis- Between STC2 (female) (9) and STC3
(female) (3) 34 to 44 z
tance
Open circuit in wiring 2. Disconnect connectors STC2, STC3 and FAR, and connect T-
harness adapters to female side of each connector.
3
(wire breakage or defective Between STC2 (female) (9) and FAR (female)
Resis- (1)
tance Between STC3 (female) (3) and FAR (female)
(2) Max. 1 z

Hot short circuit in wiring 2. Disconnect connector FAR and connect T-adapter to female side of
Voltage Between FAR (female) (1) and ground Max. 1 V
5
D65EX,PX,WX-17 40-539
40 Troubleshooting
Circuit diagram related to fan reverse solenoid
40-540 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DW7BKB] Fan reverse solenoid:Short circuit

Action level Failure code Fan reverse solenoid short circuit
Failure
L01 DW7BKB (Power train controller system)
Failure • When power is output to fan reverse solenoid circuit, unusual current flows.
Action of • Stops output to fan reverse solenoid circuit.
controller
Problem on
• Fan reverse function cannot be used.
machine
• Output condition to fan reverse solenoid can be checked with monitoring function.
Related (Code: 40909 Transmission ON/OFF 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.

solenoid 2. Disconnect connector FAR and connect T-adapter to male side of
1 connector.
wiring) Resis- Between FAR (male) (1) and (2) 34 to 44 z
tance Between FAR (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC2 and FAR, and connect T-adapter to
FAR (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and FAR, and connect T-adapter to
Short circuit in wiring female side of either connector.
3
harness Between STC2 (female) (9) and STC3
Resis- (female) (3), or between FAR (female) (1) and
Min. 1 Mz
tance (2)
4
Circuit diagram related to fan reverse solenoid
D65EX,PX,WX-17 40-541
40 Troubleshooting
Failure code [DWN1KA] Hss EPC RH:Open

D65EX-17,PX-17,WX-17
Action level Failure code HSS right solenoid open circuit
Failure
L03 DWN1KA (Power train controller system)
Failure • When power is output to HSS right EPC solenoid circuit, no current flows.
Action of • Stops output to HSS right EPC solenoid circuit.
• Machine cannot be steered to right.
• Output condition to HSS right EPC solenoid can be checked with monitoring function.
Related (Code: 50601 Right HSS EPC current (F/B))
PCCS lever (to steer to right).
Defective HSS right EPC 2. Disconnect connector HSR and connect T-adapter to male side of
1 solenoid connector.
(internal open circuit in wiring) Resis- Between HSR (male) (1) and (2)
4 to 15 z
tance
connector.
2 a If resistance is 1 Mz larger, wiring harness has disconnection. If
harness
resistance is 1 z smaller, wiring harness has short circuit.
4 to 15 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and HSR, and connect T-adapters to
contact of connector) Between STC3 (female) (15) and HSR (female)
Max. 1 z
Resis- (1)
tance Between STC3 (female) (13) and HSR (female)
(2) Max. 1 z
4
Circuit diagram related to HSS right EPC solenoid
40-542 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DWN1KB] Hss EPC RH:Short circuit

Action level Failure code HSS right solenoid short circuit
Failure
L03 DWN1KB (Power train controller system)
Failure • When power is output to HSS right EPC solenoid circuit, unusual current flows.
• Machine cannot be steered to right.
PCCS lever (to steer to right).
Defective HSS right EPC 1. Turn starting switch to OFF position.

solenoid 2. Disconnect connector HSR and connect T-adapter to male side of
1 connector.
wiring) Resis- Between HSR (male) (1) and (2) 4 to 15 z
tance Between HSR (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and HSR, and connect T-adapter to
HSR (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and HSR, and connect T-adapters to
harness
between HSR (female) (1) and (2) Min. 1 Mz
tance
4
D65EX,PX,WX-17 40-543
40 Troubleshooting
Failure code [DWN1KY] Hss EPC RH:Hot short

Action level Failure code Hot short circuit of HSS right solenoid
Failure
L04 DWN1KY (Power train controller system)
Failure • Current flows constantly to HSS right EPC solenoid circuit.
• Keeps turning to the right.
PCCS lever (in neutral).
Defective HSS right EPC 1. Turn starting switch to OFF position.

solenoid 2. Disconnect connector HSR and connect T-adapter to male side of
1 connector.
wiring) Resis- Between HSR (male) (1) and (2) 4 to 15 z
tance Between HSR (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector HSR and connect T-adapter to female side of
Voltage Between HSR (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and HSR, and connect T-adapter to
No continuity
other than (15)
heard)
Short circuit in wiring a Since T-adapter is not available for connector PL1, perform
3 troubleshooting for short circuit according to following procedure.
harness
2. Disconnect connectors STC1 to 3 and HSR, and connect T-adapter
to female side of STC1 to 3.
each pin of STC1 (female) (No sound is heard)
Continuity
each pin of STC2 (female) (No sound is heard)
4
40-544 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-545
40 Troubleshooting
Failure code [DWN2KA] Hss EPC LH:Open

Action level Failure code HSS solenoid left open circuit
Failure
Failure • When power is output to HSS left EPC solenoid circuit, no current flows.
Action of • Stops output to HSS left EPC solenoid circuit.
• Machine cannot turn to left.
• Output condition to HSS left EPC solenoid can be checked with monitoring function.
Related (Code: 50600 Left HSS EPC current (F/B)
PCCS lever (left steering).
Defective HSS left EPC 2. Disconnect connector HSL and connect T-adapter to male side of
1 solenoid connector.
(internal open circuit in wiring) Resis- Between HSL (male) (1) and (2)
4 to 15 z
tance
connector.
harness
4 to 15 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and HSL, and connect T-adapters to
contact of connector) Between STC3 (female) (5) and HSL (female)
Max. 1 z
Resis- (1)
tance Between STC3 (female) (23) and HSL (female)
(2) Max. 1 z
4
Circuit diagram related to HSS left EPC solenoid
40-546 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DWN2KB] Hss EPC LH:Short circuit

Action level Failure code HSS left solenoid short circuit
Failure
Failure • When power is output to HSS left EPC solenoid circuit, unusual current flows.
• Machine cannot turn to left.
PCCS lever (left steering).
Defective HSS left EPC 1. Turn starting switch to OFF position.

solenoid 2. Disconnect connector HSL and connect T-adapter to male side of
1 connector.
wiring) Resis- Between HSL (male) (1) and (2) 4 to 15 z
tance Between HSL (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and HSL, and connect T-adapters to
HSL (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and HSL, and connect T-adapter to
harness
between HSL (female) (1) and (2) Min. 1 Mz
tance
If no failure is found in by above checks, power train controller may be
4
D65EX,PX,WX-17 40-547
40 Troubleshooting
Failure code [DWN2KY] Hss EPC LH:Hot short

Action level Failure code HSS left solenoid hot short circuit
Failure
Failure • Current flows constantly to HSS left EPC solenoid circuit.
• Machine keeps turning to left.
PCCS lever (in neutral).
Defective HSS left EPC 1. Turn starting switch to OFF position.

solenoid 2. Disconnect connector HSL and connect T-adapter to male side of
1 connector.
wiring) Resis- Between HSL (male) (1) and (2) 4 to 15 z
tance Between HSL (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector HSL and connect T-adapter to female side of
Voltage Between HSL (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and HSL, and connect T-adapter to
No continuity
other than (5)
heard)
a Since T-adapter is not available for connector PL1, perform
Short circuit in wiring troubleshooting for short circuit according to following procedure.
harness
2. Disconnect connectors STC1 to 3 and HSL, and connect T-adapter
No continuity
Between STC3 (female) (5) and each pin of
STC1 (female) (No sound is
heard)
Continuity
No continuity
heard)
4
40-548 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-549
40 Troubleshooting
Failure code [DWN5KA] Fan pump solenoid 1 :Open

Action level Failure code Fan control solenoid 1 open circuit
Failure
Failure • When power is output to fan pump EPC solenoid circuit, no current flows.
Action of • Stops output to fan pump EPC solenoid circuit.
controller
• Fan speed is always maximum.
• Output condition to fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 31624 Fan solenoid current (F/B))
Defective fan control solenoid 2. Disconnect connector FAC and connect T-adapter to male side of
1 (internal open circuit) connector.
Resis- Between FAC (male) (1) and (2)
2 to 12 z
tance
connector.
harness
2 to 12 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and FAC, and connect T-adapters to
contact of connector) Between STC3 (female) (18) and FAC (female)
Max. 1 z
Resis- (1)
tance Between STC3 (female) (3) and FAC (female)
(2) Max. 1 z
4
Circuit diagram related to fan control solenoid
40-550 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DWN5KB] Fan pump solenoid 1 :Short circuit

Action level Failure code Fan control solenoid 1 shot circuit
Failure
Failure • When power is output to fan pump EPC solenoid circuit, unusual current flows.
controller
• Fan speed is always maximum.
Defective fan control 2. Disconnect connector FAC and connect T-adapter to male side of
1 solenoid (internal open connector.
circuit) Resis- Between FAC (male) (1) and (2) 2 to 12 z
tance Between FAC (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and FAC, and connect T-adapters to
FAC (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and FAC, and connect T-adapters to
harness
between FAC (female) (1) and (2) Min. 1 Mz
tance
4
D65EX,PX,WX-17 40-551
40 Troubleshooting
Failure code [DWN5KY] Fan pump solenoid 1: Hot short

Action level Failure code Fan control solenoid 1 hot shot circuit
Failure
Failure • Current flows constantly to fan pump EPC solenoid circuit.
controller
Problem on • Fan speed is always minimum.
machine • Machine easily overheats.
Defective fan control 2. Disconnect connector FAC and connect T-adapter to male side of
circuit) Resis- Between FAC (male) (1) and (2) 2 to 12 z
tance Between FAC (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector FAC and connect T-adapter to female side of
Voltage Between FAC (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and FAC, and connect T-adapters to
No continuity
other than (18)
heard)
harness
2. Disconnect connectors STC1 to 3 and FAC, and connect T-adapters
No continuity
heard)
Continuity
No continuity
heard)
4
40-552 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-553
40 Troubleshooting
Failure code [DXA2KA] TVC solenoid 1: Open

Action level Failure code Work equipment HSS pump TVC solenoid 1 open circuit
Failure
L01 DXA2KA (Work equipment controller system)
• When power is output to work equipment HSS pump TVC solenoid circuit, no current
Failure
flows.
Action of • Stops output to work equipment HSS pump TVC solenoid circuit.
controller
Problem on • If engine is loaded when its speed is low, it stops.
machine
• Output condition to work equipment HSS pump TVC solenoid can be checked with
information (Code: 01300 pump TVC solenoid output current (F/B))
Defective work equipment 2. Disconnect connector TVC and connect T-adapter to male side of
1 and HSS pump TVC solenoid connector.
(internal open circuit) Resis- Between TVC (male) (1) and (2)
2 to 12 z
tance
connector.
harness
2 to 12 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and TVC, and connect T-adapters to
contact of connector) Between STC3 (female) (8) and TVC (female)
Max. 1 z
Resis- (1)
tance Between STC3 (female) (23) and TVC (female)
(2) Max. 1 z
4
Note: TVC solenoid means PC-EPC valve.
Circuit diagram related to work equipment HSS pump TVC solenoid
40-554 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXA2KB] TVC solenoid 1: Short circuit

Action level Failure code Work equipment HSS pump TVC solenoid 1 short circuit
Failure
L01 DXA2KB (Work equipment controller system)
• When power is output to work equipment HSS pump TVC solenoid circuit, unusual current
Failure
flows.
controller
Problem on • If engine is loaded when its speed is low, it stops.
machine
1 HSS pump solenoid (internal connector.
open circuit) Resis- Between TVC (male) (1) and (2) 2 to 12 z
tance Between TVC (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and TVC, and connect T-adapters to
TVC (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and TVC, and connect T-adapters to
harness
between TVC (female) (1) and (2) Min. 1 Mz
tance
4
D65EX,PX,WX-17 40-555
40 Troubleshooting
Failure code [DXA2KY] TVC solenoid 1: Hot short

Action level Failure code Work equipment HSS pump TVC solenoid 1 hot short circuit
Failure
L01 DXA2KY (Work equipment controller system)
Failure • Current flows constantly to work equipment HSS pump TVC solenoid circuit.
controller
Problem on • Turning radius may increase.
machine • Work equipment speed may decrease.
1 HSS pump solenoid (internal connector.
open circuit) Resis- Between TVC (male) (1) and (2) 2 to 12 z
tance Between TVC (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector TVC and connect T-adapter to female side of
Voltage Between TVC (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and TVC, and connect T-adapter to
No continuity
other than (8)
heard)
harness
2. Disconnect connectors STC1 to 3 and TVC, and connect T-adapters
No continuity
heard)
Continuity
No continuity
heard)
Defective power train defective. (Since this is an internal defect, troubleshooting cannot be
4
40-556 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-557
40 Troubleshooting
Failure code [DXH1KA] Lock-up ECMV:Open

Action level Failure code Lockup clutch ECMV solenoid open circuit
Failure
L03 DXH1KA (Power train controller system)
• When power is output to torque converter lockup clutch ECMV solenoid circuit, no current
Failure
flows.
Action of • Stops output to torque converter lockup clutch ECMV solenoid circuit.
controller
Problem on • Torque converter lockup function does not operate.
machine
• Output condition to torque converter lockup clutch ECMV solenoid can be checked with
Related (Code: 31642 L/U ECMV output current (F/B))
information • Method of reproducing failure code: Start engine and travel in auto-gearshift mode (while
lockup is in operation).
Defective lockup clutch ECM 2. Disconnect connector L SOL and connect T-adapter to male side of
circuit) Resis- Between L SOL (male) (1) and (2)
3 to 13 z
tance
connector.
harness
3 to 13 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and L SOL, and connect T-adapters to
contact of connector) Between STC3 (female) (26) and L SOL
Max. 1 z
Resis- (female) (1)
tance Between STC3 (female) (13) and L SOL
If no failure is found in by above checks, power train controller may be
4
40-558 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-559
40 Troubleshooting
Failure code [DXH1KB] Lock-up ECMV: Short circuit

Action level Failure code Lockup clutch ECMV solenoid short circuit
Failure
L03 DXH1KB (Power train controller system)
• When power is output to torque converter lockup clutch ECMV solenoid circuit, unusual
Failure
current flows.
controller
Problem on • Torque converter lockup function does not operate.
machine
information • Method of reproducing failure code: Start engine and travel in auto-gearshift mode (while
Defective lockup clutch 2. Disconnect connector L SOL and connect T-adapter to male side of
1 ECMV solenoid (internal connector.
open circuit) Resis- Between L SOL (male) (1) and (2) 3 to 13 z
tance Between L SOL (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and L SOL, and connect T-adapters to
(contact with ground circuit) Resis- Between ground and STC3 (female) (26) or L
SOL (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and L SOL, and connect T-adapters to
harness
between L SOL (female) (1) and (2) Min. 1 Mz
tance
4
40-560 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH1KY] Lock-up ECMV: Hot short

Action level Failure code Lockup clutch ECMV solenoid hot short circuit
Failure
L03 DXH1KY (Power train controller system)
Failure • Current flows constantly to torque converter lockup clutch ECMV solenoid circuit.
• Torque converter lockup function operates constantly.
Problem on • Engine may stall during travel.
machine • Once machine stops, engine speed is restricted to medium (half).
information • Method of reproducing failure code: Start engine and travel in auto gearshift mode (while
Defective lockup clutch 2. Disconnect connector L SOL and connect T-adapter to male side of
1 ECMV solenoid (internal connector.
open circuit) Resis- Between L SOL (male) (1) and (2) 3 to 13 z
tance Between L SOL (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector L SOL and connect T-adapter to female side of
Voltage Between L SOL (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and L SOL, and connect T-adapter to
No continuity
other than (26)
heard)
harness
2. Disconnect connectors STC1 to 3 and L SOL, and connect T-
adapters to female sides of STC1 to 3.
No continuity
heard)
Continuity
No continuity
heard)
4
D65EX,PX,WX-17 40-561
40 Troubleshooting
40-562 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH4KA] 1st clutch ECMV:Open

Action level Failure code 1st speed clutch ECMV solenoid open circuit
Failure
Failure • When power is output to transmission 1st clutch ECMV solenoid circuit, no current flows.
Action of • Stops output to transmission 1st clutch ECMV solenoid circuit.
• Auto-shift down function does not operate.
• Output condition to 1st clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31612 1st ECMV output current (F/B))
information • Method of reproducing failure code: Start engine and travel in F1 or R1.
Defective 1st clutch ECMV 2. Disconnect connector 1 SOL and connect T-adapter to male side of
circuit) Resis- Between 1 SOL (male) (1) and (2)
3 to 13 z
tance
connector.
harness
3 to 13 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and 1 SOL, and connect T-adapters to
contact of connector) Between STC3 (female) (27) and 1 SOL
Max. 1 z
Resis- (female) (1)
tance Between STC3 (female) (23) and 1 SOL
4
D65EX,PX,WX-17 40-563
40 Troubleshooting
Failure code [DXH4KB] 1st clutch ECMV:Short circuit

Action level Failure code 1st speed clutch ECMV solenoid short circuit
Failure
• When power is output to transmission 1st clutch ECMV solenoid circuit, unusual current
Failure
flows.
circuit) Resis- Between 1 SOL (male) (1) and (2) 3 to 13 z
tance Between 1 SOL (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and 1 SOL, and connect T-adapters to
(contact with ground circuit) Resis- Between ground and STC3 (female) (27) or 1
tance
2. Disconnect connectors STC3 and 1 SOL, and connect T-adapters to
harness
between 1 SOL (female) (1) and (2) Min. 1 Mz
tance
4
40-564 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH4KY] 1st clutch ECMV:Hot short

Action level Failure code 1st speed clutch ECMV solenoid hot short circuit
Failure
Failure • Current flows constantly to transmission 1st clutch ECMV solenoid circuit.
• Auto-shift down function does not operator.
machine • Once machine is stops, travel is restricted to F1 and R1.
Hot short circuit in wiring 2. Disconnect connector 1 SOL and connect T-adapter to female side of
Voltage Between 1 SOL (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and 1 SOL, and connect T-adapter to
No continuity
other than (27)
heard)
harness
2. Disconnect connectors STC1 to 3 and 1 SOL, and connect T-
adapters to female sides of STC1 to 3.
No continuity
heard)
Continuity
No continuity
heard)
4
D65EX,PX,WX-17 40-565
40 Troubleshooting
40-566 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH5KA] 2nd clutch ECMV:Open

Action level Failure code 2nd speed clutch ECMV solenoid open circuit
Failure
Failure • When power is output to transmission 2nd clutch ECMV solenoid circuit, no current flows.
Action of • Stops output to transmission 2nd clutch ECMV solenoid circuit.
• Output condition to 2nd clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31613 2nd ECMV output current (F/B))
Defective 2nd clutch ECMV 2. Disconnect connector 2 SOL and connect T-adapter to male side of
3 to 13 z
tance
connector.
harness
3 to 13 z
tance
contact of connector) Between STC3 (female) (37) and 2 SOL
Max. 1 z
Resis- (female) (1)
4
D65EX,PX,WX-17 40-567
40 Troubleshooting
Failure code [DXH5KB] 2nd clutch ECMV:Short circuit

Action level Failure code 2nd speed clutch ECMV solenoid short circuit
Failure
• When power is output to transmission 2nd clutch ECMV solenoid circuit, unusual current
Failure
flows.
Ground fault in wiring 2. Disconnect connectors STC3 and 2 SOL, and connect T-adapters to
(contact with ground circuit) Resis- Between ground and STC3 (female) (37) or 2
tance
harness
tance
4
40-568 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH5KY] 2nd clutch ECMV:Hot short

Action level Failure code 2nd speed clutch ECMV solenoid hot short circuit
Failure
Failure • Current flows constantly to transmission 2nd clutch ECMV solenoid circuit.
No continuity
other than (37)
heard)
harness
2. Disconnect connectors STC1 to 3 and 2 SOL, and connect T-adapter
to female sides of STC1 to 3.
No continuity
heard)
Continuity
No continuity
heard)
4
D65EX,PX,WX-17 40-569
40 Troubleshooting
40-570 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH6KA] 3rd clutch ECMV:Open

Action level Failure code 3rd speed clutch ECMV solenoid open circuit
Failure
Failure • When power is output to transmission 3rd clutch ECMV solenoid circuit, no current flows.
Action of • Stops output to transmission 3rd clutch ECMV solenoid circuit.
• Output condition to 3rd clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31614 3rd ECMV output current (F/B))
Defective 3rd clutch ECMV 2. Disconnect connector 3 SOL and connect T-adapter to male side of
3 to 13 z
tance
connector.
harness
3 to 13 z
tance
contact of connector) Between STC3 (female) (6) and 3 SOL (female)
Max. 1 z
Resis- (1)
4
Circuit diagram related to 3rd clutch ECMV
D65EX,PX,WX-17 40-571
40 Troubleshooting
Failure code [DXH6KB] 3rd clutch ECMV:Short circuit

Action level Failure code 3rd speed clutch ECMV solenoid short circuit
Failure
• When power is output to transmission 3rd clutch ECMV solenoid circuit, unusual current
Failure
flows.
Cause
o.
2. Disconnect connector 3 SOL and connect T-adapter to male side of
Defective 3rd clutch ECMV
1 solenoid (internal open circuit) connector.
Resis- Between 3 SOL (male) (1) and (2) 3 to 13 z
Ground fault in wiring harness 2. Disconnect connectors STC3 and 3 SOL, and connect T-adapters to
tance
3 Short circuit in wiring harness female side of either connector.
tance
4
40-572 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH6KY] 3rd clutch ECMV:Hot short

Action level Failure code 3rd speed clutch ECMV solenoid hot short circuit
Failure
Failure • Current flows constantly to transmission 3rd clutch ECMV solenoid circuit.
Defective 3rd clutch ECMV 2. Disconnect connector 3 SOL and connect T-adapter to male side of
No continuity
other than (6)
heard)
harness
2. Disconnect connectors STC1 to 3 and 3 SOL, and connect T-adapter
No continuity
heard)
Continuity
No continuity
heard)
4
D65EX,PX,WX-17 40-573
40 Troubleshooting
40-574 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH7KA] R clutch ECMV:Open

Action level Failure code Reverse clutch ECMV solenoid open circuit
Failure
Failure • When power is output to transmission R clutch ECMV solenoid circuit, no current flows.
Action of • Stops output to transmission R clutch ECMV solenoid circuit.
machine • Once machine stops, travel is restricted to F1.
• Output condition to R clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31616 Reverse ECMV output current (F/B))
information • Method of reproducing failure code: Start engine and travel in reverse.
Defective R clutch ECMV 2. Disconnect connector R SOL, and connect T-adapter to male side of
circuit) Resis- Between R SOL (male) (1) and (2)
3 to 13 z
tance
connector.
harness
3 to 13 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and R SOL, and connect T-adapters to
contact of connector) Between STC3 (female) (38) and R SOL
Max. 1 z
Resis- (female) (1)
tance Between STC3 (female) (13) and R SOL
4
D65EX,PX,WX-17 40-575
40 Troubleshooting
Failure code [DXH7KB] R clutch ECMV:Short circuit

Action level Failure code Reverse clutch ECMV solenoid short circuit
Failure
• When power is output to transmission R clutch ECMV solenoid circuit, unusual current
Failure
flows.
machine • Once machine stops, travel is restricted to F1.
circuit) Resis- Between R SOL (male) (1) and (2) 3 to 13 z
tance Between R SOL (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and R SOL, and connect T-adapters to
(contact with ground circuit) Resis- Between ground and STC3 (female) (38) or R
tance
2. Disconnect connectors STC3 and R SOL, and connect T-adapters to
harness
between R SOL (female) (1) and (2) Min. 1 Mz
tance
4
40-576 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH7KY] R clutch ECMV:Hot short

Action level Failure code Reverse clutch ECMV solenoid hot short circuit
Failure
Failure • Current flows constantly to transmission R clutch ECMV solenoid circuit.
circuit) Resis- Between R SOL (male) (1) and (2) 3 to 13 z
tance Between R SOL (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector R SOL and connect T-adapter to female side
2 harness of connector.
Voltage Between R SOL (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and R SOL, and connect T-adapter to
a Check with multimeter continuity mode.
No continuity
other than (38)
heard)
harness
2. Disconnect connectors STC1 to 3 and R SOL, and connect T-adapter
No continuity
heard)
Continuity
No continuity
heard)
4
D65EX,PX,WX-17 40-577
40 Troubleshooting
40-578 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH8KA] F clutch ECMV:Open

Action level Failure code Forward travel clutch ECMV solenoid open circuit
Failure
Failure • When power is output to transmission F clutch ECMV solenoid circuit, no current flows.
Action of • Stops output to transmission F clutch ECMV solenoid circuit.
machine • Once machine stops, travel is restricted to R1.
• Output condition to F clutch ECMV solenoid can be checked with monitoring function.
Related (Code: 31622 Forward travel ECMV output current (F/B))
information • Method of reproducing failure code: Start engine and travel forward.
Defective F clutch ECMV 2. Disconnect connector F SOL, and connect T-adapter to male side of
circuit) Resis- Between F SOL (male) (1) and (2)
3 to 13 z
tance
connector.
harness
3 to 13 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and F SOL, and connect T-adapters to
contact of connector) Between STC3 (female) (28) and F SOL
Max. 1 z
Resis- (female) (1)
tance Between STC3 (female) (13) and F SOL
4
Circuit diagram related to F clutch ECMV
D65EX,PX,WX-17 40-579
40 Troubleshooting
Failure code [DXH8KB] F clutch ECMV:Short circuit

Action level Failure code Forward travel clutch ECMV solenoid short circuit
Failure
• When power is output to transmission F clutch ECMV solenoid circuit, unusual current
Failure
flows.
machine • Once machine stops, travel is restricted to R1.
circuit) Resis- Between F SOL (male) (1) and (2) 3 to 13 z
tance Between F SOL (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and F SOL, and connect T-adapters to
(contact with ground circuit) Resis- Between ground and STC3 (female) (28) or F
tance
2. Disconnect connectors STC3 and F SOL, and connect T-adapter to
harness
between F SOL (female) (1) and (2) Min. 1 Mz
tance
4
40-580 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXH8KY] F clutch ECMV:Hot short

Action level Failure code Forward travel clutch ECMV solenoid hot short circuit
Failure
Failure • Current flows constantly to transmission F clutch ECMV solenoid circuit.
circuit) Resis- Between F SOL (male) (1) and (2) 3 to 13 z
tance Between F SOL (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector F SOL and connect T-adapter to female side of
Voltage Between F SOL (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and F SOL, and connect T-adapter to
No continuity
other than (28)
heard)
harness
2. Disconnect connectors STC1 to 3 and F SOL, and connect T-adapter
No continuity
heard)
Continuity
No continuity
heard)
4
D65EX,PX,WX-17 40-581
40 Troubleshooting
40-582 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXJ4KA] Weq lock Sol.:Open

Action level Failure code Work equipment lock solenoid open circuit
Failure
L03 DXJ4KA (Power train controller system)
Failure • When power is output to work equipment lock solenoid circuit, no current flows.
Action of • Stops output to work equipment lock solenoid circuit.
• Blade and ripper cannot be operated.
information equipment lock lever (FREE).
lock solenoid 2. Disconnect connector WLK and connect T-adapter to male side of
1 connector.
wiring) Resis- Between WLK (male) (1) and (2)
20 to 60 z
tance
connector.
2 a If resistance is 1 Mz or larger, wiring harness has open connector. If
harness
20 to 60 z
tance
Open circuit in wiring 2. Disconnect connectors STC2, STC3 and WLK, and connect T-
harness adapter to female side of each connector.
3
(wire breakage or defective Between STC2 (female) (19) and WLK
Resis- (female) (1)
tance Between STC3 (female) (23) and WLK

Hot short circuit in wiring 2. Disconnect connector WLK and connect T-adapter to female side of
Voltage Between WLK (female) (1) and ground Max. 1 V
5
D65EX,PX,WX-17 40-583
40 Troubleshooting
Circuit diagram related to work equipment lock solenoid
40-584 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXJ4KB] Weq lock Sol.:Short circuit

Action level Failure code Work equipment lock solenoid short circuit
Failure
L03 DXJ4KB (Power train controller system)
Failure • When power is output to work equipment lock solenoid circuit, no current flows.
Action of • Stops output to work equipment lock solenoid circuit.
• Blade and ripper cannot be operated.
information equipment lock lever (FREE).

lock solenoid 2. Disconnect connector WLK and connect T-adapter to male side of
1 connector.
wiring) Resis- Between WLK (male) (1) and (2) 20 to 60 z
tance Between WLK (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC2 and WLK, and connect T-adapters to
WLK (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC2, STC3 and WLK, and connect T-
Short circuit in wiring adapter to female side of either connector.
3
harness Between STC2 (female) (19) and STC3
Resis- (female) (23), or between WLK (female) (1)
Min. 1 Mz
tance and (2)
4
Circuit diagram related to work equipment lock solenoid
D65EX,PX,WX-17 40-585
40 Troubleshooting
Failure code [DXJCKA] Blade angle left EPC:Open

Action level Failure code Blade angle left EPC open circuit
Failure
L01 DXJCKA (Power train controller system)
Failure • When power is output to blade angle left EPC solenoid circuit, no current flows.
Action of • Stops output to blade angle left EPC solenoid circuit.
controller
Problem on • Blade cannot be angled to left.
machine
• Output condition to blade angle left EPC solenoid can be checked with monitoring
function.
Related (Code: 71013 Blade left angle EPC current)
left angle lever.
Defective blade angle left 2. Disconnect connector PTL and connect T-adapter to male side of
1 EPC solenoid (internal open connector.
circuit) Resis- Between PTL (male) (1) and (2)
2 to 12 z
tance
connector.
harness
2 to 12 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and PTL, and connect T-adapter to
contact of connector) Between STC3 (female) (35) and PTL (female)
Max. 1 z
Resis- (1)
tance Between STC3 (female) (3) and PTL (female)
(2) Max. 1 z
4
Circuit diagram related to blade angle left EPC solenoid
40-586 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXJCKB] Blade angle left EPC:Short circuit

Action level Failure code Blade angle left EPC short circuit
Failure
L01 DXJCKB (Power train controller system)
Failure • When power is output to blade angle left EPC solenoid circuit, unusual current flows.
controller
Problem on • Blade cannot be angled to left.
machine
function.
left angle lever.
circuit) Resis- Between PTL (male) (1) and (2) 2 to 12 z
tance Between PTL (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and PTL, and connect T-adapters to
PTL (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and PTL, and connect T-adapter to
harness
between PTL (female) (1) and (2) Min. 1 Mz
tance
4
D65EX,PX,WX-17 40-587
40 Troubleshooting
Failure code [DXJCKY] Blade angle left EPC:Hot short

Action level Failure code Blade angle left EPC hot short circuit
Failure
L03 DXJCKY (Power train controller system)
Failure • Current flows constantly to blade angle left EPC solenoid circuit.
• Blade angle left EPC operates constantly.
function.
information • Method of reproducing failure code: Start engine and cancel work equipment lock, and
angle left EPC operates constantly.
1 EPC solenoid (internal short connector.
circuit) Resis- Between PTL (male) (1) and (2) 2 to 12 z
tance Between PTL (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector PTL and connect T-adapter to female side of
Voltage Between PTL (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and PTL, and connect T-adapters to
No
Continuity
is heard)
3 Short circuit in wiring harness 2. Disconnect connectors STC1 to 3 and PTL, and connect T-adapters
No
Between STC3 (female) (35) and each pin of continuity
STC1 (female) (No sound
is heard)
Continuity
No
is heard)
If no failure is not found in above checks, power train controller may be
4
40-588 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-589
40 Troubleshooting
Failure code [DXJDKA] Blade angle right EPC:Open

Action level Failure code Blade angle right EPC open circuit
Failure
L01 DXJDKA (Power train controller system)
Failure • When power is output to blade angle right EPC solenoid circuit, no current flows.
Action of • Stops output to blade angle right EPC solenoid circuit.
controller
Problem on • Blade cannot be angled to right.
machine
• Output condition to blade angle right EPC solenoid can be checked with monitoring
function.
Related (Code: 71011 Blade right angle EPC current)
right angle lever.
Defective blade angle right 2. Disconnect connector PTR and connect T-adapter to male side of
circuit) Resis- Between PTR (male) (1) and (2)
2 to 12 z
tance
connector.
harness
2 to 12 z
tance
Open circuit in wiring harness 2. Disconnect connectors STC3 and PTR, and connect T-adapters to
contact of connector) Between STC3 (female) (25) and PTR (female)
Max. 1 z
Resis- (1)
tance Between STC3 (female) (3) and PTR (female)
(2) Max. 1 z
4
Circuit diagram related to blade angle right EPC solenoid
40-590 D65EX,PX,WX-17
40 Troubleshooting
Failure code [DXJDKB] Blade angle right EPC:Short circuit

Action level Failure code Blade angle right EPC short circuit
Failure
L01 DXJDKB (Power train controller system)
Failure • When power is output to blade angle right EPC solenoid circuit, unusual current flows.
controller
Problem on • Blade cannot be angled to right.
machine
function.
right angle lever.
circuit) Resis- Between PTR (male) (1) and (2) 2 to 12 z
tance Between PTR (female) (1) and ground Min. 1 Mz
Ground fault in wiring 2. Disconnect connectors STC3 and PTR, and connect T-adapters to
PTR (female) (1) Min. 1 Mz
tance
2. Disconnect connectors STC3 and PTR, and connect T-adapter to
harness
between PTR (female) (1) and (2) Min. 1 Mz
tance
4
D65EX,PX,WX-17 40-591
40 Troubleshooting
Failure code [DXJDKY] Blade angle right EPC:Hot short

Action level Failure code Blade angle right EPC hot short circuit
Failure
L03 DXJDKY (Power train controller system)
Failure • Current flows constantly to blade angle right EPC solenoid circuit.
• Blade angle right EPC operates constantly.
function.
information • Method of reproducing failure code: Start engine and cancel work equipment lock, and
right angling operates constantly.
1 EPC solenoid (internal short connector.
circuit) Resis- Between PTR (male) (1) and (2) 2 to 12 z
tance Between PTR (female) (1) and ground Min. 1 Mz
Hot short circuit in wiring 2. Disconnect connector PTR and connect T-adapter to female side of
Voltage Between PTR (female) (1) and ground Max. 1 V
2. Disconnect connectors STC3 and PTR, and connect T-adapters to
No
Continuity
is heard)
3 Short circuit in wiring harness 2. Disconnect connectors STC1 to 3 and PTR, and connect T-adapters
No
is heard)
Continuity
No
is heard)
If no failure is not found in above checks, power train controller may be
4
40-592 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-593
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-1 Engine does not start (Engine does not crank)
Failure • Engine does not start (Engine does not crank)
• 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.
• KOMTRAX has start lock function. Engine does not start unless start lock is reset.
• Before carrying out troubleshooting, check that no related failure code is displayed.
(If failure code [D19JKZ], [D130KA], [D130KB], [DD14KA], or [DD14KB] is
Related information displayed, perform troubleshooting for the displayed code first.)
• In the case of failure symptom "The battery relay does not make operating sound"
when turning the starting switch to ON position, perform troubleshooting for E-1 also.
• If failure symptom "Machine monitor does not light up" appears when turning starting
switch to ON position, main electric power supply system is supposed to be
defective. Perform the troubleshooting for E-5 (lines of fusible link FL1-2, fuses No. 1
and No. 5 of fuse box FS12).
Loose terminal or open circuit
1 Check the terminals of starting motor, alternator, battery relay, ground
at terminal
cables GND, GND03, GND11, GND20, etc.
Between battery relay terminal BRE and
Defective contact (grounding) ground
2 between battery relay and Resis-
frame a Use machine frame as GND for Max. 1 z
tance
measurement.
a Loose or rusted terminal GND03
a Be ready with starting switch at OFF then perform troubleshooting
Insufficient battery capacity leaving starting switch at OFF.
3
Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated
4 with failure codes [DB2QKR] and [DB2RKR]. If these codes appear,
system
perform troubleshooting for causes 1 to 3 of [DB2QKR] first.
If fusible link FL2-2 is blown, the circuit probably has ground fault.
5 Defective fusible link FL2-2 Perform troubleshooting for cause 14 first.
Defective parking brake lever 2. Operate parking brake lever to perform troubleshooting.
6 switch (internal defect or
defective adjustment) Display Free position Other than "P"
"P" on monitor panel Lock position "P" is displayed.
Defective work equipment lock 1. Turn starting switch to ON position.

lever switch 2. Operate work equipment lock lever to perform troubleshooting.
7 Display of "Lock work Free position Symbol OFF
(internal defect or defective
adjustment) equipment" symbol on
monitor panel Lock position Symbol ON
Defective fuse No. 1 in fuse If the fuse is broken, the circuit probably has a ground fault, etc. (See
8 Cause 14.)
box FS22
1. Turn starting switch to ON position (to connect ACC).
9 Defective battery relay system
a If sound of battery relay turning ON is not heard, proceed to Cause
21.
40-594 D65EX,PX,WX-17
40 Troubleshooting

1. Turn the starting switch to OFF position and remove fuse No. 1 in
fuse box FS21.
Defective fusible link FL2-2, 2. Turn starting switch to ON position (to connect ACC).
10 defective wiring harness Between fuse box FS21-1 (input terminal) and
Voltage 20 – 30 V
ground
a If voltage is abnormal, proceed to cause 13.
2. Remove fuse No. 4 (30 A) in fuse box FS21. (to prevent engine
Defective starting switch, from starting during check)
neutral safety relay NSF, 3. Insert T-adapter into connector ST.
11 personal lock relay PSL, 4. Turn starting switch to START position and hold (two persons
battery relay, wiring harness required for this check).
Voltage Between ST (1) and ground 20 – 30 V
a If voltage is abnormal, proceed to cause 15.
If fusible link is broken, circuit may have ground fault. In this case,
perform troubleshooting for cause 14 first.
12 Defective fusible link FL2-2 • Fuses No. 9 and No. 15 in fuse box FS11 and fuses No. 2 and No. 6
in fuse box FS21 are connected to fusible link FL2-2.
a Connected circuit is large in scale. Accordingly, if no failure is found
by check on cause 9, reproduce trouble and find out ground fault
position by sound and burning smell.
a If no failure is found by check on cause 10, this check is not
required.
Open circuit in wiring harness 1. Turn starting switch to OFF position, and set battery disconnect
1 switch to OFF position.
13
(wire breakage or defective (To prevent short circuit during troubleshooting)
contact of connector) 2. Disconnect fusible link FL2-2 and No. 1 of fuse FS21.
Resis- Between battery relay (BRC) and FL2-2 Max. 1 z
tance Between FL2-4 and FS21-1 Max. 1 z
required.
Ground fault in wiring harness switch to OFF position.
14 1 2. Disconnect fusible link FL2-2, No. 1 of fuse FS21, and battery relay
(contact with ground circuit) terminal BRC.
Between ground and battery relay BRC (wiring
Resis- harness side) or FL2-2 Min. 1 Mz
tance
Between ground and FL2-4 or FS21-1 Min. 1 Mz
D65EX,PX,WX-17 40-595
40 Troubleshooting

required.
2. Disconnect connector KEY and connect T-adapter to male side.
3. After troubleshooting, perform troubleshooting again with starting
switch at ON and START positions.
Turn starting switch to
OFF position. Min. 1 Mz
Between KEY (male)
Defective starting switch (1) and (5) Turn starting switch to
15 Max. 1 z
(Internal open circuit) ON position.
Resis- Between KEY (male)
tance (4) and (5) Turn starting switch to
ON position. Max. 1 z
Between KEY (male)
(3) and (5) Turn starting switch to
START position. Max. 1 z

required.
Defective neutral safety relay 1. Turn starting switch to OFF position.
16 (internal open circuit)
2. Replace neutral safety relay (NSF) with another relay.
3. Starting the engine.
If engine starts, original neutral safety relay (NSF) is defective.
Defective personal lock relay required.
17 (internal open circuit or short 1. Turn starting switch to OFF position.
circuit) 2. Replace personal lock relay (PSL) with another relay.
3. Starting the engine.
If engine starts, original personal lock relay is defective.
2. Insert T-adapter into connector PRTR.
Defective alternator 3. Turn starting switch to ON position.
18
(internal short circuit) Input from
Voltage Between PRTR (2) and ground alternator Max. 1 V
generation
2. Insert T-adapter into connector ST.
3. Turn starting switch to START position to perform troubleshooting.
Between starting motor terminal B Power
(ST/B) and ground supply 20 – 30 V
Defective starting motor Starting
19 input to
(internal defect) Voltage Between ST (1) and ground 20 – 30 V
starting
motor
Charge
Between ST (2) and ground Max. 1 V
input
If power supply and starting input to starting motor are normal but
starting motor does not rotate, starting motor is defective.
40-596 D65EX,PX,WX-17
40 Troubleshooting

2. Remove connector RSD and connect T-adapter to diode.
Defective diode RSD a Use multimeter in diode range.
20 (internal open circuit or short Between RSD (male) (1) (+) and
circuit) No continuity
(2) (-)
Continuity
Between RSD (male) (2) (+) and
Continuity
(1) (-)
• Battery relay
Resis- Between terminal BRSW and KEY (female) (4)
Max. 1 z
tance
• Battery relay
a To check to where 24 V is supplied to locate open section
Between terminals BRB and R01 20 – 30 V
Between terminals BRSW and R01 20 – 30 V
Voltage
Between terminals BRC and R01 20 – 30 V
Between terminal BRE and ground Max. 1 V
• Alternator and starting motor
3. Insert T-adapters into connectors KEY, NSF, PSL, and ST.
5. Turn starting switch to START position to perform troubleshooting.
a To check to where 24 V is supplied to locate open section
Between KEY (3) and ground 20 – 30 V
Between NSF (3) and ground 20 – 30 V
Between NSF (5) and ground 20 – 30 V
Voltage Between PSL (4) and ground 20 – 30 V
Between ST (1) and ground 20 – 30 V
21 (wire breakage or defective Between alternator B terminal and ground 20 – 30 V
Between starting motor terminal B and ground 20 – 30 V
• If fuse or fusible link is blown, replace it with a new one.
2. Disconnect connectors KEY, NSF, PSL, and CM01.
3. Connect T-adapters to each female side of KEY, NSF, PSL, and
CM01.
4. Remove fuse FS22-1.
Between KEY (female) (3) and NSF (female)
(3) Max. 1 z
Between NSF (female) (5) and PSL (female)
(3) Max. 1 z
Between PSL (female) (1) and FS22-1 Max. 1 z
Between PSL (female) (2) and CM01 (female)
(6) Max. 1 z
Between PSL (female) (4) and starting motor
Resis- terminal S Max. 1 z
tance Between alternator terminal B and starting
Max. 1 z
motor terminal B
Between starting motor B and battery relay
Max. 1 z
BRC
Between alternator AL/R (terminal R) and
starting motor terminal R Max. 1 z
Between alternator AL/R and RSD (female) (2) Max. 1 z
Between RSD (female) (1) and KEY (female)
(4) Max. 1 z
D65EX,PX,WX-17 40-597
40 Troubleshooting

Defective battery relay If only terminal BRC voltage is abnormal during battery relay check for
22 cause 21, battery relay is defective.
(Is not actuated)
2. Disconnect connectors KEY, NSF, PSL, and ST.
3. Connect T-adapters to each female side of KEY, NSF, and PSL.
4. Remove No. 1 of fuse FS22.
Between ground and KEY (female) (3) or NSF
Ground fault in wiring harness Min. 1 Mz
23 (female) (3)
(contact with ground circuit) Between ground and NSF (female) (5) or PSL
Resis- (female) (3) Min. 1 Mz
tance
Between ground and PSL (female) (4) or ST
Between PSL (female) (2) and ground Min. 1 Mz
Hot short circuit in wiring 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ST.
Voltage Between ground and ST (2) or PRTR (2) Max. 1 V
40-598 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to engine start circuit
D65EX,PX,WX-17 40-599
40 Troubleshooting
E-2 Manual preheating does not work

Failure Manual preheating does not work.
a This troubleshooting section describes the procedures to be followed when manual
preheating does not function to heat the electrical intake air heater (ribbon heater)
mounting section.
• This machine has “Automatic preheating” and “Manual preheating” functions. When
either preheating works, preheating monitor lights up. (When only preheating monitor
does not light up, perform troubleshooting for failure symptom "While preheating is
Related working, preheating monitor does not light up").
information • If failure symptom "Machine monitor displays nothing" or "Battery relay does not
make operating sound" appears when turning starting switch to ON position, main
electric power supply system is supposed to be defective. In these cases, perform
troubleshooting for E-5 and E-1 respectively.
• If fuse No. 5 in fuse box FS12 is broken, machine monitor does not light up.
• Before performing troubleshooting, check that any failure code related to preheating
is not displayed.
Defective fuse No. 1 of fusible If fuse FL2-1 is broken, circuit probably has ground fault. In this case,
1 perform check on cause 8 first.
link FL2
Loose terminal or open circuit
2 Check terminals of heater relay, battery relay, electrical intake air
at terminal
heater (ribbon heater), etc.
2. Disconnect connectors CM01 and KEY, and connect T-adapter to
female side of KEY.
Resis- Between KEY (2) and ground (heater relay coil Approx. 20
tance resistance) z
• Secondary side
Open circuit or ground fault in Between HT/B (input terminal on contact side
3 Voltage 20 – 30 V
wiring harness of heater relay) and ground
• Primary side
2. Disconnect heater relay terminal HT/A.
a To prevent current from flowing in heater when starting switch is
turned to HEAT position
3. Turn starting switch to HEAT position (Connect R1).
Between heater relay terminal HT/C and
Voltage 20 – 30 V
ground
a If no failure is found by check on primary side on cause 3, this check
is not required.
Defective diode HTD 1. Turn starting switch to OFF position.
2. Remove connector HTD and connect T-adapter to diode.
4 (internal open circuit or short
circuit) a Use multimeter in diode range.
No
Between HTD (male) (1) (+) and (2) (-)
Continuity continuity
Between HTD (male) (2) (+) and (1) (-) Continuity
40-600 D65EX,PX,WX-17
40 Troubleshooting

a If no failure is found by check on primary side on cause 3, this check
is not required.
2. Turn disconnect switch to OFF position.
5 Defective starting switch 3. Disconnect connector KEY and connect T-adapter to male side.
4. Turn starting switch to OFF/HEAT position to perform
troubleshooting.
Resis- Between KEY (male) (2) and (5) OFF Min. 1 Mz
tance HEAT Max. 1 z
Defective electrical intake air 1. Turn starting switch to OFF position.
heater (ribbon heater) 2. Disconnect terminal HT/A.
6
Between terminal HT/A on harness side and
(Internal open circuit) Continuity Continuity
ground
Defective heater relay
If no failure is found by check on cause 3 and heater relay operation
7 (Is not actuated) (Terminal HT/ sound is not heard, heater relay is defective.
A)
2. Disconnect connectors KEY, CM01, and HTD and terminals HT/C,
Ground fault in wiring harness HT/A, and BRC.
8
(contact with ground circuit) Between heater relay terminal HT/C (on
Min. 1 Mz
Resis- harness side) and ground
tance Between HT/B (input terminal on contact side
of heater relay) and ground Min. 1 Mz
D65EX,PX,WX-17 40-601
40 Troubleshooting
Circuit diagram related to preheating of engine
40-602 D65EX,PX,WX-17
40 Troubleshooting
E-3 Automatic preheating does not work

Failure Automatic preheating function does not work.
• Automatic preheating starts when boost temperature is below -3 °C .
(Monitoring code: 18500 Boost temperature)
• If automatic preheating does not work, check whether manual preheating works first.
• Engine controller checks primary (coil) side of preheat relay (connector PHR) and
Related information generates failure code [CA2555] or [CA2556] if it defective.
• Engine controller checks boost temperature sensor and generates failure code
[CA153] or [CA154] if it is defective.
• If headlamp or backup lamp lights up, No.4 of fusible link FL2 is not blown.
Defective fuse No. 6 in fuse If fuse No. 6 in fuse box FS22 is blown, ground fault may have occurred
1 in circuit. In this case, perform troubleshooting for cause 6 first.
box FS22
If fuse No. 4 of fusible link FL2 is blown, ground fault may have
Defective fuse No.4 in fusible
2 occurred in circuit. In this case, perform troubleshooting for cause 6
link FL2
first.
Defective preheat relay PHR 2. Replace preheat relay (connector PHR) with another relay, for
instance, neutral safety relay (connector: NSF).
3 (internal open circuit or short 3. Turn starting switch to ON position.
circuit)
If automatic preheating functions when boost temperature is below -3 °
C , original preheat relay is defective.
2. Disconnect connectors CM01, PHR and HTD, and connect T-
adapter to female side of PHR.
Open circuit or ground fault of a If resistance is above 1 Mz , wiring harness has open circuit. If
4 wiring harness resistance is below 1 z , wiring harness has short circuit.
a Heater relay coil resistance
Resis- Between PHR (female) (5) and ground Approx. 20
tance z
2. Disconnect connectors PHR and CM01, and connect T-adapter to
Open circuit in wiring harness female side of PHR.
5 (wire breakage or defective 3. Remove fuse No. 6 in fuse box FS22.
contact of connector) Between PHR (female) (3) and FS22-6 Max. 1 z
Resis-
tance Between PHR (female) (5) and heat relay
Max. 1 z
terminal HT/C
If fuse is not blown, this check is not required.
Ground fault in wiring harness 2. Disconnect connector PHR and connect T-adapter to female side.
6
(contact with ground circuit) 3. Remove fuse No. 6 in fuse box FS22.
Resis- Between PHR (female) (3) and ground
Min. 1 Mz
tance
D65EX,PX,WX-17 40-603
40 Troubleshooting
40-604 D65EX,PX,WX-17
40 Troubleshooting
E-4 While preheating is working, preheating monitor does not light up

Failure While preheating is working, preheating monitor does not light up.
• This machine has "Automatic preheating" and "Manual preheating" functions. When
Related information either preheating works, preheating monitor lights up.
• Check if manual preheating functions first.
2. Disconnect connectors KEY, CM01 and PHR, and connect T-
Open circuit in wiring harness adapters to each female side.
1 (wire breakage or defective Between KEY (female) (2) and CM01 (female)
Max. 1 z
contact of connector) Resis- (12)
tance Between PHR (female) (5) and CM01 (female)
(12) Max. 1 z
If failure is not found by above checks, machine monitor is defective.
• Reference
2. Insert T-adapter into connector CM01.
3. Disconnect heater relay terminal HT/A.
a To prevent current from flowing in heater when starting switch is
turned to HEAT position.
4. Turn starting switch to HEAT position.
Resis- Between CM01 (12) and (3)
20 – 30 V
tance
D65EX,PX,WX-17 40-605
40 Troubleshooting
40-606 D65EX,PX,WX-17
40 Troubleshooting
E-5 When starting switch is turned to ON position, machine monitor

displays nothing
Failure • When starting switch is turned to ON position, machine monitor displays nothing.
• When starting switch is turned to ON position, machine monitor displays KOMATSU
logo screen, password input password (if set), current setting confirmation screen,
and standard screen in order.
Related information • When engine is started, battery voltage may lower suddenly, depending on ambient
temperature and condition of battery.
• Check that battery disconnect switch is set to ON.
Battery disconnect switch left Turn starting switch to OFF position and check that battery disconnect
1 in OFF position switch is in ON position.
Loose terminal or open circuit 1. Turn starting switch to OFF position.
2
at terminal Check terminals of battery relay, etc.
Defective fuses No. 1 and No. If the fuse is blown, the circuit probably has a ground fault (See causes
3 8 and 12).
5 in fuse box FS12
1. Turn starting switch to OFF position, and set disconnect switch to
OFF position.
Defective fuse No. 2 in fusible 3. Turn battery disconnect switch to the ON position.
4 link FL1, defective wiring Between fuse box FS11-1 (input terminal) and
ground 20 – 30 V
harness, defective battery Voltage
Between fuse box FS21-3 (input terminal) and
ground 20 – 30 V
a If voltage is normal, proceed to cause 8.

a Be ready with starting switch at OFF then perform troubleshooting
Insufficient battery capacity leaving starting switch at OFF.
5
Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
Defective fuse No. 2 in fusible If fusible link or fuse is blown, circuit probably has ground fault. (See
6 troubleshooting for cause 12.)
link FL1
OFF position.
Open circuit in wiring harness 2. Disconnect No. 2 of fusible link FL1, No. 1 and No. 5 of fuse FS11,
1 and No. 3 of FS21.
7 (wire breakage or defective 3. Turn starting switch to ON position with disconnect switch at OFF.
contact of connector) Between battery (-) and ground Max. 1 z
Between battery (+) and FL1-2 Max. 1 z
Resis-
Between FL1-4 and FS21-3 Max. 1 z
tance
Between FL1-4 and FS11-5 Max. 1 z
Between FS12-5 and FS11-1 Max. 1 z
If no failure is found by check on causes 3 and 4, this check is not
required.
OFF position.
Ground fault in wiring harness 2. Disconnect fusible link FL1-2, No. 1 and No. 5 of fuse FS11, No. 3
8 1 of FS21, and battery (+) terminal.
(contact with ground circuit) Between ground and battery (+) or FL1-2 Min. 1 Mz
Resis- Between ground and FL1-4 or FS11-5 Min. 1 Mz
tance Between FS12-5 and ground Min. 1 Mz
Between FS11-1 and ground Min. 1 Mz
D65EX,PX,WX-17 40-607
40 Troubleshooting

OFF position.
2. Insert T-adapter into connector CM01.
Defective wiring harness, 3. Turn disconnect switch to ON position, and turn starting switch to
9 starting switch, or machine ON position (connect ACC).
monitor Between CM01 (1) and (3) 20 – 30 V
Voltage Between CM01 (2) and (4) 20 – 30 V
Between CM01 (10) and (4) (ACC line) 20 – 30 V
a If no failure is found by check on "ACC line" of cause 9, this check is
not required.
2. Disconnect connector KEY and connect T-adapter to male side.
Defective starting switch 3. Turn starting switch to ON position and perform troubleshooting
10
(Internal open circuit in wiring) again.
Resis- Between KEY (male)
tance (1) and (5) Turn starting switch to
ON position. Max. 1 z
If no failure is found by check on cause 9, this check is not required.
OFF position.
2. Disconnect No. 3 of fuse FS22, No. 5 of FS12, and connectors KEY
and CM01.
Open circuit in wiring harness 3. Connect T-adapters to each female side of connectors KEY and
2 CM01.
11
(wire breakage or defective Between FS22-3 and CM01 (female) (1), (2) Max. 1 z
contact of connector) Between ground (GND11) and CM01 (female)
Max. 1 z
Resis- (3), (4)
tance Between FS12-5 and KEY (female) (5) Max. 1 z
Between KEY (female) (1) and CM01 (female)
(10) Max. 1 z
If no failure is found by check on cause 9, this check is not required.
OFF position.
Ground fault in wiring harness 2. Disconnect No. 6 and No. 10 of fuse FS11, No. 4 of FS21, and
2 connectors KEY, CM01, STC3, CK02, and SRV.
12 3. Connect T-adapters to female side of connectors KEY and CM01.
Between ground and FS22-3 or CM01 (female)
Min. 1 Mz
Resis- (1) and (2)
tance Between ground and FS12-1 or CM01 (female)
(10) Min. 1 Mz
If no failure is found by above checks, machine monitor is defective.
40-608 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to machine monitor power supply
D65EX,PX,WX-17 40-609
40 Troubleshooting
E-6 When starting switch is turned to ON position (with engine stopped),

basic check monitor lights up
When starting switch is turned to ON position (with engine stopped), water separator
Failure monitor (water level in pre-filter is high) lights up.
• Detection of water by water-in-fuel sensor can be checked with monitoring function.
Related information (Code: 18800 Condition of WIF sensor)
High water level in pre-filter
1 Water is detected in pre-filter. Check and drain pre-filter.
(when system works properly)
If no failure is found by check on cause 1, water-in-fuel sensor system
Defective water-in-fuel sensor
2 may be defective. Perform troubleshooting for failure codes [CA428]
system
and [CA429].
If no failure is found by checks on causes 1 and 2, machine monitor
3 Defective machine monitor may be defective
40-610 D65EX,PX,WX-17
40 Troubleshooting
E-7 Air cleaner clogging monitor lights up in yellow while engine is

running
Failure Air cleaner clogging monitor lights up in yellow while engine is running.
• Air cleaner clogging switch signal can be checked with monitoring function.
Related information (Code: 04501 Monitor input 2)
Clogging of air cleaner Air cleaner may be clogged. Check it, then clean or replace if
1
(when system works properly) necessary.
Defective air cleaner clogging
2 Perform troubleshooting for failure code [AA10NX].
switch system
D65EX,PX,WX-17 40-611
40 Troubleshooting
E-8 Charge level monitor lights up while engine is running

Failure Charge level monitor lights up while engine is running.
• Power generation signal from alternator can be checked with monitoring function.
Related information (Code: 04300 Charge voltage)
Loose terminal or open circuit 1. Turn starting switch to OFF position.
1
at terminal Check terminals of alternator etc.
Defective alternator 2. Start engine and perform troubleshooting while running engine at
2 medium speed or higher.
(insufficient power generation)
Voltage Between terminal AL/R and ground 20 – 30 V
Open circuit in wiring harness 3. Disconnect connectors CM01 and RSD, and connect T-adapter to
female side of CM01.
4. Disconnect terminal AL/R.
Between CM01 (female) (16) and alternator
Resis- terminal R Max. 1 z
tance Between AL/E and GND3 (ground) Max. 1 z
Ground fault in wiring harness 3. Disconnect connectors CM01, RSD, STC1 and ST, and connect T-
4 adapter to female side of CM01.
4. Disconnect terminal AL/R.
Min. 1 Mz
tance
• Reference
5 Defective machine monitor 3. Insert T-adapter into connector CM01.
4. Turn disconnect switch to ON position.
5. Start engine and perform troubleshooting while running engine at
medium speed or higher.
Voltage Between CM01 (16) and (3) 20 – 30 V
40-612 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to charge level monitor
D65EX,PX,WX-17 40-613
40 Troubleshooting
E-9 Engine coolant temperature monitor lights up while engine is

running
Failure Engine coolant temperature monitor lights up while engine is running.
• Signal voltage of engine coolant temperature sensor is input to engine controller and
then the data is transmitted to machine monitor through CAN communication
Related information system.
• Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)
Overheating of engine coolant Check engine coolant for overheating. If it is overheated, remove
1
(when system works properly) cause.
If no failure is found by check on cause 1, engine coolant temperature
Defective engine coolant
2 sensor system may be defective. Perform troubleshooting for failure
codes [CA144] and [CA145].
40-614 D65EX,PX,WX-17
40 Troubleshooting
E-10 Engine oil pressure monitor lights up while engine is running

Failure Engine oil pressure monitor lights up while engine is running.
• Controller does not monitor signal (ON/OFF) from engine oil pressure switch.
Related information • If engine oil pressure switch turns ON while engine is running, failure code
[B@BAZG] is transmitted from engine controller to machine monitor through CAN.
Reduction of engine oil Check the engine oil pressure as the drop of engine oil pressure is
1 pressure detected.
(when system works properly) • Perform troubleshooting for "S-12 Oil pressure drops".
If no failure is found by check on cause 1, engine oil pressure switch
Defective engine oil pressure
system
[CA435] Engine oil pressure error.
D65EX,PX,WX-17 40-615
40 Troubleshooting
E-11 Power train oil temperature monitor lights up while engine is

running
Failure Power train oil temperature monitor lights up while engine is running.
• Signal voltage of torque converter oil temperature sensor is input to power train
controller and then the data is transmitted to machine monitor through CAN
Related information communication system.
• Torque converter (power train) oil temperature can be checked with monitoring
function.
• (Code: 30100 T/C (P/L) oil temperature)
Overheating of power train oil
Power train oil may be overheating. Check it and remove the cause if it
1 temperature (when system
is overheating.
works properly)
If no failure is found by check on cause 1, torque converter oil
Defective torque converter oil
2 temperature sensor system may be defective. Perform troubleshooting
for failure codes [DGT1KA] and [DGT1KX].
40-616 D65EX,PX,WX-17
40 Troubleshooting
E-12 Hydraulic oil temperature monitor lights up while engine is running

Failure Hydraulic oil temperature monitor lights up while engine is running.
• Hydraulic oil temperature can be checked with monitoring function
Related information • (Code: 04401 Hydraulic oil temperature)

Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it is
1 overheating.
(when system works properly)
Defective hydraulic oil If no failure is found by check on cause 1, hydraulic oil temperature
2 temperature gauge system or sensor system or machine monitor may be defective. Perform
machine monitor troubleshooting for failure codes [DGS1KA] and [DGS1KX].
D65EX,PX,WX-17 40-617
40 Troubleshooting
E-13 Engine coolant temperature gauge does not indicate correct

temparature
1) While engine coolant temperature is rising normally, temperature gauge does not rise
from white range (C).
2) While engine coolant temperature is stabilized normally, temperature gauge rises to
red range (H).
Failure
3) Display of coolant temperature gauge is different from actual engine coolant
temperature.
4) Display of engine coolant temperature gauge does not accord with indication of
engine coolant temperature monitor.
• Signal voltage of engine coolant temperature sensor is input to engine controller and
then the data is transmitted to machine monitor through CAN communication
Related information system.
• Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)
Defective engine coolant Engine coolant temperature sensor system may be defective. Perform
1 temperature sensor system troubleshooting for failure codes [CA144] and [CA145].
If no failure is found by check on cause 1, machine monitor may be
defective.
• Reference
a Turn starting switch to ON position or start engine to perform
troubleshooting.
Engine coolant Coolant temperature
temperature: 105 °C gauge level: 6
Red
2 Defective machine monitor Engine coolant Coolant temperature
Color of temperature: 100 °C gauge level: 4
monitor
light (a) Engine coolant Coolant temperature
Blue
Engine coolant temperature gauge and coolant temperature monitor
40-618 D65EX,PX,WX-17
40 Troubleshooting
E-14 Fuel level gauge does not indicate correct level

1) Fuel gauge does not indicate correct fuel level.
2) Display of fuel level gauge is different from actual fuel level.
Failure
3) The indication of the fuel level gauge does not accord with indication of the fuel level
monitor.
• Input (signal voltage) from fuel level sensor can be checked with monitoring
Related information function.
(Code: 04200 Fuel level sensor voltage)
2. Disconnect connector FLV and connect T-adapter to male side.
Defective fuel level sensor Approx. 4
Between FLV (male) (1) and (2) FULL
1 (internal open circuit or short z
circuit) Resis- a Fuel level sensor Approx. 85
tance characteristics EMPTY
z
Between FLV (male) (2) and ground Max. 1 z
2. Disconnect connectors FLV, and connect T-adapter to female side.
Open circuit, short circuit, a If voltage is 0 V, wiring harness has open circuit, ground fault, or
ground fault, or hot short short circuit, and if voltage is 24 V, wiring harness has hot short
2
a Voltage of approx. 3.3 V is applied to fuel level sensor signal lines
through resistor inside machine monitor.
Voltage Between FLV (female) (1) and (2) Approx.
3.3 V
2. Disconnect connector CM01 and connect T-adapter to female side.
Open or short circuit in wiring a Use fuel level sensor characteristics table for check on cause 1 as
3 resistance criteria.
harness
a If resistance is above 1 Mz , wiring harness has open circuit. If
Resis- Between CM01 (female) (15) and (14) Approx. 4
tance – 85 z
a If no failure is found by checks on causes 2 and 3, this check is not
required.
Open circuit in wiring harness 2. Disconnect connectors CM01 and FLV, and connect T-adapters to
contact of connector) Between CM01 (female) (15) and FLV (female)
Max. 1 z
Resis- (1)
tance Between CM01 (female) (14) and FLV (female)
(2) Max. 1 z

5 2. Disconnect connectors CM01 and FLV, and connect T-adapter to
Resis- Between ground and CM01 (female) (15) or
FLV (female) (1) Min. 1 Mz
tance
D65EX,PX,WX-17 40-619
40 Troubleshooting

2. Disconnect connectors CM01 and FLV, and connect T-adapter to
female side of CM01.
a Use multimeter in continuity mode.
Between CM01 (female) (15) and No continuity
Continuity
each pin other than (15) (No sound is heard)
• Reference
troubleshooting.
Fuel level: 376 l Fuel gauge level: 6
7 Defective machine monitor Fuel level: 297 l Fuel gauge level: 5
Blue
Color of Fuel level: 219 l Fuel gauge level: 4
monitor Fuel level: 140 l Fuel gauge level: 3
light (a) Fuel gauge level: 2
Fuel level: 102 l
Fuel level: Minimum Red
Fuel gauge level: 1
61 l
Circuit diagram related to fuel level sensor
Fuel level gauge and fuel level monitor
40-620 D65EX,PX,WX-17
40 Troubleshooting
E-15 Power train oil temperature gauge (multi-gauge) does not indicate
correct temperature
1) While power train oil temperature is rising normally, temperature gauge does not rise
2) While power train oil temperature is stabilized normally, temperature gauge rises to
red range (H).
Failure
3) Display of power train temperature gauge is different from actual power train oil
temperature.
4) Display of power train oil temperature gauge does not accord with indication of power
train oil temperature monitor.
• Signal voltage of torque converter oil temperature sensor is input to power train
controller and then the data is transmitted to machine monitor through CAN
Related information communication system.
• Torque converter (power train) oil temperature can be checked with monitoring
function.
(Code: 30100 T/C (P/L) oil temperature)
Defective torque converter oil Power train oil temperature sensor system may be defective. Perform
1 temperature sensor system troubleshooting for failure codes [DGT1KA] and [DGT1KX].
defective.
• Reference
troubleshooting.
Power train oil Power train oil
temperature: 130 °C temperature gauge
level: 6
Red
2 Defective machine monitor level: 5
Color of temperature: 118 °C temperature gauge
monitor level: 4
light (a) Power train oil Power train oil
level: 3
Blue
level: 2
level: 1
Power train oil temperature gauge and power train oil temperature monitor
D65EX,PX,WX-17 40-621
40 Troubleshooting
E-16 Hydraulic oil temperature gauge (multi-gauge) does not indicate

correct temperature
1) While hydraulic oil temperature is rising normally, temperature gauge does not rise
2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red
range.
Failure
3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil
temperature.
4) Display of hydraulic oil temperature gauge does not accord with indication of
hydraulic oil temperature monitor.
• Hydraulic oil temperature can be checked with monitoring function.
Related information (Code: 04401 Hydraulic oil temperature)
1 Perform troubleshooting for failure codes [DGS1KA] and [DGS1KX].
defective.
• Reference
troubleshooting.
Hydraulic oil Hydraulic oil
level: 6
Red
2 Defective machine monitor level: 5
Color of temperature: 98 °C temperature gauge
monitor level: 4
light (a) Hydraulic oil Hydraulic oil
level: 3
Blue
level: 2
level: 1
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
40-622 D65EX,PX,WX-17
40 Troubleshooting
E-17 Operation mode does not change

1) When operation mode switch is operated, display of operation mode monitor does
Failure not change.
2) When operation mode is changed, engine output is not changed.
• Engine output mode recognized by engine controller can be checked with
monitoring function (Code: 17500 Engine mode selection).
Related information • Before carrying out troubleshooting, check that no related failure code is displayed.
(If failure codes [DB2QKR] or [DB2RKR] is displayed, perform troubleshooting the
displayed code first.)
Machine monitor may be defective. (Since this is an internal defect,
1 Defective machine monitor troubleshooting cannot be performed.)
a If you can vary the engine output by operating the operation mode
2 Defective engine controller switch, engine controller is normal.
Engine controller may be defective. (Since this is an internal defect,
D65EX,PX,WX-17 40-623
40 Troubleshooting
E-18 Gearshift mode does not change

1) When gearshift mode switch is operated, display of gearshift mode section does not
change.
Failure
2) When gearshift mode is changed, gearshift mode setting of power train is not
changed.
Related information (If failure code [DBEQKR], [DBERKR], [DK40KA], [DK40KB], [DLT3KA] or
[DLT3KB] is displayed, perform troubleshooting for the displayed code first.)
Defective power train Power train controller may be defective. (Since this is an internal
2 defect, troubleshooting cannot be performed.)
controller
40-624 D65EX,PX,WX-17
40 Troubleshooting
E-19 Operating customize switch does not display customize screen

Failure Operating customize switch does not display customize screen.
Related
information
D65EX,PX,WX-17 40-625
40 Troubleshooting
E-20 Modifying setting on customize screen does not change setting of

machine
Failure Modifying setting on customize screen does not change setting of machine.
Related
information
Defective engine controller Engine controller or power train controller may be defective. (Since this
2 or defective power train is an internal defect, troubleshooting cannot be performed.)
controller
40-626 D65EX,PX,WX-17
40 Troubleshooting
E-21 Reverse slow mode does not function properly

1) Operating the reverse slow mode switch does not light up the reverse slow mode
Failure monitor.
2) Selecting the reverse slow mode does not change the reverse speed.
Related information (If failure code [DBEQKR], [DBERKR], [DLT3KA] or [DLT3KB] is displayed, perform
troubleshooting for the displayed code first.)
Defective power train Power train controller may be defective. (Since this is an internal
2 defect, troubleshooting cannot be performed.)
controller
D65EX,PX,WX-17 40-627
40 Troubleshooting
E-22 Alarm buzzer does not sound or does not stop sounding
Failure • Alarm buzzer does not sound or does not stop.
Related
information
Defective power train Power train controller may be defective. (Since this is an internal defect,
2 troubleshooting cannot be performed.)
controller
40-628 D65EX,PX,WX-17
40 Troubleshooting
E-23 While starting switch is in OFF position, service meter is not

displayed
Failure • While starting switch is in OFF position, service meter is not displayed.
• While starting switch is in OFF position, if following switches are operated, service
Related meter is displayed at top center of screen. Operation of switches:[4]+[1] (Press
information simultaneously)
When starting switch is turned to ON position, if machine monitor
Defective backup power displays nothing, backup power supply system may be defective. In this
1 supply system case, perform troubleshooting for "E-3 When starting switch is turned to
ON position, machine monitor displays nothing".
2 Defective machine monitor defective.
D65EX,PX,WX-17 40-629
40 Troubleshooting
E-24 Service mode cannot be selected

Failure • Machine monitor cannot be set in service mode
• If following switches are operated, machine monitor is set in service mode.
Related Switch operation: [4] and [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in
information order)
40-630 D65EX,PX,WX-17
40 Troubleshooting
E-25 Horn does not sound

Failure Horn does not sound.
• Since T-adapter is not prepared for connector HRN, use connector PRT for
Related information troubleshooting in stead of connector HRN (female).
If fuse FS12-8 is blown out, circuit probably has ground fault. In this
1 Defective fuse FS12-7 case, perform troubleshooting for cause 6 first.
2. Disconnect horn switch terminals (No polarity).
2 Defective horn switch 3. Turn horn switch on and off to perform troubleshooting.
Resis- OFF Min. 1 Mz
Between horn switch terminals
tance ON Max. 1 z
2. Disconnect connector PRT and connect T-adapter to female side.
3 Defective harness 3. Turn starting switch to ON position.
4. Turn horn switch ON.
Voltage Between PRT (female) (3) and ground 20 – 30 V
Open circuit in wiring harness 2. Remove fuse FS12-7.
4
or horn 3. Turn horn switch ON.
Continuity Between FS12-8 and ground Continuity
5 Open circuit in horn 1. Turn starting switch to OFF position.
2. Disconnect connector HRN.
Continuity Between HRN (male) and ground Continuity
If check result on cause 4 is abnormal and that on cause 5 is normal,
6 (wire breakage or defective wiring harness has open circuit.
a If the fuse is not blown, this check is not required.
Ground fault in wiring harness 2. Disconnect connector HRN and insert T-adapter to PRT.
7 3. Remove fuse FS12-8.
4. Turn horn switch to ON position.
Resis- Between PRT (3) and ground
Min. 1 Mz
tance
Defective horn (internal
8 If no failure is found by above checks, horn may be defective.
defect)
Circuit diagram related to horn
D65EX,PX,WX-17 40-631
40 Troubleshooting
E-26 Horn does not stop sounding

Failure Horn does not stop sounding.
• Since T-adapter is not prepared for connector HRN, use connector PRT for
Related information troubleshooting in stead of connector HRN (female).
2. Disconnect horn switch terminals (No polarity).
1 Defective horn switch 3. Turn horn switch on and off to perform troubleshooting.
Resis- OFF Min. 1 Mz
Between horn switch terminals
tance ON Max. 1 z
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector HRN and insert T-adapter to PRT.
2 3. Turn horn switch to ON position.
(Contact with 24 V circuit)
Voltage Between PRT (3) and ground Max. 1 V
Defective horn (internal
3 If no failure is found by above checks, horn may be defective.
defect)
Circuit diagram related to horn
40-632 D65EX,PX,WX-17
40 Troubleshooting
E-27 Backup alarm does not sound

Failure Backup alarm does not sound.
Related • If ground fault occurs in backup alarm circuit, failure code [DV20KB] is displayed.
information
a Only for iB specification machine
Defective reverse signal relay 1. Turn starting switch to OFF position.
1 (internal open circuit or short 2. Remove reverse signal relay (connector: RSR).
circuit) 3. Turn starting switch to ON position.
4. Perform reverse traveling.
If backup alarm sounds, original reverse signal relay is defective.
2. Disconnect connector BKAL and connect T-adapter to female side.
2 Defective harness 3. Turn starting switch to ON position.
4. Perform reverse traveling.
Voltage Between BKAL (1) and (2) 20 – 30 V
Open circuit in wiring harness 2. Disconnect connectors STC2 and BKAL, and connect T-adapters to
contact of connector) Between STC2 (female) (28) and BKAL
Resis- (female) (1) Max. 1 z
tance
Between BKAL (female) (2) and ground Max. 1 z
Ground fault in wiring harness 2. Disconnect connectors STC2, BKAL, and 3DSG and connect T-
4 adapters to either female side.
Resis- Between ground and BKAL (female) (1) or
tance
Defective backup alarm
5 If no failure is found by above checks, backup alarm may be defective.
(internal defect)
D65EX,PX,WX-17 40-633
40 Troubleshooting
a Reverse signal relay is installed on iB specification machine alone.
40-634 D65EX,PX,WX-17
40 Troubleshooting
E-28 Backup alarm does not stop sounding

Failure Backup alarm does not stop sounding.
Related
information
Hot short circuit in wiring 2. Disconnect connector BKAL and connect T-adapter to female side.
(contact with 24 V circuit) Between BKAL (female) (1) and (2) Max. 1 V
Voltage
Between BKAL (female) (1) and ground Max. 1 V
Defective backup alarm
2 If no failure is found by above checks, backup alarm may be defective.
(internal defect)
a Reverse signal relay is installed on iB specification machine alone.
D65EX,PX,WX-17 40-635
40 Troubleshooting
E-29 Headlamp does not light up

Failure Headlamp does not light up.
• If headlamp relay, headlamp switch, diode and common wiring harness for R.H. and
L.H headlamps are defective, both R.H. and L.H. headlamps do not light up (If either
Related information of headlamps lights up, these checks for the cause are not required).
• For related circuit diagram, see 2).
Defective headlamp
1 Since headlamp may be defective, check its bulb for breakage.
(breakage of bulb)
Defective fuse (FL2-4 or When the fuse is blown, a ground fault may have probably occurred in
2 FS12-14) the circuit.
Defective headlamp relay 2. Replace relay (connector: FLP1) with preheating relay (connector:
PHR).
circuit) 4. Turn on headlamp switch.
If headlamp lights up, original headlamp relay is defective.
2. Disconnect connector FLSW and connect T-adapter to male side.
3. Turn on and off headlamp switch to perform troubleshooting.
4 Defective headlamp switch
a Head lamp switch has two ON positions for high and low beams.
Resis- Between FLSW (male) (5) and (6) OFF Min. 1 Mz
tance ON Max. 1 z
2. Remove connector LMD and connect T-adapter to diode.
a Use multimeter in diode range.
Between LMD (male) (3) (+) and
Defective diode LMD No continuity
(7) (-)
5 (internal open circuit or short Between LMD (male) (7) (+) and
circuit) Continuity
(3) (-)
Continuity
No continuity
(6) (-)
Continuity
(2) (-)
a To check location where voltage abnormality occurs and roughly
locate defective point of wiring harness
2. Disconnect connectors LHDR and LHDL, and connect T-adapters
to each female side.
4. Turn on headlamp switch.
Between LHDL (female) (1) and (2) 20 – 30 V
Voltage
Between LHDR (female) (1) and (2) 20 – 30 V
a If no failure is found by above checks, this check is not required.
Open circuit or ground fault in
6 wiring harness 1.Turn starting switch to OFF position.
2.Disconnect connector FLP1 and connect T-adapter to female side.
3.Turn starting switch to ON position.
4.Turn on headlamp switch.
Between FLP1 (female) (1) and (2) 20 – 30 V
Voltage
Between FLP1 (female) (3) and (2) 20 – 30 V
2. Disconnect connector FLSW and connect T-adapter to female side.
Voltage Between FLSW (female) (5) and (2) 20 – 30 V
40-636 D65EX,PX,WX-17
40 Troubleshooting

1.Turn starting switch to OFF position.
2.Remove fuse FS12-14.
3.Disconnect connectors FLSW, LMD, FLP1, LHDR, LHDL and KEY,
and connect T-adapters to each female side.
Between LHDR (female) (2) and ground Max. 1 z
Between LHDL (female) (2) and ground Max. 1 z
Between LHDR (female) (1) and FLP1 (female)
(5) Max. 1 z
Open circuit in wiring harness Between LHDL (female) (1) and FLP1 (female)
(5) Max. 1 z
contact of connector) Between FLP1 (female) (1) and each of LMD
(female) (2) and (3) Max. 1 z
Resis- Between FLP1 (female) (2) and ground
Max. 1 z
tance
Between FLP1 (female) (3) and FS12-14 Max. 1 z
Between FLSW (female) (6) and LMD (female)
(7) Max. 1 z
Between FLSW (female) (4) and LMD (female)
(6) Max. 1 z
Between FLSW (female) (5) and KEY (female)
(1) Max. 1 z
Between FLSW (female) (2) and ground Max. 1 z
Ground fault in wiring harness 3. Disconnect connectors LMD, FLP1, LHDR and LHDL, and connect
8
(contact with ground circuit) T-adapter to female side of FLP.
Between FLP1 (female) (1) and ground Min. 1 Mz
Resis- Between FLP1 (female) (3) and ground
Min. 1 Mz
tance
Between FLP1 (female) (5) and ground Min. 1 Mz
D65EX,PX,WX-17 40-637
40 Troubleshooting
Circuit diagram related to headlamp and rear lamp
40-638 D65EX,PX,WX-17
40 Troubleshooting
E-30 Rear lamp does not light up

Failure Rear lamp does not light up.
Related information
Defective rear lamp (beakage
1 Since the rear lamp may be defective, check its bulb for breakage.
of bulb)
Defective fuse (FL2-4 or When the fuse is blown, a ground fault may have probably occurred in
2 FS12-15) the circuit.
Defective rear lamp relay 2. Replace relay (connector: RLP) with preheating relay (connector:
PHR).
circuit) 4. Turn on rear lamp switch.
If rear lamp lights up, original rear lamp relay is defective.
2. Disconnect connector RLSW and connect T-adapter to male side.
4 Defective rear lamp switch 3. Turn on and off rear lamp switch to perform troubleshooting.
Resis- Between RLSW (female) (5) and OFF Min. 1 Mz
tance (6) ON Max. 1 z
a To check location where voltage abnormality occurs and roughly
locate defective point of wiring harness
2. Disconnect connector LREL and connect T-adapter to female side.
4. Turn on rear lamp switch.
Voltage Between LREL (female) (1) and (2) 20 – 30 V
Open circuit or ground fault in 1. Turn starting switch to OFF position.
5 wiring harness 2. Disconnect connector RLP and connect T-adapter to female side.
4. Turn on rear lamp switch.
Between RLP (female) (1) and (2) 20 – 30 V
Voltage
Between RLP (female) (3) and (2) 20 – 30 V
2. Disconnect connector RLSW and connect T-adapter to female side.
Voltage Between RLSW (female) (5) and (2) 20 – 30 V
3. Disconnect connectors RLSW, RLP, LREL and KEY, and connect T-
adapters to each female side.
Between LREL (female) (2) and ground Max. 1 z
Open circuit in wiring harness Between LREL (female) (1) and RLP (female)
6 (wire breakage or defective (5) Max. 1 z
contact of connector) Between RLP (female) (1) and RLSW (female)
Max. 1 z
Resis- (6)
tance Between RLP (female) (2) and ground Max. 1 z
Between RLP (female) (3) and FS12-15 Max. 1 z
Between RLSW (female) (5) and KEY (female)
(1) Max. 1 z
Between RLSW (female) (2) and ground Max. 1 z
D65EX,PX,WX-17 40-639
40 Troubleshooting

Ground fault in wiring harness 3. Disconnect connector RLP and LREL, and connect T-adapter to
7
(contact with ground circuit) female side of RLP.
Between RLP (female) (1) and ground Min. 1 Mz
Resis- Between RLP (female) (3) and ground
Min. 1 Mz
tance
Between RLP (female) (5) and ground Min. 1 Mz
Circuit diagram related to headlamp and rear lamp
40-640 D65EX,PX,WX-17
40 Troubleshooting
E-31 No wiper operates continuously or intermittently

Failure No wiper operates continuously or intermittently.
• If any wiper operates, fuse FL1-3 and fuse 4 in fuse box do not need to be checked.
• 24V power is supplied from wiper intermittent switch to wiper intermittent units
(CB26 and CB27) during continuous operation and intermittent operation.
• T-adapter is not prepared for connectors of wiper intermittent units (CB26 and CB27)
(troubleshooting is performed without using T-adapter).
• Wiper intermittent units (CB26 and CB27) have two wiper intermittent circuits
respectively.
Explanation of pins of wiper intermittent unit
(1): GND1
Related 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): Common 24 V input
(7): 24 V pulse input 2 from wiper motor
(9): GND2
• In this troubleshooting, open circuit in wiring harness connecting pins 1, 2, 3, 4, 6,
and 9 on wiper intermittent unit are checked since no T-adapter is available.
If fuse shown at left is broken, circuit probably has ground fault. In this
case, perform troubleshooting for cause 4 first.
Defective fuse FL2-4, No. 9 of • If fuse FL2-4, No. 9 of fuse box FS12, or fuse 4 of fuse box is
fuse box FS12, fuses No. 4, 5, defective, no wiper operates.
1
or 6 of fuse box • If fuse 5 of fuse box is defective, front and rear wipers do not
operate.
• If fuse 6 of fuse box is defective, right door and left door wipers do
not operate.
2. Disconnect connector CB11 and connect T-adapter to male side.
3. Turn on and off intermittent switch to erform troubleshooting.
Defective wiper intermittent
2 OFF Max. 1 z
switch Between CB11 (male) (3) and (4)
Resis- ON Min. 1 Mz
tance OFF Min. 1 Mz
Between CB11 (male) (5) and (6)
ON Max. 1 z
D65EX,PX,WX-17 40-641
40 Troubleshooting

a If any wiper operates, this check is not required.
Voltage Between terminal of fuse box B3 and ground 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 of fuse box.
Resis- Between fuse terminal 4 of fuse box and each
of CB11 (female) (4) and (5) Max. 1 z
tance
• Wiper intermittent unit
2. Disconnect connectors CB11 to CB15, CB23, and CB24 , and
connect T-adapters to each female side.
a Wiper intermittent unit has many diodes in its internal circuit, so use
care with polarity of multimeter when perform measurement with it.
a If multimeter does not indicate "OFF" as resistance, it is considered
that wiring harness has no open circuit.
Open circuit in wiring harness • Check pins 1 and 3 of CB26 for open circuit
3 (wire breakage or defective Between CB11 (female) (3) (+) and CB14 1 – 50 Mz
contact of connector) (female) (3) (-)
• Check pins 4 and 9 of CB26 for open circuit
Between CB11 (female) (6) (+) and CB12 1 – 50 Mz
Resis- (female) (3) (-)
tance • Check pins 1 and 3 of CB27 for open circuit
(female) (3) (-)
(female) (3) (-)
• Wiper intermittent unit
2. Insert T-adapter into connectors CB23 and CB24.
4. Turn on front and left wiper switches.
5. Turn off intermittent switch.
Between CB23 (6) and ground 20 – 30 V
Voltage
Between CB24 (3) and ground 20 – 30 V

required.
2. Remove fuses 2 to 6 of fuse box.
3. Disconnect connectors CB11, CB17, CB23, CB24, CB26, CB27,
and CB37.
Between terminal of fuse box B3 and ground Min. 1 Mz
4 Between terminal of fuse 4 of fuse box and
ground
Between terminal of fuse 5 of fuse box and
Resis- ground Min. 1 Mz
tance
Between terminal of fuse 6 of fuse box and
ground Min. 1 Mz
Between CB11 (female) (3) and ground Min. 1 Mz
Between CB11 (female) (6) and ground Min. 1 Mz
40-642 D65EX,PX,WX-17
40 Troubleshooting
Circuit diagram related to wiper
D65EX,PX,WX-17 40-643
40 Troubleshooting
E-32 Front wiper does not operate (Failure in both continuous and
intermittent operations)
Front windshield wiper does not work. (Failure in both continuous and intermittent
Failure operations)
• If rear windshield wiper does not operate either, see troubleshooting for E-31.
• Rear wiper motor is driven by power supplied from front and rear wiper intermittent
unit CB26 even in continuous operation mode.
• Wiper motor detects stop position and converts 24 V supplied from fuse into pulse
voltage.
• In intermittent operation mode, rear wiper motor operates by exchanging 24 V
pulses with front and rear wiper intermittent unit CB26.
• Following pins on wiper intermittent unit CB26 are associated with this
troubleshooting.
Related information (1): GND1
(3): Continuous (24 V) input
(4): Intermittent (24 V) input
• In this troubleshooting, open circuit in wiring harness connecting pins 2 and 8 on
wiper intermittent unit are checked.
pins, see troubleshooting for E-31.
Defective front wiper motor 1. Turn starting switch to OFF position.
1 2. Disconnect connector CB23 and connect T-adapter to male side.
Between CB23 (6) and (1) Continuity
a Check that right and left door wipers operate normally.
2. Disconnect connectors CB26 and 27, and replace wiper intermittent
Defective front and rear wiper unit with another one.
2 intermittent unit 3. Turn starting switch to ON position.
(internal open circuit) 4. Turn on front wiper switch.
If front wiper operates normally, original front and rear wiper intermittent
unit is defective.
• Reference: Between CB26 (male) (2) and (8) Max. 1 z
• Reference: Between CB26 (male) (2) and (6) Min. 1 Mz
2. Turn disconnect switch to the OFF position.
3 Defective front wiper switch 4. Turn on and off front wiper switch to perform troubleshooting.
Resis- Between CB14 (female) (2) and (3) OFF Min. 1 Mz
tance ON Max. 1 z
40-644 D65EX,PX,WX-17
40 Troubleshooting

• Ground
Resis- Between CB14 (female) (2) and ground
Max. 1 z
tance
• Wiper motor power H from fuse
Voltage Between CB23 (3) and (1) 20 – 30 V
Open circuit in wiring harness 1. Turn starting switch to OFF position.
4 (wire breakage or defective 2. Remove fuse 5 of fuse box.
contact of connector) 3. Disconnect connector CB23 and connect T-adapter to female side.
a If no failure is found by check on wiper
motor power H, this check is not required. Max. 1 z
Between CB23 (female) (3) and fuse
terminal 5 of fuse box
Resis-
tance a If no failure is found by check on wiper
Between CB23 (female) (1) and ground
Between CB23 (female) (2) and (6) Max. 1 z

Ground fault in wiring harness 2. Disconnect connector CB23 and CB26, connect T-adapters to each
5 female side.
Resis- Between CB23 (female) (2) and ground Min. 1 Mz
tance Between CB23 (female) (6) and ground Min. 1 Mz
If no failure is found by above checks, front wiper motor is defective.
• Reference
2. Insert T-adapter to connector CB23.
Defective front wiper motor 3. Turn starting switch to ON position.
6 4. Turn on front wiper switch.
(Malfunction of stop position
detection) a Voltage is applied when wiper operates (voltage is at GND level
when wiper is at stop position and is resting in intermittent
operation).
Between CB23 (2) and (1) 20 – 30 V
Voltage
Between CB23 (6) and (1) 20 – 30 V
D65EX,PX,WX-17 40-645
40 Troubleshooting
40-646 D65EX,PX,WX-17
40 Troubleshooting
E-33 Rear wiper does not operate (Failure in both continuous and
Rear windshield wiper does not work. (Failure in both continuous and intermittent
Failure operations)
• If front windshield wiper does not operate either, see troubleshooting for E-31.
• Rear wiper motor is driven by power supplied from front and rear wiper intermittent
unit CB26 even in continuous operation mode.
voltage.
• In intermittent operation mode, rear wiper motor operates by exchanging 24 V
pulses with front and rear wiper intermittent unit CB26.
troubleshooting.
Related information (3): Continuous 24 V input
(4): Intermittent(24 V input
(9): GND2
wiper intermittent unit CB26 is checked. For detection of open circuit in wiring
harness connecting other
Defective rear wiper motor 1. Turn starting switch to OFF position.
a Check that right and left door wipers operate normally.
Defective front and rear (F and unit with another one.
2 R) wiper intermittent unit 3. Turn starting switch to ON position.
(internal open circuit) 4. Turn on rear wiper switch.
If rear wiper operates normally, original front and rear wiper intermittent
unit is defective.
3 Defective rear wiper switch 4. Turn on and off rear wiper switch to perform troubleshooting.
tance ON Max. 1 z
D65EX,PX,WX-17 40-647
40 Troubleshooting

• Ground
Max. 1 z
tance

4 (wire breakage or defective 3. Disconnect connector CB37 and connect T-adapter to female side.
Resis- a If no failure is found by check on wiper
tance motor power H, this check is not required. Max. 1 z
• Check of open circuit in wiring harness
connecting pins 5 and 7 on CB26 Between Max. 1 z
CB23 (female) (4) and (3)
5 female side.
If no failure is found by above checks, rear wiper motor is defective.
• Reference
Defective rear wiper motor 3. Turn starting switch to ON position.
6 4. Turn on rear wiper switch.
operation).
Between CB37 (3) and (2) 20 – 30 V
Voltage
Between CB37 (4) and (2) 20 – 30 V
40-648 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-649
40 Troubleshooting
E-34 Left door wiper does not operate (Failure of both continuous and
Failure Left door wiper does not work. (Failure of both continuous and intermittent operations)
• If right door wiper does not operate either, see troubleshooting for E-31.
• Left door wiper motor is driven by power supplied from L.H. and R.H. door wiper
intermittent unit CB27 even in continuous operation mode.
voltage.
• In intermittent operation mode, left door wiper motor operates by exchanging 24 V
pulses with L.H. and R.H. door wiper intermittent unit CB27.
troubleshooting.
Related information (1): GND1
(3): Continuous (24 V) input
(4): Intermittent (24 V) input
wiper intermittent unit CB27 is checked. For detection of open circuit in wiring
harness connecting other
Defective left door wiper motor 1. Turn starting switch to OFF position.
a Check that front and rear wipers operate normally.
Defective L.H. and R.H. door unit with another one.
2 wiper intermittent unit (internal 3. Turn starting switch to ON position.
open circuit) 4. Turn on left door wiper switch.
If left door wiper operates normally, original L.H. and R.H. door wiper
intermittent unit is defective.
Defective left door wiper 3. Disconnect connector CB15 and connect T-adapter to male side.
3 4. Turn on and off left door wiper switch to perform troubleshooting.
switch
tance ON Max. 1 z
40-650 D65EX,PX,WX-17
40 Troubleshooting

• Ground
Max. 1 z
tance

2. Remove fuse 6 from fuse box.
5 female side.
If no failure is found by above checks, left door wiper motor is defective.
• Reference
Defective left door wiper motor 3. Turn starting switch to ON position.
6 4. Turn on left door wiper switch.
operation).
Between CB24 (2) and (1) 20 – 30 V
Voltage
Between CB24 (3) and (1) 20 – 30 V
D65EX,PX,WX-17 40-651
40 Troubleshooting
40-652 D65EX,PX,WX-17
40 Troubleshooting
E-35 Right door wiper does not operate (Failure of both continuous and
Failure Right door wiper does not work. (Failure of both continuous and intermittent operations)
• If left door wiper does not operate either, see troubleshooting for E-31.
• Left door wiper motor is driven by power supplied from L.H. and R.H. door wiper
intermittent unit CB27 even in continuous operation mode.
• Wiper motor detects stop position and converts 24 V supplied from fuse into
• In intermittent operation mode, wiper motor operates by exchanging 24 V pulses
with L.H. and R.H. door wiper intermittent unit CB27.
troubleshooting.
Related information (3): Continuous 24 V input
(4): Intermittent 24 V input
(9): GND2
wiper intermittent unit CB27 are checked.
Defective right door wiper 1. Turn starting switch to OFF position.
motor 2. Disconnect connector CB17 and connect T-adapter to male side.
1
(internal open circuit) Continuity is maintained between CB17 (3) and
Continuity
(1)
a Check that front and rear wipers operate normally.
Defective L.H. and R.H. door unit with another one.
2 wiper intermittent unit 3. Turn starting switch to ON position.
(internal open circuit) 4. Turn on right door wiper switch.
If right door wiper operates normally, original L.H. and R.H. door wiper
intermittent unit is defective.
Defective right door wiper 4. Turn on and off right door wiper switch to perform troubleshooting.
3
switch Resis-
OFF Min. 1 Mz
Between CB13 (male) (2) and (3) tance
Resis-
ON Max. 1 z
tance
D65EX,PX,WX-17 40-653
40 Troubleshooting

• Ground
Max. 1 z
tance

5 female side.
If no failure is found by above checks, right door wiper motor is
defective.
• Reference
Defective right door wiper 2. Insert T-adapter to connector CB17.
motor 3. Turn starting switch to ON position.
6 4. Turn on right door wiper switch.
(Defective stop position
operation).
Between CB17 (2) and (1) 20 – 30 V
Voltage
Between CB17 (3) and (1) 20 – 30 V
40-654 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-655
40 Troubleshooting
E-36 KOMTRAX system does not operate properly

Failure • KOMTRAX system does not operate properly.
• Perform following troubleshooting if administrator of KOMTRAX system requests to
Related check whether failure is occurring in system on machine.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Perform all troubleshooting on service menu screens of machine monitor.
2. Display “Terminal Status” screen.
1 Defective communication 1 Check item:
Monitoring
Completed
display KOMTRAX
communication
2. Display “GPS & Communication Status” screen.
N ###.##.## (Latitude)
Monitoring Check item:
2 Defective positioning by GPS E ###.##.## (Longitude)
display Positioning
In positioning
If latitude and longitude are not displayed within 5 minutes with
machine stayed outdoor where opens clearly for sky, contact
KOMTRAX service hot line.
Monitoring Check item: Satellite in View or No Satellite
Defective communication display Communication in View
3
environment If Communication Status does never display “Satellite in View” within
15 minutes with machine stayed outdoor where opens clearly for sky,
check if connector of TC330 or antenna on top of cab are properly
connected.
4 Defective communication 2 Check item:
Monitoring
0 to 60 (normally 0)
display Number of message not
yet sent
a Select “Terminal Status” from “12 Display of KOMTRAX setting” in service menu of machine monitor.
a Select “GPS & Communication Status” from “12 Display of KOMTRAX setting” in service menu of machine
monitor.
40-656 D65EX,PX,WX-17
40 Troubleshooting
D65EX,PX,WX-17 40-657
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting of hydraulic and mechanical system (H-mode)

Information mentioned in troubleshooting table (H mode)
(Rev. 2011/01)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on machine
information
1
2 Probable causes for <Contents of description>
trouble (Each number is
3 serial number, not priority • Criteria to judge probable causes
4 sequence.) • Remarks required for judgment
5
40-658 D65EX,PX,WX-17
40 Troubleshooting
mode)
System diagram of hydraulic and mechanical system
D65EX,PX,WX-17 40-659
40 Troubleshooting
mode)
a This is a system chart that is drawn up by simplifying the whole hydraulic circuit chart. Use this as a
reference material when troubleshooting the hydraulic and mechanical systems.
40-660 D65EX,PX,WX-17
40 Troubleshooting
mode)
List of Failure Mode and Cause

Pump and
Component causing failure Power train Brake
motor
Hydraulic tank strainer

Transmission main relief valve
Troubleshooting No.
Work equipment, HSS pump
HSS motor (incl. relief valve)

Transmission valve (ECMV)
Fan motor (incl. relief valve)

Transmission clutch (*1)
Brake disc and plate

Brake pedal linkage
Power train pump
Torque converter
Brake (dragging)
Engine
Parking brake
Lockup clutch
Transmission
Brake valve
Fan pump
PTO
Failure
Machine lacks power (insufficient drawbar pull) q q q q q q q q H-1
Machine does not travel (at 2nd or 3rd speed) q q q q q q H-2
Machine does not start at all gear speeds q q q q q H-3
Machine travels only in one direction, either forward or in reverse q q q q H-4

Power train system
Large time lag at gear shifting or directional selection q q q q q H-5
Machine cannot be steered. (Machine does not turn left or right q q H-6
Steering speed or power is insufficient. q q H-7
Brake does not operate q q q q H-8
Torque converter does not lock up q q q q H-9
Power train oil overheats q q q q q H-10

Unusual noise is heard from around HSS and hydraulic pump or
q q q H-11
HSS motor
All work equipment operates slowly q q H-12
All work equipment does not operate q q H-13

Work equipment system
Blade lift speed or power is low H-14
Blade tilt speed or power is low H-15
Blade angle speed or power is low H-16
Ripper lift speed or power is low H-17
The hydraulic drift of lifted blade is large H-18
Hydraulic drift of tilted blade is large H-19
Hydraulic drift of lifted ripper is large H-20
Fan speed is abnormal (high, low, or no rotation) q q H-21

Fan system
Unusual noise is heard from around fan q H-22
D65EX,PX,WX-17 40-661
40 Troubleshooting
mode)
Component causing failure Hydraulic component
Blade angle control valve (spool, pressure compensation valve)

Blade lift control valve (spool, pressure compensation valve)
Blade tilt control valve (spool, pressure compensation valve)
Ripper control valve (spool, pressure compensation valve)

Self-pressure reducing valve (control circuit pressure)
Work equipment relief valve, pressure reducing valve
Work equipment, HSS main relief valve
Troubleshooting No.
Blade angle EPC valve
Blade angle cylinder
Blade lift cylinder
Blade tilt cylinder
Fan exterior
PPC lock valve
Ripper cylinder
Suction valve
Unload valve
PPC valve
Failure
Machine lacks power (insufficient drawbar pull) H-1
Machine does not travel (at 2nd or 3rd speed) H-2
Machine does not start at all gear speeds H-3
Machine travels only in one direction, either forward or in reverse H-4

Power train system
Large time lag at gear shifting or directional selection H-5
Machine cannot be steered. (Machine does not turn left or right q H-6
Steering speed or power is insufficient. q q H-7
Brake does not operate H-8
Torque converter does not lock up H-9
Power train oil overheats H-10

Unusual noise is heard from around HSS and hydraulic pump or HSS
H-11
motor
All work equipment operates slowly q q q q q H-12
All work equipment does not operate q q q q H-13

Work equipment system
Blade lift speed or power is low q q q H-14
Blade tilt speed or power is low q q q H-15
Blade angle speed or power is low q q q H-16
Ripper lift speed or power is low q q q q H-17
The hydraulic drift of lifted blade is large q q H-18
Hydraulic drift of tilted blade is large q q H-19
Hydraulic drift of lifted ripper is large q q q H-20
Fan speed is abnormal (high, low, or no rotation) H-21

Fan system
Unusual noise is heard from around fan H-22
40-662 D65EX,PX,WX-17
40 Troubleshooting
mode)
(*1)
Clutches engaged
F 1st 2nd 3rd R
F1 Q Q
F2 Q Q
F3 Q Q
Gear
speed N
R1 Q Q
R2 Q Q
R3 Q Q
D65EX,PX,WX-17 40-663
40 Troubleshooting
mode)
H-1 Machine lacks power (insufficient drawbar pull)

Failure • Machine lacks power (insufficient drawbar pull)
• Check that the power train oil level is normal, before performing troubleshooting.
• Engine speed can also be checked on the monitor (monitoring code: 01002).
Related • If failure codes are displayed, perform troubleshooting for them first. (DXH4KA, DXH4KB,
information DXH4KY, DXH5KA, DXH5KB, DXH5KY, DXH6KA, DXH6KB, DXH6KY, DXH7KA,
DXH7KB, DXH7KY, DXH8KA, DXH8KB, DXH8KY)
Cause Criteria and remarks on troubleshooting
a Be ready with starting switch OFF, then run the engine at
high idle to perform troubleshooting
1 Defective engine
Measurement condition Engine speed
F3, torque converter stall 1,650 rpm
high idle to perform troubleshooting
Internal defect of torque Torque converter Torque converter
2 PCCS lever
converter inlet pressure outlet pressure
NEUTRAL for all Max. 0.98 MPa 0.39 to 0.89 MPa
controls {Max. 10 kg/cm2 } {4 to 9 kg/cm2 }
a Be ready with starting switch OFF, then run engine at
high idle* to perform troubleshooting.
Transmission main relief
PCCS lever pressure
Min. 3.17 MPa {Min. 32.3 kg/
Defective set pressure or NEUTRAL for all controls cm2 }
internal defect of
3
transmission main relief a Be ready with starting switch OFF, then perform
valve troubleshooting leaving starting switch OFF.
Check that the free length of spring and the number of shims
are normal and the spool moves smoothly.
Probable
causes and • Free length of large spring: 128 mm
criteria • Free length of small spring: 108 mm
• Number of shims: 7 (t = 0.5 mm)
If pressure does not reach the specified value after
4 pump adjustments are made for cause 3, pump may be defective.
Check if metal particles are adhered to the filter or strainer.
low idle to perform troubleshooting.
Transmission clutch Clutch pressure
Min. 2.60 MPa {Min. 26.5 kg/
Fwd cm2 }
Malfunction of Min. 2.99 MPa {Min. 30.5 kg/
5 transmission valve Rev cm2 }
(ECMV)
Min. 2.94 MPa {Min. 30.0 kg/
1st cm2 }
Min. 2.16 MPa {Min. 22.0 kg/
2nd cm2 }
Min. 2.99 MPa {Min. 30.5 kg/
3rd cm2 }
6 Defective brake valve Parking brake lever Brake pressure
2.55 to 2.94 MPa
FREE
{26 to 30 kg/cm2 }
40-664 D65EX,PX,WX-17
40 Troubleshooting
mode)

Defective parking brake
Probable If failure is found by check on cause 6, linkage is poorly
7 lever or brake pedal adjusted. Check around the rod end.
causes and linkage
criteria
Internal defect of If no failure is found by checks on causes 1 to 7, check for
8 metal particles adhering to the magnet plug.
transmission
*Run the engine at high idle in engine decelerator cut mode (adjustment ID 0007).
D65EX,PX,WX-17 40-665
40 Troubleshooting
mode)
H-2 Machine cannot travel (at 2nd or 3rd speed)

Failure • The machine does not travel (at 2nd or 3rd)
• Check that transmission main relief pressure is normal before performing troubleshooting
Related (see "H-1 Machine lacks power").
information • If failure codes are displayed, perform troubleshooting for them first. (DXH5KA, DXH5KB,
DXH5KY, DXH6KA, DXH6KB, DXH6KY, DXH7KA, DXH7KB, DXH7KY, DXH8KA,
DXH8KB, DXH8KY)
a Be ready with starting switch OFF, then run engine at high
idle* to perform troubleshooting.
1 PCCS lever
controls {Max. 10 kg/cm }2 {4 to 9 kg/cm2 }
Malfunction of Transmission clutch Clutch pressure
Probable 2 transmission valve Min. 2.16 MPa {Min. 22.0 kg/
causes and (ECMV) 2nd cm2 }
criteria Min. 2.99 MPa {Min. 30.5 kg/
3rd cm2 }
Malfunction (dragging) of Parking brake may malfunction (dragging), check linkage and
3 parking brake
valves.
a Move the machine to a flat ground (on a hard road surface)
Malfunction (dragging) and start the engine to perform troubleshooting.
4 If machine does not move when engine is at low idle and F2
of brake
shift is selected, brake is dragging (perform troubleshooting
refer to "H-8 Brake does not operate".
If no failure is found by checks on causes 1 to 4, the 2nd or
Internal defect of 3rd clutch may be defective specifically. Check if metal
5
transmission particles are adhered to the magnet plug.
*Run engine at high idle in engine decelerator cutting mode (adjustment ID 0007).
40-666 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-3 Machine does not start at all gear speeds

Failure • Machine does not start at all gear speeds
PCCS lever pressure
Min. 3.17 MPa {Min. 32.3 kg/
internal defect of
1
transmission main relief a Be ready with starting switch at OFF position, then perform
• Free length of large spring: 128 mm
• Free length of small spring: 108 mm
2 pump adjustments are made for cause 1, check for metal particles
adhering to the filter and strainer.
(After confirming that transmission main relief pressure is
normal.)
Probable Transmission clutch Clutch pressure
causes and
Min. 2.60 MPa {Min. 26.5 kg/
criteria Malfunction of Fwd cm2 }
3 transmission valve Min. 2.99 MPa {Min. 30.5 kg/
(ECMV) Rev cm2 }
Min. 2.94 MPa {Min. 30.0 kg/
1st cm2 }
Min. 2.16 MPa {Min. 22.0 kg/
2nd cm2 }
Min. 2.99 MPa {Min. 30.5 kg/
3rd cm2 }
a Move the machine to a flat ground and run the engine at
high idle to perform troubleshooting.
normal.)
Malfunction of brake Brake oil pressure (right and
4 Brake pedal
valve left)
2.55 to 2.94 MPa {26 to 30 kg/
Release cm2 }
Depressed 0 MPa {0 kg/cm2 }
If oil pressure is not normal, perform troubleshooting for "H-8
Brake does not operate".
transmission
*Run engine at high idle in engine decelerator cut mode (adjustment ID 0007).
D65EX,PX,WX-17 40-667
40 Troubleshooting
mode)
H-4 Machine travels only in one direction, either forward or in reverse

Failure • Machine can travel either forward or in reverse
information DXH7KY, DXH8KA, DXH8KB, DXH8KY)
PCCS lever pressure
Min. 3.17 MPa {Min. 32.3 kg/
internal defect of
1
Probable • Number of shims: 7 (t = 0.5 mm)
causes and If pressure does not reach the specified value after
criteria 2 pump adjustments are made for cause 1, pump may be defective.
Malfunction of normal.)
3 transmission valve Transmission clutch Clutch pressure
(ECMV)
Min. 2.60 MPa {Min. 26.5 kg/
Fwd cm2 }
Min. 2.99 MPa {Min. 30.5 kg/
Rev cm2 }
Defective sealing of If failure is found by check on cause 3, check the seals.
4
transmission clutch
transmission
40-668 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-5 Large time lag at gear shifting or directional selection

Failure • Large time lag at gear shifting or directional selection
PCCS lever pressure
Min. 3.17 MPa {Min. 32.3 kg/
internal defect of
1
2 pump adjustments are made for cause 1, pump may be defective.
Probable
causes and
normal.)
criteria
Transmission clutch Clutch pressure
Min. 2.60 MPa {Min. 26.5 kg/
Malfunction of Fwd cm2 }
3 transmission valve Min. 2.99 MPa {Min. 30.5 kg/
(ECMV) Rev cm2 }
Min. 2.94 MPa {Min. 30.0 kg/
1st cm2 }
Min. 2.16 MPa {Min. 22.0 kg/
2nd cm2 }
Min. 2.99 MPa {Min. 30.5 kg/
3rd cm2 }
Defective sealing of If failure is found by check on cause 3, check the seals.
4
transmission clutch
a Move the machine to a flat ground (on a hard road
Malfunction (dragging) surface) and start the engine to perform troubleshooting.
5 If machine does not move when engine is at low idle and F2
of brake
shift is selected, brake is dragging (perform troubleshooting
refer to "H-8 Brake system does not operate".
transmission
D65EX,PX,WX-17 40-669
40 Troubleshooting
mode)
H-6 Machine cannot be steered (machine does not turn left or right)
Failure • Machine cannot be steered. (Machine does not turn left or right)
Related • Check that the hydraulic oil level is normal, before performing troubleshooting.
information
a Be ready with starting switch OFF, then run the engine
Defective pressure setting at high idle to perfrom troubleshooting.
or malfunction of self- Control circuit source
Probable 1 pressure reducing valve PCCS lever
causes and pressure
(EPC source pressure) 3.97 ± 0.29 MPa
criteria
NEUTRAL
{40.5 ± 3.0 kg/cm2 }
Unusual noise from HSS Perform troubleshooting for "H-11 Unusual noise is heard
2 peripheral equipment from around HSS and work equipment pump or HSS
motor".
40-670 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-7 Steering speed or power is insufficient

Failure • Steering speed or power is insufficient.
Related • Check that the hydraulic oil level is normal, before performing troubleshooting.
information
Defective pressure setting at high idle to perfrom troubleshooting.
1 or malfunction of HSS main PCCS lever HSS relief pressure
relief valve Min. 34.3 MPa
Right or left stroke end
{350 kg/cm2 }
Probable
causes and a Be ready with starting switch OFF, then run the engine
criteria Defective pressure setting at high idle to perfrom troubleshooting.
or malfunction of self- Control circuit source
2 pressure reducing valve PCCS lever pressure
(EPC source pressure) 3.97 ± 0.29 MPa
NEUTRAL
{40.5 ± 3.0 kg/cm2 }
Unusual noise from HSS Perform troubleshooting for "H-11 Unusual noise is heard
3 peripheral equipment from around HSS and work equipment pump or HSS
motor".
D65EX,PX,WX-17 40-671
40 Troubleshooting
mode)
H-8 Brake does not operate

Failure • Brake does not operate.
Related • Check that transmission main relief pressure is normal before performing troubleshooting
information (see "H-1 Machine lacks travel power").
Brake pedal Brake oil pressure
1 Malfunction of brake valve
2.55 to 2.94 MPa
Probable When released
{26 to 30 kg/cm2 }
causes and
When pressed 0 MPa {0 kg/cm2 }
criteria
Defective adjustment of If failure is found by check on cause 1, check around the
2 brake pedal linkage
rod end.
If failure is found by check on cause 1, check the brake
3 Defective sealing of brake
seals.
Slip or abrasive wear of
4 brake disc or plate Check disc and plate.
40-672 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-9 Torque converter does not lock up

Failure • Torque converter does not lock up.
Related
• If failure code [DXH1KA], [DXH1KB], or [DXH1KY] is displayed, perform troubleshooting
information
for it first.
PCCS lever pressure
Min. 3.17 MPa {Min. 32.3 kg/
internal defect of
1
Probable If pressure does not reach the specified value after
causes and 2 pump adjustments are made for cause 1, check for metal particles
criteria adhering to the filter and strainer.
Malfunction of torque
Torque converter Clutch pressure
3 converter lockup valve
(ECMV) 1.27 to 1.57 MPa
Lockup
At lock up { 13.0 to 16.0 kg/cm2
clutch }
Defective sealing of
4 lockup clutch If failure is found by check on cause 3, check the seals.
Internal defect of lockup Check the lockup clutch
5
clutch
Internal defect of torque high idle to perform troubleshooting.
6
converter Measurement condition Engine speed
D65EX,PX,WX-17 40-673
40 Troubleshooting
mode)
H-10 Power train oil overheats

Failure • Power train oil overheats
• Check that the reading on the power train oil temperature gauge coincides with the actual
Related oil temperature and start troubleshooting. (If they do not coincide, perform the
information troubleshooting for E mode (E-9) "Power train oil temperature gauge (multi-gauge) does
not indicate properly."
• T/C oil temperature can also be checked on the monitor (monitoring code: 30100).
Engine cooling system may be defective or engine output
1 Defective engine system may be increased. Refer to the Engine part of the shop
manual.
PCCS lever pressure
Min. 3.17 MPa {Min. 32.3 kg/
internal defect of
2
transmission main relief a Be ready with starting switch at OFF position, then
valve perform troubleshooting leaving starting switch OFF.
a If pressure does not reach the specified value after
Defective power train adjustments are made for cause 2, pump may be
Probable 3 pump or air mixing in defective. Check if metal particles are adhered to the filter
causes and suction circuit or strainer.
criteria Since air may be mixing in from the suction circuit, check
for bubbles in the oil.
4 PCCS lever
controls {Max. 10 kg/cm2 } {4 to 9 kg/cm2 }
Malfunction (slide) of high idle to perform troubleshooting.
5
transmission clutch Measurement condition Engine speed
a Start the engine for troubleshooting.
1. Move the machine to a flat ground (on a hard road
Malfunction (dragging) surface) and run the engine at low idle.
6 2. Set gear shift lever to F2 position.
of brake
3. Confirm if machine moves (travels) or not. If machine
does not move, the brake is dragging (perform
troubleshooting refer to "H-8 Brake does not operate").
40-674 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-11 Unusual noise is heard from around HSS and work equipment
pump or HSS motor
• Unusual noise is heard from around HSS or work equipment pump, before performing
Failure troubleshooting.
Related • Check that the hydraulic oil level is normal.
information
1 Inappropriate oil Check for inappropriate oil used.
Clogged hydraulic tank Check strainer for clogging.
2
strainer
Check the HSS and work equipment pump suction circuit
Probable 3 Air mixing in suction circuit piping.
causes and
criteria If metal particles are found adhering to the strainer by
Internal defect of HSS
4 pump checks for cause 2, there may be an internal defect in the
HSS or work equipment pump.
If metal particles are found adhering to the strainer by
Internal defect of HSS
5 checks for cause 2, there may be an internal defect in the
motor
HSS motor.
D65EX,PX,WX-17 40-675
40 Troubleshooting
mode)
H-12 All work equipment operates slowly

Failure • All work equipment operates slowly.
Related • Check that the hydraulic oil level tank is normal, before performing troubleshooting.
information • Hydraulic pump pressure can also be checked on the monitor (monitoring code: 70700).
Defective PTO (HSS or
1 work equipment pump Check drive shaft splines.
drive)
Defective pressure setting at high idle to perform troubleshooting.
or malfunction of HSS or
2-1 PCCS lever HSS relief pressure
work equipment main relief
valve Min. 34.3 MPa
{Min. 350 kg/cm2 }
or malfunction of work Work equipment control
2-2 equipment relief valve or Tilt relief pressure
levers
pressure reduction valve Tilt cylinder Min. 27.9 MPa
stroke end {Min. 285 kg/cm2 }
Probable If pressure in the HSS and work equipment circuits does
causes and Defective HSS or work not reach the specified value after adjustments are made
criteria 3 equipment pump
for cause 2, check for metal particles adhering to the filter
and strainer.
at high idle to perform troubleshooting.
4 Malfunction of unload valve Work equipment control Unload pressure
levers
3.23 to 4.9 MPa
NEUTRAL for all controls
{33 to 50 kg/cm2 }
Malfunction of self pressure
5 reducing valve (PPC source Work equipment control Control circuit source
pressure) levers pressure
3.97 ± 0.29 MPa
{40.5 ± 3.0 kg/cm2 }
If failure is found by check on cause 5, there may be an
6 Internal defect of PPC valve
internal defect in the PPC valve. Check it.
40-676 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-13 All work equipment does not operate

Failure • All work equipment does not operate.
information • Hydraulic pump pressure can also be checked on the monitor (monitoring code: 70700).
Defective PTO (HSS or
1 work equipment pump Check drive shaft splines.
drive)
2-1 or malfunction of HSS main PCCS lever HSS relief pressure
relief valve Min. 34.3 MPa
{Min. 350 kg/cm2 }
or malfunction of work Work equipment control
2-2 equipment relief valve or Tilt relief pressure
levers
pressure reduction valve Tilt cylinder Min. 27.9 MPa
Probable stroke end {Min. 285 kg/cm2 }
causes and If pressure in the HSS and work equipment circuits does
criteria Defective HSS or work not reach the specified value after adjustments are made
3 equipment pump
for cause 2, check for metal particles adhering to the filter
and strainer.
4 Malfunction of unload valve Work equipment control Unload pressure
levers
3.23 to 4.9 MPa
{33 to 50 kg/cm2 }
Malfunction of self pressure
5 reducing valve (PPC source Work equipment control Control circuit source
pressure) levers pressure
3.97 ± 0.29 MPa
{40.5 ± 3.0 kg/cm2 }
D65EX,PX,WX-17 40-677
40 Troubleshooting
mode)
H-14 Blade lift speed or power is low

Failure • Blade lift speed or power is low.
• Check that the hydraulic oil level tank is normal, before performing troubleshooting.
Related • Check whether the blade is modified.
information • When the hydraulic drift of lifted blade is also large, perform troubleshooting for “H-18
Hydraulic drift of lifted blade is large”.
1 Malfunction of PPC valve Blade control lever PPC valve output pressure
3.19 to 4.17 MPa
RAISE stroke end
{32.5 to 42.5 kg/cm2 }
a Release remaining pressure from hydraulic tank and
pipings and then perform troubleshooting with engine
stopped.
Probable • Check for stuck or seized spool in blade lift control valve
Malfunction of blade lift
causes and 2 body (spool should move smoothly).
criteria control valve (spool)
• Take out blade lift spool from valve body and check for
defects and dirt.
a Take care for dirt not to enter the valve during
restoration.
• Check for stuck or seized spool in blade lift control valve
Malfunction of blade lift body and pressure compensation valve (spool should
3 control valve (pressure move smoothly).
compensation valve) • Take out spool from pressure compensation valve and
check for defects and dirt.
Air mixing in blade lift Air may be mixing in blade lift cylinder. Bleed air and check
4 cylinder whether the phenomenon changes.
40-678 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-15 Blade tilt speed or power is low

Failure • Blade tilt speed or power is low.
information • When the hydraulic drift of tilted blade is also large, perform troubleshooting for “H-19
Hydraulic drift of tilted blade is large”.
1 Malfunction of PPC valve Blade control lever PPC valve output pressure
3.19 to 4.17 MPa
RAISE stroke end
{32.5 to 42.5 kg/cm2 }
piping and then perform troubleshooting with engine
stopped.
Probable • Check for stuck or seized spool in blade tilt control valve
Malfunction of blade tilt
causes and 2 body (spool should move smoothly).
• Take out blade tilt spool from valve body and check for
defects and dirt.
restoration.
Malfunction of blade tilt • Check for stuck or seized spool in blade tilt control valve
control valve body and pressure compensation valve (spool should
3 move smoothly).
(pressure compensation
• Take out spool from pressure compensation valve and
valve)
Air mixing in blade tilt Air may be mixing in the blade tilt cylinder. Bleed air and
4 cylinder check wether the phenomenon changes.
D65EX,PX,WX-17 40-679
40 Troubleshooting
mode)
H-16 Blade angle speed or power is low

Failure • Blade angle speed or power is low.
information • EPC current value of angle pilot valve can also be checked on the monitor (monitoring
code: 71011, 71013).
Malfunction of EPC valve at high idle to perform troubleshooting.
1 Blade angle lever EPC valve current
(angle circuit)
RIGHT angle stroke end Max. 900 mA
LEFT angle stroke end Max. 900 mA
stopped.
Malfunction of blade angle • Check for stuck or seized spool in blade angle control
2 control valve (spool) valve body (spool should move smoothly).
Probable • Take out angle spool from valve body and check for
causes and defects and dirt
criteria
a Be careful not to let foreign matter enter the valve
during restoration.
Check for stuck or seized spool in blade langle control
Malfunction of blade angle valve body and pressure compensation valve (spool should
3 control valve (pressure move smoothly).
compensation valve) Take out spool from pressure compensation valve and
Air mixing in blade angle piping and then perform troubleshooting with engine
4 cylinder stopped.
Air may be mixing in the blade angle cylinder. Bleed air and
check whether the phenomenon changes.
40-680 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-17 Ripper lift speed or power is low

Failure • Ripper lift speed or power is low.
Related • Check whether the ripper is modified.
information • When the hydraulic drift of lifted ripper is also high, perform troubleshooting for "H-20
Hydraulic drift of lifted ripper is large".
1 Malfunction of PPC valve Ripper control lever PPC valve output pressure
3.19 to 4.17 MPa
RAISE stroke end
{32.5 to 42.5 kg/cm2 }
stopped.
Malfunction of ripper • Check for stuck or seized spool in ripper control valve
Probable 2
control valve (spool) body (spool should move smoothly).
causes and
• Take out ripper spool from valve body and check for
criteria
defects and dirt.
restoration.
The suction valve for the ripper tilt control valve may
malfunction. Inspect the check valve for defects and spring
Malfunction of ripper deterioration.
3
control valve (suction valve) a Judgement may be made by checking a change of
phenomenon after exchanging suction valves on the
head side and on the bottom side.
Air may be mixing in the ripper cylinder. Bleed air and
4 Air mixing in ripper cylinder check whether the phenomenon changes.
D65EX,PX,WX-17 40-681
40 Troubleshooting
mode)
H-18 Hydraulic drift of lifted blade is large

Failure • Hydraulic drift of lifted blade is large.
information • Check that no oil leaks in the work equipment circuit, before performing troubleshooting.

a Be ready with the engine started, then stop the engine
to perform troubleshooting.
1. Raise blade (approx. 800 mm).
2. Disconnect hose from the cylinder head side and block
the opening
3. Measure hydraulic drift at blade cutting edge.
Blade lift Hydraulic drift
Defective sealing of blade Blade lift circuit blocked Max 35 mm/ 5 minutes
Probable
1 lift
causes and a Release remaining pressure from hydraulic tank and
stopped.
• Check for stuck or seized spool in blade lift control valve
body (spool should move smoothly).
• Take out lift spool from valve body and check for defects
and dirt.
restoration.
Defective sealing of blade
2 lift cylinder The blade lift cylinder may be sealed defectively.
40-682 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-19 Hydraulic drift of tilted blade is large

Failure • Hydraulic drift of tilted blade is large.
1. Extend blade tilt cylinder rod fully.
2. Disconnect hose from the cylinder bottom side and
block the opening.
3. Measure hydraulic drift at blade cutting edge.
Blade tilt Hydraulic drift
Defective sealing of blade Blade tilt circuit blocked Max 70 mm/ 5 minutes
Probable
1 lift
causes and a Release remaining pressure from hydraulic tank and
stopped.
• Check for stuck or seized spool in blade tilt control valve
• Take out tilt spool from valve body and check for defects
and dirt.
restoration.
Defective sealing of blade
2 tilt cylinder The blade tilt cylinder may be sealed defectively.
D65EX,PX,WX-17 40-683
40 Troubleshooting
mode)
H-20 Hydraulic drift of lifted ripper is large

Failure • Hydraulic drift of lifted ripper is large.
Related • Check whether the ripper is modified.
1. Pull out the shank pin and raise the ripper to the
maximum height.
2. Disconnect hose from the cylinder head side and block
the opening.
Ripper Hydraulic drift
Defective sealing of Ripper circuit blocked Max 35 mm/ 5 minutes
Probable
1
causes and ripper control valve (spool) a Release remaining pressure from hydraulic tank and
criteria piping and then perform troubleshooting with engine
stopped.
• Check for stuck or seized spool in ripper control valve
• Take out ripper spool from valve body and check for
defects and dirt.
restoration.
Defective sealing of ripper
2 cylinder The ripper cylinder may be sealed defectively.
40-684 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-21 Fans speed is abnormal (high, low, or no rotation)

Failure • Fan speed is abnormal (high, low, or no rotation)
• When engine is started for the first time after hydraulic oil replacement, the fan may
temporarily operate at a higher speed but this is normal.
• If failure codes are displayed, perform troubleshooting for them first. (DLM3MA, DLM3MB,
DWN5KA, DDWN5KB, DWN5KY)
• Fan speed can also be checked on the monitor (monitoring code: 10007).
• Hydraulic oil temperature can also be checked on the monitor (monitoring code: 04401).
information Note: When hydraulic oil temperature is lower than 40 °C , the fan operates at 70 % even
if it is set at 100 % mode. In that case, raise the hydraulic oil temperature to above 45 °C
and then perform the check.
• Fan EPC solenoid current can also be checked on the monitor (monitoring code: 31624).
• The fan mode can be checked with the ID code of the adjustment item on the monitor (ID
code: 1005 (100 % ), 0010 (70 % )).
a Start the engine and check.
Measurement condition Engine speed
1 Defective engine speed Engine at low idle 800 to 850 rpm
*Engine at high idle 2,050 to 2,150 rpm
If engine speed is not increased to specification, perform
troubleshooting for "S-5 Engine runs rough or is unstable".
Defective PTO (fan pump
2 drive) Fan pump drive of PTO may be defective. Check it directly.

Malfunction of self-pressure Work equipment control
3 reducing valve Control circuit pressure
levers
3.68 to 4.26 MPa
NEUTRAL
{37.5 to 43.5 kg/cm2 }
If no failure is found by check on cause 3 and pressure is at
the specified level, solenoid valve may be defective.
4 Defective fan EPC valve
Probable Check that the spool is not stuck in the valve body and
causes and moves smoothly.
criteria a Be ready with engine stopped, then troubleshoot with
engine at high idle.
Malfunction of fan motor
5 (safety valve) Fan mode Fan motor drive pressure
13.2 MPa
100 %
{135 kg/cm2 }
adjustments are made for cause 5, there may be an
6 Defective fan pump internal defect in the fan pump.
Check if metal particles are adhered to the self-pressure
reducing valve inlet strainer.
stopped.
Malfunction of fan motor • Check for stuck or seized spool in direction selector
7 (direction selector valve) valve body (spool should move smoothly).
• Take out direction selector spool from valve body and
restoration.
D65EX,PX,WX-17 40-685
40 Troubleshooting
mode)
Probable Cause Criteria and remarks on troubleshooting

causes and If no failure is found by checks on causes 1 to 7, there may
criteria 8 Defective fan motor
be an internal defect in the fan motor.
40-686 D65EX,PX,WX-17
40 Troubleshooting
mode)
H-22 Unusual noise is heard from around fan

Failure • Unusual noise is heard from around fan.
Related •
information
Probable Loosening of fan and fan Check fan and fan motor mountings for looseness and
1 motor mountings rattling.
causes and
criteria 2 Interference with shroud Check fan for interference with shroud.
3 Internal defect of fan motor There may be an internal defect in the fan motor.
D65EX,PX,WX-17 40-687
40 Troubleshooting
Troubleshooting of engine (S-mode)

Information contained in troubleshooting table (S mode)
(Rev. 2011/04 114T4)
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Failure Problem on engine
information
No. Cause Check item, remark Remedy
1
Probable causes for trouble <Contents of description> • Remedy to
2
(Each number is serial • Check item to judge probable cause eliminate the
3 number, not priority • Remarks required to judge whether the probable cause for
4 sequence.) cause is good trouble
5
2. Cooling plate
3. Check valve
4. Fuel feed pump
a Check valve (3) described in the text is on cooling plate (12).
a Fuel feed pump (4) is on the back side of cooling plate (2) to which engine controller (1) is installed.
40-688 D65EX,PX,WX-17
40 Troubleshooting
S-1 When starting switch is turned to START position, engine is not

cranked
Failure When starting switch is turned to the "START" position, the engine is not cranked, or started
Related • See E mode (E-1) for troubleshooting the electrical system.
information • If any failure code is displayed, carry out troubleshooting for it first.
Defective starting circuit • When starting switch is turned to START
Diagnose and take
1 wiring system position, starting motor pinion is not pushed
remedies for E-1
out
• Grating noise is heard from starting motor
pinion
(When starting switch is turned to START
position, starting motor pinion is pushed out)
• Starting motor pinion disengages during
operation
Defective starting motor position, starting motor pinion is pushed out) Diagnose and take
2
• Rattling noise is heard and starting motor remedies for E-1
does not rotate.
position, starting motor pinion is pushed out)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
• If grating noise is heard from starting motor
3 Broken flywheel ring gear pinion and the starting motor does not crank, Replace if damaged
visually check the flywheel ring gear.
• Remove EGR cooler outlet gas piping and
check if coolant containing COOLANT flows
Cracked EGR cooler out Replace EGR cooler
4 (Reference: coolant in and drain water from
exhaust gas) a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.
D65EX,PX,WX-17 40-689
40 Troubleshooting
S-2 The engine cranks but exhaust smoke does not come out
Failure Engine cranks but no exhaust smoke comes out
Related • If any failure code is displayed, carry out troubleshooting for it first.
information
• When fuel tank is inspected, it is found to be
1 Insufficient fuel in tank empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 cap is clogged • Air breather hole in fuel tank cap is clogged in fuel tank cap and
clean surrounding area
• Check used hours of fuel filter. If used
Replace fuel filter
3 Clogged fuel filter element beyond specified hours, fuel filter element
may be clogged element
• Rust and water are found when fuel tank is Replace fuel
4 Foreign material in fuel
drained
• Air is discharged when the air is bled from Air bleeding
the fuel system
5 Air in fuel piping system (Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 system (Reference: See Testing and adjusting,
piping related parts
"Checking fuel system for leakage".)
• Excessive injector return rate (See Testing
Fuel leakage from injector and adjusting, "Measuring fuel delivery, Tighten or replace inlet
7
and inlet connector return and leakage".) connector
• See Testing and adjusting, "Measuring fuel Replace supply pump
8 Defective supply pump delivery, return and leakage". and pressure limiter
Sticking of check valve on Clean or replace check
9 cooling plate • Sticking of check valve
valve
Replace fuel feed
10 Defective fuel feed pump • No fuel from fuel feed pump
pump
• Common rail pressure does not go down
even after pressure is checked with Loosen injection piping
monitoring function and then the engine is and high pressure
Improper bleeding of common
11 rail or injection piping stopped. (Code: 36400 Common rail piping mounting nuts
pressure) on common rail and
(Pressure will not decrease if air still bleed air
remains.)
40-690 D65EX,PX,WX-17
40 Troubleshooting
S-3 Fuel is being injected but engine does not start (incomplete
combustion: engine cranks but does not start)
Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
Failure does not start)
information
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge
3 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
4
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
5
drained
the fuel system
6 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
7 (Reference: See Testing and adjusting,
system piping related parts
8
9 • Sticking of check valve
cooling plate valve
Replace fuel feed
10 Defective fuel feed pump • No fuel from fuel feed pump
pump
Testing and adjusting
11 Clogged air cleaner element • Air cleaner dust indicator in caution level
air cleaner element
• Intake air heater mount does not warm up
during preheating operation.
• When engine is preheated or when Replace intake air
12 Defective intake air heater
temperature is low, preheating monitor does heater
not indicate properly.
• Check valve clearance
(Reference: See Testing and adjusting,
Worn valve or rocker arm, "Measuring and adjusting valve clearance".) Replace valve or
13
etc. • When engine is rotated, abnormal sound is rocker arm
generated around cylinder head.
• Measuring compression pressure
Replace piston ring or
14 Defective piston ring (Reference: See Testing and adjusting,
piston
"Measuring compression pressure".)
Defective injector • Engine speed does not change even when
running engine with some cylinder cutout.
15 (clogged injector, defective Replace injector
injection) "Handling cylinder cutout mode operation".)
D65EX,PX,WX-17 40-691
40 Troubleshooting
S-4 Startability is poor

Failure Starting performance is poor.
• If any failure code is displayed, carry out troubleshooting for it first.
Related • Common rail fuel injection system (CRI) controls the fuel injection timing electrically.
information Therefore, there are cases where the engine does not start before the crankshaft makes
two rotations maximum after starting operation. This is not an abnormal state, however.
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge
• Fuel other than specified one is used.
• Fuel used does not accord with the ambient
temperature Use proper fuel
Improper fuel used (Reference: Starts when warm but does not specified in Operation
3
easily start when cold.) and Maintenance
• Deposited wax (milky) is found in clear bowl Manual
of fuel pre-filter.
cap is clogged
5
6
drained
the fuel system
9
10 Defective supply pump delivery, return and leakage". and pressure limiter
11 cooling plate • Sticking of check valve
valve
Check, clean air
cleaner element
• Intake air heater mount does not warm up
during preheating operation.
• When engine is preheated or when Replace intake air
13 Defective intake air heater
temperature is low, preheating monitor does heater
not indicate properly.
• Remove EGR cooler outlet gas piping and
check if coolant containing COOLANT flows
Cracked EGR cooler out Replace EGR cooler
14 (Reference: coolant in and drain water from
exhaust gas) a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.
40-692 D65EX,PX,WX-17
40 Troubleshooting

• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
15 Defective injector • Engine speed does not change even when Replace injector
"Handling cylinder cutout mode operation".)
• Measure the compression pressure (see
standard value table).
Defective contact of valve "Measuring compression pressure".) Correct or replace
16
with valve seat • Test the valve clearances valve or valve seat
"Measuring and adjusting valve clearance".)
• Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
"Testing exhaust gas color".) Replace piston ring or
17 Defective piston ring • Measure the compression pressure (see piston
• Check piston rings and piston ring grooves
D65EX,PX,WX-17 40-693
40 Troubleshooting
S-5 Engine does not pick up smoothly

Failure Engine does not pick up smoothly
information
cap is clogged
3
4
drained
the fuel system
7
8 Defective supply pump
delivery, return and leakage". and pressure limiter
cooling plate valve
• When error is not cleared even after KCCV
filter is replaced and crankcase pressure
high error (failure code: CA555) is still Perform the following
10 Crankcase pressure too high displayed, the blowby pressure may be high checks on cause 10
(see Testing and adjusting, "Measuring and below
blowby pressure"). At this time, KVGT may
be seized or damaged.
• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
12 KVGT seized or broken Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)
• When engine is cranked, unusual noise is
heard around cylinder head
• Check valve clearance Adjustment of valve
13 Incorrect valve clearance
(Reference: See Testing and adjusting, clearance
40-694 D65EX,PX,WX-17
40 Troubleshooting

14
exhaust gas.
D65EX,PX,WX-17 40-695
40 Troubleshooting
S-6 Engine stops during operation

Failure Engine stops during operation
information
cap is clogged
3
4
drained
the fuel system
7
cooling plate valve
Defective intake air hose
• Visually check air intake hose for breakage Replace air intake
10 (between air cleaner and
hose
KVGT inlet)
• Check air intake manifold for internal Replace air intake
11 Defective air intake manifold breakage manifold
Defective boost piping and
connections Correct or replace
12 • Air comes out from boost piping
(From KVGT outlet to air boost piping
intake manifold)
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
13 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat insulation plate)
• Check valve and rocker arm
Replace valve or
14 Damaged valve or rocker arm (Unusual noise is heard and engine stops
suddenly.) rocker arm
• Metal particles are found in oil drained from
oil pan
• Remove oil pan and check piston and
Broken or seized piston Replace piston and
15 connecting rod connecting rod
connecting rod
(Reference: Unusual noise is heard and
engine stops suddenly, or stops due to
overheat.)
• Metal particles are found in oil drained from
Broken or seized crankshaft oil pan Replace crankshaft
16 bearing • Remove oil pan and check crankshaft main main bearing
bearing
40-696 D65EX,PX,WX-17
40 Troubleshooting

• Check wiring in engine controller power
Correct wiring in
Defective wiring in engine supply
17 controller power supply engine controller
(Reference: See Troubleshooting, "Failure
power supply
code [CA343]".)
Defective starting switch Diagnose and take
18 wiring • Check starting switch wiring
remedies for E-1
• See H-mode, "H-2 Engine speed lowers Diagnosis and remedy
19 Defective hydraulic system significantly on engine stalls". by H-2
D65EX,PX,WX-17 40-697
40 Troubleshooting
S-7 Engine runs rough or is unstable

Failure Engine runs rough or is unstable
information
cap is clogged
3
4
drained
the fuel system
7
• Check boost system (between KVGT outlet Correct or replace
Fuel leakage from boost
8 and aftercooler, aftercooler and air intake boost piping related
system
manifold) for fuel leakage parts
cooling plate valve
• Replace sensor and check if problem is
Defective mass air flow and corrected Replace mass air flow
10 temperature sensor (Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor
• Check connecting part of connectors Check connecting part
Defective KVGT speed • Check KVGT speed sensor after
11 or replace KVGT speed
sensor replacement sensor
40-698 D65EX,PX,WX-17
40 Troubleshooting
S-8 Engine lacks power

Failure Engine lack output (or lacks power)
information
cap is clogged
3
4
drained
the fuel system
7
cooling plate valve
Check, clean air
cleaner element
• Check air cleaner and rectifying wire net for Correct or replace air
11 Defective air cleaner
deformation cleaner
Defective air intake hose
• Visually check air intake hose for breakage Replace air intake
12 (between air cleaner and
hose
KVGT inlet)
• Check air intake manifold for internal Replace air intake
13 Defective air intake manifold breakage manifold
14 • Air flows out from boost piping
intake manifold)
Defective mounting of boost • Air leakage from mounting part of boost Correct boost pressure
15 pressure sensor pressure sensor sensor mounting
exhaust gas leakage
17 Gas leakage from EGR piping • Gas leaks from EGR piping Replace EGR piping
Check intake and exhaust
system • Measure boost pressure
Correct and replace
18 (between KVGT outlet and air (Reference: See Testing and adjusting,
the troubled part
intake manifold, air intake "Measuring boost pressure".)
manifold and KDPF inlet)
D65EX,PX,WX-17 40-699
40 Troubleshooting

• Open the exhaust color inspection hole in
front of KDPF, check the exhaust gas (refer
Excessive soot accumulation standard value table) Clean or replace KDPF
20
in KDPF (Reference: See Testing and adjusting,
"Testing exhaust gas color".)
• KDPF clogging - check exhaust pressure Clean or replace KDPF
21 Defective KDPF
before KDPF
24
exhaust gas.
25 Defective piston ring
• Measure the compression pressure (see piston
40-700 D65EX,PX,WX-17
40 Troubleshooting
S-9 Exhaust gas is black (KDPF gets clogged in a short time)

Failure Exhaust gas is black (KDPF gets clogged in a short time)
information
No. Cause Detail of work, remarks Remedy
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual
2
drained
• Check air cleaner and rectifying wire net for Correct or replace air
3 Defective air cleaner
deformation cleaner
exhaust gas leakage
Correction of charge
Defective mounting of charge • Air leakage from mounting part of charge
5 (boost) pressure
(boost) pressure sensor (boost) pressure sensor
sensor mounting
6 • Air flows out from boost piping
intake manifold)
• KDPF clogging - check exhaust pressure Clean or replace KDPF
7 Defective KDPF
before KDPF
8 Gas leakage from EGR piping • Gas leaks from EGR piping Replace EGR piping
• Too much fuel is returned when flow is
checked
11 Defective fuel return piping
"Measuring fuel delivery, return and return piping
leakage".)
• Check fuel return piping for clogging
• Replace sensor and check if problem is
Defective mass air flow and corrected Replace mass air flow
12 temperature sensor (Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor
D65EX,PX,WX-17 40-701
40 Troubleshooting

14
exhaust gas.
40-702 D65EX,PX,WX-17
40 Troubleshooting
S-10 Engine oil consumption is excessive

Failure Engine oil consumption is excessive
Related information • If any failure code is displayed, carry out troubleshooting for it first.
Dust sucked in from intake • When intake piping between air cleaner Clean or replace
1 system and engine is removed, dust is found intake piping
inside.
• Blow-by pressure exceeds standard value
when checked
• Blow-by pressure is still high after KCCV
filter element is replaced Replace or correct
2 Broken or worn piston ring
• Measure the compression pressure (see piston ring
standard values table).
"Testing compression pressure".)
Oil leakage from KCCV oil • Check for oil leaks from KCCV oil return Correct or replace oil
3 return piping piping piping
External leakage of oil from
4 engine • Check for oil leaks Correct oil leaks
Oil leakage from oil filter Reinstall or replace oil

5 • Check for oil leaks from oil filter
filter
Correct or replace oil
6 Oil leakage from oil piping • Check for oil leaks from oil piping
piping
7 Oil leakage from oil drain plug • Check for oil leaks from oil drain plug Retighten oil drain plug
Correct or replace oil
8 Oil leakage from oil pan • Check for oil leaks from oil pan
pan
Correct or replace
9 Oil leakage from cylinder head • Check for oil leaks from cylinder head
cylinder head
• Oil level in clutch chamber or damper Correct or replace rear
10 Worn or damaged rear oil seal
chamber on machine is low. oil seal
• KVGT blower inlet and outlet, and turbine
outlet are dirty with oil.
11 Oil leakage from KVGT • Check if KVGT shaft rotates Replace KVGT
• Oil in coolant
• Remove oil cooler and check for external oil
12 Oil leakage from oil cooler leaks Replace oil cooler
• Check for leaks by applying air pressure to
oil cooler
Oil leakage from EGR valve • When EGR valve is removed, outlet port is
13 Replace EGR valve
stem found to be dirty with oil.
• Check valve guide and stem seal
• Remove cylinder head. Check inside
Worn or damaged valve guide, diameter of guide, and check stem seal for Replace valve guide
14
stem seal damages. and stem seal
(Reference: See "Maintenance standards".)
D65EX,PX,WX-17 40-703
40 Troubleshooting
S-11 Engine oil becomes contaminated early

Failure Oil becomes contaminated quickly
Use proper fuel
Improper fuel used • Non-specified fuel is being used. specified in Operation
1
and Maintenance
Manual
Use correct oil
Improper oil used • Oil other than specified one is used according to Operation
2
and Maintenance
Manual.
• Check exhaust gas color before KDPF
(See "Standard value table") Carry out
Exhaust gas before KDPF is (Reference: See Testing and adjusting, troubleshooting for "S-
3
black. "Testing exhaust gas color".) 9 Exhaust smoke is
(Exhaust gas before KDPF is black) black"
when checked
4 Much blow-by gas is produced • Blow-by pressure is still high after KCCV Perform the following
filter element is replaced
• Rotate KVGT shaft and check for play
Defective KVGT turbine side (Move KVGT vanes with hand in axial and Replace KVGT
5
seal radial directions to judge)
• Remove EGR valve and check stem seal,
guide, and stem
6 Worn EGR valve guide • When EGR valve is removed, outlet port is
Replace EGR valve
found to be dirty with oil.
• Check for excessive oil
7 Too much oil (Too much oil will cause high temperature Adjust to correct oil
and early deterioration of oil) level
• Visually check oil cooler element for
contamination Correct or replace oil
8 Dirty oil cooler element (Increased oil temperature due to dirty oil cooler element
cooler element)
when checked
• Blow-by pressure is still high after KCCV
filter element is replaced Replace or correct
9 Broken or worn piston ring • Measure the compression pressure (see piston ring
standard values table).
"Testing compression pressure".)
• Check valve guide and stem seal
• Remove cylinder head. Check inside
Worn or damaged valve guide, diameter of guide, and check stem seal for Replace valve guide
10
stem seal damages. and stem seal
(Reference: See "Maintenance standards".)
40-704 D65EX,PX,WX-17
40 Troubleshooting
S-12 Fuel consumption is excessive

Failure Fuel consumption is excessive
information
Replace injector
• Measure spill rate from injector
Too much fuel is spilled from (Reference: See Testing and adjusting, There may be
1 injector "Measuring fuel delivery, return and excessive dust in fuel.
leakage".) Confirm quality control
of fuel.
• Check fuel return piping for clogging
Correct or replace fuel
2 Clogged fuel return piping (Injection rate increased due to clogged fuel
return piping
return piping)
Fuel leakage from inside • Check for increased oil level
4 Correct defective parts
cylinder head • Check for smell of diesel fuel
• Check for increased engine oil level and
Fuel leakage from feed pump smell of diesel fuel Replace feed pump oil
5
oil seal • Check feed pump oil seal seal
6 Fuel leakage to outside • Check fuel leakage to outside of engine. Correct defective parts
D65EX,PX,WX-17 40-705
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
Failure Oil is in coolant (or coolant spurts back or coolant level goes down)
Carry out
troubleshooting for "S-
1 Engine oil is milky • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)"
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block
40-706 D65EX,PX,WX-17
40 Troubleshooting
S-14 Oil pressure drops

Failure Oil pressure drops
Related information • Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
• Oil level in oil pan is low
1 Lack of oil in oil pan • Oil pressure monitor indicates low oil Add oil
pressure when operating on slopes
Defective oil pressure sensor, Replace oil pressure
• Check oil pressure sensor, wiring harness,
2 wiring harness sensor, wiring harness,
and connector
or connector
If oil is contaminated
with fuel, carry out
• Perform oil analysis and check for fuel in oil
3 Fuel in oil troubleshooting for "S-
• Engine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
• Perform oil analysis and check for water in with water, carry out
4 Water in oil oil troubleshooting for "S-
• Oil is milky 16 Water mixes into
engine oil (milky)"
• Check oil filter
(Reference: Oil filter has been used beyond
5 Clogged oil filter the specified period, oil heavily deteriorated, Replace oil filter
etc.)
• Water in oil can cause oil filter blockage
6 Clogged oil strainer • Check oil strainer Clean oil strainer
Crushed or clogged hydraulic Replace hydraulic
7 • Hydraulic piping is crushed or clogged
piping piping
• Check oil pump
8 Defective oil pump (worn or damaged gear) Replace oil pump
• Oil pump rotation is heavy or it has play
Defective regulator valve • Check valve spring for fatigue or damage Replace regulator
9
valve
• Valve and spring of oil pump relief valve is Replace oil pump relief
10 Defective oil pump relief valve fatigued, damaged. valve
Cracks in oil pump suction • Check around oil pump suction piping Replace oil pump
11 piping (cracked piping) suction piping
Defective seal between oil
12 pump and oil pump suction • Check seal Replace seal
piping
Replace boost oil
13 Defective boost oil pump • Check boost oil pump
pump
Defective boost oil pump relief • Check boost oil pump relief valve for fatigue Replace boost oil
14 or damage on valve and spring pump relief valve
valve
Oil leakage from EGR Replace EGR
15 hydraulic piping • Check EGR hydraulic piping
hydraulic piping
• Check main journal bearing
Replace main journal
16 Worn main journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
• Check pin journal bearing
Replace pin journal
17 Worn pin journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
Worn idler bushing, damaged Replace idler bushing
18 idler gear • Check idler bushing and idler gear
or idler gear
Breakage or falling off of Replace piston cooling
19 piston cooling nozzle • Check piston cooling nozzle
nozzle
D65EX,PX,WX-17 40-707
40 Troubleshooting
S-15 Fuel mixes into engine oil

Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
1 Defective injector • When a certain cylinder is cut out, engine Injector replacement
speed does not change
"Handling of cylinder cut-out operation".)
Fuel leakage from injector O-
2 • Check injector O-ring Replace injector O-ring
ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced
40-708 D65EX,PX,WX-17
40 Troubleshooting
S-16 Water mixes into engine oil (milky)

Failure Water mixes into engine oil (milky)
• If oil mixes into the coolant, carry out troubleshooting for "S-13 Oil mixes into coolant"
When engine starting and stopping is frequently repeated in low outside temperatures,
Related the KCCV may cause condensation of water vapor in the blowby gas leading to milky oil
information or emulsification inside the engine, but this is normal. This is not a problem if coolant is
not leaking.
If coolant leakage is suspected by such as drop of coolant level in a short time, carry out
the following troubleshooting procedures.
• Coolant containing COOLANT flows out
when EGR cooler inlet and outlet gas piping
are removed.
(Make sure the water is coolant or not. It
may be condensate water)
1 Cracks in EGR cooler Replace EGR cooler
(Reference: If cracks are found in the EGR
cooler, this may be caused by low coolant
level in the cooling system. When replacing
the EGR cooler, check leakage from coolant
system piping and radiator.)
• Check oil cooler element and gasket
Damaged oil cooler element Replace oil cooler
2 • Pressure-tightness test of oil cooler shows
or gasket element or gasket
there is leakage
Broken cylinder head or • Disassemble engine and check cylinder Replace cylinder head
3 cylinder head gasket head and cylinder head gasket or cylinder head gasket
• Engine oil level has risen, oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
4
block or pitting in cylinder block
D65EX,PX,WX-17 40-709
40 Troubleshooting
S-17 Coolant temperature rises too high (overheating)

Failure Coolant temperature rises too high (overheating)
Related information • When the failure code is displayed, perform troubleshooting of that code first.
Clogged radiator core • Check radiator core for clogging, fin for
1 Clean radiator core
crush
• Thermostat does not open at cracking
temperature
2 Malfunction of thermostat a Thermostat cracking temperature: 76.5 ± 2 Replace thermostat
°C
(Full open temperature90 °C )
• Error related to coolant temperature is Replace coolant
Defective coolant temperature
3 gauge displayed, but measured value of radiator temperature sensor,
coolant temperature is correct. monitor or wiring
harness
Perform
• Fuel injection rate is high troubleshooting for "S-
4 Increased fuel injection rate
12 Fuel consumption
is excessive"
5 Coolant level is low • Check coolant level. isn't it too low? Refilling of coolant
6 Leakage of coolant • Check water leakage from coolant piping Replace coolant piping
• Visual check of water pump
7 Breakage of water pump (Check water leakage from shaft sealing, Replace water pump
damage of impeller and breakage of shaft)
Overheating due to increased
EGR ratio (EGR amount Replace mass air flow
• Check mass air flow and temperature
8 against fresh air amount) and temperature
caused by defective mass air sensor
sensor
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount
• Check deformation of air cleaner and Correct or replace air
9 against fresh air amount)
rectifier wire net cleaner
caused by air cleaner
deformation
Defective cylinder head, Perform
• Check blow-back due to excessive bubble
10 cylinder head gasket troubleshooting for "S-
in radiator
13 Oil is in coolant"
• Open the exhaust gas color inspection hole
in front of KDPF, check the exhaust gas.
(Note: see "Measuring exhaust gas color"
section of Testing and adjusting)
Replace piston ring or
11 Defective piston ring • Measure compression pressure (refer
piston
standard value table)
(Note: see "Measuring compression
pressure" section of Testing and adjusting)
• Check piston ring, piston ring groove
40-710 D65EX,PX,WX-17
40 Troubleshooting
S-18 Unusual noise is made

Failure Unusual noise is heard
• Judge if the noise source is internal or external before starting troubleshooting
• The engine is operated in the low-temperature mode while it is not warmed up
sufficiently. Accordingly, the engine sound becomes a little larger. This does not
indicate abnormality, however.
Related information • When the engine is accelerated, it is operated in the acceleration mode and its
sound becomes a little larger for up to approximately three to five seconds. This
does not indicate abnormality, however.
• Gas leakage from piping between cylinder
head and exhaust manifold, or between
exhaust manifold and KVGT, or between Repair or replace
1 Gas leakage from pipings
KVGT outlet and KDPF defective parts
• Gas leakage from EGR piping or air intake
piping
Vibration of exhaust pipe, Check and retighten
2 • Visually check for vibration
exhaust bellows piping brackets
3 KVGT seized or broken (Move KVGT vanes with hand in axial and Replace KVGT
Damage inside KDPF Clean or change
4 • Check inside KDPF
KDPF
5 Defective injector • When a certain cylinder is cut out, engine Replace injector
speed does not change
"Handling of cylinder cut-out operation".)
• Test the valve clearances
(Reference: For details, see Testing and Adjustment of valve
adjusting, "Testing and adjusting valve clearance
clearance".
Seized pin bushing, front Correct or replace
7 • Check for metal particles in oil pan
bearing, or main bearing damaged parts
• If the metallic powder is found in oil pan or
oil filter, overhaul the engine and check the
piston ring and cylinder liner.
Replace piston ring
8 Worn piston ring or cylinder • Measure the compression pressure (see
and cylinder liner
standard values table)
"Testing compression pressure")
Damaged valve or rocker arm • Overhaul engine and check valves and Replace valve or
9
rocker arms rocker arm
10 Damage at around idler gear • Overhaul engine and check idler gear parts Replace idler gear
D65EX,PX,WX-17 40-711
40 Troubleshooting
S-19 Vibration is excessive

Failure Vibration is excessive
• If unusual noise is made and vibration is excessive, carry out troubleshooting for "S-18
Related Unusual noise is heard", too.
information • If any failure code is displayed, carry out troubleshooting for it first.
Loose engine mounting bolts, • Visually check for loose engine mounting Retighten bolts or
1 bolts, cracks in cushions, and hardening replace cushions
defective cushions
• Visually check viscous damper for Replace engine
2 Damaged engine damper
discoloration damper
Defective output shaft or • Check for damage in output shaft or damper Replace defective
3 damper chamber parts
chamber
Misalignment and facial
• Measure misalignment and facial runout at
runout at connection between Replace defective
4 connection between engine and hydraulic
engine and hydraulic pump parts
pump
are out of standard range.
Worn main bearing, • If metal particles are found in oil pan or oil Correct or replace
6 connecting rod bearing filter, overhaul engine damaged parts
• If metal particles are found in oil pan or oil Correct or replace
7 Sticking valve or rocker arm filter, open head cover and check valves damaged parts
and rocker arms
• If metal particles are found in oil pan or oil
Replace camshaft
8 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings
bushings
40-712 D65EX,PX,WX-17
40 Troubleshooting
S-20 Air cannot be bled from fuel circuit

Failure Air cannot be bled from fuel circuit
Related • If any error code is displayed, carry out troubleshooting for it first.
information
• When fuel feed pump switch is turned ON,
1 Insufficient fuel in tank pump operating sound is heard. Add fuel
• Even when fuel feed pump switch is turned
2 Low battery charge level Charge battery
ON, pump operating sound is not heard.
• Check drain cock of fuel prefilter for
Loose drain cock of fuel
3 loosening Close drain cock
prefilter
(Air leaking in due to loose drain cock)
4
• Air is discharged when the air is bled from
the fuel system Correct or replace fuel
(Reference: See Testing and adjusting, piping
"Bleeding air from fuel system")
"Checking fuel system for leakage")
• With fuel feed pump switch ON, voltage to
Replace fuel feed
7 Malfunction of fuel feed pump fuel feed pump is generated but pump does
pump
not operate.
Defective wiring harness of Replace wiring
8 • Check wiring harness
fuel feed pump harness
D65EX,PX,WX-17 40-713
40 Troubleshooting
S-21 Frequent active regeneration

Failure Frequent active regeneration
information
Frequently used for light load Perform Regeneration
• Soot accumulates when exhaust
1 operations such as simple for Service to burn
temperature does not increase.
traveling. away soot completely
front of KDPF, check the exhaust gas (refer Carry out
Exhaust gas color is bad standard value table) troubleshooting for "S-
2
(Reference: See Testing and adjusting, 9 Exhaust smoke is
"Measuring exhaust gas color".) black"
• If regeneration frequency does not return to
Bad exhaust color causing
3 normal after remedies for cause 2 are taken, Clean KDOC
KDOC face plugging
KDOC is plugged
Use proper oil
Improper oil used • Oil other than specified one is used specified in Operation
4
and Maintenance
Manual.
• If regeneration frequency does not return to
KCSF plugged due to
5 normal after remedies for cause 4 are taken, Clean or replace KCSF
improper oil used
KCSF is plugged
Carry out
Coolant leaking into exhaust troubleshooting for "S-
6 system • Check for low coolant level 16 Water mixes into
engine oil (milky)"
KCSF plugged due to coolant
7 • Check for plugging at KCSF inlet Clean or replace KCSF
leaking into exhaust system
Use proper fuel
8
and Maintenance
Manual
• KDOC deteriorated by high sulfur content
KDOC deterioration due to (If regeneration frequency does not return to
9 Replace KDOC
improper fuel used normal after remedies for causes 1 to 8 are
taken, KDOC is deteriorated)
• If regeneration frequency is not improved
10 Plugged KDOC after remedies on causes 1 to 9, KDOC is Clean KDOC
blocked.
11 Damaged KDOC • Check KDOC for damage Replace KDOC
40-714 D65EX,PX,WX-17
40 Troubleshooting
S-22 Active regeneration is long

Failure Active regeneration is long
information
• Check KDOC inlet temperature when
performing regeneration for service (Min.
250 °C )
(Reference: During regeneration for service,
1 Malfunction of KVGT KVGT solenoid current becomes Replace KVGT
approximately 1000 mA continuously, while
KDOC inlet temperature does not exceed
250 °C . In this case, KVGT may
malfunction.)
front of KDPF, check the exhaust gas (refer Carry out
Exhaust gas color is bad standard value table) troubleshooting for "S-
2
(Reference: See Testing and adjusting, 9 Exhaust smoke is
"Testing exhaust gas color".) black"
Bad exhaust color causing • If regeneration time is not improved after
3 KDOC face plugging remedies on cause 2, KDOC is blocked. Clean KDOC
Carry out
engine oil (milky)"
KCSF plugged due to coolant
5 • Check KCSF for blocking Clean KCSF
leaking into exhaust system
Use proper fuel
6
and Maintenance
Manual
KDOC deterioration due to (If regeneration time is not improved after
7 Replace KDOC
improper fuel used remedies on cause 1 to 6, KDOC is
deteriorated.)
• If regeneration time is not improved after
8 Plugged KDOC Clean KDOC
remedies on cause 2, KDOC is blocked.
9 Damaged KDOC • Check KDOC for damage Replace KDOC
D65EX,PX,WX-17 40-715
40 Troubleshooting
S-23 White smoke is exhausted during active regeneration

Failure White smoke is exhausted during active regeneration
• White smoke may be observed for a short time immediately after engine is started in
Related information cold weather or during regeneration, but this is normal.
Carry out
engine oil (milky)"
• If white smoke problem is not resolved after
KDOC plugged due to coolant Clean or change
2 remedies for cause 1 are taken, KDOC is
leaking into exhaust system KDOC
plugged
Use proper fuel
Improper fuel used • Non-specified fuel is being used. specified in Operation
3
and Maintenance
Manual
KDOC deterioration due to (If white smoke problem is not resolved after
4 Change KDOC
improper fuel used remedies for causes 1 to 3 are taken, KDOC
is deteriorated)
• If white smoke problem is not resolved after
5 Plugged KDOC remedies for causes 1 to 4 are taken, KDOC Clean KDOC
is plugged
6 Damaged KDOC • Check KDOC for damage Change KDOC
7 Damaged KCSF • Check KCSF for damage Change KCSF
40-716 D65EX,PX,WX-17
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
50 Disassembly and assembly
D65EX,PX,WX-17 50-1
Table Of Contents
50 Disassembly and assembly ........................................................................................................... 50-3
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tool list................................................................................................................... 50-10
Sketches of special tools .................................................................................................... 50-20
Engine and cooling system ........................................................................................................ 50-35
Removal and installation of supply pump assembly............................................................... 50-35
Removal and installation of fuel injector assembly................................................................. 50-40
Removal and installation of cylinder head assembly.............................................................. 50-54
Removal and installation of radiator assembly ...................................................................... 50-72
Removal and installation of aftercooler and assembly ........................................................... 50-77
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-80
Removal and installation of power train oil cooler assembly ................................................... 50-82
Removal and installation of cooling fan drive assembly ......................................................... 50-84
Removal and installation of cooling fan motor assembly ........................................................ 50-86
Removal and installation of engine assembly ....................................................................... 50-88
Removal and installation of damper assembly ...................................................................... 50-95
Removal and installation of engine front seal ........................................................................ 50-98
Removal and installation of engine rear seal....................................................................... 50-101
Removal and installation of engine hood assembly ............................................................. 50-109
Removal and installation of fuel tank assembly ....................................................................50-111
Removal and installation of KDPF assembly....................................................................... 50-113
Disassembly and assembly of KDPF ................................................................................. 50-117
Removal and installation of KCCV assembly ...................................................................... 50-125
Removal and installation of air cleaner assembly ................................................................ 50-129
Power train............................................................................................................................. 50-130
Removal and installation of power train unit assembly ......................................................... 50-130
Disconnecting and connecting of power train unit assembly ................................................. 50-135
Disassembly and assembly of PTO ................................................................................... 50-140
Disassembly and assembly of torque converter .................................................................. 50-144
Disassembly and assembly of TORQFLOW transmission.................................................... 50-153
Disassembly and assembly of HSS ................................................................................... 50-177
Removal and installation of final drive assembly ................................................................. 50-196
Disassembly and assembly of final drive ............................................................................ 50-198
Removal and installation of track frame assembly ............................................................... 50-211
Removal and installation of idler assembly ......................................................................... 50-213
Disassembly and assembly of idler .................................................................................... 50-215
Removal and installation of recoil spring assembly.............................................................. 50-219
Disassembly and assembly of recoil spring ........................................................................ 50-220
Removal and installation of track roller assembly ................................................................ 50-224
Disassembly and assembly of track roller ........................................................................... 50-225
Removal and installation of carrier roller assembly .............................................................. 50-228
Disassembly and assembly of carrier roller......................................................................... 50-229
Separation and connection of track shoe assembly (Standard type track shoe) ..................... 50-232
Separation and connection of track shoe assembly (PLUS type track shoe) .......................... 50-235
Overall disassembly and assembly of track shoe (standard type track shoe) ......................... 50-236
Overall disassembly and assembly of track shoe (PLUS type track shoe) ............................. 50-249
Disassembly and assembly of one link in field (standard type track shoe).............................. 50-261
Disassembly and assembly of one link in field (PLUS type track shoe).................................. 50-268
Removal and installation of pivot shaft assembly ................................................................ 50-273
Removal and installation of equalizer bar assembly ............................................................ 50-274
Disassembly and assembly of equalizer bar side bushing.................................................... 50-276
Removal and installation of hydraulic tank assembly ........................................................... 50-277
Removal and installation of control valve assembly ............................................................. 50-280
50-2 D65EX,PX,WX-17
Disassembly and assembly of control valve........................................................................ 50-284

Disassembly and assembly of blade PPC valve.................................................................. 50-285
Disassembly and assembly of ripper PPC valve ................................................................. 50-286
Removal and installation of HSS pump and cooling fan pump assembly ............................... 50-287
Removal and installation of steering lubrication pump and power train pump
assembly ........................................................................................................... 50-289
Removal and installation of cooling scavenging pump assembly .......................................... 50-291
Removal and installation of HSS motor assembly ............................................................... 50-292
Disassembly and assembly of hydraulic cylinder................................................................. 50-294
Work equipment ..................................................................................................................... 50-300
Removal and installation of blade assembly (ST-TPP dozer)................................................ 50-300
Removal and installation of blade assembly (PAT dozer) ..................................................... 50-302
Removal and installation of ripper assembly ....................................................................... 50-304
Removal and installation of ROPS cab assembly................................................................ 50-307
Removal and installation of operator's cab glass (adhesion glass) ........................................ 50-313
Removal and installation of operator's sea.......................................................................... 50-318
Removal and installation of seat belt .................................................................................. 50-319
Removal and installation of air conditioner unit assembly..................................................... 50-320
Removal and installation of air conditioner compressor assembly......................................... 50-324
Electric system ....................................................................................................................... 50-325
Removal and installation of machine monitor assembly ....................................................... 50-325
Removal and installation of engine controller assembly ....................................................... 50-326
Removal and installation of power train controller assembly................................................. 50-327
Removal and installation of mass air flow and temperature sensor ....................................... 50-329
Removal and installation of KOMTRAX terminal ................................................................. 50-330
1 50 Disassembly and assembly
D65EX,PX,WX-17 50-3
General information on disassembly and assembly

How to read this manual
(Rev.2010.10) • Common tools that are necessary for installation
are described as [1], [2] ... etc. and their part
Removal and installation of assemblies numbers, part names and quantities are not
Special tools described.
• Marks shown in the installation section are
• Special tools which are necessary for removal or
explained below.
installation of assemblies are described as
A1•••X1 etc. and their part numbers, part names, k: This mark indicates safety-related
necessities, and quantities are described in the precautions which must be followed when
special tool list. performing the work.
• Marks used in the column of necessity are
explained below. a : This marks gives guidance or precautions
t: Tools are not substituted, must always be when performing the work.
equipped (used).
q: Tools extremely useful if available or tools 4 : This mark shows the weight of a part or the
that can be substituted with commercially assembled parts for a device.
available tool.
2 : This mark indicates a specific coating
• For details and the sketches of the special tools,
agent to be used.
see "special tool list" and "sketches of special
tools". 3 : This mark indicates the specified tightening
Removal torque.
• In the removal section, the work procedures,
precautions and know-how to do the work and 5 : This mark indicates the amount of oil or
the amount of oil and coolant to be drained are coolant to be added.
discribed. Disassembly and assembly of assembly
• Common tools that are necessary for the Special tools
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities • Special tools which are necessary for
are not described. disassembly and assembly of assemblies are
• Marks used in the removal section are explained described as A1•••X1 etc. and their part
below. numbers, part names, necessities, and
quantities are described in the special tool list.
k: This mark indicates safety-related • Marks used in the column of necessity are
precautions which must be followed when explained below.
performing the work. t: Tools are not substituted, must always be
equipped (used).
a : This mark gives guidance or precautions when q: Tools extremely useful if available or tools
performing the work. that can be substituted with commercially
[*1]: [*1]: This mark indicates that instructions or available tool.
precautions for the assembly installation work are • For details and the sketches of the special tools,
given in the installation section. see "special tool list" and "sketches of special
tools".
6 : This mark shows the amount of oil or Disassembly
coolant to be drained. • In the disassembly section, the work
procedures, precautions and know-how to do
4 : This mark shows the weight of a part or the the work, and the amount of oil and coolant to be
assembled parts for a device. drained are described.
Installation • Common tools that are necessary for the
• Unless otherwise instructed the installation of disassembly work are indicated as [1], [2] ... etc.
assemblies is to be made in the reverse order to and their part numbers, part names, and
removal. quantities are not described.
• Instructions and precautions for assembly • Marks used in the disassembly section are
installation are shown with [*1] mark in the explained below.
removal section, identifying which step the
instructions are intended for.
50-4 D65EX,PX,WX-17
k: This mark indicates safety-related

precautions which must be followed when
performing the work.
a : This marks gives guidance or precautions

when performing the work.
6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of a part or the

assembled parts for a device.
Assembly
• In the assembly section, the work procedures,
precautions and the know-how to do the work,
and the amount of oil or coolant to be added are
described.
• Common tools that are necessary for the
disassembly work are indicated as [1],[2] ... etc.
and their part numbers, part names, and
quantities are not described.
• Marks used in the assembly section are
explained below.
k ：This mark indicates safety-related
precautions which must be followed when
a : This mark gives guidance or precautions when

4 : This mark shows the weight of a part or the

assembled parts for a device.
2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified tightening
torque.
5 : This mark indicates the amount of oil or

coolant to be added.
D65EX,PX,WX-17 50-5
Coating materials list

(Rev.2009.08)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming out.
• Use for plastic (except polyethylene,
20g Polyethy- polypropylene, tetrafluoroethylene, and
LT-1B 790-129-9050 (2 pcs. lene vinyl chloride), rubber, metal, and non-
contained) container metal parts which require immediate and
strong adhesion.
• Features: Resistance to heat and
Polyethy- chemicals
LT-2 09940-00030 50 g lene • Use to prevent bolts and plugs from
container coming loose and as sealant.
790-129-9060 Adhesive:
(Set of 1 kg • Use to bond and seal metal, glass and
LT-3 Can plastics.
adhesive and Hardener:
hardener) 500 g
Polyethy-
LT-4 790-129-9040 250 g lene • Use to seal plugs for blank holes.
container
Holtz
790-129-9120 75 g Tube • Heat-resistant seal used to repair engines
MH705
• Instantaneous adhesive
Polyethy- • Curing time: From 5 sec. to 3 min.
Three- 50 g
790-129-9140 lene • Use mainly to bond metals, rubbers,
Bond1735
container plastics, and woods.
• Instantaneous adhesive
Polyethy- • Quick-curing type (max. strength is
Aron Alpha 2g
790-129-9130 lene obtained after 30 minutes)
201
container • Use mainly to bond rubbers, plastics, and
metals.
• Features: Resistance to heat and
Polyethy- chemicals
Loctite 648-50 79A-129-9110 50 cc lene • Use for fitted portions used at high
container temperatures.
50-6 D65EX,PX,WX-17
Liquid gasket
• Use to seal various thread portions, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene • Use to seal taper plugs, elbows, and
container nipples for hydraulic piping.
• Features: Silicon-based heat and cold-
resistant sealant
LG-6 790-129-9160 200 g Tube • Use to seal thread portions and flange
surface.
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, old, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based, heat and cold-
resistant, vibration-resistant, impact-
ThreeBond 419-15-18131 100 g Tube resistant sealant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the circle
LG-9 gear top seal which is not clamped by bolts,
ThreeBond 790-129-9310 200 g Tube gaps in the weld which must be caulked,
1206D etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are put on.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with solid
gaskets.
ThreeBond 790-129-9330 200 g Tube • Use for covers of the transmission case
1121 and steering case etc.
ThreeBond
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211
Molybdenum disulfide lubricant
• Use to prevent galling and seizure of
press-fitted portions, shrinkage-fitted
LM-P 09940-00040 200 g Tube portions, and thread portions.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are made
on metal surfaces to prevent the metals
— 09995-00250 190 g Can from galling.
• Use for the drive shaft splines, needle
bearings, pins and bolts of various links,
etc.
D65EX,PX,WX-17 50-7
Seizure prevention compound
• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust manifold
and the turbocharger, etc.
Grease
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
• Lithium grease with extreme pressure
G0-LI (*) SYGA- Various Various lubrication performance, general purpose
*: For cold 160CNLI type
regions SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.
Caution:
Molybdenum 400 g x 10 Bellows- • Do not use this grease for rolling
SYG2-400M
disulfide type bearings like swing circle bearings, etc.
grease SYG2-400M-A 400 g x 20 container and splines.
LM-G (G2-M) SYGA-16CNM 16 kg Can • Use this grease for work equipment
pins only when installing them, but do
not use it afterward.
Hyper White SYG2-400T-A
Grease SYG2-16CNT Bellows- • Higher seizure resistant, heat resistant and
G2-T 400 g type water resistant than molybdenum disulfide
SYG0-400T-A grease.
G0-T (*) (*) 16 kg container
• Not conspicuous on machine since color is
*: For cold SYG0-16CNT Can white.
regions (*)
Bio grease
G2-B SYG2-400B
G2-BT (*) SYGA-16CNB Bellows-
400 g type • Since this grease is biodegradable in short
*: For use at SYG2-400BT period, it has less impact on
(*) 16 kg container
high microorganisms, animals, and plants.
temperature SYGA- Can
and under high 16CNBT(*)
load
• Silicone grease with wide usable
G2-S temperature range, high resistance to
thermal-oxidative degradation and
ThreeBond — 200 g Tube performance to prevent deterioration of
1855 rubber and plastic parts
• Use for oil seals of the transmission, etc.
• Urea (organic system) grease with heat
resistance and long life. Enclosed type.
G2-U-SENS
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
grease
damper.
Caution: Do not mix it with lithium grease.
50-8 D65EX,PX,WX-17
Primer (For adhering cab glass)
• Use as primer for painted cab sheet metal
Sunstar Paint
Glass surface.
Primer 580 20 ml
container (Effective period: 4 months after
Super
417-926-3910 manufacture)
Sunstar Glass • Use as primer for cab glass surface.
Primer 580 Glass (Effective period: 4 months after
20 ml
Super container manufacture)
• Use as primer for painted cab sheet metal
Sunstar Paint Glass surface.
22M-54-27230 20 ml (Effective period: 4 months after
Primer 435-95 container
manufacture)
• Use as primer for black ceramic-coated
glass surface and for hard polycarbonate-
Sunstar Glass coated surface.
22M-54-27240 150 ml Steel can
Primer 435-41 (Effective period: 4 months after
manufacture)
• Use as primer for sash (Almite)
Sunstar Sash Glass (Effective period: 4 months after
22M-54-27250 20 ml
Primer GP-402 container manufacture)
Adhesive (For adhering cab glass)
• Use "S" in high temperature season and

Sunstar "W" in low temperature season as
Polyethy-
Penguin Seal adhesive for glass.
417-926-3910 320 ml lene
580 Super "S" (Effective period: 4 months after
container
or "W" manufacture)
Sika Japan, Polyethy- • Use as adhesive for glass.

Sikaflex 20Y-54-39850 310 ml lene (Effective period: 6 months after
256HV container manufacture)
Sunstar Ecocart • Use as adhesive for glass.
Penguin Super 22M-54-27210 320 ml (Special (Effective period: 6 months after
560 container) manufacture)
Caulking material (For adhering cab glas)
Sunstar Polyethy- • Use to seal joints of glass parts.
Penguin Seal 417-926-3920 320 ml lene (Effective period: 4 months after
No.2505 container manufacture)
Sekisui Polyethy- • Use to seal front window.
Silicone 20Y-54-55130 333 ml lene (Effective period: 6 months after
Sealant container manufacture)
• Use to seal glass-to-glass joint.
GE Toshiba Translucent white seal.
Silicones 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL 381 manufacture)
D65EX,PX,WX-17 50-9
Special tool list

a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tool.
a New/redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification
a Tools marked with Q in the sketch column have the sketches.(See "Sketches of special tools".)
New/redesign
Necessity
Sketch
Q'ty
Device Symbol Part number Part name Detail of work, remarks
Removal and
installation of fuel
supply pump
Finding top dead center
assembly, fuel
1 795-799-1131 Gear t 1 positions for 1st and 6th
injector assembly,
cylinders
cylinder head
assembly, and
engine front oil seal
Removal and
Removal and
installation of fuel
2 795-799-1390 Remover t 1 installation of fuel
supply pump
supply pump drive gear
assembly
Removal and 3 795-799-6700 Puller t 1
installation of fuel A
Removal of fuel injector
injector assembly
4 795-799-8150 Remover q 1 assembly
and cylinder head
assembly
Removal and Press fitting of engine
5 795-799-8120 Oil seal driver q 1
installation of engine front seal
rear oil seal and 795-799-1150 Repair stand q 1 Fixture of engine
engine front oil seal 6 assembly
795-799-2280 Adapter q 1
Removal and
installation of Tightening of cylinder
cylinder head 7 790-331-1120 Wrench (angle) q 1
head bolt
assembly
790-101-5401 Push tool kit (C) t 1
Separation and
790-101-5431 • Plate 1
connection of power 1 Installation of oil seal
train 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
Disassembly and 790-101-5221 • Grip 1
assembly of PTO 01010-51225 • Bolt 1
assembly Press fit of bearing
790-101-5201 Push tool kit (B) t 1
790-101-5331 • Plate 1
4
790-101-5221 • Grip 1
01010-51225 • Bolt 1
50-10 D65EX,PX,WX-17
New/redesign
Necessity
Sketch
Q'ty
5 796-430-1110 Push tool t 1

794T-422-
6 Push tool t 1 Q
1110
792T-413-
7 Push tool t 1 Q
Disassembly and 1120
790-101-5401 Push tool kit (C) t 1 Press fit of bearing
assembly of torque
converter 790-101-5491 • Plate 1
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Removal and
9 792-213-1110 Wrench assembly t 1
installation of nut
791T-415- Puller asembly t 1 Q
5300
10 791T-415- Installation of snap ring
• Plate 1 Q
5310
01010-82040 • Bolt 1
Operation check of
11 799-301-1600 Oil leak tester kit t 1
clutch 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
Disassembly and 790-101-5201 Push tool kit (B) t 1
assembly of 790-101-5281 • Plate 1
14
transmission 790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5001 Push tool kit (A) t 1 Press fit of bearing
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
793T-615- t 1
18 Push tool Q
1170
19 790-201-2830 Spacer t 1
791T-415- t 1
20 Push tool Q
5210
D65EX,PX,WX-17 50-11
New/redesign
Necessity
Sketch
Q'ty
Removal and
791T-422- Hanger
1 q 1 Q installation of brake and
1320 carrier assembly
Removal and
2 790-302-1500 Wrench kit q 1 installation of bevel
pinion nuts
3 796-730-2300 Wrench assembly q 1
Commercial
Preload adjustment of
product or Torque wrench set q 1 bearings of bevel gear
part 795-630-
4 shaft and bevel gear
1803
assembly
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 Removal of bevel
5 pinion assembly
790-101-5221 • Grip 1
01010-51225 • Bolt 1
794T-422- t 1
6 Push tool Q
1110
790-101-5401 Push tool kit (C) t 1
Disassembly and 790-101-5481 • Plate 1
assembly of HSS 7
E 790-101-5421 • Grip 1
case
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
793T-659-
9 Push tool t 1 Q
1110
796T-467- Press fit of bearing
10 Push tool t 1 Q
2160
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
790-337-1032 Lifting tool t 1
Removal and 7917-527-
Plate t 1 Slinging of final drive
installation of final 1 1110
J assembly
drive assembly 01010-81680 Bolt t 2
01643-31645 Washer t 6
50-12 D65EX,PX,WX-17
New/redesign
Necessity
Sketch
Q'ty
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
2 790-101-2470 Adapter (M20) t 2 hub assembly and
790-101-2450 Adapter (M12) t 2 bearing
790-201-2680 Plate t 1
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 1
01643-22460 Washer t 1
3 790-101-2420 Adapter (M16) t 1 Installation of bearing
790-201-2840 Spacer t 1
790-101-2102 Puller t 1
790-431-1031 Block t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
Disassembly and 01643-22460 Washer t 2
assembly of final Press fitting of sprocket
J 4 791T-527- t 1 N Q hub bearing
drive Plate
1130
791T-527-
Push tool t 1 N Q
1120
790-101-2102 Puller t 1
t 1 Installation of floating
5 791-580-8110 Installer
seal
790-101-5201 Push tool kit t 1
790-101-5321 • Plate t 1
6 790-101-5311 • Plate t 1
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
7 790-101-5431 • Plate t 1
790-101-5421 • Grip t 1
01010-51240 • Bolt t 1
790-101-5630 Plate t 1 N
8 790-101-5421 Grip t 1
01010-51240 Bolt t 1
Disassembly and
1 791-515-1520 Installer t 1
assembly of idler
Installation of floating
Disassembly and seal
assembly of track L 2 791-530-1520 Installer t 1
roller
D65EX,PX,WX-17 50-13
New/redesign
Necessity
Sketch
Q'ty
Disassembly and
t 1 Installation of floating
assembly of carrier 3 796-230-1110 Installer
seal
roller
Disassembly and L
assembly of idler 4 791-601-1000 Oil pump t 1 Refill
and track roller
791-685-8005 Compressor type B t 1
791-635-3160 Extension t 1
Disassembly and Spacer t Disassembly and
790-201-2780 1
assembly of recoil M assembly of recoil
spring 790-201-2790 Spacer t 1 spring
790-101-1102 Pump t 1
790-101-1600 Cylinder t 1
Removal and 791-450-1100 Remover assembly t 1
installation of 790-101-2102 Puller t 1
N Pulling out center pin
equalizer bar
assembly 790-101-1102 Pump t 1
Removal and 791-430-1200 Installer assembly t 1
installation of pivot P 790-101-2102 Puller t 1 Press fitting of ring
shaft assembly 790-101-1102 Pump t 1
Removal of track link
1 791-646-7531 Remover t 1
pin plug
Cleaning of track link
2 791-660-7460 Brush t 1
pin
791-432-1110 Push tool t 1
Installation of track link
3 791-646-7550 Bar t 1
Disassembly and pin (for large plug)
791-646-7560 Guide t 1
assembly of track
(standard type track R 791-932-1110 Push tool t 1
link) 4 791-646-7523 Bar t 1 pin (for small plug)
791-646-7590 Guide t 1
t 1 Sealing check of track
5 790-701-3000 Checker
link
6 791-432-1120 Installer t 1
seal
7 791-601-1000 Oil pump t 1 Refilling of track link oil
791-932-1110 Push tool t 1
Disassembly and 4 791-646-7523 Bar t 1 pin (for small plug)
assembly of track 791-646-7590 Guide t 1
(PLUS type track R Sealing check of track
link) 5 790-701-3000 Checker t 1
link
50-14 D65EX,PX,WX-17
New/redesign
Necessity
Sketch
Q'ty
791T-532- Push tool assembly t 1 Q

1100
791T-532- • Adapter 1 Q
1110
791T-532- • Ring 1 Q
1130
791T-532-
• Plate 1 Q
1140
791T-532- • Ring 1 Q
1150
791T-532-
• Push tool 1 Q
1160 Installation of wedge
18 791T-532- • Adapter 1 Q ring (on large plug side)
1170
791T-532- • Spring 1 Q
1180
791T-532- • Spring 1 Q
1190
791T-532-
• Bolt 1 Q
1210
791T-632-
• Bar 1 Q
5730
01580-11210 • Nut 1
01525-60610 • Bolt 4
1200
791T-532- • Adapter
Disassembly and 1 Q
1120
assembly of track
791T-532- • Ring
(PLUS type track R 1 Q
1130
link)
791T-532-
• Plate 1 Q
1140
791T-532- • Ring 1 Q
1150
791T-532-
• Push tool 1 Q
1160 Installation of wedge
19 791T-532- • Adapter 1 Q ring (on small plug side)
1170
791T-532- • Spring 1 Q
1180
791T-532- • Spring 1 Q
1190
791T-532-
• Bolt 1 Q
1220
791T-632-
• Bar 1 Q
5730
01580-11210 • Nut 1
01252-60610 • Bolt 4
1300
791T-532-
• Push tool 2 Q Press fitting of wedge
20 1310
ring
791T-632-
• Bar 2 Q
5730
01580-11210 • Nut 2
791T-432- t 1
21 Push tool Q Press fit of oil seal
1130
D65EX,PX,WX-17 50-15
New/redesign
Necessity
Sketch
Q'ty
791-432-1110 Push tool t 1

3 791-646-7550 Bar t 1 pin plug (for large plug)
791-646-7560 Guide t 1
791-932-1110 Push tool t 1
4 791-646-7523 Bar t 1 pin plug (for small plug)
791-646-7590 Guide t 1
t 1 Installation of track link
6 791-432-1120 Installer
seal
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
8 791-635-3180 Screw t 2
791-635-3190 Screw t 1 Removal 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
Disassembly and 790-101-1102 Pump t 1
assembly of one link Adapter t
791-645-3520 1
in field (standard R 11 Press fit of bushing
type track link) 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 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
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
14 Press fit 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
50-16 D65EX,PX,WX-17
New/redesign
Necessity
Sketch
Q'ty
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
1 790-101-1102 Pump assembly t 1
Jack Expansion of
2 790-105-2300 t 1
(196 kN {20 ton}) link
1 791-532-2201 Remover and installer t 1
• Cylinder
2 790-101-1300 (980 kN {100 ton}) 1
3 791-532-2210 • Plate 1
4 791-532-2220 • Plate 1
5 791-532-2230 • Block 1
Disassembly and
assembly of one link 6 791-532-2240 • Stud bolt 2
assembly in field 7 791-532-2390 • Rod 2
(PLUS type track R 8 791-532-2260 • Plate 1
9 791-532-2270 • Boss 2 Disas-
link)
sembly
1-
791-532-2280 • Boss 2 and
0
1- assembly
1-
7 3 1 791-532-2290 • Plate 1 of link
1-
01582-12722 • Nut 4
2
1-
791-532-2380 • Washer 2
3
1-
01252-61645 • Bolt 4
4
1-
02205-12437 • Nut 4
5
1-
791-532-2370 • Plate 1
6
Press fitting
1- of wedge
791-532-2340 • Push tool 2
7 ring
D65EX,PX,WX-17 50-17
New/redesign
Necessity
Sketch
Q'ty
790-502-1003 Repair stand t 1 Disassembly and

1 assembly of hydraulic
790-101-1102 Pump t 1 cylinder
Removal and
2 790-330-1100 Wrench assembly t 1 installation of cylinder
head
Socket (width across
790-302-1270 flats: 50 mm) t 1
Socket (width across Removal and
3 790-102-1330 flats: 75 mm) t 1
installation of nut
Socket (width across
790-302-1340 flats: 80 mm) t 1
Expansion of piston
4 790-720-1000 Expander t 1
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 Installa-
07281-01159 Clamp t 1 cylinder tion of
5 796-720-1670 Ring t 1 For blade tilt piston
cylinder, ring
blade pitch
07281-01279 Clamp t 1 cylinder, and
ripper lift
cylinder
Disassembly and 790-201-1702 Push tool kit t 1
assembly of 790-101-5021 • Grip 1
hydraulic cylinder U
01010-50816 • Bolt 1
For blade lift
790-201-1781 • Push tool 1 cylinder
For blade tilt Press fit
6 cylinder, of
blade pitch bushing
790-201-1811 • Push tool 1 cylinder, and
ripper lift
cylinder
For blade
790-201-1791 • Push tool 1 angle
cylinder
790-101-5021 • Grip 1
01010-50816 • Bolt 1
For blade lift
790-201-1590 • Plate 1 cylinder
For blade tilt Press
7 cylinder, fitting of
blade pitch dust seal
790-201-1620 • Plate 1 cylinder, and
ripper lift
cylinder
For blade
790-201-1610 • Plate 1 angle
cylinder
50-18 D65EX,PX,WX-17
New/redesign
Necessity
Sketch
Q'ty
Removal and
installation of
Installation of window
operator's cab glass 1 793-498-1210 Lifter (Suction cup) t 2
X glass
(adhered window
glass)
D65EX,PX,WX-17 50-19
Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tool manufactured according to this sketch.
D6 Push tool
D7 Push tool
50-20 D65EX,PX,WX-17
D10 Puller assembly
D10 Plate
D65EX,PX,WX-17 50-21
D18 Push tool
D20 Push tool
50-22 D65EX,PX,WX-17
E1 Hanger
E6 Push tool
E9 Push tool
D65EX,PX,WX-17 50-23
E10 Push tool
J1 Plate
50-24 D65EX,PX,WX-17
J4 Push tool
J4 Plate
D65EX,PX,WX-17 50-25
R18 Push tool assembly
R18 Adapter
50-26 D65EX,PX,WX-17
R18 and R19 Rings
R18 and R19 Plates
D65EX,PX,WX-17 50-27
R18 and R19 Rings
R18 and R19 Push tools
50-28 D65EX,PX,WX-17
R18 and R19 Adapters
R18 and R19 Springs
D65EX,PX,WX-17 50-29
R18 and R19 Springs
R18 Bolt
50-30 D65EX,PX,WX-17
R18, R19, and R20 Bars
D65EX,PX,WX-17 50-31
R19 Adapter
R19 Bolt
50-32 D65EX,PX,WX-17
R20 Push tool
D65EX,PX,WX-17 50-33
R21 Push tool
50-34 D65EX,PX,WX-17

Removal and installation of supply pump assembly
a Special tools
New/redesign
Necessity
Sketch
Sym-
Q'ty
bol
1 795-799-1131 Gear t 1
A
2 795-799-1390 Remover t 1

apply the parking brake.
5. Disconnect air conditioner hose clamp (4).
k Lower the work equipment to the ground and 6. Remove air hose mounting bolts (6) of bracket
stop the engine. (5) and disconnect air conditioner hose fixing
bracket (5) from air hose (7).
k Turn the battery disconnect switch to the 7. Remove two mounting bolts (9) of bracket (8).
OFF position and remove the key. Then, disconnect receiver (10) and bracket (8)
as a unit from the machine.
Removal
1. Open cover (1) under the fuel tank. a Reposition the receiver close to the machine.
2. Set the fuel valve under the fuel tank to the 8. Remove air hose (7). [*1]
CLOSE position.
3. Open engine left side cover (2) and lock the

opened cover.
a Check that the opened cover is locked
securely.
9. Remove air conditioner compressor (11)

according to the following procedure.[*2]
1) Disconnect wiring connectors AC (12) and
AGS (13), and ground GND09 (14).
2) Disconnect wiring clamps (12a) and (13a).
D65EX,PX,WX-17 50-35
11.Remove fuel spray prevention cap (23) and

disconnect high-pressure fuel pipe (24).[*3]
12.Disconnect overflow tube (25).[*4]
13.Disconnect fuel hoses (26), (27), and (28)
according to the following procedure.[*5]
1) While pressing the notches at part (a) of fuel
hose (26) in direction (J) of the arrow, pull out
part (b) in the direction of the arrow to
disconnect.
2) Remove fuel hoses (27) and (28) in the same
manner.
a Since the connector is fitted with the
3) Loosen four air conditioner compressor rubber cap, press the notches from above
mounting bolts (16) and fixing nut (16b) of that cap.
drive belt tension adjustment bolt (16a) a Turn the notches to a position where they
4) Loosen drive belt tension adjustment bolt can be pressed easily.
(16a) and remove drive belt (17).
5) Remove four mounting bolts (19) of bracket

(18). Then, remove air conditioner
compressor assembly (11) and bracket (18)
as a unit from the engine.
a Secure the separated air conditioner
compressor assembly to the machine
using ropes.
a Since hose (21) between the air
conditioner compressor assembly and air
conditioner condenser is short, take care
not to damage is when fixing the air
conditioner condenser assembly. 14.Remove cap (29) from the flywheel housing, and
install the engine cranking tool A1 (see the
special tools table).
a See Testing and adjusting, "Adjusting valve
clearance".
10.Disconnect wiring connector (22).
50-36 D65EX,PX,WX-17
15.Loosen cap (30) to remove. 19.Remove bracket (33).

20.Remove four mounting nuts (34) to remove fuel
a Remove cap (30) using a filter wrench or the
supply pump assembly (35).
like.
16.Using tool A1, rotate the crankshaft clockwise
(counterclockwise when viewed from the
flywheel side) to match the marking (M) on driver
gear (GY) to the marking "TDC".(See the special
tools table.)
a Use a mirror or the like to check the marking
and others.
clearance".
17.Remove mounting nut (31) and washer (32)
from shaft (SH) of the supply pump.
a Take care not to drop mounting nut (31) and Installation
washer (32) into the case when removing
them. • Install supply pump assembly (35) according to
18.Tighten tool A2 evenly to disconnect shaft (SH) the following procedure.
of the fuel supply pump from drive gear (GY). 1. When installing, match convex part (P) of shaft
(SH) of supply pump assembly (35) to groove
(G) of gear (GY).
2. Install bracket (33) to supply pump assembly

(35).
3 Mounting bolts (33a):
43 ± 6 Nm {4.4 ± 0.6 kgm}
3 Mounting bolt (33b):
77 ± 12 Nm {7.9 ± 1.2 kgm}
3. Install four mounting nuts (34).
D65EX,PX,WX-17 50-37
3 Mounting nut (34):

43 ± 6 Nm {4.4 ± 0.6 kgm}
4. Fit washer (32) and tighten mounting nut (31).
a Take care not to drop mounting nut (31) and
washer (32) into the case when installing
them.
3 Mounting nut (31):
180 ± 13 Nm {18.4 ± 1.3 kgm}
3 Air hose mounting clamp:

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
a Adjust the air conditioner compressor belt
tension. For details, see Testing and adjusting,
"Testing and adjusting air conditioner
compressor belt tension".
[*3]
• Carry out the rest of installation in the reverse a Install high-pressure fuel pipe (24) and install the
order to removal. fuel spray prevention caps to its both ends.
[*1] a Finger-tighten the sleeve nuts of high-pressure
a Insert air hose (7) until it stops at the tube fuel pipe (24) on the common rail side and
stopper, and install the clamps to the following supply pump side, and then tighten them to the
dimensions. specified torque.
Clamp Portion Dimensions a If the common rail assembly was removed,
L1 57 mm install the high-pressure fuel pipe. For detail, see
7a L2 10 mm "Installation procedure for high-pressure fuel
L3 31 mm pipe and injection pipe ([*7] and [*8])" in
L4 60 mm "Removal and installation of injector assembly".
7b L5 10 mm 3 Sleeve nut for fuel high-pressure pipe (24):
L6 31 mm 37.3 ± 4 Nm {3.8 ± 0.4 kgm}
[*4]
3 Mounting joint bolt of overflow tube (25):
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*5]
k Replace fuel hoses (26), (27), and (28) with
new ones since the internal parts at their
50-38 D65EX,PX,WX-17
fittings might have been damaged when they

were removed.
• Checking for fuel leakage (fuel system)

Check the fuel system for leakage. For details,
see Testing and adjusting, "Checking fuel
system for leakage".
• Bleeding air (fuel system)
Bleed air from the fuel circuit. For details, see
Testing and adjusting, "Bleeding air from fuel
circuit".
D65EX,PX,WX-17 50-39
Removal and installation of fuel injector assembly

a Special tools 5. Remove KDPF assembly. For details, see
"Removal and installation of KDPF assembly".
New/redesign
[*1]
Necessity
Sketch
Sym- 6. Remove the KDPF assembly in the following
Q'ty
Part number Part name procedure.
bol
1) Disconnect wiring connector (4) of the air
conditioner and clamp (5).
1 795-799-1131 Gear t 1 2) Disconnect wiring (6), (7) and (8).
A 3 795-799-6700 Puller t 1 3) Disconnect wiring clamps (6a), (7a) and (7b).
4 795-799-8150 Remover q 1

k Lower the work equipment to the ground,

and stop the engine.
k Turn the battery disconnect switch to the

OFF position and remove the key.
Removal
1. Open cover (1) under the fuel tank.
2. Set the fuel valve under the fuel tank to the 4) Disconnect clamps (8a) and (9a) of VGT air
CLOSE position. bleeding hoses (8) and (9).
5) Disconnect VGT air bleeding hoses (8) and
(9) from rear tubes of bracket (3).
6) Remove mounting bolts (11a) of the air tube
fixing bracket.
7) Disconnect wiring clamps (10) and (11).
8) Remove clamp (13) from KDPF water drain
tube (12).
9) Sling bracket (3) temporarily, and remove
eight mounting bolts (14).
10)Sling and remove and remove bracket (3).
4 Bracket:
25 kg
3. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
4. Remove bottom side cover (2).
50-40 D65EX,PX,WX-17
2) Loosen fixing nut (28) of air conditioner

compressor belt adjustment bolt (27).
3) Loosen air conditioner compressor drive belt
adjustment bolt (27) and remove drive belt
(29).
7. Remove exhaust pipe clamp (15).

8. Sling exhaust pipe (16) and remove exhaust
pipe mounting bolts (17).
9. Sling and remove exhaust pipe (15).
4) Remove four bracket mounting bolts (30),

and remove air conditioner compressor
assembly (25) and bracket (31) together.
10.Remove bracket (18) according to the following

procedure.
1) Loosen clamp (22) of air tube (21).
2) Remove two mounting bolts (20) of bracket
(19) and turn bracket (19) out. 12.Remove clamp (34) from bracket (33).
3) Remove 3 bracket mounting bolts(23). 13.Remove one bracket mounting bolt (32a) (from
* Each bolt has a collar, and take care not to air conditioner compressor side) and two
drop the collar when removing the bolt. mounting bolts (32) (from engine block side).
4) Remove seven mounting bolts (24), then Then, remove bracket (33).
sling and remove bracket (18).
11.Disconnect air conditioner compressor (25) in

the following procedure.[*2]
1) Loosen air conditioner compressor mounting
bolts (26).
D65EX,PX,WX-17 50-41
3) Disconnect hydraulic tubes (53) and (54).

4) Remove nut (55a), and remove wiring
bracket (55).
5) Remove mounting bolts (56a) and (56b), and
remove EGR valve assembly (56).
14.Remove air hose and tube assembly (44) in the

1) Disconnect wiring connector (41).
2) Remove tube mounting bolts (43) and
disconnect the tube from air connector .
3) Loosen hose clamp (42), and remove air
hose and tube assembly (44).[*3]
15.Remove air connector and electrical intake air
heater (ribbon heater) assembly (46) in the
1) Disconnect dipstick pipe clamp (35).
3) Remove clamp (38) of tube (37).
4) Loosen hose clamp (39), and disconnect air
hose (40).[*4]
5) Disconnect electric intake air heater (ribbon
heater) wiring (35).[*5]
6) Remove four air connector mounting bolts
(46e), and remove air connector and
17.Remove bracket mounting bolt (57a), and
electrical intake air heater (ribbon heater)
remove bracket (57b) of injection pipe #3 (61c).
assembly (46).
[*7]
a The engine block of electrical intake air 18.Remove seven bolts (58a), and remove intake
heater (ribbon heater) has a plate, and air connector (58).
take care not to drop it when handling.
16.Remove EGR valve assembly (47) in the

1) Disconnect wiring connectors (48), (49), and
(50).
2) Disconnect hydraulic hoses (51) and (52).
[*6]
50-42 D65EX,PX,WX-17
23.Remove the cylinder head cover according to

19.Disconnect three connectors (60) of injector the following procedure.
wiring (59).
20.Remove bolts (60a), and disconnect three 1) Disconnect hose clamps (63).
connectors (60b).[*8] 2) Loosen hose clamps (64a), (65a), and (66a),
and disconnect hoses (64), (65), and (66).
3) Disconnect wiring clamp (67).
5) Remove four mounting bolts (69a), and
disconnect the KCCV and bracket assembly
(69).
21.Remove fuel spray prevention cap (100).[*9]

22.Loosen sleeve nut (101), and remove six
injection pipes (61).[*10]
6) Disconnect hose (70).

7) Remove nuts (73), and remove tube bracket
(75).[*11]
8) Remove head cover mounting bolts (71),
(72), and (74).[*12]
Bolt (71): 19/32 in. (six bolts)
Bolt (72): 10 mm (one bolt)
Nut (73): 13 mm (one nut), above bracket
(75)
D65EX,PX,WX-17 50-43
Nut (74): 19/32" in. (one nut), below bracket

(75)
9) Remove cylinder head cover (62).
a Note the installed position and direction

(shapes of holes (a) and (b)) of each
crosshead.(To ensure the correct direction in
reinstallation)
24.Loosen two capture nuts (76) at the top of fuel
injector, and disconnect fuel injector harness
(77).
a Loosen the capture nuts alternately.
a The capture nuts cannot be removed from
the wiring harness.
a Installed positions of wiring harnesses
Cable color Cylinder No.
p Yel-
low You may install the
1,3,5
q Or- cables alternately.
ange
r 27.Remove retaining nut (82) and remove inlet
Red You may install the
2,4,6 connector (83).
s Bro- cables alternately.
wn a Before removing retaining nuts (82), remove
25.Loosen locknut (78), and loosen adjusting screw all dirt from the nuts and its periphery.
(79) by two or three turns.
a Pull out inlet connector (83) using tool A4
a This adjustment is required to avoid an (remover). (See the special tools table.)
excessive force to the push rod when
installing the rocker arm.
26.Remove mounting bolts (80) to remove rocker
arm and crosshead assembly (81).
28.Remove two mounting bolts (84) of the fuel

injection holder.
29.Using tool A3, remove fuel injection holder (85)
and fuel injector assembly (86) with together.
a Take care that dirt and foreign material do not
enter the amounting area of fuel injector
assembly (87).
50-44 D65EX,PX,WX-17
a Never hold the solenoid valve unit at the top If so, replace the inlet connector and fuel injector
of fuel injector with pliers, etc. assembly with a new one.
Installation
• Fuel injector assembly
a Check that the fuel injector mounting bore is free
from scratch and dirt.
a When replacing the fuel injector assembly with
new one, be sure to replace the inlet connector
with new one, too.
a Check the inlet connector visually. If it has any of
the following faults, replace it with a new one.
(a): The input or output port of inlet connector is
burred or deformed.
(b): If the edge filter is clogged or dirty or there is 1. Install gasket (87) and O-ring (88) on fuel
sediment in it, do not use the inlet connector. injector assembly (86).
(c): O-ring is cracked or deteriorated.
2 O-ring (88) and fuel injector mounting
(d): The sealing surface at output port side has bore:
an abrasion, poor contact, or trace of leakage.
Engine oil (EO15W-40)
a If high-pressure fuel leaks, the seating surface 2. Install fuel injector holder (86) to fuel injector
will erode and fine streaks or cracks will appear. assembly (85).
a Fit the convex (A) and concave (B) parts to
each other.
3. Install fuel injector assembly (86) into the
cylinder head with its fuel inlet hole facing the air
intake manifold.
4. Finger-tighten mounting bolts (85) of fuel injector
holder (84) three to four turns.
D65EX,PX,WX-17 50-45
5. Temporarily secure inlet connector (83) using

retaining nut (82).
2 O-ring of inlet connector (83) and the
mounting hole at cylinder head side:
Engine oil
3 Retaining nut (82):
15 ± 5.0 Nm {1.5 ± 0.5 kgm}
6. Tighten mounting bolts (85) of fuel injector

holder (84) alternately.
3 Fuel injector holder mounting bolts (84):
10 ± 2 Nm {1.0 ± 0.2 kgm}
a The top of fuel injector holder (85) must be in • Rocker arm and crosshead assembly
parallel with the top of cylinder head. a When reusing the crosshead, install it to the
Maximum allowance: 2.4 deg. same intake and exhaust valves in the same
7. Tighten inlet connector (83) using retaining nut direction because the shapes of its holes (a)
(82) to the specified torque. and (b) are different. (They can be in any
direction if new crossheads are used.)
2 Retainer (82) and shaded area (t) of
cylinder head in the following figure: a Check that two valves are inserted into holes
Caulking agent (GE TOSHIBA SILICON (a) and (b).
TOSSEAL 381)
50 ± 4 Nm {5.1 ± 0.4 kgm}
8. Install cross head (87) and rocker arm assembly

(88). Then, finger-tighten mounting bolts (80).
a Check that the ball of adjustment screw (79)
is fully inserted into the push rod socket.
a Check that the crosshead side cap of rocker
arm contacts the crosshead flatly.
a Clean the oil hole of mounting bolts (80), and
tighten the bolts.
50-46 D65EX,PX,WX-17
2 Mounting bolts (80) and seating surface:

Engine oil
9. Tighten mounting bolts (80) permanently.
3 Mounting bolts (80):
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
13.Adjust the valve clearance. For details, see

Testing and adjusting, "Adjusting valve
clearance".
3 Lock nut (78):
24 ± 4 Nm {2.45 ± 0.41 kgm}
14.Install fuel injector harness (77).
10.Remove cap (89) from the flywheel housing, and
install the engine cranking tool A1 (see the 3 Capture nut (76):
special tools table). 2 ± 0.25 Nm {0.2 ± 0.03 kgm}
a Referring to Testing and adjusting, "Adjusting a Tighten the capture nuts alternately.
valve clearance", check to see if the No. 1
cylinder is at the top dead center or the No. 6
the wiring harness.
cylinder is at the top dead center.
p Yel-
1,3,5
ange
r Red You may install the
Bro- cables alternately. 2,4,6
s
wn
11.Loosen and remove cap (127).

a Remove cap (127) using a filter wrench or
others.
(counterclockwise when viewed from the
flywheel side) to match the marking (M) on driver
gear (GY) to the marking "TDC". (See the
special tools table.)
and others.
clearance".
D65EX,PX,WX-17 50-47
• Perform subsequent installation in the reverse

a Install fuel injector harness terminal (77a) in
order to removal.
the direction in which the wiring harness
[*1]
does not interfere with rocker arm (88) when
it moves up and down. a Install the KDPF assembly and brackets. For
details, see "Removal and installation of KDPF
assembly".
[*2]
[*3]
a Install the clamp so that the clamp bolt is
positioned at 45 degrees from the top.
3 Air hose (42) mounting clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
a Insert air hose (40) until it stops at the tube
stopper, and install clamp (39) to the following
dimensions.
a Secure the clamp mounting bolts in the direction
as specified in the figure.
Clamp Portion Dimensions
L1 57 mm
39 L2 10 mm
L3 31 mm
a Install fuel injector harness (77) so that it
does not strongly hit to the inner wall of
rocker arm housing (90) or it does not run off
the guide (u) or bend.
a Be sure to maintain a minimum clearance (E)
of 3 mm between wiring harness (77) and
rocker arm housing (90).
a Be sure to maintain the minimum clearance
(F) of 3 mm between wiring harness (77) and
rocker arm (88).
50-48 D65EX,PX,WX-17
3 Connector mounting bolt (60a):

10 ± 2 Nm {1.02 ± 0.2 kgm}
[*7][*9][*10]
• Install the high-pressure fuel pipe and fuel
injection pipe according the following procedure.
k Do not try to correct the high-pressure fuel
pipe and fuel injection pipe by bending them.
k Be sure to use the genuine fuel high-

pressure pipe clamps and observe the
tightening torque.
3 Air hose (40) mounting clamp (39): k Install the high-pressure fuel pipe and the
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} wiring harness by separating them at least 10
[*5] mm from each other.
• Install air connector (46d) and electrical intake a If the taper seal portion of the high-pressure fuel
air heater (ribbon heater) (46c) assembly (46) pipe joint part has any of the following problems,
according to the following procedure. replace the high-pressure fuel pipe with a new
1. Install guide [1] into two upper bolt holes (portion one.
(A)).
2. Install gasket (46a), plate (46b), gasket (46a), 1. Visible scratches in longitudinal direction (b)
electrical intake air heater (ribbon heater) (46c), or patchy dents (c) in 2-mm range (a) from
gasket (64a), and air connector (46d) in this the end.
order to guide [1]. 2. Taper seal end (d) at 2 mm from the end has
3. Install two lower bolts (46e) and finger-tighten stepped-type wear which your nail can feel.
them.
4. Remove guide [1], and install remaining two
bolts (46e).
5. Tighten four bolts (46e) to the specified torque.
3 Air connector mounting bolts (52a):
24 ± 4 Nm {2.4 ± 0.4 kgm}
6. Install the wiring terminal in part (E) of electrical
intake air heater (ribbon heater) (46c).
(If the common rail assembly was removed or

loosened)
a Check that the inlet connectors are tightened to
the specified torque.
3 Retaining nut:
50 ± 4 Nm {5 ± 0.4 kgm}
1. Install common rail (102) by finger-tightening
three mounting bolts (103) and (104).
[*6]
3 Sleeve nut (51) of KVGT-to-EGR hose:
15 ± 1 Nm {1.53 ± 0.1 kgm}
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
[*8]
D65EX,PX,WX-17 50-49
2. Install high-pressure fuel assembly (115) 5. Tighten bracket mounting bolts (105) of high-
between the supply pump and common rail, and pressure fuel pipe and bracket mounting bolts
tighten the sleeve nuts on the supply pump and (57a), (106), and (108) of fuel injection pipe to
common rail sides to the specified torque . the specified torque.
3 Sleeve nut of high-pressure fuel pipe a Install bracket (109) of fuel injection pipe #2
(115): (61b) above high-pressure fuel pipe bracket
37 ± 4 Nm {3.7 ± 0.4 kgm} (110), and secure it by tightening bolts (107).
a Width across flats a Secure bracket (111) of fuel injection pipe #3

(61c) by tightening mounting bolts (57a) after
Supply pump side: 19 mm
installing air intake connector assembly
Common rail side: 22 mm (57a).
3 Bracket mounting bolts (57a), and (105)
to (108):
24 ± 4 Nm {2.4 ± 0.4 kgm}
3 Sandwich clamp mounting bolts of high-
pressure fuel pipe and fuel injection
pipe:
6 Nm {0.6 kgm}
3. Install fuel injection pipes (61a) to (61f) between

the common rail and inlet connector, and tighten
the sleeve nuts to the specified torque on the
common rail and inlet connector sides.
3 Sleeve nuts to install fuel injection pipes
(61a) and (61f):
37 ± 4 Nm {3.7 ± 0.4 kgm}
a Width across flats
Common rail side: 22 mm
Air inlet manifold side: 19 mm
4. Tighten two common rail mounting bolts (103)
and one bolt (104) to the specified torque.
50-50 D65EX,PX,WX-17
2. Install fuel injection pipes (61a) to (61f) between

the common rail and inlet connector, and tighten
the sleeve nuts to the specified torque on the
common rail side and inlet connector side.
(61a) and (61f):
37 ± 4 Nm {3.7 ± 0.4 kgm}
6. Install the fuel spray prevention cap at the both

ends of high-pressure fuel pipe.
a Install fuel spray prevention caps with its slit
downward at the fuel injector side, and in the
opposite direction of the cylinder block at the
common rail side.
a The fuel scatter prevention caps are installed
so that fuel does not spout over the hot parts
of the engine and catch fire when it leaks for
some reason.
3. Tighten bracket mounting bolts (57a) and (106)
(If the common rail is not loosened but the fuel
to (108) of the high-pressure fuel pipe and fuel
injection pipe alone is removed)
injection pipe to the specified torque.
a Check that the inlet connectors are tightened to
a Install bracket (109) of fuel injection pipe #2
the specified torque.
(61b) above high-pressure fuel pipe bracket
3 Retaining nut: (110), and secure it by tightening bolts (107).
50±4 Nm {5 ± 0.4 kgm} a Secure bracket (111) of fuel injection pipe #3
1. Loosen two mounting bolts (103) and one bolt (61c) by tightening mounting bolts (57a) after
(104) of common rail (102), and then finger- installing air intake connector assembly (58).
tighten them.
3 Bracket mounting bolts (57a), and (106)
to (108):
24 ± 4 Nm {2.4 ± 0.4 kgm}
3 Sandwich clamp mounting bolts of high-
pressure fuel pipe and fuel injection
pipe:
6 Nm {0.6 kgm}
D65EX,PX,WX-17 50-51
1) Clean the mounting area of relief valve

(PV) before installing it.
2) Check the relief valve (PV) and common
rail assembly (102) for any damage on
their high-pressure sealing surface.
3) Check the adapter (b) of relief valve (PV)
for damage.
a If you have removed the adapter (b),
install a new copper sealing washer
(c), apply new gear oil (#90), and
secure it.
3 Tightening torque:
37 ± 4 Nm {3.77 ± 0.41 kgm}
4) If the leakage through the fuel pressure
relief valve (PV) exceeds the specified
value, do not reuse that relief valve and
replace it with a new one.
5) Do not reuse the seal washer, and
replace it with a new one.
6) Install a new relief valve (PV) and a new
seal washer.
a Apply clean gear oil (#90) to the valve
threads.
7) Tighten the relief valve (PV) to the
specified torque below.
27 ± 4 Nm {2.75 ± 0.4 kgm}
8) After tightening the valve, retighten it to
the angle specified below.
3 Retightening angle:
90 ± 5deg.
9) Rotate the engine and check that no fuel
leaks.
a For the inspection procedure, see
"Testing and adjusting" in the Engine
Shop Manual.
ends of high-pressure fuel pipe.
a Install fuel spray prevention caps with its slit
downward at the fuel injector side, and in the
opposite direction of the cylinder block at the
common rail side.
a The fuel scatter prevention caps are installed
so that fuel does not spout over the hot parts
some reason.
• Do not remove the fuel pressure sensor
(FPS) from common rail (102).
(If you have removed it erroneously, replace
the sensor and common rail (102) as a unit.)
• If you have removed the relief valve (PV)
from common rail (102), install it according to
50-52 D65EX,PX,WX-17
[*11]
3 Clamps of KCCV hoses (64), (65), and (66):
2.9 – 3.4 Nm {0.3 – 0.35 kgm}
[*12]
3 Mounting bolt of cylinder head cover (63):
12 ± 2 Nm {1.2 ± 0.2 kgm}
circuit".
D65EX,PX,WX-17 50-53
Removal and installation of cylinder head assembly

a Special tools
Necessity
Sym-
Q'ty
bol
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

k Lower the work equipment to the ground, see "Removal and installation of engine hood
and stop the engine. assembly".
6. Remove lower side cover (2).
k If the radiator coolant temperature is high,

wait until it decreases and then drain the
coolant so that you will not be scalded.
Removal
2. Set the fuel valve under the fuel tank to the
CLOSE position.
7. Remove the KDPF assembly. For details, see

"Removal and installation of KDPF assembly".
8. Disconnect wiring connector (4) of the air
1) Disconnect wiring connector (4) of the air
2) Disconnect wiring (6), (7) and (8).
3) Disconnect wiring clamps (6a), (7a) and (7b).
3. Remove inspection cover (1a) from the engine

undercover.
4. Drain the coolant from the radiator.
6 Radiator:
54 l
4) Disconnect clamps (8a) and (9a) of VGT air

bleeding hoses (8) and (9).
5) Disconnect VGT air bleeding hoses (8) and
(9) from tubes fixed behind bracket (3).
6) Remove mounting bolts (11a) of the air tube
bracket.
50-54 D65EX,PX,WX-17
7) Disconnect wiring clamps (10) and (11). 3) Remove 3 bracket mounting bolts(23).
8) Remove clamp (13) of KDPF water drain
a Each bolt has a collar, and take care not
tube (12).
to drop the collar when removing the bolt.
9) Sling bracket (3), and remove eight mounting
4) Remove seven mounting bolts (24), then
bolts (14).
sling and remove bracket (18).
10)Sling and remove bracket (3).
4 Bracket:
25 kg
13.Disconnect air conditioner compressor (25)

according to the following procedure. [*2]
1) Disconnect two air conditioner hoses (26).
2) Loosen air conditioner compressor mounting
bolts (27).
3) Loosen drive belt adjustment bolt (28) and
remove belt (29).
9. Remove exhaust pipe clamp (15).

10.Sling exhaust pipe (16) and remove exhaust
pipe mounting bolts (17).
11.Sling and remove exhaust pipe (15).
4) Remove bracket mounting bolts (30), and
remove air conditioner compressor (25) and
bracket (31) as a unit.
12.Remove bracket (18) according to the following

procedure.
1) Loosen clamp (22) of air tube (21). 14.Remove clamp (34) from bracket (33).
2) Remove two mounting bolts (20) of bracket 15.Remove one bracket mounting bolt (32a) (on air
(19). Leave bracket (19) fixed in the outside conditioner compressor side) and two mounting
position.
D65EX,PX,WX-17 50-55
bolts (32) (on engine block side). Then, remove

bracket (33).
18.Remove EGR valve assembly (47) according to

1) Disconnect wiring connectors (48), (49), and
(50).
2) Disconnect hydraulic hoses (51) and (52).
[*6]
3) Disconnect hydraulic tubes (53) and (54).
4) Remove nut (55a), and remove wiring
bracket (55).
5) Remove mounting bolts (56a) and (56b), and
remove EGR valve assembly (56).
16.Remove air hose and tube assembly (44)

2) Remove tube mounting bolts (43) and
disconnect the tube from air connector .
3) Loosen hose clamp (42), and remove air
hose and tube assembly (44). [*3]
17.Remove air connector and electrical intake air
heater (ribbon heater) assembly (46) according
3) Remove clamp (38) of tube (37).
4) Loosen hose clamp (39), and disconnect air
hose (40). [*4]
5) Disconnect electric intake air heater (ribbon
heater) wiring (35). [*5]
6) Remove four air connector mounting bolts,
and remove electrical intake air heater
(ribbon heater) assembly (46).
a The electrica intake air heater (ribbon
heater) has a plate on its engine block
side, so take care not to drop it when 19.Remove bracket mounting bolt (57a), and
removing the heater. remove bracket (57b) of injection pipe #3 (61c).
[*7]
20.Remove seven bolts (58a), and remove intake
air connector (58).
50-56 D65EX,PX,WX-17
25.Remove the KCCV and bracket assembly

21.Disconnect three connectors (60) of injector iaccording tothe following procedure.
wiring (59). 1) Disconnect hose clamps (63).
22.Remove bolts (60a), and disconnect three 2) Loosen hose clamps (64a), (65a), and (66a),
connectors (60b). [*8] and disconnect hoses (64), (65), and (66).
3) Disconnect wiring clamp (67).
5) Remove four mounting bolts (69a), and
disconnect KCCV and bracket assembly
(69).
23.Remove fuel spray prevention cap (100). [*9]

24.Loosen sleeve nut (101), and remove six
injection pipes (61). [*10]
D65EX,PX,WX-17 50-57
26.Remove KVGT assembly (80a) according to the 7) Remove four mounting nuts (80). [*16]
following procedure. 8) Sling and remove KVGT assembly (80a).
1) Loosen three wiring hose clamps (70), and
remove hose (71) and tube (72) as a unit. 4 KVGT assembly:
[*11] 30 kg
2) Remove covers (73) and (74).
3) Disconnect cooling hoses (75) and (76).

[*12]
4) Disconnect hose (77). [*13]
5) Disconnect lubricating oil inlet tube (78).
[*14]
6) Disconnect lubricating oil outlet hose (79).
[*15]
27.Remove bracket assembly (81) according to the

1) Remove two bolts (82), and remove clamp
bracket (83) and wirings as a unit.
2) Disconnect hoses (84) and (85).
3) Remove two bolts (86), and remove bracket
assembly (81).
50-58 D65EX,PX,WX-17
28.Disconnect sensor wiring connector (90). 33.Remove cylinder head cover (135) according to
29.Remove bolts (87), and remove bracket (93). the following procedure.
30.Remove tube (88) and bracket (89) as a unit. 1) Disconnect hose (136).
31.Disconnect radiator hose (91) and heater hose 2) Remove nuts (133), and remove tube
(92). bracket (134). [*18]
3) Remove head cover mounting bolts (130),
(131), and (132). [*19]
Bolt (130): 19/32 in. (six bolts)
Bolt (131): 10 mm (one bolt)
Nut (132): 13 mm long (one nut), above
bracket (134)
Nut (133): 19/32" in. (one nut), below bracket
(134)
4) Remove head cover (135).
32.Remove exhaust manifold (94) according to the

1) Remove oil splash prevention cover (95).
2) Remove two mounting bolts (97) of the
exhaust manifold, fixing it to EGR assembly
(96).
34.Loosen two capture nuts (106) at the top of fuel

injector, and disconnect fuel injector harness
(107).
a Loosen the capture nuts alternately.
the wiring harness.
3) Remove 12 mounting bolts (98), and sling p Yel-
and remove exhaust manifold (94). [*17] low You may install the
1,3,5
ange
s
wn
D65EX,PX,WX-17 50-59
35.Loosen locknut (108), and loosen adjustment a Tool A4 (remover) is available for removal of
screw (109) two or three turns. inlet connector (113). (See the special tools
table.)
a This adjustment is required to avoid an
excessive force to the push rod when
installing the rocker arm.
36.Remove mounting bolts (110), and remove
rocker arm (124) and crosshead (125).
38.Remove two mounting bolts (114) of the fuel

injector holder.
39.Using tool A3, remove fuel injector holder (115)
and fuel injector assembly (116) as a unit.
a Take care that dirt and foreign material do not
enter the installed position of fuel injector
assembly (116).
a Never hold the solenoid valve unit at the top
of fuel injector with pliers, etc.
a Note the installed position and direction

(focus on hole shapes (a) and (b)) of each
crosshead. (They must be reinstalled in the
same direction.)
40.Remove push rod (117).

41.Remove spacer (118).
42.Remove them from other cylinders in the similar
way.
43.Remove rocker arm housing (119).
37.Remove retaining nut (112) and remove inlet

connector (113).
a Before removing retaining nuts (112), remove
all dirt from the nuts and its periphery.
50-60 D65EX,PX,WX-17
44.Remove 26 cylinder head mounting bolts, and

remove cylinder head assembly (120).
45.Remove cylinder head gasket (121).
3. Check the cylinder head mounting bolts for the

followings. If any defect is found, do not reuse
but replace them with new ones.
• The number of bolt tightening reaches to 6
Installation times (the five punches showing the number
• Cylinder head assembly of tightening times are found).
• Bolt stem length (a): Min. 162.6 mm
a Check that the cylinder head mounting face
and inside of the cylinders are free from
foreign matter.
1. Set cylinder head gasket (121) to the cylinder
block.
a Match the holes of cylinder head gasket
(121) to the cylinder block holes.
a When installing the cylinder head gasket,
take care not to peel off or drop the
grommets.
4. Tighten the cylinder head mounting bolts

1) Install the cylinder head mounting bolts, and
finger-tighten them in the order of [1] to [26].
2 Cylinder head mounting bolt:
2) Tighten the cylinder head mounting bolts in
the following sequence.
1] 50 ± 7 Nm {5.0 ± 0.7 kgm}
2. Sling cylinder head assembly (120) and set it to 2] 150 ± 10 Nm {15.3 ± 1.0 kgm}
cylinder block. 3] Loosen all bolts for 360 ° .
4] 115 ± 5 Nm {11.7 ± 0.5 kgm}
4 Cylinder head assembly (120): 5] Check that the they are tightened to 115 ±
5 Nm {11.7 ± 0.5 kgm}.
85 kg
6] Retightening 120 ± 5 ° .
a Tap the valve stem lightly with a plastic
a Tool A7 is available for angle
hammer to check that the half collet fits in the
tightening. (See the special tools
groove of valve stem.
table.)
a Check that the holes of cylinder head gasket
(121) match the cylinder block holes.
D65EX,PX,WX-17 50-61
• If tool A7 is not used:

1) Mark the cylinder head and mounting
bolts using a paint. (See the following
figure.)
2) Retighten the cylinder head mounting
bolts by 120 ± 5 deg.
a When installing a new mounting bolt, do not
put a punch mark.
• Fuel injector assembly

a Check that the fuel injector mounting bore is
free from scratch and dirt.
a When replacing the fuel injector assembly
with a new one, be sure to replace the inlet
connector with a new one, too.
a Check the inlet connector visually. If it has
any of the following faults, replace it with a
• Rocker housing assembly
new one.
5. Install push rod (117).
(a): The inlet or outlet of the inlet connector is
a Check that the push rod is in the tappet. burred or deformed.
2 Push rod socket: (b): If the edge filter is clogged or dirty or
Engine oil (EO15W-40) there is sediment in it, do not use the inlet
6. Install the gasket, and install rocker arm housing connector.
(119). (c): O-ring is cracked or deteriorated.
7. Tighten the rocker arm housing mounting bolts (d): The sealing surface at its outlet shows
in the order of [1] to [7] as shown below. wear, poor contact, or trace of leakage.
3 Rocker arm housing mounting bolt: a If high-pressure fuel leaks, the sealing
24 ± 4 Nm {2.4 ± 0.4 kgm} surface erodes and fine streaks or cracks
8. Install spacer (118). appear. If so, replace the inlet connector and
fuel injector assembly with a new one.
50-62 D65EX,PX,WX-17
2 O-ring of inlet connector (113) and

mounting hole in cylinder head:
Engine oil
15 ± 5.0 Nm {1.5 ± 0.5 kgm}
14.Tighten mounting bolts (114) of fuel injector

holder (115) alternately.
3 Fuel injector holder mounting bolts (114):
10 ± 2 Nm {1.0 ± 0.2 kgm}
a The top of fuel injector holder (115) must be
in parallel with the top of cylinder head.
9. Install gasket (122) and O-ring (123) to fuel Maximum allowance: 2.4 deg.
injector assembly (116). 15.Tighten inlet connector (113) using retaining nut
2 O-ring (123) and fuel injector mounting (112) to the specified torque.
bore: 2 Retaining nut (112) and shaded area (t)
Engine oil of cylinder head:
10.Install fuel injector holder (115) to fuel injector Caulking agent (GE TOSHIBA SILICON
assembly (116). TOSSEAL 381 or equivalent)
a Fit the convex (A) and concave (B) parts to 3 Retaining nut (112):
each other.
51 ± 4 Nm {5.1 ± 0.4 kgm}
11.Insert fuel injector assembly (116) into the
cylinder head with its fuel inlet hole facing the air
intake manifold.
12.Finger-tighten the mounting bolts (114) of fuel
injector holder (115) three or four turns.
13.Temporarily install inlet connector (113) using

retaining nut (112).
D65EX,PX,WX-17 50-63
a Clean the oil hole of mounting bolts (110),

and tighten the bolts.
2 Mounting bolts (110) and seating
surface:
Engine oil
17.Tighten mounting bolts (110) to the specified
torque.
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
18.Remove cap (126) from the flywheel housing,

and install engine barring tool A1 (see the
special tools table).
• Rocker arm and crosshead assembly
a Referring to Testing and adjusting, "Adjusting
a When reusing the crosshead, install it for the
valve clearance", check to see either of the
same intake and exhaust valves in the same
No. 1 cylinder and is No. 6 cylinder is at the
direction because the shapes of its holes (a)
top dead center.
and (b) are different with each other. (They
can be installed in any direction if new
crossheads are used.)
a Check that two valves are fitted in holes (a)
and (b).
19.Loosen and remove cap (127).

a Use a filter wrench or the like to remove cap
(127).
(or counterclockwise when viewed from the
16.Install crosshead (125) and rocker arm
flywheel side) to locate the marking (M) of drive
assembly (124), and then finger-tighten
gear (GY) to the TDC (top) position. (See the
mounting bolts (110).
special tools table.)
a Check that the ball of adjustment screw (109)
is fully fitted in the push rod socket.
and others.
a Check that the the crosshead side cap of
rocker arm contacts with the crosshead flatly.
clearance".
50-64 D65EX,PX,WX-17
21.Adjust the valve clearance. For details, see

a Install fuel injector harness terminal (128) in
Testing and adjusting, "Adjusting valve
the direction in which the wiring harness
clearance".
does not interfere with rocker arm (125)
3 Lock nut (108): when it moves up and down.
24 ± 4 Nm {2.45 ± 0.41 kgm}
22.Install fuel injector harness (107).
3 Capture nut (106):
2 ± 0.25 Nm {0.2 ± 0.03 kgm}
a Tighten the capture nuts alternately.
the wiring harness.
p Yel-
1,3,5
ange
s
wn
a Install fuel injector harness (107) so that it

does not strongly hit to the inner wall of
rocker arm housing (119) or it does not run
off the guide (u) or bend.
a Be sure to maintain a minimum clearance (E)
of 3 mm between wiring harness (107) and
rocker arm housing (119).
a Be sure to maintain the minimum clearance
(F) of 3 mm between wiring harness (107)
and rocker arm (124).
D65EX,PX,WX-17 50-65
• Perform subsequent instration in the reverse 3 Air hose (40) mounting clamp (39):
order to removal. 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*1]
[*5]
a Install the KDPF assembly and brackets. For • Install the air connector and electrical intake air
details, see "Removal and installation of KDPF heater (ribbon heater) (46) according to the
assembly". following procedure.
[*2] 1. Install guide [1] into two upper bolt holes (portion
(A)).
2. Install gasket (46a), plate (46b), gasket (46a),
electrical intake air heater (ribbon heater) (46c),
gasket (64a), and air connector (64d) in this
order to guide [1].
[*3] 3. Install two lower bolts (46e) and finger-tighten
a Install the clamp so that clamp bolt is positioned them.
at 45 degrees from the top. 4. Remove guide [1], and install remaining two
bolts (46e).
3 Air hose (42) mounting clamp: 5. Tighten four bolts (46e) to the specified torque.
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
3 Air connector mounting bolt (46e):
[*4]
24 ± 4 Nm {2.4 ± 0.4 kgm}
a Insert air hose (40) until it stops at the tube 6. Install the wiring terminal to part (E) of electrical
stopper, and mount clamp (39) to the following intake air heater (ribbon heater) (46c).
dimensions.
a Install the clamp bolts in the direction as
specified in the figure.
L1 57 mm
39 L2 10 mm
L3 31 mm
[*6]
15 ± 1 Nm {1.53 ± 0.1 kgm}
25 ± 1 Nm {2.55 ± 0.1 kgm}
[*8]
50-66 D65EX,PX,WX-17
3 Connector mounting bolt (60a):

10 ± 2 Nm {1.02 ± 0.2 kgm}
[*7][*9][*10]
• Install the high-pressure fuel pipe and fuel
injection pipe according to the following
procedure.
k Do not try to correct the high-pressure fuel
pipe and fuel injection pipe by bending them.
k Be sure to use the genuine fuel high-

pressure pipe clamps and observe the
tightening torque. 2. Install high-pressure fuel pipe assembly (155)
between the supply pump and common rail
k Install the high-pressure fuel pipe and the assembly, and tighten the sleeve nuts on the
wiring harness by separating them at least 10 supply pump and common rail sides to the
mm from each other. specified torque.
a If the taper seal portion of the high-pressure fuel 3 Sleeve nut of high-pressure fuel pipe
pipe joint part has any of the following problems, (155):
replace the high-pressure fuel pipe with a new 37 ± 4 Nm {3.7 ± 0.4 kgm}
one.
a Supply pump side (width across flats): 19
1. Visible scratches in longitudinal direction (b) mm
or patchy dents (c) in 2-mm range (a) from
the end. Common rail side: 22 mm
2. Taper seal end (d) at 2 mm from the end has
stepped-type wear which your nail can feel.
3. Install fuel injection pipes (61a) and (61f)

between the common rail and inlet connectors,
and tighten the sleeve nuts on the common rail
(If the common rail assembly was removed or and inlet connector sides to the specified torque.
loosened)
3 Sleeve nut to mount fuel injection pipes
a Check that the inlet connectors are tightened to (61a) and (61f):
the specified torque. 37 ± 4 Nm {3.7 ± 0.4 kgm}
3 Retaining nut: a Width across flats
50 ± 4 Nm {5 ± 0.4 kgm} Common rail side: 22 mm
1. Install common rail assembly (142) and finger- Air inlet manifold side: 19 mm
tighten three mounting bolts (143) and (144). 4. Tighten two common rail mounting bolts (143)
and one bolt (144) to the specified torque.
D65EX,PX,WX-17 50-67
5. Tighten bracket mounting bolts (145) of high-

pressure fuel pipe and bracket mounting bolts 6. Install the fuel spray prevention cap at the both
(57a), and (146) to (148) of fuel injection pipe to ends of high-pressure fuel pipe.
the specified torque. a Install fuel spray prevention caps with its slit
a Install bracket (149) of fuel injection pipe #2 downward at the fuel injector side and in the
(61b) above high-pressure fuel pipe bracket opposite direction of the cylinder block at the
(140), and secure it by tightening bolts (137). common rail side.
a Secure bracket (151) of fuel injection pipe #3 a The fuel scatter prevention caps are installed
(61c) by tightening mounting bolts (57a) after so that fuel does not spout over the hot parts
installing air intake connector assembly (58). of the engine and catch fire when it leaks for
some reason.
3 Bracket mounting bolts (57a), (145) and (If the common rail is not loosened but the fuel
(148): injection pipe alone is removed)
24 ± 4 Nm {2.4 ± 0.4 kgm} a Check that the inlet connectors are tighened to
3 Sandwich clamp mounting bolts of high- the specified torque.
pressure fuel pipe and fuel injection 3 Retaining nut:
pipe:
50 ± 4 Nm {5 ± 0.4 kgm}
6 Nm {0.6 kgm}
1. Loosen two mounting bolts (143) and one bolt
(144) of common rail (142), and then finger-
tighten them.
2. Install fuel injection pipes (61a) and (61f)

between the common rail and inlet connectors,
and tighten the sleeve nuts on the common rail
and inlet connector sides to the specified torque.
(61a) and (61f):
37 ± 4 Nm {3.7 ± 0.4 kgm}
50-68 D65EX,PX,WX-17

3. Tighten bracket mounting bolts (57a), (146) to

(148) of high-pressure fuel pipe and fuel
injection pipe to the specified torque.
a Install bracket (149) of fuel injection pipe #2
(61b) above high-pressure fuel pipe bracket
(150), and secure it by tightening bolts (147).
a Secure bracket (151) of fuel injection pipe #3
(61c) by tightening mounting bolts (57a) after
installing air intake connector assembly (58).
3 Bracket mounting bolts (57a), (146) and ends of high-pressure fuel pipe.
(148):
a nstall fuel spray prevention caps with its slit
24 ± 4 Nm {2.4 ± 0.4 kgm} downward at the fuel injector side, and in the
3 Sandwich clamp mounting bolts of high- opposite direction of the cylinder block at the
pressure fuel pipe and fuel injection common rail side.
pipe: a The fuel scatter prevention caps are installed
6 Nm {0.6 kgm} so that fuel does not spout over the hot parts
some reason.
• Do not remove the fuel pressure sensor (FP)
from common rail (142).
(If you have removed it erroneously, replace
the sensor and common rail as a unit.)
• If you have removed the relief valve (PV) and
common rail (142), install them according to
1) Clean the mounting area of relief valve (PV)
before installing it.
2) Check the relief valve (PV) and common rail
(142) for any damage on their high-pressure
sealing surfaces.
3) Check the adapter (b) of relief valve (PV) for
damage.
a If you have removed the adapter (b),
install a new copper sealing washer (c),
apply new gear oil (#90), and secure it.
37 ± 4 Nm {3.77 ± 0.41 kgm}
D65EX,PX,WX-17 50-69
4) If the leakage through the fuel pressure relief Clamp Portion Dimensions
valve (PV) exceeds the specified value, do 71a L4 33.4 mm
not reuse that relief valve and replace it with L1 60 mm
a new one. 72a L2 10 mm
5) Do not reuse the seal washer, and replace it L3 31 mm
with a new one.
6) Install a new relief valve (PV) and a new seal
washer.
a Apply clean gear oil (#90) to the valve
threads.
7) Tighten the relief valve (PV) to the specified
torque below.
27 ± 4 Nm {2.75 ± 0.4 kgm}
8) After tightening the valve, retighten it to the
angle specified below.
3 Retightening angle:
90 ± 5deg.
9) Start the engine and check that no fuel leaks.
a For the inspection procedure, see
"Testing and adjusting" in the Engine
Shop Manual.
[*12]
3 Joint bolts of hoses (75) and (76) at KVGT
side:
40 ± 4 Nm {4.08 ± 0.41 kgm}
3 Sleeve nuts to install hose (76):
[*11]
36 ± 4 Nm {3.67 ± 0.41 kgm}
a Connect hose and tube assemblies (71) and
[*13]
(72) to the following dimensios.
3 Sleeve nuts to install hose (77):
a Match the marking (Mh) on hose (72b) to the
marking (MC) on tube (72). 36 ± 4 Nm {3.67 ± 0.41 kgm}
[*14]
50-70 D65EX,PX,WX-17
3 Joint bolt of lubrication inlet tube (78):

40 ± 5 Nm {4.08 ± 0.51 kgm}
[*15]
3 Mounting bolts of lubricating oil outlet tube
(79):
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*16]
3 KVGT assembly mounting bolts:
52 ± 6 Nm {5.61 ± 0.61 kgm}
[*17]
• Secure mounting bolts (98) of KVGT exhaust
manifold assembly according to the following
procedure.
1. Tighten all bots in the order of [1] to [12]
shown below.
3 53 ± 5 Nm {5.4 ± 0.5 kgm}
2. Retighten only bolts [1] to [4] shown in the
figure.
3 53 ± 5 Nm {5.4 ± 0.5 kgm}
[*18][*19]
3 Cylinder head cover mounting bolts (130) to
(133):
12 ± 2 Nm {1.2 ± 0.2 kgm}
• Refilling of coolant (radiator)
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant, and then check the coolant level again.
5 Radiator:
54 l
(For details, see "List of lubricant and
water")
circuit".
D65EX,PX,WX-17 50-71
Removal and installation of radiator assembly




Removal 5. Disconnect wiring connectors (3), (4), and (5).

(Left radiator)
assembly".
2. Sling engine undercover (1) with the sling,
remove the bolts, and remove the undercover.
a For the hinged undercover (optional), remove
the mounting bolt on the left side and sling
the undercover.
4 Engine undercover (1):

130 kg
6. Remove bracket with sponge rubber (7).
6 Radiator: 7. Disconnect upper hoses (8), (9), and (10). [*1]
54 l
8. Remove lower hose (11). [*2]

4. Remove bracket (2).
50-72 D65EX,PX,WX-17
9. Remove lower hose (12). [*3] a For the installed position of the hose, see the
following figure.
• Radiator connection hoses (10) and (11)
10.Remove bolts (13) and (13a), and remove

bracket (13b) from the radiator. [*4]
• Radiator lower outlet hose (12)
11.Sling and remove left radiator assembly (14).

[*5]
[*4]
4 Left radiator assembly: 3 Radiator mounting bolts (13a):
30 kg 29.4–44.1 Nm {3.0–4.5 kgm}
[*5]
Installation
• Carry out installation in the reverse order to
removal.
[*1][*2][*3]
3 Mounting clamp of radiator hoses (10), (11)
and (12):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
D65EX,PX,WX-17 50-73
a Check that projection (a) at the bottom of 2. Sling engine undercover (1) with the sling,
radiator is securely fitted in mounting hole (b). remove the bolts, and remove the undercover.
the mounting bolt at one side and sling the
undercover.

130 kg
6 Radiator:
54 l
a The clearance between the bottom of radiator

(14a) and rubber cushion (LC) (l) must be 2.5
mm.

6. Disconnect upper hoses (4), (5), and (6). [*1]

5 Radiator:
54 l
Removal
(Right radiator)
1. Remove the engine hood assembly. For details, 7. Remove lower hose (7). [*2]
assembly".
50-74 D65EX,PX,WX-17
a For the installed position of the hose, see the

following figure.
• Radiator connection hoses (5) and (7)
8. Remove mounting bolts (8) and (9), and remove

bracket (10). [*3]
• Radiator upper inlet hose (6)
9. Sling and remove right radiator assembly (11).

[*4]
4 Right radiator assembly:

15 kg [*3]
3 Radiator mounting bolt (8):
29.4–44.1 Nm {3.0–4.5 kgm}
[*4]
Installation
removal.
[*1][*2]
3 Mounting clamp of radiator hoses (5), (6)
and (7):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
D65EX,PX,WX-17 50-75
a Check that projection (a) at the bottom of

radiator is securely fitted in mounting hole (b).
a The clearance between the bottom of radiator

(14a) and rubber cushion (LC) (l) must be 2.5
mm.

5 Radiator:
54 l
50-76 D65EX,PX,WX-17
Removal and installation of aftercooler and assembly



Removal
assembly". 6. Disconnect lower hose (4a). [*2]
2. Sling engine undercover (1) with the sling, and
remove the bolts to remove the undercover.
the mounting bolts on the left side and sling
the undercover.

130 kg
7. Remove mounting bolts (5) and (6), and remove

aftercooler mounting bracket (7). [*3]
8. Sling and remove aftercooler assembly (8). [*4]
4 Aftercooler assembly (6):

15 kg

5. Disconnect upper hose (4). [*1]
D65EX,PX,WX-17 50-77
[*3]
Installation
3 Aftercooler mounting bolt (5):
removal. 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*1] [*4]
3 Mounting clamp of aftercooler inlet air hose a Check that projection (b) at the bottom of the
(4): aftercooler is fitted in mounting hole (c) securely.
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
following figure.
(Aftercooler inlet side)
[*2]
3 Mounting clamp of aftercooler outlet air hose
(4a):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
a Install the hose with white mark (a) at its end up.
following figure.
(Aftercooler outlet side)
50-78 D65EX,PX,WX-17
a Clearance (l) between the lower part of the

aftercooler and rubber must be l: 2.5 (+0.5/-0)
mm.
D65EX,PX,WX-17 50-79
Removal and installation of hydraulic oil cooler assembly

k Place the machine on a level ground and 6. Disconnect air hose (3) and radiator hoses (4)
apply the parking brake. and (5). [*1]
k Lower the work equipment to the ground and

stop the engine. Loosen the oil filler cap of
the hydraulic tank slowly to release the
pressure in the hydraulic tank.


Removal 7. Disconnect lower hydraulic hose (6).

1. Remove inspection cover (1) from the engine
undercover.
6 Radiator:
54 l
8. Remove upper connection hose (7)
3. Remove cover (2) under the hydraulic tank.

4. Drain the hydraulic oil from the hydraulic tank.
6 Hydraulic tank:
55 l
9. Remove mounting bolts (8) and remove

hydraulic oil cooler assembly (9).

assembly".
50-80 D65EX,PX,WX-17

Supply the coolant through the coolant filler port
to the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again.
5 Radiator (engine coolant):

54 l
• Refilling of 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.
Installation 5 Hydraulic tank (Hydraulic oil):
• Carry out installation in the reverse order to 55 l
removal.
[*1]
3 Mounting clamp of aftercooler inlet air hose
(3):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
following figure.
(Aftercooler inlet side)
[*2]
3 Mounting clamp of radiator hose (5):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
following figure.
• Radiator connection hose (5)
D65EX,PX,WX-17 50-81
Removal and installation of power train oil cooler assembly




coolant so that you will not be scalded. 5. Disconnect hose clamps (4) and (5).
Removal
1. Sling engine undercover (1) with the sling, and
remove the bolts to remove the undercover.
the mounting bolts on the left side and sling
the undercover.

130 kg
6 Radiator: 6. Disconnect hydraulic hoses (6) and (7).

54 l
7. Disconnect power train oil cooler inlet hose (8).

3. Remove cover (2) under the hydraulic tank. [*1]
4. Drain the hydraulic oil from the hydraulic tank. 8. Disconnect power train oil cooler outlet hose
(8a). [*2]
6 Hydraulic tank:
55 l
50-82 D65EX,PX,WX-17
a Install them referring to the following figure.

5 Radiator (coolant):
54 l
water")
9. Sling power train oil cooler assembly (9) and • Refilling of oil (Hydraulic tank)
remove mounting bolts (106). Add oil through the oil filler to the specified level.
10.Sling and remove power train oil cooler Run the engine to circulate the oil through the
assembly (9). system. Then, check the oil level again.
a Take care not to damage the peripheral
hoses and piping. 5 Hydraulic tank (Hydraulic oil):
55 l
4 Power train oil cooler assembly (9): (For details, see "List of lubricant and
100 kg water")
• Refilling (Power train case)
5 Power train case (power train oil):

Refilling only (For details, see "Table of
fuel, coolant and lubricants")
Installation
removal.
[*1][*2]
3 Mounting clamps of power train oil cooler
inlet hose (8) and outlet hose (8a):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
D65EX,PX,WX-17 50-83
Removal and installation of cooling fan drive assembly

k Place the machine on a level ground and a Plug the hoses and adapters to prevent the
apply the parking brake. oil from flowing out.
8. Remove cooling fan guard (9).

Removal
6 Hydraulic tank:
55 l 9. Sling the cooling fan drive assembly.
10.Remove two upper mounting bolts (10) and two
lower mounting bolts (11).
3. Remove the mounting bolts, and sling and

remove radiator grille (2).
11.Sling and remove cooling fan drive assembly
4 Radiator grille (2): (12).
40 kg
a Remove cooling fan drive assembly (12)
without interfering to the surrounding
components.
4 Cooling fan drive assembly (12):

50 kg
5. Remove two wiring harness clamps (4).

6. Disconnect wiring harness connectors CN-FAR
(5) and CN-FRS (5a).
7. Disconnect hydraulic tube (6) and hydraulic
hoses (7) and (8).
50-84 D65EX,PX,WX-17
Installation
removal.
• Refilling with oil (hydraulic tank)
Add oil through oil filler port to the specified level.
system. Then check the oil level again.
5 Hydraulic tank:
55 l
water")
D65EX,PX,WX-17 50-85
Removal and installation of cooling fan motor assembly



Removal
1. Remove cover (1b) under the hydraulic tank. 6. Using puller [1], remove fan (4) from the fan
2. Drain the hydraulic oil from the hydraulic tank. motor shaft.
7. Remove nuts (3) mentioned above, and remove
6 Hydraulic tank: fan (4).
55 l
8. Remove four mounting bolts, and remove fan

3. Remove the cooling fan drive assembly. For motor assembly (5). [*3]
details, see "Removal and installation of cooling
fan drive assembly".
4. Remove mounting bolts (1), and remove lock
plate (2). [*1]
Installation
removal.
5. Loosen nuts (3). [*2] [*1][*2]
a Leave nuts (3) tightened two or three turns. 3 Mounting nut (3):
132–157 Nm {13.5–16.0 kgm}
50-86 D65EX,PX,WX-17
a Install lock plate (2) according to the following

procedure.
1. Perform positioning of the mounting bolt hole
using both front and rear sides of lock plate
(2).
2. Select a plate side that requires less
adjustment, and tighten nuts (3) until the hole
positions match.
3. Tighten mounting bolts (1).
Adhesive (LT-2)
[*3]
a Wipe off the dirt and oils from the fitting part of
fan motor shaft and fan boss.
5 Hydraulic tank (Hydraulic oil):

55 l
water")
D65EX,PX,WX-17 50-87
Removal and installation of engine assembly

k Place the machine on a level ground and 4 Engine undercover (1a):
130 kg
k Lower the work equipment to the ground, 5. Drain the coolant from the radiator.
6 Radiator:
k Turn the battery disconnect switch to the 54 l

k If the refrigerant (air conditioner gas: R134a)

gets in your eyes, you may lose your sight.
Also, if your skin is exposed to the gas, you
may suffer from frostbite. Always wear safety
goggles, globes, and working suits with long
sleeves when collecting the refrigerant or
charging the air conditioner with the
refrigerant. 6. Remove the engine hood assembly. For details,
a Never release the refrigerant (R134a) to the assembly".
atmosphere. 7. Remove the radiator assembly. For details, see
"Removal and installation of radiator assembly".
a Ask a qualified person for collection, and charge
8. Remove the aftercooler assembly. For details,
of the refrigerant (R134a).
see "Removal and installation of aftercooler
a Note connector numbers and installed positions assembly".
before disconnecting wiring and hoses. 9. Remove the power train oil cooler assembly. For
details, see "Removal and installation of power
Removal train oil cooler assembly".
1. Collect the air conditioner refrigerant (R134a) 10.Remove the KDPF assembly. For details, see
from the air conditioner circuit. "Removal and installation of KDPF assembly".
11.Remove the KCCV assembly. For details, see
a Refrigerant to be collected: 900 ± 50 g
"Removal and installation of cylinder head
assembly".
CLOSE position. a To prevent the assembly from being
damaged by interference with the engine
assembly when lift the engine assembly.
12.Remove right and left lower side covers (2).
4. Sling engine undercover (1a) using the sling,

and then remove the mounting bolts to remove
the cover.
13.Disconnect fuel hose (3a).
14.Remove two mounting bolts (3b), and remove
the mounting bolt on the left side and sling
fuel pre-filter assembly (3).
the undercover.
50-88 D65EX,PX,WX-17
15.Remove hydraulic oil cooler assembly (4), air 5) Sling and remove hydraulic oil cooler
conditioner assembly (5), and bracket (6) as a assembly (4), air conditioner assembly (5),
unit according to the following procedure. and bracket (6) as a unit.
1) Disconnect all of hose clamp (6a) and wiring
clamp (6b) from bracket (6).
2) Disconnect hydraulic oil hoses (4a) and (4b)
from hydraulic oil cooler assembly (4).
16.Disconnect heater hoses (7) and (8).
3) Disconnect air conditioner hoses (5a) and

(5b) from air conditioner assembly (5). [*1]
17.Remove air conditioner compressor (11)

according to the following procedure. [*2]
1) Disconnect wiring connectors AC (12), AGS
(13), and ground GND09 (14).
2) Disconnect wiring clamps (12a) and (13a).
(6).
D65EX,PX,WX-17 50-89
a Disconnect the wiring clamp from the engine.
3) Loosen four air-conditioner compressor

mounting bolts (16) and drive belt tension
20.Disconnect air conditioner hose clamp (26).
adjusting nut (16a), and remove drive belt
21.Remove air hose mounting bolts (27a) of
(17).
bracket (27), and disconnect bracket (27) from
air hose (28).
22.Remove two mounting bolts (29a) of bracket
(29). Then, disconnect receiver (30) and bracket
(29) as a unit from the machine.
a Reposition the receiver close to the machine.
23.Remove air hose (28). [*3]

(18). Then, remove air conditioner
compressor assembly (11) and bracket (18)
as a unit from the engine.
a Secure the separated air conditioner
compressor assembly to the machine
using ropes.
24.Remove alternator assembly (34) according to

18.Disconnect wiring connectors (20) to (23). the following procedure.
(20): Connector ST
(21): Connector EG1 a To remove the engine mounting bolt on the
(22): Connector PRTR front right-hand side
(23): Connector EG2 1) Remove cover (35).
19.Disconnect starting motor cables (24) and (25). 2) Disconnect wiring connectors AL/E (36), AL/
B (37), and AL/R (38).
50-90 D65EX,PX,WX-17
3) Remove alternator belt (39) according to the 26.Disconnect fuel hose (44).
following procedure. [*4]
1] Set wrench [1] on part (A) of tensioner
assembly (40) (width across flats: 12.7
mm).
2] Rotate wrench [1] in the direction
opposite to winding-up direction to
decrease the tension of alternator belt
(39), then remove alternator belt (39).
k Rotate wrench [1] after making sure

that it is securely set to part (A) of
tensioner assembly (40).
(The spring of tensioner assembly 27.Remove the drive shaft assembly according the
(40) is strong. If you rotate the wrench following procedure.
that is loosely set to the part, it can
accidentally come off and this is 1) Remove undercover (45) at the bottom of the
extremely dangerous.) power train.
k After removing alternator belt (39),

return tensioner assembly (40) slowly
and carefully.
k Be careful not to let your fingers

caught between the pulley and
alternator belt (39) during work.
2) Sling drive shaft assembly (46).

3) Remove all drive shaft mounting bolts (47)
from the bottom of the power train. [*6]
4) Sling and remove drive shaft assembly (46).
4) Remove mounting bolts (41) and (42) of

alternator (34).
5) Remove alternator (34).
25.Disconnect hose (43) between the radiator and
the power train oil cooler. [*5]
D65EX,PX,WX-17 50-91
(p1)(p2): The hanging brackets for lifting and

4 Drive shaft assembly (46):
removal or installation of the KDPF
25 kg
28.Disconnect engine ground cable (48a) at the

Installation
right rear of the engine mount. • Carry out installation in the reverse order to
29.Remove four mounting bolts (48). [*7] removal.
[*2]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a When installing the air conditioner hoses, check
that O-ring (70) is fitted to each of their fittings.
a Check that O-ring (70) is free from flaw and
deterioration.
a When connecting the refrigerant pipes apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8) to O-ring (70).
3 Screw size (M16 x 1.5) (width across flats:
30.Sling and remove engine assembly (49).
19):
a Install the lifting device to brackets (e1) and 12 – 15 Nm {1.2 – 1.5 kgm}
(e2) as shown below.
4 Engine assembly (49): 24):
1,000 kg 20 – 25 Nm {2.0 – 2.6 kgm}
27):
29 – 34 Nm {3.0 – 3.5 kgm}
3 Receiver tank refrigerant tube mounting bolt
(M6 x 1.0) (width across flats: 10):
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):
8 – 12 Nm {0.8 – 1.2 kgm}
[*1]
a Do not use the hanging brackets shown • After installation of the air conditioner
below to lift the engine assembly. compressor, adjust the belt tension. For details,
(If used, the KDPF may be damaged.) see Testing and adjusting, "Testing and
(d1)(d2): The hanging brackets to lift the KDPF adjusting air conditioner compressor belt
assembly. tension".
[*3]
50-92 D65EX,PX,WX-17
a Insert air hose (31) until it stops at the tube

stopper, and install the clamps to the following
dimensions.
L1 57 mm
32 L2 10 mm
L3 31 mm
L4 60 mm
7b L5 10 mm
L6 31 mm
[*5]
3 Hose (43) between radiator and power train
oil cooler:
8.8 ± 0.5 Nm {1.09 ± 0.05 kgm})
following figure.
3 Air hose mounting clamp (4):

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
• Install alternator belt (39) according to the
1.
1) Place alternator belt (39) on the pulleys.
2) Set wrench [1] on part (A) of tensioner [*6]
assembly (40) (width across flats: 12.7
mm). 2 Drive shaft mounting bolt (47):
3) Rotate wrench [1] in the opposite Adhesive (LT-2)
direction to wind-up direction, and place
3 Drive shaft mounting bolt (47):
alternator belt (39) on the pulley of
tensioner assembly (40). 98 – 123 Nm {10.0 – 12.5 kgm}
[*7]
k Rotate wrench [1] after making sure that
2 Engine mounting bolt (48):
it is securely set to part (A) of tensioner
assembly (40). Adhesive (LT-1A)
(The spring of tensioner assembly (40) is • Charging of refrigerant (R134)
strong. If you rotate the wrench that is Refill the air conditioner circuit with refrigerant.
loosely set to the part, it can accidentally a Filling quantity: 900 ± 50 g
come off and this is extremely • Refilling of air compressor oil
dangerous.) See Air conditioner, "Handling of compressor oil".
k After installing alternator belt (39), return Supply the coolant through the coolant filler port
tensioner assembly (40) slowly and to the specified level. Run the engine to circulate
carefully. the coolant through the system. Then, check the
k Be careful not to let your fingers caught
between the pulley and alternator belt 5 Radiator (engine coolant):
(39) during work. 54 l
D65EX,PX,WX-17 50-93


55 l
circuit".
50-94 D65EX,PX,WX-17
Removal and installation of damper assembly

6 Fuel tank:
415 l
k Lower the work equipment to the ground and 5. Remove the fuel tank assembly. For details, see
stop the engine. Loosen the oil filler cap of "Removal and installation of fuel tank assembly".
the hydraulic tank slowly to release the 6. Remove the ROPS cab assembly. For details,
pressure in the hydraulic tank. see "Removal and installation of ROPS cab
assembly."
k Turn the battery disconnect switch to the 7. Remove the power train and lubrication pump
OFF position and remove the key. assembly. For details, see "Removal and
installation of power train and lubrication pump
k If the radiator coolant temperature is high, assembly".
wait until it decreases and then drain the 8. Remove the drive shaft assembly according to
coolant so that you will not be scalded. the following procedure.
1) Remove undercover (2) at the bottom of the
Removal power train.
1. Collect the air conditioner refrigerant (R134a)
from the air conditioner circuit. [*1]
a Ask a qualified person for collecting, adding
and filling operations of the refrigerant
(R134a).
a Never release the refrigerant to the
atmosphere.
k If refrigerant 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 2) Sling the drive shaft assembly.
refrigerant or filling the air conditioner circuit 3) Remove all drive shaft mounting bolts (3)
with the refrigerant. Collecting and f illing from the bottom of the power train. [*2]
work must be conducted by a qualified
person.
undercover.
3. Drain the engine coolant from the radiator.
6 Radiator:
36 l
4) Sling and remove drive shaft assembly (4).

25 kg
4. Drain the fuel from the fuel tank from the fuel
valve at the fuel tank bottom.
D65EX,PX,WX-17 50-95
9. Remove drain plug (5) to drain oil from the Installation

damper case. [*3]
6 Damper case: removal.
[*1]
1.7 l
10.Remove coupling (6). a When installing the air conditioner circuit hoses,
deterioration.
19):
12–15 Nm {1.2–1.5 kgm}
11.Using guide bolt [1], sling and remove damper
cover (7). [*4] 3 Screw size (M22 x 1.5) (width across flats:
24):
4 Damper cover (7): 20–25 Nm {2.0–2.6 kgm}
20 kg 3 Screw size (M24 x 1.5) (width across flats:
27):
29–34 Nm {3.0–3.5 kgm}
3.9–6.9 Nm {0.4–0.7 kgm}
10):
8–12 Nm {0.8–1.2 kgm}
12.Remove damper assembly (8) using guide bolt

[2]. [*5]
50-96 D65EX,PX,WX-17


36 l
water")
• Refilling (Power train case)
[*2] 5 Power train case (power train oil):

2 Drive shaft mounting bolt (53):
Adhesive (LT-2) • Filling of oil (damper case)
3 Drive shaft mounting bolt (53): Add oil through the oil filler to the specified level.
98–123 Nm {10.0–12.5 kgm}
[*3]
3 Drain plug (5): 5 Damper case (power train oil):
58.8–78.5 Nm {6–8 kgm} 1.7 l (TO30)
[*4] • Refilling of fuel (fuel tank)
a Using guide bolt [1], sling and remove damper 5 Fuel tank (diesel fuel):
cover (7).
415 l
2 Mounting surface on damper cover (7): (For details, see "List of lubricant and
Liquid gasket (LG-7) water")
3 Mounting bolt of damper cover (7):
98–123 Nm {10.0–12.5 kgm} see Testing and adjusting, "Checking fuel
circuit".
[*5]
3 Mounting bolt of damper assembly (8):
98 –123 Nm {10.0 –12.5 kgm}
• Charging of refrigerant (R134)
Refill the air conditioner circuit with refrigerant.
a Filling quantity: 900 ± 50 g
• Refilling of air compressor oil
See Air conditioner, "Handling of compressor oil".
D65EX,PX,WX-17 50-97
Removal and installation of engine front seal

a Special tools
New/redesign
Necessity
Sketch
Sym-
Q'ty
bol
795-799- t 1
1 Gear
1131
A
795-799-
5 Oil seal driver q 1
8120

apply the parking brake. 5. Remove the engine hood assembly. For details,
k Lower the work equipment to the ground and assembly".
stop the engine. Loosen the oil filler cap of 6. Remove the hydraulic oil cooler assembly. For
the hydraulic tank slowly to release the details, see "Removal and installation of
pressure in the hydraulic tank. hydraulic oil cooler assembly".
7. Remove the radiator assembly. For details, see
k Turn the battery disconnect switch to the "Removal and installation of radiator assembly".
OFF position and remove the key. 8. Remove the aftercooler assembly. For details,
k If the radiator coolant temperature is high, assembly".
wait until it decreases and then drain the 9. Remove alternator belt (3) according to the
coolant so that you will not be scalded. following procedure.
1) Set wrench [1] to part (A) of tensioner
Removal assembly (4) (width across flats: T12.7 mm).
1. Remove inspection cover (1a) from the engine 2) Rotate wrench [1] in the direction opposite to
undercover. winding-up direction to decrease the tension
2. Drain the engine coolant from the radiator. of alternator belt (3), then remove alternator
belt (3).
6 Radiator:
k Rotate wrench [1] after making sure that
54 l
it is securely set to part (A) of tensioner
assembly (4). (The spring of tensioner
assembly (4) is strong. If you rotate the
wrench that is loosely set to the part, it
can accidentally come off and this is
extremely dangerous.)
k After removing alternator belt (3), return

tensioner assembly (4) slowly and
carefully.
k Be careful not to let your fingers caught

between the pulley and alternator belt (3)
3. Remove cover (2) under the hydraulic tank. during work.
6 Hydraulic tank:
55 l
50-98 D65EX,PX,WX-17
10.Remove five mounting bolts (5), and remove Installation

crankshaft pulley and vibration damper (6). [*1] 1. Using a clean cloth, remove foreign matter
a Using engine cranking tool A1 (see special deposited on the crankshaft flange.
tool table), lock the crankshaft. For details, 2. Set engine front oil seal (10) to tool A5 with pilot
see "Removal and installation of fuel supply [3] ahead.
pump assembly". a Do not remove plastic pilot [3] on the inside
a Make match marks on crankshaft pulley and of engine front oil seal (10) from engine front
vibration damper assembly (6) and the front oil seal (10), since it acts as the guide when
cover. (Since the crankshaft pulley has the installing the seal to the crankshaft.
stamp of "1.6 TOP" on its surface) a Pilot [3] is included in the supply parts of
engine front oil seal (10).
11.Remove six mounting nuts (7), then remove oil

seal carrier (8). 3. Install engine front oil seal (10) set on tool A5 to
12.Remove dust seal (9) and engine front oil seal oil seal carrier (8) from the inner face side of the
(10) from oil seal carrier (8). carrier.
a Install engine front oil seal (10) so that it is
flush with the inner flat face of oil seal carrier
(8).
a Installed dimension (a) of oil seal from outer
face of oil seal carrier (8): 0.5 to 1.0 mm
4. Apply pilot [3] to the crankshaft and push it and
front oil seal carrier (8) as a unit by hand.
5. Remove pilot [3].
D65EX,PX,WX-17 50-99
• Carry out the following installation in the reverse

order to removal.
[*1]
200 ± 10 Nm {20.4 ± 1 kgm}
a Using engine barring tool A1 (see special tool
table), lock the crankshaft. For details, see
"Removal and installation of fuel supply pump
assembly".
6. Install oil seal carrier (8) to the front cover. to the specified level. Run the engine to circulate
2 Flange surface of oil seal carrier (8):
Liquid gasket (LG–7)
a Apply liquid gasket (LG-7) not only to the 5 Radiator (engine coolant):
flange surface but also to periphery (b) of five 54 l
stud bolts (11) and threaded portions (c) of (For details, see "List of lubricant and
nuts (7). water")
3 Mounting nut (7): • Refilling of oil (Hydraulic tank)
9.8 ± 2 Nm {1 ± 0.2 kgm}
a Tighten mounting nuts (7) in the order of [1] system. Then, check the oil level again.
to [5] shown in the following figure.
a Check again that installed dimension (a)
shown above is 0.5 to 1.0 mm. 55 l
7. Install dust seal (9) (For details, see "List of lubricant and
water")
a Push in dust seal (9) until it contacts engine
front oil seal (10) described above.
50-100 D65EX,PX,WX-17
Removal and installation of engine rear seal

a Special tools
New/redesign
Necessity
Sketch
Sym-
Q'ty
bol
795-799- Repair stand t 1

1150
A 6
795-799- Adapter q 1
2280

apply the parking brake. 4. Remove inspection cover (1a) from the engine
undercover.
k Lower the work equipment to the ground and 5. Drain the engine coolant from the radiator.
the hydraulic tank slowly to release the 6 Radiator:
pressure in the hydraulic tank. 54 l


Removal
a Ask a qualified person for collecting,
adding and filling operations of the 6. Remove cover (2) under the hydraulic tank.
refrigerant (R134a). 7. Remove cover (2) under the hydraulic tank.
a Never release the refrigerant (R134a) to
the atmosphere. 6 Fuel tank:
55 l
with long sleeves while you are collecting the
refrigerant or filling the air conditioner circuit
with the refrigerant. Collecting and f illing
person.
CLOSE position. 8. Remove the engine hood assembly. For details,
assembly".
9. Remove the hydraulic oil cooler assembly. For
details, see "Removal and installation of
hydraulic oil cooler assembly".
D65EX,PX,WX-17 50-101
10.Remove the radiator assembly. For details, see

"Removal and installation of radiator assembly".
11.Remove the aftercooler assembly. For details,
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 17.Remove the engine rear oil seal according to the
"Removal and installation of damper assembly". following procedure.
15.Remove the flywheel assembly according to the 1) Remove rear cover (8).
1) Using blocks [1], fix the engine assembly. a When separating the lower portion of rear
cover (8) from the engine oil pan gasket,
a Tool A6 (repair stand and adapter) is take care not to damage the engine oil
available. (See the special tools table.) pan gasket.
2) Sling flywheel assembly (3).
3) Remove the mounting bolts. a Insert a feeler gauge between the lower
4) Using guide bolts [2], sling and remove portion of rear cover (8) and engine oil
flywheel assembly (3). [*3] pan gasket, then move the feeler gauge
back and forth to separate them.
4 Flywheel assembly (3): a If the engine oil pan gasket is damaged
60 kg [*5]
1] Drain the engine oil from the engine oil
pan.
6 Engine oil pan:

24 l
2] Remove the engine oil pan.
a Replace the engine oil pan gasket
with a new one.
2) Remove engine rear oil seal (9) from rear
cover (8).
16.Remove the flywheel housing according to the

1) Disconnect wiring harness (6) from flywheel
housing (5).
2) Set the blocks under the engine oil pan to
float the flywheel housing (5) off the floor.
3) Sling flywheel housing (5).
4) Remove mounting bolt (7).
5) Lift off the flywheel housing (5).
[*4]
4 Flywheel housing (5): Installation

60 kg 1. Clean, degrease, and dry the gasket contact
faces on the rear cover and cylinder block.
2. Clean, degrease, and dry the engine rear oil seal
contact face on the crankshaft.
50-102 D65EX,PX,WX-17
3. Apply neutral detergent to the periphery of the 7. Apply liquid gasket according to the following
engine rear oil seal. procedure.
a Since plastic pilot [3] on the inside of the 1) Apply liquid gasket to bold line area (a) on
engine rear oil seal acts as a guide to the the bottom face of rear cover (8).
crankshaft when installing the seal, do not 2 Apply a bead of liquid gasket 3 mm in
remove it from the engine rear oil seal. diameter to bold line area (a) on the
4. Install engine rear oil seal (9) to rear cover (8). bottom face of rear cover (8):
2) Apply a thick film of liquid gasket to two

hatched portions (b) in the following figure.
2 Hatched portions (b):
5. Using alignment tool [4], push engine rear oil

seal (9) into rear cover (8) to the proper depth.
a Alignment tool [4] (positioning tool) is an
accessory to the engine rear oil seal.
6. Remove alignment tool [4].
8. Install guide pin [5] to the cylinder block.

9. While positioning with guide pin [5], install
gasket (10).
10.Apply pilot [3] to the crankshaft and push it and
rear cover (8) as a unit by hand.
D65EX,PX,WX-17 50-103
a Cut gasket (10) so that its protrusion 2 Around mounting bolt hole on cylinder
dimension (c) to the engine oil pan is as block face, bead of liquid gasket 1 to 3
follows. mm in diameter:
Protrusion dimension (c): Max 0.25 mm Liquid gasket (LG-6)
11.Remove pilot [3].
3 Flywheel housing mounting bolt:
77 ± 12 Nm {7.9 ± 1.2 kgm}
a Tighten mounting bolts in the following order.
12.Install alignment tool [4] again and check that

engine rear oil seal (9) is pushed in to proper
depth.
a Do not remove alignment tool [4] but keep it • Carry out installation in the reverse order to
installed. removal.
13.Remove guide pin [5] described above. [*1]
14.Tighten the eight mounting bolts of rear cover a When installing the air conditioner circuit hoses,
(8) in the order shown in the figure below. take care so that dirt, water, may not enter.
3 Mounting bolt of rear cover (8): a When installing the air conditioner hoses, check
12.7 ± 2.0 Nm {1.3 ± 0.2 kgm} that O-ring (70) is fitted to each of their fittings.
15.Remove alignment tool [4].
deterioration.
19):
12–15 Nm {1.2–1.5 kgm}
24):
20–25 Nm {2.0–2.6 kgm}
27):
29–34 Nm {3.0–3.5 kgm}
3.9–6.9 Nm {0.4–0.7 kgm}
10):
8–12 Nm {0.8–1.2 kgm}
16.Install flywheel housing.
50-104 D65EX,PX,WX-17
3 Flywheel mounting bolt:

137 ± 7 Nm {14.0 ± 0.7 kgm}
[*2]
3 Drain plug :
58.8 –78.5 Nm {6 –8 kgm} a Measure radial runout and facial runout of the
[*3] flywheel.
a Using guide bolts [2], sling and install flywheel • Radial runout: Max 0.13 mm
assembly (3). • Facial runout: Max 0.24 mm
• Measurement of radial runout
4 Flywheel assembly (3): 1. Install dial gauge [7] to the flywheel housing.
55 kg 2. Set the probe of dial gauge [7]
perpendicularly to the faucet joint portion (d)
or periphery of the flywheel.
3. Set the pointer of dial gauge [7] to "0".
4. Rotate the crankshaft one turn and measure
the difference between the maximum
positive and negative readings of dial gauge
[7].
a After the crankshaft is rotated one turn,
check that the pointer of dial gauge [7]
indicates the value at the start of rotation.
• Measuring facial runout
1. Similarly to the setting for the radial runout
measurement, set the probe of dial gauge [7]
a Fix the flywheel and flywheel housing with bar perpendicularly to end face (e) of the
[6]. flywheel.
a When measuring, push the crankshaft to
the front or rear so that an error is not
caused by the end play.
[7].
a Tighten the mounting bolts in the following order.

2 Flywheel mounting bolt:
D65EX,PX,WX-17 50-105

[7].
[*4]
a Measure the radial runout and face runout of the
flywheel. [*5]
• Radial runout: Max 0.20 mm
a If the engine oil pan was removed, install it
• Facial runout: Max 0.20 mm
• Measurement of radial runout
1. Apply liquid gasket to part (e) of the cylinder
1. Install dial gauge [7] to the end of the
block.
crankshaft.
2. Set the probe of dial gauge [7] 2 Part (e) of cylinder block:
perpendicularly to the faucet joint portion (d) Liquid gasket (LG-7)
of the flywheel.
[7].
a After the crankshaft is rotated one turn,
check that the pointer of dial gauge [7]
indicates the value at the start of rotation.
2. Install the gasket to the bottom of the cylinder

block.
a Do not apply liquid gasket to either side of
the gasket.
3. Install bed plate (12) to cylinder block (11).
a Do not apply liquid gasket to either side of
the bed plate.
• Measuring facial runout

1. Similarly to the setting for the radial runout
measurement, set the probe of dial gauge [7]
perpendicularly to the end face of the
flywheel housing.
a When measuring, push the crankshaft to
the front or rear so that an error is not
caused by the end play.
50-106 D65EX,PX,WX-17
4. Apply liquid gasket to hatched part (j) on the bed 2 Hatched part (k) of installed face on
plate installation face of gasket (13). engine oil pan (17):
2 Hatched part (j) of bed plate installation Liquid gasket (LG-7)
face of gasket (13): 7. Install engine oil pan (17) to the cylinder block.
a Do not apply liquid gasket to oil pan
installation face.
5. Install gasket (14) to the end flange of suction
tube (15) and install the suction tube.
2 End flange portion:
3 Flange mounting bolt (16):
7.8 ± 2 Nm {0.8 ± 0.2 kgm}
8. Tighten the mounting bolts in the order of the

numbers shown in the following figure.
3 Mounting bolt of engine oil pan (17):
24 ± 4 Nm {2.4 ± 0.4 kgm}


54 l
water")
• Filling of oil (engine oil pan)
6. Apply liquid gasket to hatched part (k) of the system. Then, check the oil level again.
installed face on engine oil pan (17).
D65EX,PX,WX-17 50-107
5 Engine oil pan (engine oil):

33 l
water")
• Filling of oil (damper case)
5 Damper case (power train oil):

1.7 l (TO30)

55 l
water")
circuit".
50-108 D65EX,PX,WX-17
Removal and installation of engine hood assembly


stop the engine.

Removal
1. Open engine side cover (1) and lock the opened
cover.
a Check that the opened cover is locked 6. Remove cover (7) according to the following
securely. procedure.
1) Remove cover (8).
2. Disconnect wiring connector AFS (2).

3. Disconnect hose (3) coming from the dust 2) Disconnect wiring connectors SSJ (9), MM1
indicator. (10), and MC2 (11).
4. Disconnect air hose (4). [*1] 3) Disconnect wiring clamp (12).
4) Remove plate (13).
5. Remove nameplate (5).

5) Remove the four mounting bolts, and sling
and remove cover (7).
By using tapped hole, remove the cover.
D65EX,PX,WX-17 50-109
4 Cover assembly (7):

40 kg
7. Sling engine hood assembly (14), and remove

four mounting bolts (15).
8. Lift off engine hood assembly (14).
4 Engine hood assembly (7):

130 kg
Installation
removal.
[*1]
3 Mounting clamp of air hose (4):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
50-110 D65EX,PX,WX-17
Removal and installation of fuel tank assembly


k Disconnect the cable from the negative (-)

terminal of the battery.
Removal
1. Remove cover (1) under the fuel tank.
5. Disconnect connector CN-FTK (4) of the fuel
6 Fuel tank: level sensor wiring harness.
415 l 6. Disconnect fuel return hose (5).
a Plug the hoses and adapters to prevent the
fuel from flowing out.
3. Disconnect fuel outlet hose (2).

fuel from flowing out. 7. Sling the fuel tank assembly.
8. Remove three mounting bolts (6) each on the
right and left sides of the fuel tank from under
the fenders at the rear portion of the machine.
4. Open battery cover (3) on the left side of the

machine and fix it with the lock.
a Lock the opened cover securely. 9. Sling and remove fuel tank assembly (7).
a Check that all the wiring and piping are
disconnected before lifting off the operator
cab assembly.
4 Fuel tank assembly:

240 kg (when empty)
D65EX,PX,WX-17 50-111
Installation
removal.
• Refilling of fuel (fuel tank)
5 Fuel tank (diesel fuel):

415 l
water")
circuit".
50-112 D65EX,PX,WX-17
Removal and installation of KDPF assembly


stop the engine.
k Set the disconnect switch to the OFF

position and remove the key.
k The temperature of KDPF increases above

500 °C . Accordingly, wait until the piping
around the engine cools down after the
engine is stopped, and then start the removal
work. 3. Remove eye-joint (3). [*1]
Removal
assembly".
2. Disconnect wiring connectors PDPF (1) and
TDPF (2) according to the following procedure.
1) Slide the lever (red) of the connector in the

direction of the arrow to unlock it.
5. Using tool A9, remove V-clamp (5). [*2]

a Since tube (6) is a datum location for
installation, do not loosen it.
a Make match marks on the KDPF and tube (6).
[*3]
2) Pull out the connector in the direction of the

arrow while pressing the knob.
D65EX,PX,WX-17 50-113
a Width across flats of V-clamp fastening nut: 2) Remove heat insulation plate (13).
7/16 in (11.1 mm) 3) Remove bracket (14).
6. Disconnect wiring connector (7).

7. Remove mounting bolts (9) (three each on the 4) Using tool A9, remove V-clamp (15) and
right and left) of bracket (8). remove exhaust pipe (16) and the gasket.
a Width across flats of V-clamp fastening
nut: 7/16 in (11.1 mm)
5) Sling KDPF assembly (10) and remove U-
bolt (17).
a When slinging KDPF assembly (10), be
sure to use hanging plate (P).
6) Sling KDPF assembly (10) to disconnect it
from bracket (18).
8. Sling and remove KDPF assembly (10) and

bracket (8) as a unit. [*4]
a Be sure to install the sling to hanging plate
(S).
a When lifting, take care that the gasket of the
joint of tube (6) does not fall.
4 KDPF Ass'y(10):
90 kg Installation
1. Install KDPF assembly (10) to bracket (11)
1) Place bracket (18) on block [2] 10 cm by 20
cm.
2) Sling and install KDPF assembly (10) to
bracket (18).
a When slinging KDPF assembly (10), be
sure to use hanging plate (P).
3) Install U-bolt (17) and washers (17a), and
tighten first nut (17b) of the double nut at four
places evenly.
a When the nut is chamfered only one side,
9. Remove the accessories according to the
install it with the chamfered side down.
1) Remove heat insulation plate (11) and 3 U-bolt tightening nut (first nut):
bracket (12) as a unit. 18.6–44.1 Nm {1.9–4.5 kgm}
50-114 D65EX,PX,WX-17
4) Tighten second nut (17c) of the double nut at 3 V-clamp fastening nut:
four places evenly. 13.5 ± 0.5 Nm {1.38 ± 0.05 kgm}
3 U-bolt tightening nut (second nut):
25.5–62.7 Nm {2.6–6.4 kgm}
5) Install a new gasket between exhaust pipe
(16) and KDPF assembly (10).
a Clean the installed portions of exhaust
pipe (16) and KDPF assembly (10) with
parts cleaner fluid.
a Install exhaust pipe (16) with the notch
(part R) facing the face (part Q) of heat
insulation plate (11).
6) Install V-clamp (15) and tighten it using tool
A9 (long socket).
a V-clamp can be reused, however, replace
it with a new one in the following
conditions.
• Deformation of V-clamp
• Damage on T-bolt thread portion
• Deformation of V-groove
• Peeling at V groove
a Width across flats of V-clamp fastening
nut: 7/16 in (11.1 mm)
7) Install bracket (14).

8) Install heat insulation plate (13).
9) Install bracket (12) and heat insulation plate
(11).
D65EX,PX,WX-17 50-115
• Carry out the following installation in the reverse

order to removal.
[*1]
• Insert I-joint (3) into KDPF water drain tube (3a)
and install the I-joint to the KDPF assembly.
a Tighten the bolt while holding the I-joint so as
not to make any deformation on the tube.
Tube fitting depth (l): 32 mm
3 I-joint mounting bolt:
13.5 ± 0.5 Nm {1.38 ± 0.05 kgm}
[*2], [*3], [*4]
a When installing KDPF assembly (10), align
match marks (M1) and (M2) made on inlet flange
(19) of KDPF assembly (10) and tube (6).
a When installing, take care not to let the gasket
fall.
3 V-clamp (5) fastening nut:
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
a If tube (6) on the KVGT side was removed or its
mounting bolt (6a) was loosened, install the tube
1. Install tube (6) to KVGT, and then leave
fastening nut (20a) of V-clamp (20) and fixing
bolt (6a) of tube (6) loosened.
2. Install KDPF assembly (10).
a When installing KDPF assembly (10), align
match marks (M1) and (M2) made on inlet
flange (19) of KDPF assembly (10) and tube
(6).
a When installing, take care not to let the
gasket fall.
3. Install V-clamp (5) on the KDPF side.
3 V-clamp (5) fastening nut:
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
4. Fix V-clamp (20) on the KVG side.
3 Fastening nut of V-clamp (20a):
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
5. Tighten fixing bolt (6a) of tube (6).
50-116 D65EX,PX,WX-17
Disassembly and assembly of KDPF

a Special tools
Necessity
Sym-
Q'ty
bol
Commercially Long socket (1/2 in)

11 q 1
available
A
Commercially Long socket (7/16 in)
12 q 1
available
k Since the temperature of KDPF or KDOC

becomes 500 °C or higher, take care not to
get burn injury.
a Prepare block [1] referring to the figure below,
k Stop the engine and wait until the and use it with wooden plate to float the inlet
temperature of piping around engine drops, side flange from the ground.
then remove KDPF.
k When cleaning, replacing or disposing KDPF

and CSF, use dust mask during the work to
prevent inhaling deposited soot, ash, mat
material or metallic powder inside KDPF.
k Install KCSF with care to the mounting

direction.
k KDPF is fragile against shock such as falling,

handle with care, and never use damaged
part.
2. Put a match mark on the assembly for correct
k Keep the record for each KDPF unit to
alignment of inlet and outlet angles at
monitor the life, and never use the KDPF
reassembly.
exceeded its life.
a Put a match mark on the V-clamp and inlet
a V-clamp and band used in KDPF is made of and outlet portions in alignment with the
stainless steel, accordingly never use air tool for pressure sensor mounting portion of the filter.
removal and installation of nut to avoid damage
on the thread part. a The angle can be adjusted at the installation
of the KDPF assembly, slight misalignment of
a Prepare new gaskets or bands when removing match mark is allowed.
them.
• Inlet side
Disassembly
1. Using V-block [1], secure the KDPF assembly at
4 places to support its inlet, filter, and outlet
portions.
• Outlet side
D65EX,PX,WX-17 50-117
3. Disconnect connectors of KDOC inlet 4. Remove KDOC outlet temperature sensor (2),
temperature sensor (1), KDOC outlet and KDPF outlet temperature sensor (3).
temperature sensor (2), and KDPF outlet • Width across flats of the nut for temperature
temperature sensor (3) from sensor table (13). sensor: 14 mm
a Close the sensor mounting portions with
plugs [2].
Plug [2] threads: M12 x 1.25
a Connector disconnecting procedure

1) Slide the lever (white) of the connector to
unlock.
5. Remove differential pressure sensor pipes (5)
and (6).
1) Loosen the nuts on the filter.
• Width across flats of the nut for pipe (5):
11/16 in (17.5 mm)
• Width across flats of the nut for pipe (6):
5/8 in (15.9 mm)
2) When disconnecting connectors of
differential pressure sensor pipes (5) and (6),
pull them out while pushing lock (L) at the
fitting.
2) While pressing the knob on the upper portion

of the connector, pull out the connector.
50-118 D65EX,PX,WX-17
a Lock (L) at the fitting of differential 7. Remove gaskets (17) and (18) to get KDPF filter
pressure sensor pipe (6) is located assembly (11).
behind.
8. When replacing KDPF filter (16), remove sensor

3) Remove differential pressure sensor pipes table (13) and hanger (15) according to the
(5) and (6). following procedure.
a Since the tube is inserted inside of CSF, 1) Remove band (12) by using tool A12 (long
pull out pipe (5) upright. socket) to remove sensor table (13).
2) Remove band (14) by using tool A12 (long
a Close the sensor mounting portions with
socket) to remove hanger (15).
plugs [3] and [4].
• Width across flats of band (12), (14)
Plug [3] threads: M16 x 1.5 tightening nut: 7/16 in (11.1 mm)
Plug [4] threads: M14 x 1.5 3) Remove the plug from KDPF filter assembly
(11), if so attached.
6. Remove V-clamps (7) and (8) by using tool A11

(long socket), and remove inlet body (9) and
outlet body (10).
• Width across flats of V-clamp (7), (8)
tightening nut: 1/2 in (12.7 mm)
9. Remove differential pressure sensor (19)

1) Loosen mounting bolt (20), and remove
differential pressure sensor (19) from sensor
table (13).
D65EX,PX,WX-17 50-119
2) Disconnect the fitting of differential pressure

sensor pipes (5) and (6) to remove
differential pressure sensor (19)
a When disconnecting connectors of
differential pressure sensor pipes (5) and
(6), pull them out while pushing lock (L) at
the fitting.
a Lock (L) at the fitting of differential
pressure sensor pipe (6) is located
behind.
Assembly
1. Install KDPF assembly inlet body (9), KDPF filter
assembly (11) and outlet body (10) in sequence.
a The blocks used at disassembly are used at
assembly.
a Since a lock nut is applied to the V-clamp,
tighten the clamp for partial tightening by
using tool A11 (long socket) to the extent that
the V-clamp does not move.
a V-clamp can be reused, however, replace it
with a new one in the following conditions.
• Damage on T-bolt thread portion
• Crack at V groove
10.When replacing KDOC inlet temperature sensor

(1), remove it according to the following
procedure.
1) Disconnect wiring harness clamp (4) for
KDOC inlet temperature sensor (1) from
sensor table (13).
• Width across flats of clamp bolt: 10 mm 1) Place new gasket (17) on end of KDPF filter
2) Remove KDOC inlet temperature sensor (1). assembly (11).
• Width across flats of the nut for
temperature sensor: 14 mm
50-120 D65EX,PX,WX-17
2) Assemble inlet body (9) to KDPF filter

assembly (11) matching with the location of
fitting for differential pressure sensor pipe
according to the marking put before removal.
a Place V-clamp (7) to inlet body (9) before
installing them to KDPF filter assembly
(11).
a When assembling inlet body (9) and
KDPF filter assembly (11), take care that
gasket (17) does not come out.
3) Tighten V-clamp (7) lightly according to the
marking put before removal and the angle
5) Assemble outlet body (10) to KDPF filter
shown below.
• Width across flats of V-clamp fastening fitting for differential pressure sensor pipe
nut: 1/2 in (12.7 mm) according to the marking put before removal.
• V-clamp T-bolt mounting angle: 35 ± 5 °
• Mounting angle of V-clamps (7) and (8) a Place V-clamp (8) to outlet body (9)
before installing them to KDPF filter
assembly (11).
a When assembling outlet body (10) and
shown below.
• Width across flats of V-clamp fastening
nut: 1/2 in (12.7 mm)
• Mounting angle of V-clamps (7) and (8)
4) Install new gaskets (18) on end of KDPF filter

assembly (11).
D65EX,PX,WX-17 50-121
2. Tighten V-clamps (7) and (8) according to the • Width across flats of band (14) fastening
following procedure. nut: 7/16 in (11.1 mm)
1) Using tool A11 (long socket), tighten the nuts 2) Fasten sensor table (13) partially with new
of V-clamps (7) and (8). band (12) by using tool A12 (long socket).
• Width across flats of V-clamp fastening a Install sensor table (13) at a position that
nut: 1/2 in (12.7 mm) permits easy installation of piping and
adjust it during installation of the piping.
3 V-clamp fastening nut:
• Width across flats of band (12) fastening
18 – 22 Nm {1.8 – 2.2 kgm}
nut: 7/16 in (11.1 mm)
2) Tap the entire periphery of the V-clamp with a
rubber hammer in the following order: aob,
cod.
3) Tighten the nuts of V-clamps (7) and (8)
again.
nut: 1/2 in (12.7 mm)
18 – 22 Nm {1.8 – 2.2 kgm}
a Adjust the direction of band and its

installing place according to the marking
location put before removal and the angle
shown below.
• Installed angle of band T-bolt: 135 ± 5 °
a Since lock nut is applied to the band,
tighten lightly until band does not move.
a When new KDPF filter assembly (11) is
installed, put hanger (15) at the same
angle with hanger (21) at inlet body, and
adjust it upwards when installed on the
machine, and then fasten band (14).
nut: 7/16 in (11.1 mm)
3 Band (14) fastening nut (tightening to
the specified torque):
6.3 – 8.3 Nm {0.6 – 0.8 kgm}
3. When a new KDPF filter is installed, follow the

procedure below to install sensor table (13) and
hanger (15).
a Once the band is tightened, bend marks are
made on it by the corners of the fixed part.
Those marks can cause looseness when the
band is reused. Accordingly, replace the
used band with a new one.
1) Fasten hanger (15) partially with new band
(14) by using tool A12 (long socket).
4. Install differential pressure sensor pipes (5) and
a Install hanger (15) on the upper side and (6) according to the following procedure.
adjust it when the V-clamp is installed.
50-122 D65EX,PX,WX-17
a Remove any plugs put on the mounting holes 3 Lo side pipe (6) mounting nut:
at the removal. 13.6 – 19 Nm {1.39 – 1.9 kgm}
1) Install them so that differential pressure
sensor pipes (5) and (6) extend horizontally
and then lightly tighten the nuts.
a When a new KDPF filter is installed,
adjust the position of sensor table (13), at
which differential pressure sensor pipes
(5) and (6) can be installed easily, then
fasten band (12) by using tool A12 (long
socket).
nut: 7/16 in (11.1 mm)
3 Band (12) fastening nut:
6.3 – 8.3 Nm {0.6 – 0.8 kgm}
2) Install connectors of differential pressure
sensor pipes (5) and (6) to sensor (19).
a Push in fitting of connectors until locking
sound is heard.
3) Install differential pressure sensor pipes (5)
and (6).
• Width across flats of the nut for Hi side
pipe (5): 11/16 in (17.46 mm)
3 Hi side pipe (5) mounting nut:
24.5 – 36.5 Nm {2.5 – 3.7 kgm}
5. Install KDOC outlet temperature sensor (2), and
• Width across flats of the nut for Lo side
KDPF outlet temperature sensor (3).
pipe (6): 5/8 in (15.88 mm)
a Remove any plugs put on the mounting holes
at the removal.
a When installing the temperature sensor,
apply seizure prevention compound to thread
portion.
3 Thread portion of temperature sensor:
Seizure prevention compound (LC-G)
• Width across flats of the nut for temperature
sensor: 14 mm
3 Temperature sensor mounting nut:
24 – 36 Nm {2.5 – 3.7 kgm}
D65EX,PX,WX-17 50-123
6. Install connectors of KDOC inlet temperature

sensor (1), KDOC outlet temperature sensor (2),
and KDPF outlet temperature sensor (3) to
sensor table (13).
a Do not install connectors at wrong positions.
7. Install differential pressure sensor (19)

1) Tighten mounting bolt (20) of differential
sensor (19) lightly.
sound is heard.
sensor (19) to the specified torque.
• Width across flats of differential pressure
sensor mounting bolt: 10 mm
50-124 D65EX,PX,WX-17
Removal and installation of KCCV assembly

k Place the machine on a level ground and using tool A11 (long socket) to the extent that
apply the parking brake. the V-clamp does not move.
a V-clamp can be reused, however, replace it
with a new one in the following conditions.
stop the engine.
k Set the disconnect switch to the OFF • Damage on T-bolt thread portion
position and remove the key. • Crack at V groove
Removal
cover.
a Check that the opened cover is locked
securely.
1) Place new gasket (17) on end of KDPF filter

assembly (11).

4. Disconnect KCCV outlet hose (4), KCCV inlet
hose (5), and KCCV drain hose (6). [*1]
5. Remove two mounting bolts (7) each on the right
and left sides and remove KCCV assembly (8).
2) Assemble inlet body (9) to KDPF filter

fitting for differential pressure sensor pipe
a Place V-clamp (7) to inlet body (9) before
installing them to KDPF filter assembly
(11).
a When assembling inlet body (9) and
Assembly 3) Tighten V-clamp (7) lightly according to the
1. Install KDPF assembly inlet body (9), KDPF filter shown below.
assembly (11) and outlet body (10) in sequence.
a The blocks used at disassembly are used at nut: 1/2 in (12.7 mm)
assembly. • V-clamp T-bolt mounting angle: 35 ± 5 °
a Since a lock nut is applied to the V-clamp,
tighten the clamp for partial tightening by
D65EX,PX,WX-17 50-125
4) Install new gaskets (18) on end of KDPF filter

assembly (11).
2. Tighten V-clamps (7) and (8) according to the
1) Using tool A11 (long socket), tighten the nuts
of V-clamps (7) and (8).
nut: 1/2 in (12.7 mm)
18 – 22 Nm {1.8 – 2.2 kgm}
2) Tap the entire periphery of the V-clamp with a
rubber hammer in the following order: aob,
cod.
3) Tighten the nuts of V-clamps (7) and (8)
5) Assemble outlet body (10) to KDPF filter again.
assembly (11) matching with the location of • Width across flats of V-clamp fastening
fitting for differential pressure sensor pipe nut: 1/2 in (12.7 mm)
a Place V-clamp (8) to outlet body (9)
before installing them to KDPF filter
assembly (11).
a When assembling outlet body (10) and
shown below.
nut: 1/2 in (12.7 mm)
50-126 D65EX,PX,WX-17

18 – 22 Nm {1.8 – 2.2 kgm}
a Adjust the direction of band and its

installing place according to the marking
location put before removal and the angle
shown below.
• Installed angle of band T-bolt: 135 ± 5 °
a Since lock nut is applied to the band,
tighten lightly until band does not move.
a When new KDPF filter assembly (11) is
installed, put hanger (15) at the same
angle with hanger (21) at inlet body, and
adjust it upwards when installed on the
machine, and then fasten band (14).
nut: 7/16 in (11.1 mm)
3. When a new KDPF filter is installed, follow the
procedure below to install sensor table (13) and 3 Band (14) fastening nut (tightening to
hanger (15). the specified torque):
a Once the band is tightened, bend marks are 6.3 – 8.3 Nm {0.6 – 0.8 kgm}
made on it by the corners of the fixed part.
Those marks can cause looseness when the
band is reused. Accordingly, replace the
used band with a new one.
1) Fasten hanger (15) partially with new band
(14) by using tool A12 (long socket).
a Install hanger (15) on the upper side and
adjust it when the V-clamp is installed.
nut: 7/16 in (11.1 mm)
2) Fasten sensor table (13) partially with new
band (12) by using tool A12 (long socket).
4. Install differential pressure sensor pipes (5) and
a Install sensor table (13) at a position that (6) according to the following procedure.
permits easy installation of piping and
adjust it during installation of the piping. a Remove any plugs put on the mounting holes
at the removal.
nut: 7/16 in (11.1 mm) 1) Install them so that differential pressure
sensor pipes (5) and (6) extend horizontally
and then lightly tighten the nuts.
a When a new KDPF filter is installed,
adjust the position of sensor table (13), at
which differential pressure sensor pipes
(5) and (6) can be installed easily, then
D65EX,PX,WX-17 50-127
fasten band (12) by using tool A12 (long 3 Thread portion of temperature sensor:
socket). Seizure prevention compound (LC-G)
• Width across flats of band (12) fastening • Width across flats of the nut for temperature
nut: 7/16 in (11.1 mm) sensor: 14 mm
3 Band (12) fastening nut: 3 Temperature sensor mounting nut:
6.3 – 8.3 Nm {0.6 – 0.8 kgm} 24 – 36 Nm {2.5 – 3.7 kgm}
sound is heard.
3) Install differential pressure sensor pipes (5)
and (6).
• Width across flats of the nut for Hi side
pipe (5): 11/16 in (17.46 mm)
3 Hi side pipe (5) mounting nut:
24.5 – 36.5 Nm {2.5 – 3.7 kgm}
• Width across flats of the nut for Lo side
pipe (6): 5/8 in (15.88 mm)
6. Install connectors of KDOC inlet temperature
3 Lo side pipe (6) mounting nut: sensor (1), KDOC outlet temperature sensor (2),
13.6 – 19 Nm {1.39 – 1.9 kgm} and KDPF outlet temperature sensor (3) to
sensor table (13).
a Do not install connectors at wrong positions.
7. Install differential pressure sensor (19)

sensor (19) lightly.
sound is heard.
sensor (19) to the specified torque.
5. Install KDOC outlet temperature sensor (2), and
• Width across flats of differential pressure
KDPF outlet temperature sensor (3).
sensor mounting bolt: 10 mm
a Remove any plugs put on the mounting holes
at the removal.
a When installing the temperature sensor,
apply seizure prevention compound to thread
portion.
50-128 D65EX,PX,WX-17
Removal and installation of air cleaner assembly


stop the engine.

Removal
assembly".
2. Place blocks [1] of about 50 cm under the four
corners of the engine hood.
3. Place block [2] of about 5 cm under air cleaner
assembly (1).
a Support the right and left of the air cleaner
assembly with cloths etc. so that it does not
rotate when it is disconnected.
4. Remove band (2). [*1]
5. Sling and remove engine hood assembly (1).
4 Engine hood assembly:

110 kg
Installation
removal.
[*1]
3 Band mounting bolt:
9.8 – 12.7 Nm {1.0 – 1.3 km}
D65EX,PX,WX-17 50-129
Power train
Power train
Removal and installation of power train unit assembly



coolant so that you will not be scalded. 6. Remove the ROPS cab assembly. For details,
see "Removal and installation of ROPS cab
Removal assembly."
7. Remove the HSS motor assembly. For details,
1. Collect the air conditioner refrigerant (R134a) see "Removal and installation of HSS motor
from the air conditioner circuit. [*1] assembly".
a Ask a qualified person for collecting, adding a This is because the right HSS case bevel
and filling operations of the refrigerant gear shaft cover and cap cannot be
(R134a). removed.
a Never release the refrigerant to the 8. Remove under cover (1) at the bottom of the
atmosphere. power train.

person.
valve at the fuel tank bottom. 9. Sling the drive shaft assembly.
10.Remove all drive shaft mounting bolts (2) from
6 Fuel tank: the bottom of the power train. [*2]
415 l
3. Remove the fuel tank assembly. For details, see
"Removal and installation of fuel tank assembly".
4. Remove cover (1b) under the hydraulic tank.
6 Hydraulic tank:
82 l
50-130 D65EX,PX,WX-17
Power train
11.Remove drive shaft assembly (3) by slinging and

lowering it.

25 kg
19.Remove five wiring harness clamps (13).

20.Remove two hose clamps (14).
a Fix harness (15) to the machine.
12.Disconnect pressure pickup pilot hose (4).

13.Disconnect wiring harness connector CN-RFD
(5).
21.Remove hose clamp (16) from the left side of

the transmission.
22.Disconnect two hydraulic hoses (17).
oil from flowing out.
14.Disconnect HSS case oil filler pipe (6). [*3]
15.Remove two hose clamps (7).
16.Disconnect suction hose (8). [*4]
17.Disconnect hydraulic hoses (9), (10) and (11).
23.Remove right and left covers (18) from the

inside of sprocket. [*5]
18.Disconnect two power train oil filter hoses (12).

D65EX,PX,WX-17 50-131
Power train
24.Using forcing screws [1], draw out right and left 27.Sling the power train unit assembly.
drive shafts (19) until the spline portion is pull 28.Remove right and left power train front mounting
out. bolts (24). [*7]
a If drive shaft (19) cannot be pulled out, push
up the track shoe grouser by using a jack etc.
and fine-adjust the position where the shaft
can be pulled out easily.
29.Lift off power train unit assembly (25). [*8]

cab assembly.
25.Remove the right and left HSS case bevel gear
shaft cap covers (20) and caps (21). 4 Power train unit assembly (25):
1,700 kg
26.Loosen right and left clamps (22) and pull seals

(23) together to the outer side. [*6]
Installation
removal.
[*1]
50-132 D65EX,PX,WX-17
Power train
a When installing the air conditioner hoses, check 3 Cover (18) mounting bolt:
that O-ring (70) is fitted to each of their fittings. 98 – 123 Nm {10.0 – 12.5 kgm}
a Check that O-ring (70) is free from flaw and [*6]
deterioration.
a Install seal (23) with its punching mark (UP)
a When connecting the refrigerant pipes apply facing up.
a Check that clamp (22) clamps the entire
periphery of the seal of the coupling securely.
3 Seal mounting clamp (22):
19):
4.9 – 8.3 Nm {0.50 – 0.85 kgm}
12 – 15 Nm {1.2 – 1.5 kgm}
24):
20 – 25 Nm {2.0 – 2.6 kgm}
27):
29 – 34 Nm {3.0 – 3.5 kgm}
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
mounting bolt (M6 x 1.0) (width across flats: [*7]
10):
2 Power train front mounting bolt (24):
8 – 12 Nm {0.8 – 1.2 kgm}
Adhesive (LT-1A)
[*8]
a Install by taking care not to damage seals (23) of
the right and left bevel gear shafts.
[*2] system. Then, check the oil level again.
2 Drive shaft mounting bolt (2): 5 Hydraulic tank (Hydraulic oil):

Adhesive (LT-2) 82 l
3 Drive shaft mounting bolt (2): (For details, see "List of lubricant and
98 – 123 Nm {10.0 – 12.5 kgm} water")
[*3]
3 HSS case oil filler pipe (6) hose mounting 5 Fuel tank (diesel fuel):
clamp: 415 l
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} (For details, see "List of lubricant and
[*4] water")
3 Suction hose (8) mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} see Testing and adjusting, "Checking fuel
[*5] system for leakage".
D65EX,PX,WX-17 50-133
Power train

circuit".
50-134 D65EX,PX,WX-17
Power train
Disconnecting and connecting of power train unit assembly

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
790-101- Push tool kit (C) t 1

5401
790-101-
• Plate 1
5431
D 1
790-101- • Grip 1
5421 8. Remove the hose clamp, and disconnect
01010-
• Bolt 1 hydraulic hose (9).
51240
a Check and note the installed position of each
Disconnection of the branched hoses for installation
1. Place the power train unit assembly on the purpose.
blocks horizontally. 9. Remove the wiring harness clamp and
2. Drain the oil from the power train case. disconnect wiring harness (10).
a Check and note the installed position of each
6 Power train case:
of the branched wiring harnesses for
53 l installation purpose.
3. Remove the mounting bolt and remove HSS and
• Locations of wiring harness connectors (See
cooling fan pump assembly (1).
the figure below)
(10a): CN-FAC
4 HSS and cooling fan pump assembly (1):
(10b): CN-TVC
130 kg (10c): CN-RFD
(10d): CN-LSOL
(10e): CN-LSW
(10f): CN-HHP
(10g): CN-RSW
(10h): CN-RSOL
(10j): CN-3SOL
(10k): CN-3SW
(10m): CN-1SW
(10n): CN-1SOL
(10p): CN-BVRV
(10q): CN-2SW
(10r): CN-2SOL
(10s): CN-FSW
4. Disconnect brake rod (2). (10t): CN-FSOL
5. Disconnect parking brake cable (3). [*1] (10u): CN-TCT
a Check and note the installed dimension of (10v): CN-TIP
parking brake cable (3) for installation (10w): CN-RF02
purpose.
6. Remove the hose clamps, and disconnect
hydraulic hoses (4), (5), (6), and (7).
7. Remove plate (8).
D65EX,PX,WX-17 50-135
Power train
13.Using two forcing screws [1], separate the

transmission assembly and HSS assembly (12).
a Use above-described transmission mounting
bolts (13) as forcing screws [1].
14.Sling and remove HSS assembly (12).
4 HSS Ass'y(12):
750 kg
10.Disconnect hydraulic hose (11).
15.Remove two brackets (13).

16.Disconnect PTO lubrication tube (14). [*3]
11.Sling HSS assembly (12).

disconnected.
12.Remove all transmission mounting bolts (13).
[*2]
17.Disconnect hydraulic tube (15). [*4]

18.Remove the mounting bolt, and sling and
remove power train pump and lubrication pump
assembly (16). [*5]
4 Power train and lubrication pump

assembly (16):
20 kg
50-136 D65EX,PX,WX-17
Power train
19.Remove the mounting bolt and remove 27.Remove oil seal (24) from retainer assembly
scavenging pump assembly (17). (23). [*7]
20.Remove left and right transmission mount
brackets (18).
a Place blocks etc. under the transmission
assembly to support the assembly securely
before removing the brackets.
21.Place the transmission assembly on blocks [2]

with PTO assembly (19) up.
22.Remove oil strainer assembly (20).
23.Remove coupling (21). [*6]
24.Remove torque converter side block (22).
28.Remove all mounting bolts (26).
25.Remove two sleeves (25).

a Hook a wire etc. to the hole of sleeve (25) to
pull out.
29.Sling and remove PTO assembly (27). [*8]
a The torque converter assembly is left on the
transmission side.
4 PTO Ass'y(27):
210 kg
26.Using forcing screws [3], remove retainer

assembly (23).
D65EX,PX,WX-17 50-137
Power train
3 Transmission mounting bolt (13):

245 to 309 Nm {25.0 to 31.5 kgm}
[*3]
3 Joint bolt for PTO lubricating tube (14):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*4]
3 Mounting clamp of hydraulic tube (15):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
3 Mounting bolt of power train and lubrication
30.Remove nine mounting bolts (28) and sling and
pump assembly (16):
remove torque converter assembly (29). [*9]
98 to 123 Nm {10.0 to 12.5 kgm}
4 Torque converter assembly (29): [*6]
140 kg 2 O-ring between coupling (21) and shaft end:
Grease(G2-LI)
2 Mounting bolt of coupling (21):
Adhesive (LT-2)
3 Mounting bolt of coupling (21):
245 to 309 Nm {25.0 to 31.5 kgm}
[*7]
a Using tool D1, press fit oil seal (24) to retainer
(23).
2 Lip of oil seal (24):
Grease(G2-LI)
31.Sling and remove transmission assembly (30).
2 Periphery of press-fitting face of oil seal (24)
4 Transmission assembly (30): and inner periphery of retainer (23):
380 kg Liquid gasket (LG-5)
a Wipe off the extruded liquid gasket.
Connection
• Connect in the reverse order of disconnection. [*8]
[*1]
3 PTO assembly mounting bolt (26):
a If parking brake cable (3) was disconnected, 98 to 123 Nm {10.0 to 12.5 kgm}
adjust it. For detail, see Testing and adjusting,
[*9]
"Testing and adjusting parking brake cable".
[*2]
50-138 D65EX,PX,WX-17
Power train
2 Mounting bolt of torque converter assembly

(28):
Adhesive (LT-2)
3 Mounting bolt of torque converter assembly
(28):
98 to 123 Nm {10.0 to 12.5 kgm}
• Refilling (power train case)

53 l (For details, see "List of lubricant
and water")
D65EX,PX,WX-17 50-139
Power train
Disassembly and assembly of PTO

a Special tools
New / Redesign
Necessity
Sketch
Sym-
Q'ty
bol
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 2. Idle gear
D
790-101-5201 Push tool kit (B) t 1 1) Remove mounting bolt (4) to remove plate
790-101-5331 • Plate 1 (5).
4
790-101-5221 • Grip 1
01010-51225 • Bolt 1
5 796-430-1110 Push tool t 1
Disassembly
1. Cover assembly
1) Remove the mounting bolts and remove
cover assembly (1) by using forcing screws
[1].

shaft (6) by using forcing screws [2].
a Support gear (7) that will fall down.
2) Drive gear assembly (2) out of cover

assembly (1).
3) Remove bearings (8a) and (8b) from gear

(7).
4) Remove outer races (10a) and (10b).
a When reusing, keep the bearings and
outer races (10a) and (10b) in the original
combinations.
3) Remove bearings (3a) and (3b) from gear

(2a).
50-140 D65EX,PX,WX-17
Power train
Assembly
• Precautions for assembly
a Clean the all parts and check them for dirt or
damage before installing.
a Apply power train oil (for details, see "List of
lubricant and water") to the sliding surfaces of
each part before installing.
a After press fitting the bearing, drip power train oil
(for details, see "List of lubricant and water")
onto it and rotate it about 10 turns.
3. Scavenging pump drive gear a Check that snap ring is fitted to the groove
1) Remove snap rings (11) and (12). securely.
2) Drive gear (13) out of the snap ring side. 1. Input shaft bearing
Press fit bearing (15).
3) Remove bearing (14).

2. Scavenging pump drive gear
1) Using tool D3, press fit bearing (14).
4. Input shaft bearing

Remove bearing (15).
2) Using tool D2, press fit the inner race of
bearing (14).
3) Press fit gear (13).
D65EX,PX,WX-17 50-141
Power train
4) Install snap rings (12) and (11). 3) Using tool D4, press fit outer races (10a) and
(10b) to gear (7).
3. Idle gear
1) Fit the O-ring to shaft (6) and install them to 4) Install gear (7) and bearing (8b).
the case. a When reusing, keep the bearings and
2 O-ring: outer races (10a) and (10b) in the original
combinations. (See above)
Grease(G2-LI)
a Press fit the inner race of bearing (8b).
2) Reverse the case and install bearing (8a).

5) Install plate (5) and mounting bolt (4).
Adhesive (LT-2)
156.9 to 196.1 Nm {16.0 to 20.0 kgm}
50-142 D65EX,PX,WX-17
Power train
4. Cover assembly
1) Using tool D5, install bearings (3a) and (3b)
to gear (2a).
2) Install the O-ring to cover (1a).

2 O-ring:
Grease(G2-LI)
3) Install gear assembly (2) to cover (1a).
4) Install cover assembly (1), engaging the idle

gear with PTO gear.
D65EX,PX,WX-17 50-143
Power train
Disassembly and assembly of torque converter

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
794T-422- t 1
6 Push tool Q
1110
792T-413- t 1
7 Push tool Q
1120
790-101-5401 Push tool kit (C) t 1
D 790-101-5431 • Plate 1
8 2. Gear and input shaft assembly
790-101-5421 • Grip 1 1) Remove 20 mounting bolts (4).
01010-51240 • Bolt 1
Wrench
9 792-213-1110 assembly t 1
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
bottom.
2) Using forcing screws [1], remove gear and
input shaft assembly (5).
3) Sling and remove housing and turbine

assembly (3).
4 Housing and turbine assembly (3): 3) Remove inner race (6) from gear and input
shaft assembly (5).
85 kg
50-144 D65EX,PX,WX-17
Power train
3. Housing assembly 4) Remove 36 mounting bolts (39a).

1) Remove snap ring (7) and spacer (8).
5) Sling and remove clutch housing (11).
2) Using puller [2], remove clutch housing 6) Remove piston (12) from clutch housing (11).
assembly (10) from turbine and gear
assembly (9).
7) Remove bearing (13) from clutch housing

(11).
3) Remove turbine and gear assembly (9).
a Snap ring (14) is installed to bearing (13).
D65EX,PX,WX-17 50-145
Power train
1) Remove stator assembly (20) from pump and

stator shaft assembly (19).
8) Remove two seal rings (15) from clutch

housing (11).
2) Remove snap ring (21) from stator (20a) and
remove free wheel assembly (22).
3) Remove outer race (23), two bushings (24),
two balls (25), and free wheel (26) from free
wheel assembly (22).
a Take care not to lose balls (25).
9) Remove two seal rings (16) from piston (12).
10)Remove one disc (18) from housing (17).
5. Pump and stator shaft assembly

1) Using tool D9, remove nut (27) from pump
and stator shaft assembly (19).
a Using a bar, hold housing (28) from
turning.
4. Stator assembly
50-146 D65EX,PX,WX-17
Power train
6) Remove seal ring (31) from housing (28).

bearing cage assembly (33) from pump
assembly (32).
2) Reverse pump and stator shaft assembly

(19) and place it on block [3].
3) Remove place mounting bolts and remove
stator shaft (29) by using forcing screws [4].
4) Remove housing (28).
5) Remove inner races (30a) and (30b) from 8) Remove snap ring (34) from bearing cage
stator shaft (29). assembly (33) and remove bearing (35).
Assembly
a Clean each part, and check for dirt or damage.
a After press fitting the bearing, drip power train oil
(for details, see "List of lubricant and water")
onto it and rotate it about 10 turns.
D65EX,PX,WX-17 50-147
Power train
a Check that snap ring is fitted to the groove 2 Seal ring (31):
securely. Grease(G2-LI)
1. Pump and stator shaft assembly
1) Using tool D8, press fit bearing (35) to
bearing cage (33).
2) Install snap ring (34).
5) Install stator shaft (29) to housing (28).

2 Mounting bolt of stator shaft (29):
Adhesive (LT-2)
3 Mounting bolt of stator shaft (29):
98 to 123 Nm {10.0 to 12.5 kgm}
3) Install bearing cage assembly (33) to pump

(32).
2 Mounting bolt of bearing cage 6) Reverse housing (28) and install inner race
assembly (33): (30b) to stator shaft (29).
Adhesive (LT-2) 7) Install pump (32) and inner race (30a) to
stator shaft (29).
3 Mounting bolt of bearing cage 8) Using tool D6, press fit inner race (30a).
assembly (33):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
4) Install seal ring (31) to housing (28).

a When installing seal ring (31), take care
not to open its end gap too wide.
50-148 D65EX,PX,WX-17
Power train
a When inserting, be careful that drag clip c

on the periphery of free wheel (26) will not
be hitched in the ball groove of the outer
race.
2) Install free wheel assembly (22) to stator
(20a) and install snap ring (21).
2 Free wheel assembly (22):
Power train oil (For details, see "List
of lubricant and water")
9) Install nut (27) to pump and stator shaft

assembly (19) and tighten it with tool D9.
3 Nut (27):
441.3 to 490.3 Nm {45 to 50 kgm}
3 Using a bar, housing (28) is being
held from turning.
2. Stator assembly
1) Install free wheel (26), two balls (25), and two
bushings (24) to outer race (23).
3) Install stator assembly (20) to pump and
a When installing free wheel (one-way stator shaft assembly (19).
clutch) (26), direct arrow (b) on the front
side of the bearing cage toward the input
side and check the rotation direction of
the stator.
Clockwise: Turning with no load
Counterclockwise: LOCK
a Do not remove sprag (d).
D65EX,PX,WX-17 50-149
Power train
3. Housing assembly
1) Set turbine and gear assembly (9) to cylinder
[5].
5) Install piston (12).
2) Install housing (17) and one disc (18) to

turbine and gear assembly (9).
6) Sling and install clutch housing (11).

a When installing the clutch housing, match
its projections with holes (3 places) on
the top of the piston.
3) Install two seal rings (15) to clutch housing
(11). 4 Clutch housing (11):
4) Install two seal rings (16) to piston (12).
25 kg
2 Seal rings (15), (16):
Grease(G2-LI)
Adhesive (LT-2)
a Install seal rings (15) and (16) in the
direction of the figure shown below.
59 to 74 Nm {6.0 to 7.5 kgm}
50-150 D65EX,PX,WX-17
Power train
4. Gear and input shaft assembly

1) Press fit inner race (6) to gear and input shaft
assembly (5).
7) Using tool D7, press fit bearing (13) to clutch

housing (11).
a Snap ring (14) is installed to bearing (13).
2) Install gear and input shaft assembly (5) and
install mounting bolts (4).
Adhesive (LT-2)
98 to 123 Nm {10.0 to 12.5 kgm}
8) Install spacer (8) and snap ring (7).
5. Housing and turbine assembly

1) Sling and install housing and turbine
assembly (3).
a Match the mounting hole of the drain plug
with the oil groove of the housing.
4 Housing and turbine assembly (3):

85 kg
D65EX,PX,WX-17 50-151
Power train
2) Install mounting bolts (2) to torque converter

assembly (1) from underside.
Adhesive (LT-2)
49.0 to 58.8 Nm {5.0 to 6.0 kgm}
3 Two drain plugs:
5.9 to 8.8 Nm {0.6 to 0.9 kgm}
50-152 D65EX,PX,WX-17
Power train
Disassembly and assembly of TORQFLOW transmission

a Special tools
Necessity
Sketch
Sym-
Q'ty
N/R
bol
791T-415- Puller asembly t 1 Q

5300
1- 791T-415-
0 5310 • Plate 1 Q
01010-82040 • Bolt 1
1- Oil leak tester kit
799-301-1600 (A) t 1
1
790-101-5201 Push tool kit (B) t 1 2) Remove the mounting bolts, and sling and
1- 790-101-5311 • Plate 1 remove transmission control valve assembly
2 790-101-5221 • Grip 1 (2).
01010-51225 • Bolt 1
790-101-5401 Push tool kit (C) t 1 4 Transmission control valve assembly
(2):
1- 790-101-5461 • Plate 1
3 790-101-5421 • Grip 1 25 kg
01010-51240 • Bolt 1
790-101-5201 Push tool kit (B) t 1
1- 790-101-5281 • Plate 1
D 4 790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5001 Push tool kit (A) t 1
1- 790-101-5081 • Plate 1
5 790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5401 Push tool kit (C) t 1
1- 790-101-5471 • Plate 1
6 790-101-5421 • Grip 1
3) Using tool [2], remove five sleeves (3).
01010-51240 • Bolt 1
1-
790-201-2760 Spacer t 1
7
1- 793T-615- t 1
Push tool Q
8 1170
1-
790-201-2830 Spacer t 1
9
2- 791T-415- t 1
Push tool Q
0 5210
Disassembly
a Keep the removed disc and plate on a flat
surface so that they do not warp.
1. Related parts
4) Remove main relief valve assembly (4) and
1) Sling and set transmission assembly (1) to
plate (5).
block [1].
5) Remove sleeve (6).
4 Transmission assembly (1): a Hitch a wire etc. to the hole of sleeve (6)
380 kg to pull out.
D65EX,PX,WX-17 50-153
Power train
2) Sling transmission case (10) and remove 11

through bolts (11).
a Do not use an impact wrench to loosen
through bolts (11), since doing so can
damage the cushion sleeve.
2. Snap ring
Remove snap ring (8) from output shaft (7).
a Perform this work in advance for removal of
output shaft (7).
3) Lift off transmission case (10).
4 Transmission case (10):

120 kg
3. Transmission case
1) Sling and set transmission assembly (9)
vertically to block [3].
4 Transmission assembly (9):

350 kg 4. Input shaft, front cover and No. 1 carrier
assembly
1) Remove remaining three through bolts (12).
a Do not use an impact wrench to loosen
through bolts (12), since doing so can
damage the cushion sleeve.
50-154 D65EX,PX,WX-17
Power train
2) Lift off input shaft, front cover and No. 1 4) Set front cover (20) to block [4].
carrier assembly (13). 5) Using tool D20, remove the input shaft, No. 1
carrier assembly (21), and spacer (21a).
4 Input shaft, front cover and No. 1
carrier assembly (13):
35 kg
6) Remove snap ring (22) and remove No. 1

carrier assembly (24) from input shaft (23).
5. Disassembly of input shaft, front cover and

No. 1 carrier
1) Remove snap ring (14), No. 2 sun gear (15),
and snap ring (16).
2) Remove snap ring (17) and No. 1 sun gear
(18).
7) Remove two each of seal rings (35) and (36),

snap rings (37) and (38a), and bearing (38)
from input shaft (23).
3) Remove snap ring (19).
D65EX,PX,WX-17 50-155
Power train
8) Remove snap ring (25) from No. 1 carrier 8. No. 1 discs, plates, and springs
assembly (24) and remove No. 1 ring gear 1) Remove five springs (39).
(26). 2) Remove the following in turn.
Plate (40): 6
Disc (41): 5
3) Remove five guide pins (42).
6. Disassembly of No. 1 carrier

Remove four shafts (28), ball (29), two thrust
washers (30), bearing (31), and planetary gear
(32) from No. 1 carrier assembly (24). 9. No. 1 piston
a Take care not to lose ball (29). 1) Remove No. 1 piston (43).
7. Disassembly of front cover 2) Remove seal ring (44) from No. 1 piston (43).
1) Remove snap ring (33) from front cover (20)
and remove bearing (34).
2) Remove seal ring (34a).
50-156 D65EX,PX,WX-17
Power train
10.No. 1 housing 2) Remove seal ring (49) from No. 2 piston (48).
1) Lift off No. 1 housing (45).
4 No. 1 housing (45):

25 kg
12.No. 2 discs, plates, and springs

1) Remove five springs (50).
2) Remove the following in turn.
Plate (51): 8
2) Remove seal rings (46) and (47) from No. 1 Disc (52): 7
housing (45). 3) Remove five guide pins (53).
11.No. 2 piston 4) Remove 14 cushion sleeves (55) from No. 2

housing (54).
1) Remove No. 2 piston (48).
a Check and record slit position (a) of each
cushion sleeve (55).
5) Remove lubrication relief valve (56) and
spring (57).
D65EX,PX,WX-17 50-157
Power train
3) Set the 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).
13.No. 2 housing and No. 2 carrier assembly

5) Remove spacer (61a) and No. 2 ring gear

(61b) from No. 2 carrier assembly (61).
2) Lift off No. 2 housing and No. 2 carrier

assembly (59).
4 No. 2 housing and No. 2 carrier

assembly (59):
45 kg 14.Disassembly of No. 2 housing
Remove snap ring (71), bearing (72), and seal
ring (73) from No. 2 housing (62).
50-158 D65EX,PX,WX-17
Power train
15.Disassembly of No. 2 carrier and No. 1 ring 17.Output shaft and No. 3 carrier assembly
gear 1) Remove No. 3 carrier assembly (78).
1) Remove five shafts (64), ball (65), two thrust
washers (66), bearing (67), and planetary
gear (68) from No. 2 carrier assembly (61).
a Take care not to lose ball (65).
2) Using pins [6], push out snap ring (69) and
remove No. 1 ring gear (70).
a Insert pins [6] into diagonal two holes of
four on the outside of No. 1 ring gear (70).
2) Remove output shaft (80).
3) Remove snap ring (81) from output shaft

(80).

Plate (75): 5
Disc (76): 4
18.Disassembly of No. 3 carrier
D65EX,PX,WX-17 50-159
Power train
1) Remove three seal rings (83) from No. 3 2) Remove four shafts (95), pin (96), two thrust
carrier assembly (79). washers (97), bearing (98), and planetary
2) Remove snap ring (84) and remove bearing gear (99) from No. 4 carrier assembly (91).
(85).
a Take care not to lose pin (96).
3) Remove four shafts (86), ball (87), two thrust
3) Remove snap ring (100) and remove bearing
washers (88), bearing (89), and planetary
(101) and spacer (102) as an assembly.
gear (90) from No. 3 carrier assembly (79).
4) Remove bearing (101) from spacer (102).
21.No. 3 piston
19.No. 3 ring gear and No. 4 carrier assembly 1) Remove No. 3 piston (103).
Lift off No. 3 ring gear and No. 4 carrier
assembly (91).
2) Remove seal ring (104) from No. 3 piston

(103).
20.Disassembly of No. 3 ring gear and No. 4
carrier
1) Using pins [7], push out snap ring (92) and
remove No. 3 ring gear (93).
a Insert pins [7] into diagonal two holes of
four on the outside of No. 3 ring gear (93).
22.No. 3 housing
50-160 D65EX,PX,WX-17
Power train
2) Remove seal ring (106) from No. 3 housing 25.Disassembly of No. 5 carrier and No. 4 ring
(105). gear
1) Remove four shafts (113), ball (114), two
thrust washers (115), bearing (116), and
planetary gear (117) from No. 5 carrier
assembly (112).

Plate (108): 5
Disc (109): 4
2) Remove snap ring (118) from No. 5 carrier
assembly (112) and remove No. 4 ring gear
(119).
a If above-described No. 5 carrier assembly
is not disassembled first,snap ring (118)
cannot be removed.
24.No. 5 carrier and No. 4 ring gear assembly

1) Remove four hexagonal socket head bolts
(110).
2) Remove No. 5 carrier and No. 4 ring gear
assembly (111).
26.No. 4 piston
D65EX,PX,WX-17 50-161
Power train

Plate (125): 5
Disc (126): 4
3) Remove five guide pins (127).

(120).
29.No. 5 piston
27.No. 4 housing

(128).
2) Remove seal ring (123) from No. 4 housing

(122).
30.No. 5 ring gear and No. 5 sun gear

1) Remove No. 5 ring gear (130) and No. 5 sun
gear (131).
50-162 D65EX,PX,WX-17
Power train
31.Disassembly of No. 5 housing 4) Remove bearing (136) from bearing cage

1) Remove snap ring (133) and spacer (134) (135).
from No. 5 housing assembly (132).
5) Reverse No. 5 housing assembly (132) and

2) Using puller [8], remove bearing cage (135) remove snap ring (139).
and bearing (136) as an assembly.
4 No. 5 housing assembly (132):
30 kg
3) Remove seal rings (137) and (138) from

bearing cage (135).
6) Using push tool [9], remove spacer (140) and
bearing (141) from No. 5 housing assembly
(132).
D65EX,PX,WX-17 50-163
Power train
a Apply grease (G2-LI) to the metal seal ring and

install it evenly.
7) Remove bearing (140) from spacer (141).
1. Assembly of No. 5 housing

1) Set No. 5 housing assembly (132) to blocks
[10].

30 kg
8) Remove seal ring (142) from No. 5 housing

(132).
2) Using tool D12, press fit bearing (141) to

spacer (140).
Assembly
a Clean each part, and check for dirt or damage.
a After press fitting the bearing, drip power train oil 3) Using the push tool, install spacer (140) and
(for details, see "List of lubricant and water") bearing (141) to No. 5 housing assembly
onto it and rotate it about 10 turns. (132).
a Check that spring is fitted to the groove securely.
a Install seal ring (a) for each piston with the
pressure receiving side (b) directed to the
housing (c) as shown in the figure.
50-164 D65EX,PX,WX-17
Power train
5) Using tool D13, press fit bearing (136) to 9) Install seal ring (142) to No. 5 housing (132).
bearing cage (135).
2 Seal ring (142):
6) Install seal rings (137) and (138) to bearing
cage (135). Grease(G2-LI)
2 Seal rings (137), (138): a When installing the seal ring, check the
direction of the pressure-receiving side.
Grease(G2-LI)
(See "Precautions for assembly")
7) Using tool D18, press fit bearing cage

assembly (135) to No. 5 housing (132). 2. No. 5 piston
1) Install seal ring (129) to No. 5 piston (128).
a Press fit the inner race of the bearing.
2 Seal ring (129):
Grease(G2-LI)
a When installing the seal ring, check the
8) Set spacer (134) to No. 5 housing assembly

(132) and install snap ring (133).
2) Install No. 5 piston (128) and No. 5 ring gear

(130).
D65EX,PX,WX-17 50-165
Power train
a Check that the spring is fitted to the

groove of the piston.
3. No. 5 discs, plates, and springs

1) Install five guide pins (127).
2) Install the following in turn. 5. No. 4 piston
Plate (125): 5
Disc (126): 4
3) Install five springs (124). 2 Seal ring (121):
a Free length of spring: 59 mm Grease(G2-LI)
4. No. 4 housing
1) Install seal ring (123) to No. 4 housing (122).
2 Seal ring (123):
2) Install No. 4 piston (120).
Grease(G2-LI)
6. Assembly of No. 5 carrier and No. 4 ring gear

1) Set No. 4 ring gear (119) to No. 5 carrier
(112) and install snap ring (118).
2) Sling and install No. 4 housing (122).
50-166 D65EX,PX,WX-17
Power train
2) Install bearing (116) to planetary gear (117), 9. No. 4 discs, plates, and springs
fit thrust washers (115) on both sides, then 1) Install the following in turn.
set them to No. 5 carrier (112). Plate (108): 5
3) Install ball (114) to shaft (113) and install Disc (109): 4
them to No. 5 carrier (112). (4 places) 2) Install five springs (107).
a Free length of spring: 59 mm
7. No. 5 carrier and No. 4 ring gear assembly

1) Using guide bolts [11], install No. 5 carrier 10.No. 3 housing
and No. 4 ring gear assembly (111).
2) Tighten four hexagon socket head bolts 1) Install seal ring (106) to No. 3 housing (105).
(110). 2 Seal ring (106):
2 Hexagon socket head bolt (110): Grease(G2-LI)
Adhesive (LT-2) a When installing the seal ring, check the
3 Hexagon socket head bolt (110): direction of the pressure-receiving side.
27 – 34 Nm {2.8 – 3.5 kgm} (See "Precautions for assembly")
8. No. 5 sun gear 2) Sling and install No. 3 housing (105).

Install No. 5 sun gear (131). a Check that the spring is fitted to the
D65EX,PX,WX-17 50-167
Power train
11.No. 3 piston 2) Using the push tool, press fit bearing (101)
1) Install seal ring (104) to No. 3 piston (103). and spacer (102) to No. 4 carrier (91).
2 Seal ring (103): 4) Install bearing (98) to planetary gear (99), fit
Grease(G2-LI) thrust washers (97) on both sides, then set
a When installing the seal ring, check the them to No. 4 carrier (91).
direction of the pressure-receiving side. 5) Install shaft (95) to No. 4 carrier (91) and
drive in pin (96). (4 places)
(See "Precautions for assembly") 6) Set No. 3 ring gear (93) to No. 4 carrier (91)
and install snap ring (92).
12.Assembly of No. 3 ring gear and No. 4 carrier 13.No. 3 ring gear and No. 4 carrier assembly
1) Using tool D14, press fit bearing (101) to Sling and install No. 3 ring gear and No. 4 carrier
spacer (102). assembly (91).
50-168 D65EX,PX,WX-17
Power train
2 Seal ring (83):

Grease(G2-LI)
14.Output shaft
1) Install snap ring (81) to output shaft (80).
2 Spline of output shaft (80):
Grease (LM-G) or molybdenum
disulfide grease (LM-P)
16.No. 3 carrier assembly

Install No. 3 carrier assembly (78).
2) Install output shaft (80) to No. 3 ring gear and

No. 4 carrier assembly (91).

1) Install five guide pins (53).
2) Install the following in turn.
15.Assembly of No. 3 carrier Plate (75): 5
1) Install bearing (89) to planetary gear (90), fit Disc (76): 4
thrust washers (88) on both sides, then set 3) Install five springs (74).
them to No. 3 carrier (79). a Free length of spring: 59 mm
2) Install ball (87) to shaft (86) and install them
to No. 3 carrier (79). (4 places)
3) Using tool D15, press fit bearing (85).
5) Install three seal rings (83) to No. 3 carrier
assembly (79).
D65EX,PX,WX-17 50-169
Power train
18.Assembly of No. 2 housing

1) Using tool D16, press fit bearing (72) to No. 2
housing (62).
2) Install seal ring (73).
2 Seal ring (73):
Grease(G2-LI)
20.Assembly of No. 2 housing and No. 2 carrier

1) Install spacer (61a) and No. 2 ring gear (61b)
to No. 2 carrier assembly (61).
2) Set the No. 2 carrier assembly (61) to

cylinder [12].
3) Install No. 2 housing assembly (62).
4) Using tool D17, press fit No. 2 housing
assembly (62).
19.Assembly of No. 2 carrier and No. 1 ring gear
a Press fit the inner race of the bearing.
1) Set No. 1 ring gear (70) to No. 2 carrier (61)
and install snap ring (69).
2) Install bearing (67) to planetary gear (68), fit
thrust washers (66) on both sides, then set
them to No. 2 carrier (61).
to No. 2 carrier (61). (4 places)
50-170 D65EX,PX,WX-17
Power train
3) Tighten the bolt of tool D10 to pull up No. 2

carrier assembly (78), and then install snap
ring (58).
21.No. 2 housing and No. 2 carrier assembly

1) Sling and install No. 2 housing and No. 2
carrier assembly (59). 4) Install 14 cushion sleeves (55) for the
through bolts to No. 2 housing (54).
4 No. 2 housing and No. 2 carrier
assembly (59): a Match slit position (a) of each cushion
sleeve (55) to the position recorded at
45 kg disassembly.
a Check that the spring is fitted to the 5) Install spring (57) and lubrication relief valve
groove of the piston. (56).
2) Insert tool D10 into groove (b) of No. 2 carrier

assembly (78) and rotate it about 90 ° to part
(c)
a Securely set tool D10 so that its both
ends will be in grooves (d) on the inside
wall of No. 2 carrier assembly (78).
D65EX,PX,WX-17 50-171
Power train
22.No. 2 discs, plates, and springs 24.No. 1 housing

1) Install the following in turn. 1) Install seal rings (46) and (47) to No. 1
Plate (51): 8 housing (45).
Disc (52): 7 2 Seal rings (46), (47):
2) Install five springs (50).
Grease(G2-LI)
a Free length of spring: 77 mm
23.No. 2 piston
2 Seal ring (49): 2) Sling and install No. 1 housing (45).
Grease(G2-LI)
direction of the pressure-receiving side. 25 kg
(See "Precautions for assembly") a Check that the spring is fitted to the

25.No. 1 piston
50-172 D65EX,PX,WX-17
Power train
2 Seal ring (44):

Grease(G2-LI)
2) Press fit bearing (38) to input shaft (23).

3) Install two each of seal rings (35) and (36),
and snap rings (38a) and (37).
2 Seal rings (35), (36):
Grease(G2-LI)
2) Install No. 1 piston (43). 2 Spline portion (e) on transmission

side:
Grease (LM-G) or molybdenum
disulfide grease (LM-P)
a Do not apply grease to spline portion (f)
on torque converter side.
26.Building of No. 1 carrier assembly

1) Install bearing (31) to planetary gear (32), fit
thrust washers (30) on both sides, then set
them to No. 1 carrier (24).
to No. 1 carrier (24). (4 places) 4) Install input shaft (23) to No. 1 carrier
assembly (24), and then install snap ring
(22).
27.Assembly of input shaft and No. 1 carrier

1) Set No. 1 ring gear (26) to No. 1 carrier
assembly (24), and install snap ring (25). 5) Install No. 1 sun gear (18) and snap ring (17)
to input shaft (23).
D65EX,PX,WX-17 50-173
Power train
6) Install snap ring (16), No. 2 sun gear (15), 2 Seal ring (34a):
and snap ring (14). Grease(G2-LI)
28.Input shaft and No. 1 carrier assembly

Install input shaft and No. 1 carrier assembly
(21).
31.Front cover
1) Install spacer (21a).
1) Install the following in turn.
Plate (40): 6
Disc (41): 5
2) Install five springs (39).
a Free length of spring: 69.5 mm
2) Install front cover (20).

a Check that the spring is fitted to the
3) Install three through bolts (12).
a Push in each through bolt (12) by hand
until it reaches the tap hole to prevent
30.Assembly of front cover damage of the cushion sleeve.
1) Using tool D19, press fit bearing (34) to front a Use an impact wrench only after the
cover (20). threads are engaged completely.
2) Install snap ring (33) to front cover (20). 3 Through bolt (12):
3) Install seal ring (34a).
157 – 177 Nm {16 – 18 kgm}
50-174 D65EX,PX,WX-17
Power train
4) Install snap ring (19) according to the 33.Transmission case

following procedure. 1) Sling and install transmission case (10).
1] Using tool [13], sling input shaft (23) a
little. 4 Transmission case (10):
a At this time, check that the groove to 120 kg
install snap ring (19) is fully exposed.
2] Install snap ring (19).
2) Install 11 through bolts (11) to transmission

case (10).
a Push in each through bolt (11) by hand
until it reaches the tap hole to prevent
damage of the cushion sleeve.
a Use an impact wrench only after the
threads are engaged completely.
3 Through bolt (11):
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 34.Snap ring
1) Sling the transmission assembly and set it
horizontally.
D65EX,PX,WX-17 50-175
Power train
4 Transmission assembly:
350 kg
2) Install snap ring (8) to output shaft (7).
4) Install the O-ring to the groove, and then

sling and install transmission control valve
assembly (2).
35.Related parts 4 Transmission control valve assembly

1) Install sleeve (6). (2):
2) Install the O-ring to the groove and install 25 kg
plate (5) and main relief valve assembly (4).
3 Mounting bolt of main relief valve
assembly (4):
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
3) Using tool [2], install five sleeves (3).
50-176 D65EX,PX,WX-17
Power train
Disassembly and assembly of HSS

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
791T-422- Hanger
1 q 1 Q
1320
2 790-302-1500 Wrench kit q 1
Wrench
3 796-730-2300 assembly q 1
Commercially 2. Brake valve assembly
available or Torque wrench
q 1 Remove brake valve assembly (4).
set
795-630-1810
4
• Torque
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
790-101-5221 • Grip 1
01010-51225 • Bolt 1
794T-422-
6 Push tool t 1 Q
1110
790-101-5401 Push tool kit (C) t 1
790-101-5481 • Plate 1
7
790-101-5421 • Grip 1
E 3. Cover assembly
01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) t 1 1) Using eyebolts [1], remove cover assembly
(5).
790-101-5491 • Plate 1
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
793T-659- t 1
9 Push tool Q
1110
1- 796T-467-
Push tool t 1 Q
0 2160
1- t 1
790-201-2730 Push tool
1
790-101-5201 Push tool kit (B) t 1
790-101-5221 • Grip 1
1-
01010-51225 • Bolt 1
2
790-101-5271 • Plate 1
790-101-5311 • Plate 1
2) Remove five sleeves (24) and two sleeves
790-101-5001 Push tool kit (A) t 1
(25) from the HSS case.
1- 790-101-5091 • Plate 1
3 790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly
1. Transmission speed sensors
Remove cover (1) and remove transmission
speed sensor (2) by pulling it out.
D65EX,PX,WX-17 50-177
Power train
4. Disassembly of cover 2) Intermediate gear

1) Input gear assembly 1] Remove tube (11).
1] Remove snap ring (12).
2] Remove bolt to remove holder (13).

2] Remove gear assembly (6) with cage (7) 3] Remove gear (15) by driving out shaft
using puller [2] and remove gear (14) from the bolt side.
assembly (6) from cage (7). a Take care not to lose the balls.
4] Remove bearing (17) and spacer (17a)

3] Remove bearing (10) from gear (9). from gear (15).
50-178 D65EX,PX,WX-17
Power train
3) L.H. carrier drive gear 6] Remove bearing (26) from shaft (21).
1] Remove bolt (19) to remove holder (20).
2] Remove gear (22).
4) Remove plug and remove spring (30) and

valve (31).
3] Using gear puller [3], push out shaft (21).
5. Removal of brake and carrier assembly

4] Remove snap ring (23), then remove Remove the mounting bolts. Using tool E1,
bearing (28) from cover (32). remove brake and carrier assembly (34).
5] Remove outer race (29) from cover (32). a Do not remove 4 hexagonal socket head
bolts.
D65EX,PX,WX-17 50-179
Power train
6. Disassembly of brake 5) Remove springs (42).

1) Remove flange (36). 6) Using eyebolts [5], remove piston (43).
2) Remove snap ring (37) and then remove
spacer (38).
7) Push up and remove cage (51), taking care

not to damage the disc.
3) Set puller [4] and remove cover (41) while 8) Remove seal rings (53) and (27) from cage
loosening four hexagonal socket head bolts (51).
(40). 9) Using eyebolt [7], remove drum (45) together
with disc and plate.
a The inner race of the bearing is removed.
a Do not remove bolt (40)
until cover (41) is removed completely.
10)Remove disc (46), plate (47), and spring (48)

from drum (45).
4) Remove bearing (60) from cover (41).
50-180 D65EX,PX,WX-17
Power train
11)Remove snap ring (59), then remove bearing 7. Disassembly of carrier

(57). 1) Turn over the hub and carrier assembly,
a Pry open the bearing on the notch of the remove bolt (89), then remove carrier
hub. assembly (64) from hub (54).
12)Remove 18 mounting bolts and remove hub 2) Remove hub (92) from carrier assembly (64),
(39) from hub (54). remove snap ring (50), then remove ring
gear (52).
13)Remove bushing (60) from hub (39).

14)Remove snap ring (58), then remove stopper 3) Knock roll pin (65) into shaft.
(56) from the hub. 4) Remove shaft (66), then remove gear (52),
thrust washer (67) and bearing (69).
a Remove roll pin (65) from the shaft.
D65EX,PX,WX-17 50-181
Power train
5) Remove bushing (91) from carrier (90). 9. Bevel pinion assembly

8. Sun gear 1) Remove the mounting bolts.
1) Remove snap ring (70), then remove collar 2) Using guide bolt [9] and forcing bolt [10],
(73). remove bevel pinion assembly (95) and shim
(96).
a Store shims after checking the number
and thickness of the shims.
2) Using gear puller [8], remove sun gear (72)

and bearing (98).
3) Assembly of bevel pinion

1] Remove bolt (97), then remove plate (99)
and pin (100).
3) Using bearing race puller, remove bearing

(74).
4) Remove collar (71).
a Right side of machine only 2] Hold the pinion with the press to keep the
pinion from moving, remove nut (101)
using tool E2.
3] Using tool E5, remove bevel pinion (102)
from cage (103).
50-182 D65EX,PX,WX-17
Power train
4] Remove bearing (104). 3) Move the bevel gear and shaft assembly (75)
5] Remove outer races (105) and (107) from to the left. Using puller [12], remove bearing
cage (103). (78).
a Apply the claw of the puller to the part
(portion (P) where the bolt hole pitch is
increases.
a Remove only the bearing on the left side
of the machine.
6] Remove bearing (106) and spacer (108)

from bevel pinion (102).
10.Bevel gear shaft and bevel gear assembly

1) Sling bevel gear and shaft assembly (75).
2) Remove cage assemblies (76) and (86).
a Check and record the thickness, number
and the mounting position of shims (77). 4) Sling bevel gear (79) and remove mounting
nut (80). Remove bevel gear shaft assembly
a The right and left cages differ with each
(81) by pulling it out toward the right side of
other, so mark them beforehand.
the machine.
D65EX,PX,WX-17 50-183
Power train
a Apply grease (G2-L1) to the piston seal ring with

its pressure-receiving side facing the housing
and install it evenly.
2 Rotation seal ring:
Fix the seal ring with grease (G2-LI) and
install it, taking care that the seal ring will
not be caught.
a Check that the snap ring is fitted securely into
the groove.
5) Remove bevel gear (78) from bevel gear

shaft (82).
6) Remove bolt (83).
7) Remove outer race (84) from cage (76).
1. Suction tube
Install suction tube (55).
8) Remove seal ring (85) from bevel gear shaft

(81).
2. Bevel gear shaft and bevel gear assembly

1) Install bolt (83) to bevel gear shaft (82).
2) Heat bearing (78) with a bearing heater and
shrink-fit it on the right side of the machine.
a The heat treated hardness is lowered if
the temperature of the bearing is
Assembly increased too much. For this reason,
• Precautions for assembly never heat the bearing higher than 120 °
C.
a Clean all parts, and check them for dirt and
damage before installing. a After installing the bearing, drip power
train oil (for details, see "List of lubricant
a Drip power train oil (for details, see "List of and water") on the rotating part of the
lubricant and water") on the rotating part of the bearing and rotate it several times.
bearing and rotate it several times.
a Check that the clearance in the end
a Apply power train oil (for details, see "List of surface of the bearing is not more than
lubricant and water") to the sliding surfaces 0.03 mm.
before installing. 3) Install outer race (84) to cages (76) and (86).
50-184 D65EX,PX,WX-17
Power train
a Check that the clearance in the end

surface of the bearing is not more than
0.03 mm.
4) Install seal ring (85) to bevel gear shaft (81).
7) Install cages (76) and (86) to bevel gear and

shaft assembly (75).
a Note that the cages differ between the
right and the left.
a Insert shims (77) of the thickness and
quantity checked when removed.
• Standard shim thickness: 1.5 mm
• Available shim thickness: 0.2, 0.3, 0.5
mm
5) Insert bevel gear shaft (81) into bevel gear 3 Mounting bolt:
(79) being lifted at the case center from the 98 – 123 Nm {10 – 12.5 kgm}
right side of the machine. 8) Tighten the bevel gear mounting nut to the
a Tighten mounting nut (80) temporarily. specified torque.
a Lock the bevel gear by putting a plastic
hammer into a space between the bevel
gear and the case.
3 Mounting nut:
245 – 309 Nm{25 – 31.5 kgm}
6) Heat bearing (78) with a bearing heater and

shrink-fit it on the left side of the machine.
a The heat treated hardness is lowered if
the temperature of the bearing is
increased too much. For this reason,
never heat the bearing higher than 120 °
9) Preload adjustment
C.
a Make preload adjustment with the bevel
a After installing the bearing, drip power
pinion assembly removed.
train oil (for details, see "List of lubricant
and water") on the rotating part of the 1] Assemble the bevel gear and shaft
bearing and rotate it several times. assembly several times to allow the
bearing to settle.
D65EX,PX,WX-17 50-185
Power train
2] Fit tool E3 to the end of bevel gear shaft 3] Place bevel pinion (102) on the press
(81) and measure the rotation torque stand and set cage (103).
using E4 (torque wrench).
• Standard rotating torque :
10.3 to 14.7 Nm {1.05 to 1.50 kgm}
a If the rotation torque is lower than the
standard value, decrease the number
of shims (77) in step 7). If it is higher
than the standard value, increase the
number of shims (77).
3. Bevel pinion assembly

1) Assembly of bevel pinion
1] Using tool E6, press fit bearing (106) into
bevel pinion (102) and install spacer
(108).
4] Using tool E9, press fit bearing (104) into

cage (103).
5] Hold the pinion with the press to keep the
pinion from moving, tighten lock nut (101)
using tool E2.
2 Locknut:
Adhesive (LT-2)
3 Locknut:
392 – 441 Nm {40 – 45 kgm}
6] After the nut is tightened, return the nut to
the position where one of the eight holes
in the nut for pins is aligned to one of the
five holes in the pinion shaft fro pins.
2] Use tools E7 and E8 to press fit outer
a Turn the nut back 0 to 9 ° .
race (105) and (107) into cage (103).
50-186 D65EX,PX,WX-17
Power train
a Tighten the nut while rotating the Put the probe of dial gauge [13] in contact
cage. with the tip of the bevel gear teeth at right
angles. Hold the bevel pinion in position, and
a After tightening the nut, check that the
read the measurement when the bevel gear
bevel pinion rotates smoothly.
is moved forward and backward.
a Standard value for backlash: 0.2 to 0.28
mm
a Measure the backlash at diagonal three
points or more.
• If the measured backlash is out of the
standard range, adjust it according to the
following procedure:
7] Install pin (100), install plate (99), and

tighten bolt (97).
3 Bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
a Adjust the backlash by increasing or

decreasing on both sides. Do not change
the total thickness of the right side and
left side shims in order not to change the
preload. (If the number of shims on one
side is added, remove the same number
of them on the other side. If the number of
shims on one side is reduced, add the
same number of them on the other side.)
2) Using guide bolt [9], install shim (96), and
install bevel pinion assembly (95). • When backlash is too small
Decrease the shims on the right side of
a Insert shims of the thickness and quantity the machine and add as many shims to
checked when removed. the left side
• Standard shim thickness: 2 mm (to move the bevel gear in the direction of
• Available shim thickness: 0.2, 0.3, 1.0 (A)).
mm
• When there is a big backlash:

4. Adjusting backlash and tooth contact
1) Adjusting backlash
D65EX,PX,WX-17 50-187
Power train
Decrease the shims on the left side of the a In the drawing below, (C) denote the
machine and add as many shims to the small end and (D) denotes the large
right side end.
(to move the bevel gear in the direction of
(B)).
Adjustment
If the result of the inspection shows that the
2) Adjusting tooth contact tooth contact pattern is not proper, adjust
Testing again according to the following procedure.
Coat the bevel gear tooth surface slightly 1] If the bevel pinion is too far from the
with red lead, then rotate the bevel gear back center line of the bevel gear, the tooth
and forth to check the tooth contact pattern contact pattern is that the small end of the
on the bevel gear. bevel gear tooth faces curved outward
1] Check that there is not a strong contact at contact with the large end of the bevel
addendum (A), dedendum (B), small end gear tooth faces curved inward.
(C), or large end (D). • Make adjustment in the following
manner.
Shift the bevel pinion in direction (A)
by adjusting the shims on the bevel
pinion side.
Move the bevel gear in direction (B),
then check the tooth contact pattern
and backlash again.
2] The values for the tooth contact are as

follows:
(the standard value is based on the
addendum of the bevel gear)
Center of tooth contact (a): 20 to 40% of
tooth width
Width of tooth contact (b): 30 to 50% of
tooth width 2] If the bevel pinion is too close to the
Center of tooth contact (c): 35 to 65% of center line of the bevel gear, the tooth
tooth height contact pattern is that the large ends of
Width of tooth contact (d): 60 to 80% of the bevel gear tooth faces curved
tooth height outward contact with the small ends of
the bevel gear tooth faces curved inward.
a If the adjustment is made in this way,
right tooth contact is ensured, when • Make adjustment in the following
load is applied. manner.
Shift the bevel pinion in direction (A)
by adjusting the shims on the bevel
pinion side.
50-188 D65EX,PX,WX-17
Power train
Move the bevel gear in direction (B), 5) Using tool E11, press fit bearing (98).
then check the tooth contact pattern
a Press fit the inner and outer races
and backlash again.
simultaneously.
a Do not change the total number of the
shims on both sides.
3] When adjustment is completed, tighten
the mounting bolts of the cage and bevel
pinion assembly to the specified torque.
3 For both of the mounting bolts of
cage and bevel pinion assembly:
98 – 123 Nm {10 – 12.5 kgm}
5. Sun gear
1) Install snap rings (93) to the shaft.
a Right side of machine only
2) Install collar (71).
6) Fit collar (73) and install snap ring (70).
3) Using tool E10, install bearing (74).
6. Assembly of carrier
1) Install bushing (91) to carrier (90).
2) Install bearing (69) into gear (52), fit thrust

washers (67) to top and bottom of the
bearing, then set the gear to carrier.
3) Install shaft (66) , matching the inside of the
thrust washers and bearing to the shaft hole
of the carrier.
a Align the roll pin holes accurately.
4) Install roll pin (65).
4) Install sun gear (72).
D65EX,PX,WX-17 50-189
Power train
5) Set hub (92) to ring gear (52), and install 3) Install hub (39) to hub (54) and tighten 18
snap ring (50). bolts.
6) Install hub (92) to carrier assembly (64).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
7) Install hub and carrier assembly (64) to hub

(54) and install bolt (89).
4) Install bearing (57) to hub (39).
3 Mounting bolt: 5) Install snap ring (59).
59 – 74 Nm {6 – 7.5 kgm}
6) Set brake drum (45) to hub (39).

7. Assembly of brake 7) Install disc (46), plate (47), and spring (48).
1) Install stopper (56) to the hub and install
snap ring (58).
2) Install bushing (60) to hub (39).
50-190 D65EX,PX,WX-17
Power train
8) Install cage (51) with seal rings (27) and (53). 11)Install springs (42).
12)Install guide bolt [14]. to cage (51).
a Align the oil hole in the cage and four oil
13)Install bearing (60) to cover (41).
holes in the drum by eye.
a Press fit the cage into the outer race of
the bearing.
14)Using eyebolt [15], align cover (41) with the

guide bolt and set it.
9) Install the seal ring to piston (43). a Check that the spring is fitted to the piston
10)Install piston (43), aligning matchmark (a) and case.
and 13.5 mm hole (c) in the drum. 15)Press fit the inner race of the bearing to the
hub assembly while compressing the spring
(b): Spot facing of piston
(d): Opposite side of the drum side hole with forcing screw [17] and nut [16].
16)Fit spacer (38) and install snap ring (37).

17)Install flange (36).
D65EX,PX,WX-17 50-191
Power train
18)Remove the bolt and nut used to compress 2) L.H. carrier drive gear
the spring and install four bolts (40). 1] Press fit bearing (26) to shaft (21) by
using tool E11.
8. Installation of brake and carrier assembly

1) Set the seal ring on the carrier so that it 2] Press fit outer race (29) to cover (32) by
extends from the shaft uniformly. using tool E12.
2) Using tool E1, install brake and carrier 3] Using tool E12, press fit bearing (28) to
assembly (34). cover (32) and install snap ring (23).
9. Assembly of cover
1) Install valve (31) and spring (30) to the cover,
then install the plug.
50-192 D65EX,PX,WX-17
Power train
4] Press fit shaft (21) to the inner race side

of bearing (28).
2] Using tool E13, press fit shaft (14) to the

inner face side of bearing (17), during
5] Install gear (22). which time ball (16) is to be installed.
6] Install holder (20) and tighten bolt (19). a Adjust the position of the ball
3 Mounting bolt: accurately before the shaft enters the
cover.
98 – 123 Nm {10 – 12.5 kgm}
3] Install holder (13) and tighten bolt (12).

3) Intermediate gear assembly
1] Using tool E12, press fit bearing (17) to 3 Mounting bolt:
gear (15) and install spacer (17a). 98 – 123 Nm {10 – 12.5 kgm}
D65EX,PX,WX-17 50-193
Power train
4] Install tube (11). 10.Installation of cover assembly

1) Install two sleeves (25) and five sleeves (24)
to the HSS case.
4) Input gear assembly

1] Install bearing (10) to gear (9).
2) Using eyebolts [1], install cover assembly
(5).
2 Cover mating face:
a Apply gasket to both surfaces of the case
and cover.
a Apply the gasket continuously on the
mating surface.
2] Install gear assembly (6).

3] Align the hole of ball (8) and install cage
(7) and ball (8).
4] Install snap ring (12).
11.Brake valve assembly

Install brake valve assembly (4).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
50-194 D65EX,PX,WX-17
Power train
12.Transmission speed sensors

When installing speed sensor (2) and install
cover (1), refer to "Adjusting transmission speed
sensor (replacement procedure)" in Testing and
adjusting.
D65EX,PX,WX-17 50-195
Power train
Removal and installation of final drive assembly

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
790-337-1032 Lifting tool t 1

791T-527-
Plate t 1 N Q
J 1 1110
01010-81680 Bolt t 2
01010-31645 Bolt t 2
Removal 5. Remove cover (2). [*2]

6. Using forcing screws [3], draw out drive shaft (3)
1. Separate track shoe assembly. For details, see
until the spline portion is pull out.
"Separation and connection of track shoe
assembly". a If drive shaft (3) cannot be pulled out, push
2. Using jacks, lift up the machine body and set up the track shoe grouser by using a jack etc.
stands [1] and [2] under the front frame and and fine-adjust the position where the shaft
steering case. can be pulled out easily.
7. Remove eleven inner mounting bolts (4) and
k Set the stand securely. 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.
4. Remove bracket (1). [*1]
8. Remove three cover mounting bolts (4a) of the

final drive case. Set tool J1 and the lever block
onto sling tap (P), and sling final drive assembly
(5). [*4]
50-196 D65EX,PX,WX-17
Power train
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}
• 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
Installation
removal.
[*1]
2 Threaded portion of mounting bolt for
bracket (1):
Adhesive (LT-2)
[*2]
D65EX,PX,WX-17 50-197
Power train
Disassembly and assembly of final drive

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
2 790-101-2470 Adapter (M20) t 2
3) Using eyebolts, remove shaft (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
3 790-101-2420 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 2. Sprocket hub assembly
791-112-1180 Nut t 2
1) Remove mounting bolts (3) and plate (4).
J 01643-22460 Washer t 2
4 791T-527- t 1 N Q
Plate
1130
791T-527-
Push tool t 1 N Q
1120
790-101-2102 Puller t 1
5 791-580-8110 Installer t 1
790-101-5321 • Plate t 1
6 790-101-5311 • Plate t 1
790-101-5221 • Grip t 1
01010-51225 • Bolt t 1
790-101-5401 Push tool kit t 1 2) Remove shim (5).
790-101-5441 • Plate t 1
7 790-101-5431 • Plate t 1
790-101-5421 • Grip t 1
01010-51240 • Bolt t 1
790-101-5630 Plate t 1 N
8 790-101-5421 Grip t 1
01010-51240 Bolt t 1
Disassembly
1. Shaft
1) Set the final drive assembly on the blocks
with the sprocket side up.
2) Remove mounting bolts (1).
50-198 D65EX,PX,WX-17
Power train
3) Using tool 2, disconnect sprocket hub

assembly (6) and bearing (7).
4) Using eyebolts, remove sprocket hub
assembly (6).
4) Remove floating seal (14).
5) Remove floating seal (8).

6) Remove bearing outer race (9).
7) Reverse sprocket hub assembly (6) and
remove bearing outer race (10).
5) Set two bars [2] under bearing (15) and pull

out bearing (15) about 5 mm by using flange
(P) of the cover as a fulcrum.
a Pull out the bearing evenly by a couple of
worker.
3. Cover assembly
1) Remove spacer (11).
2) Remove mounting bolts (12).
6) Using puller [3], pull out bearing (15).
3) Sling and remove cover assembly (13).
D65EX,PX,WX-17 50-199
Power train
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).
4) Remove two bearing outer races (25c) from

4. Carrier assembly the planetary gear.
1) Using three eyebolts, remove carrier
assembly (19).
5. Hub and case assembly

1) Remove thrust washer (26) and sun gear
2) Remove bolts (20) to remove holder (21). (27).
3) Pull out planetary gear shaft (22) and remove
planetary gear (23) and bearings (25a) and
(25b).
50-200 D65EX,PX,WX-17
Power train
5) Using tool J2, separate hub assembly (32)

from the case.
2) Remove gear mounting bolts (28).
6) Remove bearing (33).

7) Using the eyebolts, remove hub assembly
(32).
3) Using eyebolts, remove gear (29).
8) Remove bearing outer race (33a) from the

hub assembly.
4) Remove mounting bolts (30) and plate (31).
9) Remove spacer (34).
D65EX,PX,WX-17 50-201
Power train
10)Use puller [3], remove bearing (35). 4) Remove outer race (41) and oil seal (42)
from cage (40).
6. Cage assembly
1) Reverse the case and remove mounting 7. Gear assembly
bolts (38) of cage assembly (37). 1) Remove gear assembly (43).
2) Using forcing screws [4], remove cage
assembly (37) from the case.
2) Using puller [5], remove bearings (44) and

(45) from gear (46).
3) Remove shim (39).
50-202 D65EX,PX,WX-17
Power train
8. Case
1) Remove outer race (47) and oil seal (48)
from the case.
3) Using push tool [6], press fit bearings (44)

and (45) to gear (46).
• Press fitting force of bearing: 6 to 19 kN
{0.6 to 2.0 ton}
Assembly 4) Install gear assembly (45).
a Clean the all parts and check them for dirt or
a Lower and install the gear assembly
damage before installing.
gradually so that the oil seal lip will not be
a Coat the sliding surfaces of the all parts with damaged.
engine oil before installing.
1. Gear assembly
1) Using J5, install oil seal (48) to case (49).
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
projected part.
2 Oil seal lip:
Grease(G2-LI)
2 Between oil seal lips (part G): 2. Cage assembly
Grease (G2-LI) (Filling rate 40 to 60 1) Using tool J6, install oil seal (42) to cage
%) (40).
2 Oil seal press-fitting portion: a When installing the oil seal, take care of
Liquid gasket (LG-5) 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
projected part.
2 Oil seal lip:
Grease(G2-LI)
2) Using tool J7, press fit bearing outer race

(47) to the case.
• Press fitting force of bearing: 0 to 8 kN {0
to 0.9 ton}
D65EX,PX,WX-17 50-203
Power train
2 Oil seal press-fitting surface: 2] Using feeler gauges under this condition,
Liquid gasket (LG-5) measure clearance a and b between
cage (40) and case (49).
3] Referring to Table 1, set shim quantity c
from the total of clearances a and b.
4] 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}

(41) to cage (40).
• Press fitting force of bearing: 0 to 8 kN {0
to 0.9 ton}
3) Install the O-ring to cage assembly (37) and

adjust shim (39).
4) Adjustment of shim
• Adjust the clearance of the pinion bearing
1] Tighten cage (40) mounting bolts B, C, E,
and F evenly.
3 Mounting bolt:
20 Nm {2 kgm}
50-204 D65EX,PX,WX-17
Power train
Table 1
a + b (mm) Combination of shims Total
14X- 14X- 14X- shim
27- 27- 27- thick-
Larger
Below 11260 11270 11280 ness δ
than
(mm)
(t = 0.2) (t = 0.3) (t = 1.0)
0.98 1.18 2 1 0.70
1.18 1.38 1 2 0.80
1.38 1.58 3 0.90 3) Using tool J6, press fit two bearing outer
1.58 1.78 1 1.00 races (33a) to hub (32).
1.78 1.98 1 3 1.10 {0.1 to 1.0 ton}
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

4) Using eyebolts, set hub assembly (31) to the
3.58 3.78 2 2.00 shaft.
3.78 3.98 1 3 1 2.10
3.98 4.18 1 2 2.20
4.18 4.38 1 2 2.30
4.38 4.58 2 2 2.40
4.58 4.78 1 1 2 2.50
4.78 4.98 2 2 2.60
4.98 5.18 2 1 2 2.70
5.18 5.38 1 2 2 2.80

5) Set the bearing to the shaft.
5.38 5.58 3 2 2.90
5.58 5.78 3 3.00
3. Hub and case assembly

1) Using tool J3, press fit bearing (35) to case
(49).
{1.3 to 3.4 ton}
2) Install spacer (34).
D65EX,PX,WX-17 50-205
Power train
6) Using tool J3, press fit bearing (33) to case 9) Tighten gear mounting bolts (28).
(49).
2 Mounting bolt:
Adhesive (LT-2)
{1.3 to 3.4 ton}
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
7) Install plate (31).

Adhesive (LT-2) 10)Install sun gear (27) and thrust washer (26).
230 – 289 Nm {23.5 – 29.5 kgm}
4. Carrier assembly
a Match the identification marks of the inner
8) Using eyebolts, install gear (29). race, outer race and spacer when
assembling because the bearings for the
planetary gears are kept in matched set.
(25C) to planetary gear (24).
{0.4 to 1.6 ton}
50-206 D65EX,PX,WX-17
Power train
3 Mounting bolt:
230 – 289 Nm {23.5 – 29.5 kgm}
2) Install bearings (25A) and (25B) and spacer

(25D) to planetary gear (24).
5) Using 3 eyebolts, install carrier assembly

(19).
3) Set the planetary gear assembly to the

carrier and press fit shaft (23).
a Aligning the holes of the bearing and 5. Cover assembly
spacer, press-fit the shaft gradually. 1) Install ring gear (18) and tighten four lock
plates (16).
4) Install bolts (21) and holders (22).

2 Mounting bolt:
2) Install spacer (15a).
Adhesive (LT-2) 3) Using tool J4, press fit bearing (15). Press
fitting force of bearing: 11 to 39 kN {1.2 to
3.9 ton}
D65EX,PX,WX-17 50-207
Power train
a After installing the floating seal, check

that its leaning is less than 1 mm.
4) Using eyebolts, install the O-ring to cover

assembly (13), and then install them to the
case assembly.
6. Sprocket hub assembly
a Check that there is no dent, rust, oil, 1) Using tool J8, press fit bearing outer race (9).
grease, or water on the mating surfaces
of the case and cover.
{0.7 to 3.2 ton}
5) Tighten mounting bolts (12).

2) Install sprocket teeth (10) to the sprocket
3 Mounting bolt: hub.
230 – 289 Nm {23.5 – 29.5 kgm}
3 Mounting bolt:
6) Install spacer (11).
931 ± 98 Nm {95 ± 10 kgm}
7) Using tool J5, press fit floating seal (14).

3) Using tool J5, press fit floating seal (7).
a Remove oil and grease completely from
the O-ring and O-ring contact surface, a Remove oil and grease completely from
and dry before installing. the O-ring and O-ring contact surface,
and dry before installing.
50-208 D65EX,PX,WX-17
Power train
a After installing the floating seal, check a Adjust the clearance between the end
that its leaning is less than 1 mm. face of cover (3) and bearing (6)
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.)
4) Using eyebolts, install sprocket hub

assembly (6) to the cover assembly.
a Check that the sliding surface of the
floating seal is free from dirt and apply
engine oil to it lightly.
5) Set bearing (7).
δA + δB (mm) Quantity of shims Total

14X-27 14X-27 shim
Larger -51370 -51380 thickness
Below
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
0.90 1.10 0 2 0.4
1.10 1.50 1 0 0.5
6) Using tool [3], press fit bearing (6). 1.50 1.90 1 1 0.7
1.90 2.10 1 2 0.9
a Rotate the sprocket hub assembly while
2.10 2.50 2 0 1.0
performing the press fitting.
7) Install plate (4) and secure it with the
mounting bolts.
{1.2 to 3.9 ton}
a Tighten the nine bolts evenly.
2 Mounting bolt:
Adhesive (LT-2)
D65EX,PX,WX-17 50-209
Power train
3 Mounting bolt:
230 – 289 Nm {23.5 – 29.5 kgm}
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}
• 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}
50-210 D65EX,PX,WX-17

Removal and installation of track frame assembly
Removal
assembly".
2. Using jacks, raise the machine off the ground
and place stands [1] and [2] under the front
frame and steering case.
k Set the stand securely.
6. Sling the track frame assembly.

7. Remove lock (5) and pull off pin (6). [*1]
3. Remove the protection cover pitch or tilt cylinder

hose and disconnect hoses (1) and (2).
8. Remove bolt (7) and plate (8), and sling and

remove track frame assembly (9). [*2]
a Place an oil container since oil flows out from
the pivot shaft case.
4 Track frame assembly:

1,600 kg (D65EX-16)
1,800 kg (D65PX-16)
4. Remove pivot shaft cover (3). 6 Pivot shaft case:

a The following figure shows D65EX-16. 4.5 l
D65EX,PX,WX-17 50-211
a Add oil to the pivot shaft case, up to a level of

100 mm from the oil filler plug (see the drawing).
Installation
• Perform installation in the reverse order to
removal.
[*1]
k When aligning the mounting holes for the pin,
never insert your fingers in the holes.
[*2]
a Apply power train oil (TO30) to (a) surface of
track frame (9) when installing the track frame
into the pivot shaft.
3 Plate mounting bolt :
455 to 565 Nm {46.5 to 58 kgm}
5 Pivot shaft case:

4.5 l (TO30)
50-212 D65EX,PX,WX-17
Removal and installation of idler assembly

k For safety reasons, no one is allowed to be in

front of the idler assembly during the work.
Removal
1. Remove the blade assembly. For details see
"Removal and installation of blade assembly".
assembly".
3. Loosen mounting bolt (2) and spring seat 7. Remove yoke (8).
clamping bolt (3), and remove support (1).
8. Sling and remove idler assembly (4).

4. Pass a wire through the hook hole of the idler.
Sling idler assembly (4), slide it along the top of
the track frame, and pull it forward.
4 Idler assembly:
200 kg
5. Remove guide plate (5).
Installation
removal.
a Install the idler assembly to the machine with the
oil filler plug facing toward the left side of the
machine.
6. Remove spring (6) and seat (7).
D65EX,PX,WX-17 50-213
a Adjust shim
Adjust clearance (a) between idler support (1)
and guide plate (5) to 2 mm.
50-214 D65EX,PX,WX-17
Disassembly and assembly of idler

a Special tools a When lifting the idler using sling rope [2],
prevent sling rope [2] from fanning out using
New/Redesign
wire or rope [3].
Necessity
8. Remove floating seals (11) and (12) from idler
Sketch
Sy-
Q'ty
Part number Part name (7).
mbol
791-515- t 1
1 Installer
1520
L
791-601- Oil pump t 1
2
1000
Disassembly
1. Remove the oil filler plug to drain oil.
6 Idler:
0.24 to 0.26 l
2. Place idler assembly (1) on the block.
3. Remove mounting bolt (2) to remove support (3).
a Check and note the number of shims
removed.
4. Remove nut (4) and remove bolt (5) by driving it
out from the nut side.
9. Remove floating seal (13) from shaft and

support assembly (10).
5. Using push puller tool [1], remove support (8)

from idler (7).
6. Remove floating seal (9) from support (8).
10.Remove nut (14) and remove bolt (15) by driving

it out from the nut side.
11.Using push puller [1], remove shaft (17) from
support (16) following the same procedure in
Step 5.
7. Sling and remove idler (7) from shaft and

D65EX,PX,WX-17 50-215
12.Remove two bushings (18) from idler (7). 4. Using tool L1, install floating seal (9) to shaft and
Assembly
1. Using push tool [4], press fit two bushings (18) to a When installing the floating seal, clean,
idler (7). degrease and completely dry the contact
surfaces (hatched area) of O-ring and
floating seal.
Take care not to allow dirt and foreign matter
to attach on the contact surface of the
floating seal.
a After installing the floating seal, check the
following.
Leaning of seal: Max. 1 mm
Protrusion of seal (a): 7 to 11 mm
2. Fit the O-ring to shaft (17) and install the shaft to

support (16).
a When installing shaft (17), align the groove in
the shaft with the one in the support.
a When installing the shaft, be sure to insert it
into the support through the side with no oil
filler port.
3. Drive in bolt (15) and tighten nut (14).
3 Mounting nut:
5. Install the O-ring to the shaft.
230.4–308.9 Nm {23.5–31.5 kgm} 6. Using tool L1, install floating seal (8) to idler (3).
a For the installation procedure, see step 4.
50-216 D65EX,PX,WX-17
a Completely degrease and dry the O-ring and

the O-ring contact surfaces before installing.
O-ring and O-ring contact before installing.
a After installing the floating seal, check that its
leaning is less than 1 mm.
7. Sling and install idler (3) to shaft and support

assembly (6).
a Use wire or rope to prevent sling rope [3]
from fanning out. (Part A)
10.Install support (8) to idler (7).

a When installing shaft (17), align the groove in
the shaft with the one in the support.
11.Drive in bolt (5) and tighten nut (4).
3 Mounting nut:
230.4 to 308.9 Nm {23.5 to 31.5 kgm}
12.Set shims (3a) and install support mounting bolt

(3).
13.Install spring seat clamping bolt (2).
8. Add oil to the idler.

a The idler may be filled with oil at this time.
For the normal method of refilling, see
"Refilling oil".
5 Idler:
0.24 to 0.26 l
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). 14.Refilling
• Normal method of refilling
D65EX,PX,WX-17 50-217
Remove plug (20) from shaft (17), add oil

through the oil filler port, and install plug (20).
5 Idler:
0.24 to 0.26 l
3 Oil filler plug:
98.0 to 137.2 Nm {10 to 14 kgm}
• Filling by evacuation
1) Remove plug (20) from shaft (17).
2) Using tool L2, add the oil through the oil filler
port and install plug (20).
5 Idler:
0.24 to 0.26 l
3 Oil filler plug:
98.0 to 137.2 Nm {10 to 14 kgm}
50-218 D65EX,PX,WX-17
Removal and installation of recoil spring assembly

Removal
1. Remove the idler assembly. For details see
"Removal and installation of idler assembly".
2. Sling and remove recoil spring assembly (1).
[*1]
4 Recoil spring assembly:

500 kg
Installation
removal.
[*1]
a Install recoil spring assembly (1) in the track
frame.
1. Lift the end of recoil spring assembly (1)
using chain block [1] and level the assembly.
2. Push in recoil spring assembly (1) to install it
to the track frame.
D65EX,PX,WX-17 50-219
Disassembly and assembly of recoil spring

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
Compressor
791-685-8005 type B t 1
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 3. Remove holder (13) from recoil spring assembly
790-101-1600 Cylinder t 1 (12).
Disassembly k For safety reasons, no one is allowed to be

1. Remove yoke and piston assembly (2) from in front and back of the recoil spring
recoil spring assembly (1). assembly during the work.
4. Disassemble the holder.
1) Remove cover (14) from holder (13).
2. Disassemble the yoke and piston.

1) Remove snap ring (3), then remove ring (4),
packing (5) and ring (6). 2) Remove seal (15) from holder (13).
2) Remove bolt (7) to remove plate (8) and
washer (9).
5. Set recoil spring assembly (1) to tool M.
3) Using push tool [1], remove piston (11) from k Since the load at installed length of the
yoke (10) by using a press. spring is large and dangerous, set recoil
spring assembly securely to the tool.
a If cylinder (19) is not broken and shaft
end nut (16) is not fallen out, disassemble a Load at installed length of spring:
the yoke and piston as follows: 189.5 kN {19,320 kg}
50-220 D65EX,PX,WX-17
the recoil spring is removed and safety is

confirmed.
1) Set recoil spring assembly (1) to tool M.
k Since the load at installed length of the

spring is large and dangerous, set recoil
a Load at installed length of recoil spring:
193.2 kN {19,700 kg}
2) Apply hydraulic pressure slowly to secure the
recoil spring assembly.
6. Apply hydraulic pressure gradually to compress 3) Under the condition of Step 2) above,
the spring. Tighten nut (16) until spacer (17) remove mounting bolt (21) from holder (13).
comes off, remove spacer (17) and nut (16). 4) Release hydraulic pressure gradually and
relieve tension of the recoil spring.
7. Release hydraulic pressure gradually and

relieve tension of the spring.
8. Remove spring (18) and cylinder (19) from case
(12), and remove bushing (20) from cylinder
(19).
Assembly
1. Press fit bushing (20) to cylinder (19), and
temporarily assemble case (12), spring (18) and
cylinder (19).
2. Set temporarily assembled recoil spring
k If mounting bolt (21) is removed from holder
assembly (1) to tool M.
(13) when there are broken cylinder (19) and
fallen out shaft end nut (16), the recoil spring
k Since the load at installed length of the
fly off to the front of the machine. Thus,
spring is large and dangerous, set recoil
disassemble the yoke and position as
follows:
k Do not allow anyone to remain in front of and

at the back of the recoil spring assembly until
the holder (13) is separated from case (12),
D65EX,PX,WX-17 50-221
5. Release hydraulic pressure gradually to relieve

tension of spring, then remove recoil spring
assembly (1) from tool M.
6. Install seal (15) to holder (13), then install cover
(14).
2 Seal lip:
Grease (G2-LI)
7. Install holder (13) to case (12) of the recoil
spring.
3. Apply hydraulic pressure slowly to compress the

recoil spring so that the installed length of the
spring becomes specified value.
a To protect the threaded portion when the
spring is compressed, use chain block [2] to
center the recoil spring and compress it.
a Installed length of recoil spring: 580 mm
4. Install nut (16) and install spacer (17).

8. Assemble the yoke and piston.
1) Using push tool [2], press fit piston (11) to
yoke (10).
50-222 D65EX,PX,WX-17
2) Install washer (9) and plate (8), and tighten

bolt (7).
a Bend the plate securely.
3) Install ring (6), packing (5) and ring (4), and
install snap ring (3).
9. Install yoke, piston assembly (2) to recoil spring

assembly (1).
D65EX,PX,WX-17 50-223
Removal and installation of track roller assembly

Removal 2 Track roller mounting bolt thread:
1. Decrease the track tension. For details, see Adhesive (LT-2)
"Separation and connection of track shoe 3 Track roller mounting bolt:
assembly".
343 to 427 Nm {35.0 to 43.5 kgm}
2. Remove the mounting bolts of track roller guard
(1). [*1] a Install the oil plug so that it faces outside of the
3. Remove track roller mounting bolts (2). machine.
4. Start the engine and raise the machine by

operating the blade and hydraulic jack.
k When the machine has been raised, place a

block on the track shoe and lock the work
equipment lock lever and brake lever.
5. Remove track roller assembly (3).[*2]
4 Track roller assembly:

Single flange: 55 kg
Double flange: 65 kg
Installation
removal.
[*1]
2 Roller guard mounting bolt thread:
Adhesive (LT-2)
[*2]
50-224 D65EX,PX,WX-17
Disassembly and assembly of track roller

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
2 791-530-1520 Installer t 1
L
4 791-601-1000 Oil pump t 1
Disassembly
1. Remove the oil filler plug to drain oil.
6. Sling roller (7) and remove it from shaft
6 Track roller: assembly (8).
0.34 l
2. Set track roller assembly (1) to block [1].
3. Push in collar (3) by using push puller [2], then
remove lock (4) to remove collar (3).
7. Remove floating seal (9) and bushing (10) (one

on each side) from roller (7).
4. Remove floating seal (5) from collar (3).
8. Remove floating seal (11) from shaft assembly

(8).
9. Remove lock pin (12), then remove collar (14)
from shaft (13).
5. Remove floating seal (6) from track roller
assembly (1).
D65EX,PX,WX-17 50-225
a When installing the floating seal, clean,

degrease and completely dry the contact
faces of O-ring and floating seal (hatched
area). Take care not to allow dirt and foreign
matter to attach on the contact surface of the
floating seal.
following.
Leaning of seal: Max. 1mm
10.Remove floating seal (15) from collar (14).
3. Install collar (14) with the O-ring to shaft (13),

and install lock pin (12).
Assembly
1. Using push tool [3], press fit two bushings (10) to
roller (7).
4. Using tool L2, install floating seal (11) to shaft

(8).
2. Using tool L2, install floating seal (15) to collar

(14).
5. Using tool L2, install floating seal (9) to roller (7).

50-226 D65EX,PX,WX-17
6. Sling roller (7) and install it to shaft assembly (8). 9. Place track roller assembly (1) on block [1].
10.Install collar (3) with the O-ring to the shaft.
Using push puller [2], push in collar (3), and
install lock (4).
7. Using tool L2, install floating seal (6) to roller

assembly (1).
11.Add oil to the track roller.
1) Remove plug (16) and add oil through the oil
filler using tool L4.
5 Track roller:
0.34 l (GO140)
2) Tighten plug (16).
3 Plug:
98 to 137.2 Nm {10 to 14 kgm}
8. Using tool L2, install floating seal (5) to collar (3).

D65EX,PX,WX-17 50-227
Removal and installation of carrier roller assembly

a The following figure shows D65EX-16.
Installation
Removal • Perform installation in the reverse order to
1. Decrease the track tension. For details, see removal.
"Separation and connection of track shoe • Adjust the track tension. For details, see Testing
assembly". and adjusting, "Adjusting track shoe tension".
2. Use the hydraulic jack [1] to raise the track shoe.
3. Remove mounting bolts (1) of the carrier roller

assembly.
4. Sling carrier roller assembly (2) and pull it out of

support (3).
4 Carrier roller assembly:

35 kg
50-228 D65EX,PX,WX-17
Disassembly and assembly of carrier roller

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
L 3 796-230-1110 Installer t 1
Disassembly
1. Remove oil filler plug (1) to drain oil.
6 Carrier roller : 6. Remove bearing (9) and two outer races (10)
0.24 l from roller (8).
2. Remove snap ring (2), then remove cover (3).
7. Remove collar (12), floating seal (13), and

3. Remove bolt (4) to remove spacer (5). bearing (14) from shaft (11).
8. Remove floating seal (15) from collar (12).
4. Place carrier roller assembly (6) on block [1].

5. Using push tool [2], remove shaft assembly (7) Assembly
by using press.
1. Press fit two outer races (10) to roller (8).
D65EX,PX,WX-17 50-229
2. Using push tool [3], press fit collar (12) to shaft 4. Install floating seal (13) to the shaft.
(11).
a For precautions to take when installing the
floating seal, 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).
a When installing the floating seal, completely

clean, degrease and dry the contact surfaces
of the O-ring and floating seal (hatched area).
Take care not to allow dirt and foreign matter 7. Using push tool [6], install bearing (9).
to attach on the contact surface of the a Press fit roller (8) while rotating it by hand.
floating seal.
following.
Leaning of seal: 1 mm
50-230 D65EX,PX,WX-17
8. Install spacer (5) and tighten bolt (4).

3 Bolt:
245 to 309 Nm {25.0 to 31.5 kgm}
9. Add oil to the carrier roller.
5 Carrier roller (gear oil):

0.24 l (GO140)
10.Fit the O-ring to cover (3) and install it to the
roller, then install snap ring (2) .
11.Tighten plug (1).
D65EX,PX,WX-17 50-231
Separation and connection of track shoe assembly (Standard type track

shoe)
Checking before separation of the Separation of track shoe assembly
track shoe assembly
(normal)
k In some cases, it may be extremely a If no abnormality is detected by "Checking
dangerous to separate the track shoe before separation of track shoe assembly",
assembly. To prevent danger, perform the perform the following procedure.
following checks before separation of the
track shoe assembly. 1. Start the engine and Locate master link (3)
above the idler (a little backward from the
center).
k Do not loosen the lubricator more than one a Place block [1] between the carrier rollers
turn. If the grease does not come out and place block [2] under the front track so
sufficiently, move the machine backwards that the mating faces of master link do not
and forwards. open until the master bolts are removed.
1. Remove cover (1), loosen lubricator (2) of the

adjustment cylinder to discharge the grease.
k Do not loosen the lubricator more than one

turn.
2. Loosen track tension.[*1]
k Do not loosen lubricator (2) more than one

turn.
a If the track tension is not decreased even
when the lubricator is loosened, move the
machine backwards and forwards.
2. After the track tension is decreased, follow the
procedure in the "Separation of track shoe
assembly (normal)".
3. If the track tension is not decreased and is still
high,
follow the procedure in the "Separation of track
shoe assembly (when track frame has internal
defect)".
a A problem may have occurred inside the
track frame (such as damaged recoil spring
case, broken recoil spring set bolt, coming off
of shaft end nut, etc.).
3. Remove track shoe (4). [*2]
a Loosen each of four mounting bolts (5) by
one or two turns. Do not remove only one
bolt without loosening the other three. Check
that they can be unscrewed smoothly, and
then remove them.
50-232 D65EX,PX,WX-17
a If a bolt does not turn smoothly and it is a Check that all the grease is discharged.
unscrewed forcibly, the threads of the bolt
and master link (3) may be damaged.
2. Move the machine forward slowly to press the

track shoes on the idler side against large block
4. Sling the front end of master link (3), move the [3] or a wall (or a blade of another machine of
machine backward slowly to spread track shoe same size). When the recoil spring and the track
assembly (5). shoe assembly sags, stop the machine and
apply the brake.
a Length of track: Approx. 9.5 m
a Locate master link (3) between the idler and
front carrier roller.
a Apply chain block [4] between the carrier
roller support and link to assure safety.
3. Remove track shoe (4) and disconnect master
link (3).[*2]
a Loosen each of the four bolts by one or two
turns. Do not remove only one bolt without
loosening the other three. Check that they
can be unscrewed smoothly, and then
remove them.
a If a bolt does not turn smoothly and it is
Separation of track shoe assembly unscrewed forcibly, the threads of the bolt
(When track frame has internal and master link (3) may be damaged.
defect) 4. Move the machine slowly in reverse to separate
the track shoe assembly.
a If any abnormality is detected by "Checking
before separation of track shoe assembly",
perform the following procedure.
k If a problem has occurred inside the track
frame, the track shoe may spring back when
the assembly is separated. Also, the idler
may fly out when the track shoe assembly is
separated. This is potentially very dangerous.
Be sure to separate the track shoe assembly
as follows.
1. Loosen track tension.[*1]
k Do not loosen lubricator (2) more than one Installation

turn.
• Perform connection in the reverse to separation.
a If the track tension is not decreased even
when the lubricator is loosened, move the
[*1]
machine backwards and forwards.
D65EX,PX,WX-17 50-233
a Adjust the track tension. For details, see Testing

and adjusting, "Testing and adjusting track
tension".
[*2]
a Tighten the shoe mounting bolts for the master

link in the following order.
a Finger-tighten the four bolts until the mating

faces of the master link are fitted.
a If the bolts are tightened forcibly before the

master link mating faces are fitted, the threads of
bolts and master link may be damaged.
2 Shoe bolt (master link):

Molybdenum disulfide lubricant (LM-P)
3 Shoe bolt:
1st time: 343 ± 39 Nm {35 ± 4 kgm}
2nd time: 180 degrees (0/-20 degrees)
(angle tightening)
50-234 D65EX,PX,WX-17
Separation and connection of track shoe assembly (PLUS type track

shoe)
a In this section, the difference from the standard 3 Shoe bolt (Master link)
type track shoe is explained. Initial torque: 343 ± 39 Nm {35 ±4 kgm}
Separation Retightening angle: 180 (+0/-20) deg.
a The details of separation and connection of track
shoe assembly are same as those of the
standard type track shoe. Therefore, see
assembly (standard type track shoe)".
Installation
a Install the track shoe for the master link
Install the track shoe by specifying the positions
of shoe-side master link (1) and shoe grouser (2)
as shown in the following figure.
a Tighten the shoe bolt for the master link

• Finger-tighten the four shoe bolts until the
mating faces of the master link (a) are fitted.
• If shoe bolts (3) are tightened forcibly before
the master link mating faces (a) are fitted, the
threads of shoe bolts and master link may be
damaged.
• Tighten four shoe bolts (3) in the order
shown in the following figure.

D65EX,PX,WX-17 50-235
Overall disassembly and assembly of track shoe (standard type track

shoe)
a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
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
791-646-7560 Guide t 1
t 2. Disassembly of track link
R 791-932-1110 Push tool 1
4 791-646-7523 Bar t 1 1) Place the link assembly on the link press and
791-646-7590 Guide t 1 hit it with a hammer to fit the bushing to jaw
t [1] firmly.
5 790-701-3000 Checker 1
6 791-432-1120 Installer t 1 a If the link tread or outer periphery of the
7 791-601-1000 Oil pump t 1 bushing is worn, adjust the height of jaw
[1] or guide plate to align the pin or
Overall disassembly bushing with disassembly jigs [2] and [3]
1. Removal of track shoe in the lateral direction so that the pin-bore
Sling the track shoe assembly and place the or bushing-bore in the link is not
assembly on the floor with the shoes up. damaged during disassembly.
Remove the track shoe bolt by using the impact a If the pin or bushing is not aligned with
wrench, and remove the shoe. the jig, the bore in the link may be
a If the shoe bolt is not loosened (if its damaged or the pin or bushing may be
rotational torque is not reduced to zero) even broken during disassembly.
after it is loosened by one turn, loosen other
bolts so that the bolt can be loosened
smoothly.
a Forcibly rotating the bolt the rotational torque
of which is not reduced to zero may cause
adhesive transformation between the bolt
and link, which may require repairs.
a When repositioning the shoe assembly, take
care not to damage the master links.
a If the shoe nut needs to be removed by gas
cut, keep the temperature in the seal section
below 80 °C to prevent thermal deterioration
of the seals and take measures to prevent a Using tool R1, drive in the small plug of
the spatters from entering through the the pin toward inside after disassembly
clearances between the links. so that the work place does not become
dirty.
50-236 D65EX,PX,WX-17
2) Operate the left cylinder to pull out the left 3. Checking

link and the press fit portion of the pin and Check the removed parts for following items,
bushing simultaneously. then determine to reuse them for a lubricated
track or grease lubricated track, depending on
a Check the pulling-out force of the pin and
the check results. Also, comprehensively
bushing to see if the press-fitting force is
determine to reuse the link assembly for a
obtained, that is required when they are
lubricated track.
reused by being turned 180 degrees.
a For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage,
Lubricated track".
1) Check the parts visually for damage. If a
parts seems to be damaged, check it by dye
check or magnaflux inspection. If it has any
crack, it cannot be reused. Discard it.
3) Return the left cylinder and operate the right

cylinder to pull out the right link and the press
fit portion of the pin and bushing
simultaneously.
2) Measure the outside diameter of the press-

fitting portions of the pin and bushing and the
inside diameter of the pin and bushing press-
fitting bores of the link by using the
micrometer and cylinder gauge, to see if the
allowable interference is obtained. Note that
the standard interference must be secured
between the pin and link when they are
reused for a lubricated track.
4) Return the right cylinder, take out the right a If the allowable interference is not
and left links, pins, bushings and spacers, obtained, replace the parts with new
and feed the next set of the link assembly to ones.
the jaw.
a If the bushing end faces and its sealing
surface are damaged, oil will leak.
Accordingly, handle them carefully.
D65EX,PX,WX-17 50-237
a For the dimensional criteria, see (trichloroethylene, etc.) Wipe off the
"Structure, function and maintenance cleaning agent with a cloth from them.
standard, Track shoe".
2) When reusing the pin, chamfer the edges of

a Precautions for storage its end faces with a grinder. Remove the
nodules formed on its press-fitting portions
1. Store the seal without removing it from the with the grinder.
link so that the counterbore portion of the link
does not rust, and take care not to damage a If the edge of its end face is worn and
the seal lip. sharpened, the press-fitting portion of the
2. Apply rust-preventive oil to the pin and pin may cause galling, resulting in oil
bushing press-fitting bores, shoe mounting leak.
surface of the link, and mating face of the
master link.
3. Apply rust-preventive oil to the all surfaces of
the pin, bushing, and spacer prior to storage.
Take extreme care not to damage the
bushing end faces.
3) Clean the dirty links, pins, bushings, and

spacers. Remove the nodules formed on the
link and bushing with the grinder, too.
a Clean the parts immediately before the
assembly because they easily rust.
a Do not grind the bushing end faces
Overall assembly because doing so may cause oil leak.
a For the overall assembly, see "Parts judgment 4) If large plug (3) was removed from the pin,
guide, Undercarriage, Reversal procedure of drive in the plug according to the following
lubricated track". procedure.
Rebuilding the lubricated track 1] Clean the pin hole by using tool R2.
1. Preparation work
1) Cleaning of seal assembly
Remove seal assembly from the link, divide it
into seal ring (1) and load ring (2), and clean
them.
a Clean the seal ring and the load ring
quickly because they are easily
deteriorated by the cleaning agent
50-238 D65EX,PX,WX-17
2] Insert large plug (3) into the hole 6) Adjust the installed dimensions of the link
periphery of the guide through the press press-fitting jigs to keep the protrusion
window of the guide of tool R3. of the pin and bushing constant and to keep
the installed dimensions of the seal within the
a Apply oil (G090) to the outside
standard range.
periphery of the large plug and install
it with the small diameter end facing • Dimension (c): 3 mm
the pin. (d): 3 mm
3] Press the bar of tool R3 with the hand (e): 49.7 mm
until the plug stops. a If the pin end face (portion f) or link side
4] Press the large plug with the bar until the faces (portion g) and (h) are worn, add
guide touches pin (4). the wear reduction to the standard
5] Hit the bar with a hammer to drive in the installed dimensions of the press-fitting
plug. jigs so that the right and left projections of
a Driving distance (a) from pin end face: the pins and bushings on both sides are
even.
6 ± 2 mm
a If chamfered face of the pin hole is lost
due to wear, chamfer it by using a
small-sized grinder (grindstone end
angle: 45 to 60 degrees) so that the
plug is not damaged.
a Set the link receiving face of jaw [4]

upright.
a Replaceable wear plate [5] is desirable.
5) Installation of seal assembly

Clean and degrease the portions indicated
with heavy line b (counterbore portion of the
link and seal assembly), and push in the seal
assembly to the bottom by using tool R6.
a Do not apply oil or grease to the
counterbore portion of the link and the
seal assembly because any adhered oil
or grease causes the seal to turn and its
sealing performance is lowered.
D65EX,PX,WX-17 50-239
7) Adjust the relief pressure of the link press so

that the pressing force of the press does not
exceed the standard value.
a If the pressing force is excessive, the
spacer is pressed against the bushing
excessively. As a result, the spacer may
be broken or abnormal wear may occur
between the spacer and bushing end
face.
a Pressing force for pin and bushing: 539
kN {55 ton}
Pressing force C 1.8 x Average pressure 3) While checking the distance between the
(Adjust the relief pressure of the link shoe bolt holes of the right and left master
press to obtain the pressing force.) links by using the shoe bolt pitch gage, press
2. Assembly of link fit the master links to the bushing until the
1) Apply oil (GO90) to the mating surfaces of distance is the standard value.
the pin and bushing with a clean brush and a Remove all steel chips generated by the
assemble them, then set them on the press-fitting process completely with
bushing jaw of the link press. compressed air.
a When reusing the bushing (by turning it 4) Turn over the master links and check that
180 degree), set it with the worn outside they are press-fitted in parallel.
surface facing the shoe mounting face of
the link (set the bushing on the link press
with the face up).
5) Measure the right and left projections of the

bushing with a depth gauge.
a Adjust the link press press-fitting jigs so
2) Set the right and left master links having that the right and left protrusions of the
bushing-bore with their shoe mounting faces bushing are even.
up, and press fit them to the bushing.
a At this time, use the master links having
pin-bore as supports.
a Bushing press-fitting force: 98 to 147 kN
{10 to 15 ton}
6) Send out the master link portion, and then

set the next pins and bushings.
50-240 D65EX,PX,WX-17
a Install the pin, even it is reused, with its

cross hole facing the link tread as in the
case of new one.
a If it is not installed so, the strength of the
assembly may be lowered. Accordingly,
indicate the direction of the cross hole on
the end face to prevent wrong installation.
9) Use minor adjustment spacer [6] to press fit

the pin until its end face reaches the bottom
of the receiver jig.
a Adjust the depth of the receiver jig hole so
that the right and left protrusions of the
pin are even.
7) Set the right link and install the spacer to the

pin.
a Check that the seal surfaces and bushing
end faces are free from dirt, then apply
gear oil (GO90) on them using a clean
cloth or brush.
a Wipe the spacer with a clean cloth before
installing.
10)Set the left link and install the spacer to the

pin.
a Apply gear oil (GO90) similarly to the right
link.
8) Using the right jig as receiver jig and the left

jig as pusher jig, press fit the pin and bushing
simultaneously.
a Press fit them smoothly because bumpy
press-fitting may cause the seal to come
off the link.
a When the seal comes off the link, stop the 11)By using the left jig as receiver jig, and the
press-fitting and set the seal to the link right jig as pusher jig, press fit the left link.
correctly, then restart the press-fitting. a When press fitting, take care that the right
a Press-fitting force for pin and bushing: and left seals and spacers do not come
245 to 343 kN {25 to 35 ton} off.
Press-fitting force for pin and bushing:
245 to 343 kN {25 to 35 ton}
D65EX,PX,WX-17 50-241
12)Perform the press fitting until the link, 14)Use tool R5 for each link assembly to
spacers, and bushing are mutually fitted. remove air from inside the pin, and check the
sealing performance.
a Actually, you cannot see from outside if
the above parts are fitted. Accordingly, a Keep the degree of vacuum inside the pin
control the hydraulic pressure of the link at 91 to 95 kPa {680 to 710 mmHg} for 5
press. Set the relief pressure to a proper seconds to check that the pressure does
level and raise the pressure of the link not change. If the pressure changes,
press to that level while performing the disassemble the link assembly to check
press fitting. the seals. If no abnormality is found,
assemble them.
a For the relief pressure settings, see "1.
Preparatory work."
a Check that adjacent two sets of links pivot
on the pin.
15)Use tool R7 to add gear oil (GO90) until the

charged pressure rises to 196 to 294 kPa {2
to 3 kg/cm2 }.
a For cold or extremely cold district, supply
13)Using the shoe bolt pitch gage, check that Komatsu genuine engine oil (150-09-
the distance between the shoe bolt holes is 19270 or 195-32-61990), which has
within the standard range. excellent low-temperature characteristics,
a If the distance between the shoe bolt instead of gear oil (GO90).
holes is longer than the standard range,
disassemble and check for abnormality,
then assemble them again if no
abnormality is found.
a If the distance between the shoe bolt
holes is less than the standard range and
the track shoe cannot be installed, then
wear of the spacer or bushing end face
may exceeds the allowable limit. In this
case, disassemble it and replace the
relevant part.
50-242 D65EX,PX,WX-17
a If the charged oil pressure is increased

too much, it has bad effects on the seals.
17)Install the master links having pin-bore at

last.
a Check that the right and left master links
a Add oil up to the level where depth (j) of
are press fitted in parallel.
the space between pin (4) upper surface
3. Installation of track shoe
and the top of the oil level is in the
following range when the pin is left with 1) Place the link assembly on the bed, and
the large plug (3) side up (the link install the track shoe by using the shoe bolt
assembly placed on its side) for thirty impact wrench and torque wrench.
minutes. 2 Shoe bolt:
• Dimension (j): 50 to 80 mm Molybdenum disulfide lubricant (LM-
P)
3 Shoe bolt (regular link)
Initial torque: 539 ± 49 Nm {55 ± 5
kgm}
Retightening angle: 120 ± 10 deg.
16)After supplying oil, drive in the small plug to

the specified position by using tool R4.
a For the driving procedure, see the large
plug side ("1. Preparations for work, Step
4)").
a Apply oil (GO90) on the outside periphery 2) For the track that has two master link joints
of the small plug. and consists of two track shoe assemblies,
• Driving depth from end face: 2.5 ± 1 mm place the two assemblies on a level place in
a line with the track shoes up.
3) Pull master links with pin-bore (5) of one
assembly and master links with bushing-bore
(6) together and contact their mating faces
each other.
4) Place shoe (7) on the master links and their
mating faces are in close contact.
5) Check that shoe bolts (8) can be tightened
with fingers easily, then connect the links
with the master bolts.
D65EX,PX,WX-17 50-243
2) When reusing the pin, chamfer the edges of

2 Shoe bolt:
its end corners faces with a grinder to allow
Molybdenum disulfide lubricant (LM- for smooth press- fitting.
P)
3 Shoe bolt (Master link)
kgm}
Retightening angle: 180 deg. (0/-20
deg.)
a Tighten the bolts in the order of 1 to 4.
3) Using tools R3 and R4, drive in the large and

small plugs.
• Tool R3 (for large plug)
• Tool R4 (for small plug)
a Although tools R3 and R4 have different
shapes, use them similarly to drive in the
plugs.
Rebuilding the link assembly for grease 1] Insert plug (3) into the hole of the guide
lubricated track through the plug inserting window of the
guide of tools R3 and R4.
1. Preparation work
1) Cleaning of seal assembly a Apply oil (GO90) to the outside
Remove seal assembly from the link, divide it periphery of the plug and install it with
into seal ring (1) and load ring (2), and clean the small diameter end on the pin
them. side.
2] Press the bar of tools R3 and R4 with the
a Clean seal ring and load ring quickly hand until the plug stops.
because they are easily deteriorated by 3] Press the plug with the bar until the guide
the cleaning agent. Wipe off the cleaning touches pin (4).
agent with a cloth from them. 4] Hit the bar with a hammer to drive in the
plug.
a Driving distance (a) from pin end face:
Large plug: 2.5 ± 1 mm
Small plug: 6 ± 2 mm
a If the plugs were not pulled out from
the pin when disassembling the track
shoe assembly, reuse them as they
are.
50-244 D65EX,PX,WX-17
4) Clean any dirty surfaces among the outside the installed dimensions of the seal within the
periphery of the pin, spacer surface, and end standard range.
faces and inside surface of the bushing. • Dimension (c): 3 mm
5) Apply grease on the outside periphery of the (d): 3 mm
pin and surfaces of the spacer. (e): 49.7 mm
a If the pin end faces (portion f) or the link
side face (portion g) and (h) are worn,
add the wear reduction to the standard
installed dimensions of the press-fitting
jigs so that the right and left projections of
the pins and bushings on both sides are
even.

upright.

Clean and degrease the portions indicated
with heavy line b (counterbore portion of the
link and seal assembly), and push in the seal
assembly to the bottom by using tool R6.
seal assembly because any adhered oil
or grease causes the seal to turn and its
sealing performance is lowered.
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 on the
bushing jaw of the link press.
a When reusing the bushing (by turning it
180 degree), set it with the worn outside
surface facing the shoe mounting face of
the link (set the bushing on the link press
with the face up).
7) Adjust the installed dimensions of the link

press press-fitting jigs to keep the protrusion
of the pin and bushing constant and to keep
D65EX,PX,WX-17 50-245
5) Measure the right and left projections of the

bushing on both sides by using a depth
gauge.
a Adjust the link press press-fitting jigs so
that the right and left protrusions of the
bushing are even.
2) Set the right and left master links having

bushing-bore with their shoe mounting faces
up, and press fit them to the bushing.
a At this time, use the master links on the
pin side as supports.
a Bushing press-fitting force: 98 to 147 kN
{10 to 15 ton} 6) Send out the master link portion, and then
set the next pins and bushings.
a Install the pin, even it is reused, with its
cross hole facing the link tread as in the
case of new one.
a If it is not installed so, the strength of the
assembly may be lowered. Accordingly,
indicate the direction of the cross hole on
the end face to prevent wrong installation.
a If the outside of the pin is worn, assemble
it with the un-worn portion facing the
traction side. Even in this case, assemble
it with its cross hole facing the link tread.
3) While checking the distance between the
shoe bolt holes of the right and left master
links by using the shoe bolt pitch gauge,
press fit the master links to the bushing until
the distance is the standard value.
a Remove all steel chips generated by the
press-fitting process completely with
compressed air.
4) Turn over the master links and check that
they are press-fitted in parallel.
7) Set the right and left links, and operate the

right and left press-fitting jigs to press fit the
pin and bushing simultaneously.
a Press fit them smoothly because bumpy
press-fitting may cause the seal to come
off the link. When the seal comes off the
link, stop the press-fitting and set the seal
to the link correctly, then restart the
press-fitting.
50-246 D65EX,PX,WX-17
a Pressing force for pin and bushing: 539

kN {55 ton}
Pressing force C 1.8 x Average press-
fitting force
(Adjust the relief pressure of the link
press to obtain the pressing force.)
2) For the track that has two master link joints

and consists of two track shoe assemblies,
place the two assemblies on a level place in
a line with the track shoes up.
3) Pull master links with pin-bore (5) of one
assembly and master links with bushing-bore
(6) together to contact their mating faces
8) Check the distance between the shoe bolt each other.
holes by using the shoe bolt pitch gage, and 4) Place shoe (7) on the master links and their
when it reaches the standard range, stop the mating faces are in close contact.
press-fitting. 5) Check that shoe bolts (8) can be tightened
with fingers easily, then connect the links
with the master bolts.
2 Shoe bolt:
Molybdenum disulfide lubricant (LM-
P)
kgm}
Retightening angle: 180 deg. (0/-20
deg.)
a Tighten the bolts in the order of 1 to 4.
9) Assemble the master link on the pin side last.
are press-fitted in parallel.
3. Installation of track shoe
1) Place the link assembly on the bed, and
install the track shoe by using the shoe bolt
impact wrench and torque wrench.
2 Shoe bolt:
Molybdenum disulfide lubricant (LM-
P)
kgm}
Retightening angle: 120 deg. ± 10
deg.
D65EX,PX,WX-17 50-247
50-248 D65EX,PX,WX-17
Overall disassembly and assembly of track shoe (PLUS type track shoe)
a In this section, the difference from the
conventional type track shoe is explained. 21 791T-432-1130 Push tool t 1 Q
a Special tools Disassembly
New/Redesign
Necessity
Sketch
Sym- a The details of overall disassembly of track shoe
Q'ty
Part number Part name are same as those of the conventional type track
bol
shoe. Therefore, see "Overall disassembly and
assembly of track shoe (conventional type track
791-932-1110 Push tool t 1 shoe)".
4 791-646-7523 Bar t 1
791-646-7590 Guide t 1 a Before disassembly, refer to the following
5 790-701-3000 Checker t 1 documentation to determine whether to reuse or
7 791-601-1000 Oil pump t 1 replace parts.
Push tool • Parts judgment guide, Undercarriage,
791T-532-1100 t 1 Q
assembly Lubricated track
791T-532-1110 • Adapter 1 Q • Parts judgment guide, Undercarriage,
791T-532-1130 • Ring 1 Q Reversing procedure for pin and bushing
791T-532-1140 • Plate 1 Q
791T-532-1150 • Ring 1 Q k Use the track press attached with protective
• Push cover [1].
791T-532-1160 1 Q
tool
18 791T-532-1170 • Adapter 1 Q
791T-532-1180 • Spring 1 Q
791T-532-1190 • Spring 1 Q
791T-532-
• Bolt 1 Q
1210
791T-632-
• Bar 1 Q
5730
01580-11210 • Nut 1
01252-60610 • Bolt 4
R 791T-532- Push tool
t 1 Q
1200 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 k When disassembling the pin, wrap with thick
• Push cloth [3] which completely covers pin end
791T-532-1160 1 Q
tool press-fitting jig [2] and wedge ring (1) to
19 791T-532-1170 • Adapter 1 Q
791T-532-1180 • Spring 1 Q
791T-532-1190 • Spring 1 Q
791T-532-
• Bolt 1 Q
1220
791T-632-
• Bar 1 Q
5730
01580-11210 • Nut 1
01252-60610 • Bolt 4
791T-532- Push tool
assembly t 2 Q
1300
791T-532- • Push
2 Q
20 1310 tool
791T-632-
• Bar 2 Q
5730
01580-11210 • Nut 2
D65EX,PX,WX-17 50-249
prevent chipping of wedge ring (1) from k The cut surface of the wedge ring is sharp
being scattered. and is dangerous. Always wear leather
gloves while working.
Assembly
1. Preparation work
1] Install the seal assemblies to the
counterbore portion of the link, the
counterbore portion of the inner link sub
assembly, the counterbore portion of the
outer link, and the counterbore portion of
the offset link.
2] Clean and degrease the portions
indicated with heavy line (a) (counterbore
portion of the link and seal assembly),
and push in the seal assembly to the
bottom by using tool R21.
seal assembly because any adhered
oil or grease causes the seal to turn
and its sealing performance is
lowered.
a If only an odd number of sets is
available for the link assembly, use a
k Set on the work after checking that thick single set of the offset link.
close [3] and protective cover [1] are
attached.
2) Adjust the dimensions of the press fitting jig

of the link press.
a This is to keep the projection of the pin
and bushing constant and keep the
k The operators and workers of the track press installed dimensions of the seal within the
must wear a helmet, safety goggles and ear standard range.
plugs.
k The wedge ring is broken with a bang. This

sound does not indicate abnormality.
50-250 D65EX,PX,WX-17
a Dimensions of press jig and installation a If the pressing force is excessive, the
dimensions following problems may occur.
Dimension (b): 4.7 mm • The spacer is pressed against the
Dimension (c): 87 mm bushing excessively and the spacer
may be broken.
Dimension (d): 100 mm
• Abnormal wear may occur between
the spacer and bushing end face.
2. Assembly of link (if an odd number of sets is
available for the link assembly)
1) Temporarily assemble pin (1), bushing (2)
and two spacers (3), and prepare three pin
sub assemblies (4).
2) Set pin sub assemblies (4a) and (4b) on the

jaw and (4c) in front of the jaw.

upright.
3) Install inner link (5) with seal attached to the

right and left pin sub assemblies (4b) and
(4c) with shoe installation surface (e) up.
3) Adjust the relief pressure of the link press so

that the pressing force of the press does not
exceed the following standard value.
Standard pressing force: 353 kN {36 ton}
D65EX,PX,WX-17 50-251
a Adjust the position by taking care the a Use depth gauge [6] to measure pin
spacer and seal are not caught. protrusion (g), and press fit the pin until
the reaches the specified dimension.
Protrusion dimension (g): 4.7 ± 0.2 mm
4) Set spacer (7) to the right and left pin sub

assembly (4b) at the center.
5) Install offset link (6) with seal attached to the
following position with shoe installation
surface (f) up.
6) Press fit offset link sub assembly (6) to pin
sub assembly (4b) at the center.
a Before press-fitting, align the pin hole of
the link with the pin.
a Take care not to drop the right and left
seals or the seal and spacer (7) being
caught while installation.
a Press fit pin sub assembly (4b) at both
sides simultaneously.
a The press-fitting force of the pin sub assembly (4a) at the front.
assembly must not exceed the following 8) Install master link (9) with seal attached on
value. the shoe installation side to the following
Press-fitting force: 353 kN {36 ton} position with shoe installation surface (h) up.
9) Press fit master link (9) on the shoe
installation side to pin sub assembly (4a) at
the front.
a Press fit pin sub assembly (4a) at both
50-252 D65EX,PX,WX-17
a The press-fitting force of the pin sub a Install wedge ring (10) with opening (j)
assembly must not exceed the following facing the shoe mounting face of the link.
value.
a A click is heard when wedge ring (10) is
Press-fitting force: 353 kN {36 ton} fitted in the pin groove.
13)Using tool R19 (small plug side), install the
wedge ring of the opposite side in the same
manner. (See the special tools table.)
10)Using shoe bolt pitch gage [7], check that

the distance between the shoe bolt holes is
within the standard range.
If the value exceeds the specified value:
Disassemble and check for abnormality, then
assemble them again if no abnormality is
found.
If the value is less than the specified value:
The wear of the spacer or bushing end face
may exceeds the allowable limit.
Disassemble it and replace with a new one.
14)Using tool R20, press fit the wedge ring.

a The press-fitting force of the wedge ring
must not exceed the following value.
Press- fitting force: 147 to 275 kN {15 to
28 ton}
11)Set wedge ring (10) to tool R18.
15)Use tool R5 for each link assembly to

remove air from inside the pin, and check the
sealing performance.
12)Match tool R18 (large plug side) to the pin a Keep the degree of vacuum inside the pin
and push wedge ring (10) in until the ring is at 91 to 95 kPa {680 to 710 mmHg} for 5
fitted in the pin groove.
D65EX,PX,WX-17 50-253
seconds to check that the pressure does 17)After adding oil, drive in the small plug to the
not change. specified position by using tool R4.
If the pressure changes, disassemble the a Apply gear oil (G090) to the outside
link assembly to check the seals. If no periphery of the small plug and drive in.
abnormality is found, assemble them.
a Driving depth from pin end surface of
small plug:
1 ± 1 mm
16)Using tool R7 to add oil (G090) until the

charged pressure rises to 196 to 294 kPa {2
to 3 kg/cm2 }.
18)Temporarily assemble pin (1), bushing (2)
a If the charged oil pressure is increased and two spacers (3), and prepare three pin
too much, it has bad effects on the seals. sub assemblies (4).
a Check the oil level when the link 19)Feed assembled link assembly (11) forward
assembly is left with the small plug side of the link press head.
up for 30 minutes. 20)Set pin sub assembly (4d) at the center of
the jaw and (4e) in front of the jaw.
a Add gear oil (G090) up to the level where
depth (L) of the hollow of the hole of pin is
in the following range.
Depth of the hollow (L): 30 to 50 mm
21)Install inner link (5) with seal attached to the

right and left pin sub assemblies (4d) and
(4e) with shoe installation surface (e) up.
50-254 D65EX,PX,WX-17
22)Set spacer (7) to the right and left pin sub

assembly (4c) at the front and pin sub
assembly (4d) at the center.
23)Install outer link (12) with seal attached to
the following position with shoe installation
surface (k) up.
24)Press fit outer link (12) to pin sub assembly
(4c) at the front and pin sub assembly (4d) at
the center.
a Press fit pin sub assemblies (4c) and (4d) 25)Perform steps 10) to 17) described above.
at both sides simultaneously. 26)Perform steps 18) to 24) described above.
27)Install the master link on the roller tread side
a The press-fitting force of the pin sub at last.
assembly must not exceed the following
value. a Check that the right and left master links
Press-fitting force: 353 kN {36 ton} 3. Assembly of link (if an even number of sets
is available for the link assembly)
1) Temporarily assemble pin (1), bushing (2)
sub assemblies (4).
2) Set pin sub assemblies (4a) and (4b) to the

jaw.
D65EX,PX,WX-17 50-255
a The press-fitting force of the pin sub

value.
Press-fitting force: 353 kN {36 ton}
3) Install inner link (5) with seal attached to the

right and left pin sub assemblies (4a) and
(4b) with shoe installation surface (e) up.
a Adjust the position by taking care the
spacer and seal are not caught.
a Use depth gauge [6] to measure pin
protrusion (g), and press fit the pin until

assembly (4a) at the front.
5) Install master link (13) with seal attached on
the roller tread side to the following position
with meshing surface of the master link (m)
up.
6) Press fit master link (13) on the roller tread
side to pin sub assembly (4a) at the front.
a Press fit pin sub assembly (4a) at both
a Check that the right and left master links 7) Using shoe bolt pitch gage [7], check that the
are press fitted in parallel. distance between the shoe bolt holes is
within the standard range.
If the value exceeds the specified value:
Disassemble and check for abnormality, then
assemble them again if no abnormality is
found.
If the value is less than the specified value:
50-256 D65EX,PX,WX-17
The wear of the spacer or bushing end face

may exceeds the allowable limit.
Disassemble it and replace with a new one.
11)Using tool R20, press fit the wedge ring at

both sides simultaneously.
a The press-fitting force of the wedge ring
8) Set wedge ring (10) to tool R18. must not exceed the following value.
Press-fitting force: 147 to 275 kN {15 to
28 ton}
9) Match tool R18 (large plug side) to the pin

and push wedge ring (10) in until the ring is
fitted in the pin groove. 12)Use tool R5 for each link assembly to
a Install wedge ring (10) with opening (j) remove air from inside the pin, and check the
facing the shoe mounting face of the link. sealing performance.
a A click is heard when wedge ring (10) is a Keep the degree of vacuum inside the pin
fitted in the pin groove. at 91 to 95 kPa {680 to 710 mmHg} for 5
10)Using tool R19 (small plug side), install the seconds to check that the pressure does
wedge ring of the opposite side in the same not change.
manner. (See the special tools table.) If the pressure changes, disassemble the
link assembly to check the seals. If no
abnormality is found, assemble them.
D65EX,PX,WX-17 50-257
13)Using tool R7 to add oil (G090) until the a Driving depth from pin end surface of
charged pressure rises to 196 to 294 kPa {2 small plug:
to 3 kg/cm2 }. 1 ± 1 mm
15)Temporarily assemble pin (1), bushing (2)

sub assemblies (4).
a Check the oil level when the link
assembly is left with the small plug side
up for 30 minutes.
a Add gear oil (G090) up to the level where
depth (L) of the hollow of the hole of pin is
in the following range.
Depth of the hollow (L): 30 to 50 mm
16)Feed assembled link assembly (11) forward

of the link press head.
17)Set pin sub assembly (4d) at the center of
the jaw and (4e) in front of the jaw.
14)After adding oil, drive in the small plug to the

specified position by using tool R4.
a Apply gear oil (G090) to the outside of the
small plug and drive in.
18)Install inner link (5) with seal attached to the

right and left pin sub assemblies (4d) and
(4e) with shoe installation surface (e) up.
50-258 D65EX,PX,WX-17
19)Set spacer (7) to the right and left pin sub

assembly (4c) at the front and pin sub
assembly (4d) at the center.
20)Install outer link (12) with seal attached to
the following position with shoe installation
surface (k) up.
21)Press fit outer link (12) to pin sub assembly
(4c) at the front and pin sub assembly (4d) at
the center.
a Press fit pin sub assemblies (4c) and (4d) 22)Perform steps 7) to 14) described above.
at both sides simultaneously. 23)Perform steps 15) to 19) described above.
24)Install the master link on the roller tread side
a The press-fitting force of the pin sub at last.
value. a Check that the right and left master links
Press-fitting force: 353 kN {36 ton} 4. Installation of track shoe
a Install the track shoe by specifying the
positions of shoe-side master link (1) and
D65EX,PX,WX-17 50-259
shoe grouser (2) as shown in the following

figure.
a Place the link assembly on the bed of the link

press, and install the track shoe by using the
shoe bolt impact wrench and torque wrench.
a Tighten the shoe bolts in the order shown in
the drawing below.
2 Shoe bolt (regular link):
Initial torque: 539 ± 49 Nm {55 ± 5 kgm}
50-260 D65EX,PX,WX-17
Disassembly and assembly of one link in field (standard type track shoe)
a In this section, the method of using the special
New/Redesign
tools is explained mainly.
Necessity
Sketch
Sym-
Q'ty
a For the details of disassembly and assembly, Part number Part name
bol
see "Disassembly and assembly of track shoe".
a Special tools
791-635-
New/Redesign
3190
Necessity
791-645-
Sketch
Sym- Adapter t 1
Q'ty
Part number Part name 3510
bol 791-645- Adapter t 1
3520
791-645- t 1
Pusher
791-432-1110 Push tool t 1 3530
791-646- 791-432- Spacer
Bar t 1 t 1
3 7550 1210
791-646- 791-432- Spacer t 1
Guide t 1
7560 1220
791-932-1110 Push tool t 1 791-635-3110 Frame t 1
791-646- 791-635-
Bar t 1 Extension t 1
4 7523 3160
791-646- 791-635- t 4
Guide t 1 Nut
7590 3170
6 791-432-1120 Installer t 1 791-635- t 2
Screw
791-601- 3180
7 Oil pump t 1 14 791-635-
1000 Screw t 1
791-635-3110 Frame t 1 3190
791-635- 791-645- Adapter t 1
Extension t 1 3520
3160
791-635- 791-645- t 1
Nut t 4 Guide
3170 3540
791-635- 791-645-
t 2 R Pusher t 1
8 Screw 3550
3180
791-635- 791-646-
t 1 15 Guide t 1
Screw 3270
3190
791-645- 791-635-3110 Frame t 1
R Adapter t 1 791-635-
3510 Extension t 1
791-646- 3160
Pusher t 1 791-635-
3260 Nut t 4
790-101-1102 Pump t 1 3170
9 16 791-635-
790-101- Cylinder Screw t 2
t 1 3180
1300
Jack 791-635-
790-105- Screw t 1
t 1 3190
10 2300 196 kN {20 ton} 791-645-
Pump Adapter t 1
790-101-1102 t 1 3510
791-645- Adapter t 1
3520 Disassembly
11
791-432- Spacer t 1
1210
1. Pin
791-645-
12 Guide t 1 1) Place the track shoe assembly on blocks.
3540
791-635-3110 Frame t 1 2) Pull out pins (1) and (2) by using tool R8
791-635- (frame, extension, nut, screw, screw, adapter
Extension t 1
3160 and pusher) and tool R9 (pump and
791-635- cylinder).
13 Nut t 1
3170
791-635- a If the pin end surface or the sides of the
Screw t 1 link are worn unevenly, correct the
3180
Screw t 1
D65EX,PX,WX-17 50-261
surface with a grinder to ensure that tool

R8 is applied at right angle.
Assembly
2. Link
1. Bushing
1) Set tool R10 and spacer [1] (outside Set tool R11 to the end face of link (4), and
diameter: 55 mm, thickness: 47 mm) to the press-fit bushing (7).
tread side of links (3) and (4).
a Bushing press-fitting force: 98 to 147 kN {10
a Set tool R10 to the link tip end as far as to 15 ton}
possible.
2) Apply hydraulic pressure to the puller and a Be sure to use a new bushing.
slowly disconnect the links until the link tip
opens for 6 to 8 mm.
a Take care not to apply excessive
hydraulic pressure as the bushing may be
pulled out.
a An electric pump is not allowed to use
because it may apply excessive hydraulic
pressure. Always use manual pump.
2. Pin
1) Drive in the large plug into the oil hole of pin
(1) by using tool R3.
a Be sure to use a new pin.
3) Separate links (5) and (6) similarly.
2) To determine the pressing force in final

assembly, measure the outside diameter of
the pin with a micrometer, and record the
value.
50-262 D65EX,PX,WX-17
3) Apply liquid gasket (198-32-19890) to pin 4. Link sub assembly

press-fitting hole (a) in link (4). 1) Install link sub assembly (10).
a When reusing the removed link, finish the a Check that the seal surfaces and bushing
pin press-fitting hole smoothly with end faces are free from dirt, then apply
sandpaper etc. gear oil (GO90) on them using a clean
cloth or brush.
4) Set tool R11 to the end face of link (4), and

press-fit pin (1). 2) Install tool R12 (guide for press fitting the
link) to bushing (7).
a Install the pin with the cross hole (b)
facing the link tread.
a Press-fitting force for pin: 147 to 196 kN
{15 to 20 ton}
3. Spool
Using tool R6, install seal (8).
a Make sure the contact faces of link and seal
are free from oil.
5. Link
1) To determine the pressing force in the final
assembly, measure the dimension of pin
press-fitting hole in link (3) with a cylinder
gauge, and record the value.
D65EX,PX,WX-17 50-263
2) Apply liquid gasket (198-32-19890) to pin 4) Check that the seal surfaces and bushing
press-fitting hole (a) in link (3). end faces are free from dirt, then apply gear
oil (G090) on them using a clean cloth or
a When reusing the removed link, finish the
brush.
pin press-fitting hole smoothly with
5) Using tool R13, press fit the pin portion of link
sandpaper etc.
(3) to link sub assembly (10).
a Press-fitting force for pin: 294 to 392 kN
{30 to 40 ton}
3) Using tool R6, install seal (8).

a Make sure the contact faced of link and
seal are free from oil.
6) Using tool R14, press fit the bushing portion
of link (3) to link sub assembly (10).
a Press fit the pin and bushing alternately
so that excessive force is not applied to
the press-fitting portion.
a Press-fitting force for pin and bushing:
245 to 343 kN {25 to 35 ton}
6. Connection of link
50-264 D65EX,PX,WX-17
1) Finish the inner surface of the pin press- 5) Check that the seal surfaces and bushing (7)
fitting hole of links (5) and (6) to be end faces are free from dirt, then apply gear
connected smoothly with sandpaper etc. oil (G090) on them using a clean cloth or
brush.
6) Apply hydraulic pressure to the puller until
the tips of links (5) and (6) open for 6 to 8
mm.
a Take care not to apply excessive
hydraulic pressure as the bushing may be
pulled out.
a An electric pump is not allowed to use
because it may apply excessive hydraulic
pressure. Always use manual pump.
7) Operate chain block [2] to align the link hole
with the center of the bushing hole, and
2) Lower the track shoe assembly to the connect the links to tool R15 (guide pin).
ground.
a Operate chain block [2] slowly by taking
3) Set chain blocks [2] to the right and left link
care not to damage the seal and that dirt
assemblies as shown in the figure. Set tool
does not stick to the seal.
R10 and spacer [1] (outside diameter: 55 mm,
thickness: 47 mm) to the tread side of links
(5) and (6).
a Set tool R10 to the link tip end as far as
possible.
7. Pin
1) Drive in the large plug into the oil hole of pin
(2) by using tool R3.
4) Using tool R6, install seals (13) and (14) to
links (5) and (6).
a Be sure to use a new seal.
a Make sure the contact faced of link and
seal are free from oil.
2) To determine the pressing force, measure

the outside diameter of pin (2) with a
micrometer, and record the value.
3) Place again the track shoe assembly on
blocks.
4) Using tool R16, press fit pin (2) to links (5)
and (6).
D65EX,PX,WX-17 50-265
a Install the pin with the cross hole facing a Pressing force for pin and bushing: 539
the link tread. kN {55 ton}
a Press-fitting force for pin: 98 to 147 kN Pressing force C 1.8 x Average pressure
{10 to 15 ton} (Adjust the relief pressure of the link
5) Stop press fitting temporarily when the press to obtain the pressing force.)
remaining dimension of pin (2) reaches 15 to
20 mm.
8. Vacuum test
Using hand vacuum pump [3] to remove air from
6) Apply liquid gasket (198-32-19890) to the the small plug hole at pins (1) and (2) end
remaining press-fitting portion of pin (2). surfaces, and check the sealing performance.
a Keep the degree of vacuum at 92.7 ± 1.9 kPa
{695 ± 15 mmHg} for 5 seconds to check that
the sealing performance is maintained.
7) Apply liquid gasket (198-32-19890) to the pin

press-fitting hole in link (6), and press fit pin
(2) again.
9. Filling of oil
1) Using tool R7 to add gear oil (G090) from the
small plug hole of the pin.
a Do not add oil excessively by taking
thermal expansion etc. of oil into
consideration.
8) Using tool R13, apply the standard pressing

force to links (3) and (4), and to links (5) and
(6).
50-266 D65EX,PX,WX-17
2) Drive in the small plug quickly to the

following standard position by using tool R4.
a Apply gear oil (G090) on the outside
periphery of the small plug.
• Driving depth from end face: 2.5 ± 1 mm
D65EX,PX,WX-17 50-267
Disassembly and assembly of one link in field (PLUS type track shoe)
a In this section, the method of using the special
tools is explained.
a For the details of disassembly and assembly,
see "Disassembly and assembly of track shoe
(PLUS type track shoe)".
a Special tools
New/Redesign
Necessity
Sketch
Q'ty
Symbol Part number Part name
790-101- Pump
1 t 1
1102 assembly
Jack
790-105-
2 (196 kN {20 t 1
2300
ton})
Remover &
791-532- installer t 1
1
2201 assembly
Cylinder
790-101-
2 (980 kN {100 1
1300
ton})
791-532-
3 • Plate 1
2210
4
791-532-
• Plate 1 Disassembly
2220
791-532-
5 • Block 1
2230 1. Track shoe
791-532- 1) Place the link to be disconnected facing
6 • Stud bolt 2
2240 upward.
R 791-532- 2) Remove four mounting bolts (1) of the track
7 • Rod 2
2390
shoe and remove shoe (2). For details, see
791-532-
8 • Plate 1 "Disassembly and assembly of track shoe
17 3 2260
791-532- (PLUS type track shoe)".[*1]
9 • Boss 2
2270 a To facilitate the removal of pin, remove
791-532- shoes (2a) and (2b) similarly.
10 • Boss 2
2280
791-532-
11 • Plate 1
2290
01582-
12 • Nut 4
12722
791-532-
13 • Washer 2
2380
01252-
14 • Bolt 4
61645
02205-
15 • Nut 4
12437
791-532-
16 • Plate 1
2370
791-532-
17 • Push tool 2
2340
2. Wedge ring
• Tool schematic view (See the special tools table) • If the wedge ring sticks, release it according
1) Sling tool R17-3 and set to the link assembly.
50-268 D65EX,PX,WX-17
a Do not reuse the removed wedge ring.
2) While sling tool R17-3, align the tool with the

center position of the pin.
3. Master link
3) Set tool R17-3-11 to outer link (3) of the
wedge ring to be removed. 1) Remove the shoe of the master link. For
4) Operate tool R17-1 (see the special tools details, see "Separation and connection of
table) to press tool R17-3-11 to the direction track shoe assembly (PLUS type track
of arrow, to create a gap between wedge ring shoe)".
(4) and outer link (3). 2) Disconnect two master links (5), and
separate the link assembly.[*2]
a The pressing force of tool R17-3-11 must
be 353 kN {36 ton} or less.
5) Remove tool R17-3.
4. Regular link
1) Place the link assembly on a level ground.
2) Sling tool R17-3 and set to the link assembly.
3) While tool R17-3 Sling, set outer link (3)
between tools R17-3-11 and R17-3-8, and
align the tool with the center position of the
pin.
a Put outer link (3) between the tool
securely and fix it. If the outer link is fixed
improperly, the right and left pins may not
be pulled off simultaneously.
a Tool R17-3-8 contacts with a rusty
surface of outer link (3) and is slanted.
Using shims, adjust so that it is parallel
6) Using snap ring pliers [1] and flat-head with tool R17-3-11.
screwdriver, remove wedge ring (4). 4) Operate tool R17-1 (see the special tools
table) to push tool R17-3-8 to the direction of
a When removing the wedge ring, do not arrow, to remove outer link (3).
damage the wedge ring contact faces of 5) Remove tool R17-3.
the outer link and pin.
D65EX,PX,WX-17 50-269
a Set dimension (j) of inner link (8) to a

degree that bushing (9) is pulled out
easily. If dimension (j) is too wide, the oil
seal of the non-disassembly side may be
broken.
3) Remove bushing (9).
• Disassembly condition (See the special tool

table)
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
6. Oil seal and ring
f. Dimension: 90 mm
Remove the oil seal and spacer from the
g. Dimension: 35 mm
removed link, and clean them.
h. Draft: 25 mm
Arrow: Cylinder moving direction of tool R17- Assembly
3-2
(3) Outer link
(6) Outer link • Assemble in the reverse order of disassembly.
1. Install the oil seal and spacer to the link.

2. Bushing
1) Using tool R17-2, increase dimension (j) of
inner link (8) slightly.
a Set dimension (j) of inner link (8) to a
degree that bushing (9) is pushed in
easily. If dimension (j) is too wide, the oil
seal of the non-disassembly side may be
broken.
2) Install bushing (9) to inner link (8).
5. Pin and bushing

1) Remove outer link (6) and two pins (7).
3. Pin and outer link

1) Install outer link (6) and two pins (7).
2) Using tool R17-2, increase dimension (j) of

inner link (8) slightly.
50-270 D65EX,PX,WX-17
2) Sling tool R17-3 and set to the link. 6) Use depth gauge [2] to measure pin
3) While sling tool R17-3, align the tool with the protrusion (k) of pin (7) from outer link (3).
center position of the pin. Standard protrusion dimension (k): 4.7 ± 0.2
a Put outer link (3) between the tool mm
securely and fix it. If the outer link is fixed
improperly, the right and left pins may not
be pushed in simultaneously.
a Tool R17-3-8 contacts with a rusty
surface of outer link (3) and is slanted.
Using shims, adjust so that it is parallel
with tool R17-3-11.
4) Operate tool R17-1 (see the special tools
table) to push tool R17-3-11 to the direction
of arrow, to press fit outer links (3) and (6).
5) Remove tool R17-3.
• Assembly condition (See the special tool

7) Using snap ring pliers [1], install wedge ring
table)
(4).
a. Thickness of tool R17-3-3: 36 mm
b. Thickness of tool R17-3-12: 22 mm a Install wedge ring (4) with its opening
c. Thickness of tool R17-3-11: 32 mm facing the shoe mounting face of the link.
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. Draft: 25 mm
Arrow: Cylinder moving direction of tool
R17-3-2
(3) Outer link
(6) Outer link
D65EX,PX,WX-17 50-271
a Install the wedge ring so that its height is

the same as the link side face.
Retightening angle: 180 (+0/-20) deg.
• Adding oil
Add oil similarly to the normal lubricated track.
For details, see "Overall disassembly and
assembly of track shoe (PLUS type track shoe)".
5 Track shoe pin:

Gear oil (G090)
8) Sling tool R17-3 and set to the link.

9) While sling tool R17-3, align the tool with the
center position of the pin.
10)Operate tool R17-1 (see the special tools
table) to push tool R17-3-17 to the direction
of arrow with the following specified pressure,
to contact the pin with wedge ring tightly.
Specified pressure: 147 to 275 kN {15 to 28
ton}
11)Remove tool R17-3.
• For the subsequent assembly, perform in the

reverse order of disassembly.
[*1]
2 Shoe bolt (regular link):


[*2]

50-272 D65EX,PX,WX-17
Removal and installation of pivot shaft assembly

a Special tools
Installation
New/Redesign
Necessity
removal.
Sketch
Sym-
Q'ty
bol
[*1]
Installer 3 Pivot shaft mounting bolt:

791-430-1200 assembly t 1
P 455 to 565 Nm {46.5 to 58.0 kgm}
790-101-2102 Puller t 1
790-101-1102 Pump t 1
[*2]
Removal
1. Remove the track frame assembly. For details, a Assemble seal (2) according to the following
see "Removal and installation of track frame procedure.
assembly." 1. Reverse the seal so that the embossed
2. Sling pivot shaft assembly (1). character (a) of the seal faces inside.
3. Remove the mounting bolt, and using forcing 2. With seal (2) reversed, insert it to pivot shaft
screw [1], sling and pull out the pivot shaft (1).
assembly.[*1]
a When inserting the seal, take care not to
4 Pivot shaft assembly: damage the surface.
90kg (D65EX-16)
100kg (D65PX-16,
D65EX-16 PAT)
[*3]
4. Remove seal (2).[*2] a Use tool P to press fit ring (3).

5. Remove ring (3). [*3]
a Press-fitting force: 18.6 kN {1.9 ton}
D65EX,PX,WX-17 50-273
Removal and installation of equalizer bar assembly

a Special tools
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
Remover
791-450-1100 assembly t 1
N
790-101-2102 Puller t 1
790-101-1102 Pump t 1
Removal 5. Remove lock plate (6), and using tool N, pull out
1. Remove cover (1) of the side pin. center pin (7).[*2]
k Perform the hydraulic operation of tool N not

at the front or below the puller but from a
distance as far as possible.
6. Lower and remove equalizer bar assembly (5).
4 Equalizer bar assembly:

130 kg
2. Using jacks, raise the machine and place the

stand under the front frame.
k Set the stand securely.

3. Remove lock (3) and pull off pin (4).[*1]
4. Sling equalizer bar assembly (5).
Installation
removal.
[*1]
50-274 D65EX,PX,WX-17
k When aligning the mounting holes pin, never

insert your fingers in the holes.
[*2]
k When aligning the mounting holes pin, never
insert your fingers in the holes.
2 Frame boss portion:

D65EX,PX,WX-17 50-275
Disassembly and assembly of equalizer bar side bushing

Disassembly
1. Remove seal (1).
2. Remove ring (2).
3. Remove spherical bushing (3).
Assembly
1. Install ring (2) to one side.
2. Press fit spherical bushing (3) by using push tool
[1].
a Press-fitting force: 15.7 kN {1.6 ton}
3. Install ring (2) on the opposite side.
4. Install seal (1).
2 Between bushing and seal:
Grease(G2-LI)
50-276 D65EX,PX,WX-17
Hydraulic system
Hydraulic system
Removal and installation of hydraulic tank assembly
k Stop the machine on a level ground and

stop the engine. Loosen the cap of hydraulic
tank slowly to release the remaining

k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant
temperature drops before starting the work. 5. Remove the fuel tank assembly. For details, see
Removal 6. Remove the ROPS cab assembly. For details,
1. Collect the air conditioner refrigerant (R134a) assembly."
from the air conditioner circuit. [*1] 7. Disconnect HSS case oil filler pipe (2). [*2]
adding and filling operations of the
refrigerant (R134a).
the atmosphere.

with the refrigerant. Collecting and f illing 8. Remove two clamps (3) and two hydraulic hoses
work must be conducted by a qualified (4).
person. 9. Remove two clamps (5) and two hydraulic hoses
a Refrigerant to be collected: 900 ± 50 g (6) and two hydraulic hoses (7).
2. Drain the fuel from the fuel tank from the fuel a Plug the hoses and adapters to prevent the
valve at the fuel tank bottom. oil from flowing out.
10.Disconnect suction hose (8). [*3]
6 Fuel tank:
415 l
6 Hydraulic tank:
82 l
11.Remove harness clamp (9) and disconnect

harness connector CN-HDT (10).
D65EX,PX,WX-17 50-277
Hydraulic system
12.Disconnect hydraulic hose (11). a When installing the air conditioner circuit hoses,
oil from flowing out. a When installing the air conditioner hoses, check
deterioration.
a When connecting the refrigerant pipes, apply
19):
12 to 15 Nm {1.2 to 1.5 kgm}
24):
13.Sling the hydraulic tank assembly.
20 to 25 Nm {2.0 to 2.6 kgm}
14.Remove four hydraulic tank mounting bolts (12)
from the bottom. [*4] 3 Screw size (M24 x 1.5) (width across flats:
27):
29 to 34 Nm {3.0 to 3.5 kgm}
3.9 to 6.9 Nm {0.4 to 0.7 kgm}
10):
8 to 12 Nm {0.8 to 1.2 kgm}
15.Sling and remove tank assembly (13).
4 Hydraulic tank assembly (13):

90 kg
cab assembly.
[*2]
3 HSS case oil filler pipe (2) hose mounting
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]
Installation 3 Hydraulic tank mounting bolt (16):
• Perform installation in the reverse order to 230–289 Nm {23.5–29.5 kgm}
removal.
• Filling of refrigerant (R134)
[*1]
50-278 D65EX,PX,WX-17
Hydraulic system

Add the coolant through the coolant filler port to
the specified level. Run the engine to circulate

Only necessary quantity
water")

415 l
water")
• Refilling of oil (hydraulic tank)
5 Hydraulic tank (hydraulic oil):

82 l
water")
• Bleeding air (work equipment circuit)
Bleed air from the piping. For details, see
Testing and adjusting "Bleeding air from
hydraulic circuit".
circuit".
D65EX,PX,WX-17 50-279
Hydraulic system
Removal and installation of control valve assembly




temperature drops before starting the work. 8. Remove the hose clamp, and disconnect 12
hydraulic hoses (10) and two hydraulic hoses
Removal (11).
(5-spool control valve) a Plug the hoses and adapters to prevent the
9. Remove the clamp, and disconnect HSS case
oil filler pipe (12).[*2]
adding and filling operations of the
refrigerant (R134a).
the atmosphere.

with the refrigerant. Collecting and filling
10.Sling the control valve assembly.
11.Remove four control valve mounting bolts (13).
person.
6 Fuel tank:
415 l
4. Remove the ROPS cab assembly. For details,
assembly."
5. Remove two wiring harness clamps (1) and (2).
6. Disconnect the following wiring harness 12.Sling and remove control valve assembly (14).
connectors.
(3): CN-HSL 4 Control valve assembly (14):
(4): CN-WLK 90 kg
(5): CN-PTP
(6): CN-HDT
disconnected before remove off the operator
(7): CN-HSR
cab assembly.
7. Disconnect hydraulic hoses (8) and (9).
50-280 D65EX,PX,WX-17
Hydraulic system
Installation [*2]
• Perform installation in the reverse order to 3 HSS case oil filler pipe (2) hose mounting
removal. clamp:
[*1] 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
a When installing the air conditioner circuit hoses, • Filling of refrigerant (R134)
take care so that dirt, water, may not enter. Refill the air conditioner circuit with refrigerant.
a When installing the air conditioner hoses, check a Filling quantity: 900 ± 50 g
that O-ring (70) is fitted to each of their fittings. • Refilling of air compressor oil
deterioration.
a When connecting the refrigerant pipes apply to the specified level. Run the engine to circulate
compressor oil for new refrigerant (R134a) the coolant through the system. Then, check the
(DENSO: ND-OIL8) to O-ring (70). coolant level again.
19): 5 Radiator (engine coolant):
12 to 15 Nm {1.2 to 1.5 kgm} Only necessary quantity
3 Screw size (M22 x 1.5) (width across flats: water")
24): • Refilling of fuel (fuel tank)
20 to 25 Nm {2.0 to 2.6 kgm}
3 Screw size (M24 x 1.5) (width across flats: 5 Fuel tank (diesel fuel):
27): 415 l
29 to 34 Nm {3.0 to 3.5 kgm} (For details, see "List of lubricant and
water")
(M6 x 1.0) (width across flats: 10): Add oil through the oil filler to the specified level.
3.9 to 6.9 Nm {0.4 to 0.7 kgm} Run the engine to circulate the oil through the
3 Air conditioner compressor refrigerant tube system. Then, check the oil level again.
10): 5 Hydraulic tank (hydraulic oil):
8 to 12 Nm {0.8 to 1.2 kgm} Only necessary quantity
water")
hydraulic circuit".
D65EX,PX,WX-17 50-281
Hydraulic system

circuit".
Removal
(4-spool control valve)

stop the engine.
a Oil flows out when the hose is disconnected.

Plug the disconnected hose and fitting to
prevent oil leakage.
a If a wiring or hose is disconnected, identify the
connecting location with a color band etc.
2. Disconnect wiring connectors HSL (2), WLK (3),

HDT (4) and HSR (5).
3. Disconnect wiring clamp (6) and hose clamp (7).
4. Disconnect hoses (8) to (14).
5. Remove accumulator and block assembly (15).
6. Disconnect hoses (16) to (22).
10.Disconnect hoses (29) and (30).
50-282 D65EX,PX,WX-17
Hydraulic system
Installation
removal.
5 Hydraulic tank (hydraulic oil): Only

necessary quantity
11.Disconnect hoses (31), (32) and (33). water")
hydraulic circuit".
12.Remove four mounting bolts (34) of the control

valve.
13.Sling and remove control valve assembly (35).
4 Control valve assembly (35):

65 kg
D65EX,PX,WX-17 50-283
Hydraulic system
Disassembly and assembly of control valve

• This section explains only the precautions for
assembling the control valve.
• For the details and tightening torque of each
portion, see Structure, function and
maintenance standard - Hydraulic system -
Control valve.
Assembly
1. Tighten the upper cover (1) mounting bolts in the
following order.
1) Tighten in the order of [1] to [4] shown in the
drawing below.
2) Tighten to the following torque.
3 Mounting bolt
1st time: 19.6 to 29.4 Nm {2 to 3
kgm}
2nd time: 39.2 to 49.0 Nm {4 to 5
kgm}
3rd time: 58.8 to 73.5 Nm {6.0 to 7.5
kgm}
2. Tighten under cover (2) mounting bolts in the
following order.
1) Tighten in the order of [1] to [4] shown in the
drawing below.
2) Tighten to the following torque.
3 Mounting bolt
1st time: 58.8 to 68.6 Nm {6 to 7
kgm}
2nd time: 78.5 to 88.3 Nm {8 to 9
kgm}
3rd time: 98.1 to 113 Nm {10.0 to
11.5 kgm}
50-284 D65EX,PX,WX-17
Hydraulic system
Disassembly and assembly of blade PPC valve

• In this section, only precautions for assembling 2. Apply Loctite to two places at dimension (a) from
the blade lift and tilt PPC valve assembly are the threaded hole end of the body.
explained.
2 Two places at dimension (a) from end (1
drop, 0.02 mg each):
Lcctite (No. 648)
• Dimension (a): 5 to 7 mm
3. Tighten joint (19) to the following torque.
3 Joint (19):
39 to 49 Nm {4 to 5 kgm}
a Tighten nut (22) to the following torque.

3 Nut (22):
93.1 to 112.7 Nm {9.5 to 11.5 kgm}
a Adjust the play of the lever. For details, see
• No spares are supplied for parts other than Testing and adjusting, "Adjusting play of work
below. equipment PPC valve".
(15), (16), (19), (22), (36) and (38)
Assembly
a Tighten mounting bolt (38) (to be tightened
together) of plates (17) and (18) to the following
torque.
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a Apply grease to the sliding surface of joint (19)
and to the contact surfaces of disc (20) and
pistons (23), (24) and (25).
2 Sliding surface of joint (19) (7 to 10 ml
/circumference):
Grease (G2-LI)
2 Contact surfaces of disc (20) and pistons
(23), (24) and (25) (0.3 to 0.8 ml /place):
Grease (G2-LI)
a Install joint (19) to valve body (1) according to
1. Thoroughly degrease and dry the threaded
portions of the joint and body hole.
D65EX,PX,WX-17 50-285
Hydraulic system
Disassembly and assembly of ripper PPC valve

• In this section, only precautions for assembling 2 Sliding surface of lever (11) and contact
the ripper PPC valve assembly are explained. surface of piston (7):
Grease(G2-LI)
• No spares are supplied for the parts other than

below.
(3) to (10) and (14) to (17)
Assembly
a Install spring (6) according to the following
procedure.
a Each port is stamped on the bottom of the valve
body.
Port Spring Free length
(mm)
P1, P2 (6) 33.88
a When installing piston (7), apply grease to the

periphery of the piston and inside of the valve
body hole.
2 Periphery of piston and valve body hole:
Grease (G2-LI)
a Tighten mounting bolt (15) (to be tightened
together) of plates (17) and (12) to the following
torque.
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a Apply grease to the sliding surface of lever (11)
and contact surface of piston (7).
50-286 D65EX,PX,WX-17
Hydraulic system
Removal and installation of HSS pump and cooling fan pump assembly

k Disconnect the negative (-) terminal from the

battery.

temperature drops before starting the work. 5. Remove the fuel tank assembly. For details, see
Removal 6. Remove the ROPS cab assembly. For details,
1. Collect the air conditioner refrigerant (R134a) assembly."
from the air conditioner circuit. [*1] 7. Remove the power train unit assembly. For
a Ask a qualified person for collecting, details, see "Removal and installation of power
adding and filling operations of the train unit assembly".
refrigerant (R134a). 8. Place the power train unit assembly on the
blocks horizontally.
a Never release the refrigerant (R134a) to 9. Remove the mounting bolt and remove HSS and
the atmosphere. cooling fan pump assembly (1).
k If refrigerant gets in your eyes, you may lose 4 HSS and cooling fan pump assembly (1):
130 kg
protective goggles, gloves and working suits a HSS pump and cooling fan pump assembly
with long sleeves while you are collecting the (1) cannot be removed when mounted on the
refrigerant or filling the air conditioner circuit machine. (Because the suction tube
with the refrigerant. Collecting and f illing interferes with the ROPS cab mounting
work must be conducted by a qualified frame.)
person.
6 Fuel tank:
415 l
6 Fuel tank:
82 l
Installation
removal.
[*1]
D65EX,PX,WX-17 50-287
Hydraulic system

deterioration.
415 l
water")
3 Screw size (M16 x 1.5) (width across flats: Add oil through the oil filler to the specified level.
19): Run the engine to circulate the oil through the
12 to 15 Nm {1.2 to 1.5 kgm} system. Then, check the oil level again.
3 Screw size (M22 x 1.5) (width across flats: 5 Hydraulic tank (hydraulic oil):
24):
82 l
20 to 25 Nm {2.0 to 2.6 kgm}
3 Screw size (M24 x 1.5) (width across flats: water")
27): • Checking for fuel leakage (fuel system)
29 to 34 Nm {3.0 to 3.5 kgm} Check the fuel system for leakage. For details,
3 Receiver tank refrigerant tube mounting bolt system for leakage".
(M6 x 1.0) (width across flats: 10): • Bleeding air (fuel system)
3.9 to 6.9 Nm {0.4 to 0.7 kgm} Bleed air from the fuel circuit. For details, see
circuit".
10):
8 to 12 Nm {0.8 to 1.2 kgm}

Add the coolant through the coolant filler port to
the specified level. Run the engine to circulate

water")
50-288 D65EX,PX,WX-17
Hydraulic system
Removal and installation of steering lubrication pump and power train

pump assembly


Removal
1. Open right and left doors (1) of the ROPS cab,
and secure them by using the locks.
a Be sure to lock securely. 3) Disconnect harness connector CN-PAC (4)
from the bottom of the floor plate.
2. Remove the floor plate assembly according to 4) Disconnect the turnbuckle of brake rod (5).
the following procedure. For details, see Testing and adjusting,
1) Remove floor mat (2). "Adjusting brake pedal".[*1]
5) Sling and remove floor plate assembly (6).
4 Floor plate assembly (6):

30 kg
a The crane cannot be used inside the
ROPS cab. Sling and remove floor plate
assembly (6) by using a bar etc.
2) Remove inspection cover (3) of the floor

plate.
3. Remove under cover (7) at the bottom of the

power train.
D65EX,PX,WX-17 50-289
Hydraulic system
Installation
removal.
[*1]
a Install the turnbuckle of brake rod (5). For details,
see Testing and adjusting, "Adjusting brake
pedal".
[*2]
3 Hydraulic tube (8) hose mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
4. Disconnect hydraulic tube (8) at the bottom of [*3]
the power train pump and lubrication pump
assembly.[*2] 3 Power train and lubrication pump assembly
5. Disconnect upper hydraulic hoses (9) and (10). (11) mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
• Refilling (power train case)

6. Sling power train pump and lubrication pump

assembly (11).
7. Remove the mounting bolt, and sling and
remove power train pump and lubrication pump
assembly (11).[*3]
4 Power train and lubrication pump

assembly (11):
18 kg
a The crane cannot be used inside the ROPS
cab. Sling and remove power train pump and
lubrication pump assembly (11) by using a
bar etc.
50-290 D65EX,PX,WX-17
Hydraulic system
Removal and installation of cooling scavenging pump assembly

53 l (For details, see "List of lubricant and
k Lower the work equipment to the ground, water")

Removal
1. Remove under cover (1) at the bottom of the
power train.
2. Drain the oil from the power train case.
6 Power train case:

53 l
3. Disconnect hydraulic hose (2).
4. Remove the mounting bolt and remove
scavenging pump assembly (3).
Installation
removal.
• Refilling
Add oil through oil filler port to the specified level.
system. Then check the oil level again.
D65EX,PX,WX-17 50-291
Hydraulic system
Removal and installation of HSS motor assembly




temperature drops before starting the work. 6. Remove the ROPS cab assembly. For details,
Removal assembly."
1. Collect the air conditioner refrigerant (R134a) a This is to disconnect hydraulic hoses (3) and
from the air conditioner circuit. [*1] (4).
7. Disconnect hydraulic hoses (1), (2), (3) and (4).
adding and filling operations of the a Plug the hoses and adapters to prevent the
refrigerant (R134a). oil from flowing out.

the atmosphere.

person.
a Refrigerant to be collected: 900 ± 50 g 8. Remove hose clamp (5) and bracket (6), and
2. Drain the fuel from the fuel valve at the fuel tank reposition two hydraulic hoses (7) together on
bottom. the machine side.
a This is to secure space to remove the HSS
6 Fuel tank: motor assembly.
415 l
6 Hydraulic tank:
82 l
9. Sling HSS motor assembly (8).

10.Remove the mounting bolts, and sling and
remove HSS motor assembly (8).
50-292 D65EX,PX,WX-17
Hydraulic system
4 HSS motor assembly (8):

45 kg

Installation • Refilling of air compressor oil
• Perform installation in the reverse order to See Air conditioner, "Handling of compressor oil".
removal. • Refilling of oil (hydraulic tank)
[*1] Add oil through the oil filler to the specified level.
a When installing the air conditioner circuit hoses, system. Then, check the oil level again.
a When installing the air conditioner hoses, check 5 Hydraulic tank (hydraulic oil):
that O-ring (70) is fitted to each of their fittings. Only necessary quantity
a Check that O-ring (70) is free from flaw and (For details, see "List of lubricant and
deterioration. water")
415 l
19):
water")
12 to 15 Nm {1.2 to 1.5 kgm} • Checking for fuel leakage (fuel system)
3 Screw size (M22 x 1.5) (width across flats: Check the fuel system for leakage. For details,
24): see Testing and adjusting, "Checking fuel
20 to 25 Nm {2.0 to 2.6 kgm}
3 Screw size (M24 x 1.5) (width across flats: Bleed air from the fuel circuit. For details, see
27): Testing and adjusting, "Bleeding air from fuel
29 to 34 Nm {3.0 to 3.5 kgm} circuit".

3.9 to 6.9 Nm {0.4 to 0.7 kgm}
10):
8 to 12 Nm {0.8 to 1.2 kgm}
D65EX,PX,WX-17 50-293
Hydraulic system
Disassembly and assembly of hydraulic cylinder

Special tools 790-201-
1610
New/Redesign
Necessity
Sketch
Sym-
Q'ty
bol
790-502- Repair stand t 1

1003
1
790-101- Pump t 1
1102
790-330- Wrench assembly t 1
2
1100
Socket
790-302- t 1
(Width across
1270
flats: 50 mm)
Socket
790-102-
3 (Width across t 1
1330
flats: 75 mm)
Socket
790-302- t 1
(Width across
1340
flats: 80 mm)
790-720- Expander t 1
4
1000
796-720- Ring t 1
1650
07281- Clamp t 1
01029
796-720- Ring t 1
1660
5
07281- Clamp t 1
01159
U 796-720- Ring t 1
1670
07281- Clamp t 1
01279
790-201- t 1
Push tool kit
1702
790-101- • Grip 1
5021
01010-
• Bolt 1
50816
6
790-201-
• Push tool 1
1781
790-201-
• Push tool 1
1811
790-201-
• Push tool 1
1791
790-201- t 1
Push tool kit
1500
790-101- • Grip 1
5021
01010-
• Bolt 1
7 50816
790-201-
• Plate 1
1590
790-201-
• Plate 1
1620
• Plate 1
50-294 D65EX,PX,WX-17
Hydraulic system
Disassembly
a Details of work equipment and cylinder name
Symbol Attachment Name Cylinder
ST-T Straight tilt dozer Blade lift, blade
SGM Sigma dozer tilt
Sigma power
SGM-PP pitch dozer Blade lift, blade
Straight tilt power tilt, blade pitch
ST-TPP pitch dozer
Power angle Blade lift, blade
PAT power tilt dozer angle, blade tilt
A Angle dozer Blade lift 3) With cylinder assembly (1) set to tool U1,
– Ripper Ripper lift sling and pull out piston rod assembly (3)
from cylinder (1).
1. Piston rod assembly
1) Set cylinder assembly (1) to tool U1.
2) Using a hydraulic pump or a torque multiplier
wrench, remove cylinder head assembly (2)
by using tool U2.
2. Piston assembly and cylinder head assembly

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).
a (A) indicates blade lift cylinder except for Width across
Cylinder
PAT. flats of nut (mm)
• Except for blade tilt cylinder and blade Blade lift 50
pitch cylinder for ST-TPP and SGM-PP Blade angle (PAT) 75
Blade tilt, blade pitch 80
Blade tilt (PAT) 80
Ripper lift 80
• Blade tilt cylinder and blade pitch cylinder

for ST-TPP and SGM-PP
3. Disassembly of piston
1) Remove wear ring (7).
2) Remove piston ring (8).
D65EX,PX,WX-17 50-295
Hydraulic system
• Blade tilt cylinder, blade pitch cylinder,

ripper lift cylinder
4. Disassembly of cylinder head

1) Remove O-ring and backup ring (15).
• Blade lift cylinder, blade angle cylinder 2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
a O-ring (21) of Step 6) applies to the blade
lift cylinder, blade angle cylinder, blade tilt
cylinder, blade pitch cylinder and ripper
lift cylinder only.
6) Remove O-ring (21).
a Steps 3) and (4) apply to the blade lift

cylinder only.
3) Remove two covers (9) and two pins (10).
4) Remove four shafts (11) and eight seats (12).
Assembly
a Apply hydraulic oil (For details, see "List of
each part.
a When assembling the piston rod, packing, dust
seal and O-ring, take care not to damage them.
a Before installing the backup ring, warm it in hot
a Steps 5), 6) and 7) apply to the blade water at about 50 to 60 °C .
angle cylinder only. 1. Assembly of cylinder head
5) Remove one cover (9) and one pin (10).
1) Using tool U6, press fit bushing (20).
6) Remove four shafts (11) and four seats (12).
2) Install buffer ring (19).
7) Remove four valves (13) and remove four
3) Install rod packing (18).
springs (14).
4) Using tool U7, install dust seal (17) and
secure it with snap ring (16).
5) Install the backup ring and O-ring (15).
50-296 D65EX,PX,WX-17
Hydraulic system
a O-ring (21) of Step 6) applies to the blade

lift cylinder, blade angle cylinder, blade tilt
cylinder and ripper lift cylinder only.
6) Install O-ring (21).
• Blade lift cylinder, blade angle cylinder
a Steps 5) and 6) apply to the blade lift

cylinder only.
5) Install eight seats (12) and four shafts (11).
2. Assembly of piston 6) Install two pins (10) and install two covers
1) Set piston ring (8) to tool U4 and rotate the (9).
handle eight to eleven turns to expand the
piston ring.
2) Remove piston ring (8) from tool U4 and
install it to piston (6).
3) Using tool U5, compress piston ring (8).
a Steps 7), 8) and 9) apply to the blade

angle cylinder only.
7) Install four springs (14) and four valves (13).
8) Install four seats (12) and four shafts (11).
9) Install one pin (10) and one cover (9).
4) Install wear ring (7).
• Blade tilt cylinder, blade pitch cylinder,
ripper lift cylinder
D65EX,PX,WX-17 50-297
Hydraulic system
4) With cylinder assembly (1) set to tool U1,

sling and install piston rod assembly (3) to
cylinder (1).
3. Piston rod assembly

1) Thoroughly clean, degrease and dry the
threaded portion of piston rod (3).
2 Threaded portion of piston rod (3): 5) Using a hydraulic pump or a torque multiplier
wrench, tighten cylinder head assembly (2)
Liquid adhesive (Loctite No. 262 or
by using tool U2.
equivalent)
2) Set piston rod (3) to tool U1, and install 3 Cylinder head assembly (2):
cylinder head assembly (2) and piston Cylinder head
assembly (6). Cylinder
tightening torque
3) Using tool U3, tighten nut (5). 677 ± 67.5 Nm
PAT
a When installing nut (5), direct its {69 ± 6.90 kgm}
machined surface toward the piston. Blade lift
Except for 637 ± 63.5 Nm
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}
3 Nut (5):
Width
across Tightening torque
Cylinder
flats of of nut (kNm {kgm})
nut (mm)
1.08 ± 0.11
Blade lift 50
{110 ± 11.0}
3.14 ± 0.31
Blade angle (PAT) 75
{320 ± 32}
3.97 ± 0.41
Blade tilt, blade pitch 80 a (A) indicates blade lift cylinder except for
{405 ± 40.5}
PAT.
3.97 ± 0.41
Blade tilt (PAT) 80 • Except for blade tilt cylinder and blade
{405 ± 40.5}
pitch cylinder for ST-TPP and SGM-PP
3.97 ± 0.41
Ripper lift 80
{405 ± 40.5}
50-298 D65EX,PX,WX-17
Hydraulic system
• Blade tilt cylinder and blade pitch cylinder

for ST-TPP and SGM-PP
D65EX,PX,WX-17 50-299
Work equipment
Work equipment
Removal and installation of blade assembly (ST-TPP dozer)
• ST-TPP: Straight tilt power pitch dozer 3. Use the same procedure to separate the right
blade lift cylinder from the blade.

Removal
1. Place blocks [1] under the right and left straight
frames.
4. Remove right and left steps (4) and trunnion

cover (5).
2. Disconnect the left blade lift cylinder assembly

from the blade according to the following
procedure.
1) Remove cap (2) from blade lift cylinder rod
(1). [*1] 5. Disconnect two hydraulic hoses (6) each from
the right and left side.
a Check and note the number and
thickness of the shims. a Plug the hoses and adapters to prevent the
6. Remove two mounting bolts (7) each from the
right and left side, and remove trunnion cap (8)
and shims (9). [*2]
a Check and note the number and thickness of
the shims.
2) Sling the blade lift cylinder assembly (3)

temporarily. Start the engine and retract
blade lift cylinder rod (1) fully.
3) Secure blade lift cylinder assembly (3) to the
machine by using stay [2].
a Secure blade lift cylinder rod (1) by using
wire etc. to prevent it from coming out.
50-300 D65EX,PX,WX-17
Work equipment
7. Start the engine and move the machine a Using blocks (3), adjust height (b) and width (c)
backward slowly to separate straight frame (11) of the right and left straight frames to the
from trunnion (10). [*3] following dimensions.
• Height (b): 494 mm (D65EX-16)
494 mm (D65PX-16)
• Width (c): 2,600 mm (D65EX-16)
3,136 mm (D65PX-16)
Installation
removal.
[*1]
a Adjust clearance (a) between cap (2) mating
surfaces to the following dimension by using
shims.
• Standard clearance (a): 0.2 to 0.5 mm
• Standard shim thickness: 4 mm
a Check that cap (2) rotates smoothly.
• Refilling (hydraulic tank)


[*2]
water")
a Adjust trunnion cap (8) by using shims. For • Bleeding air (work equipment circuit)
details, see Testing and adjusting, "Adjusting Bleed air from the work equipment cylinder. For
blade". details, see Testing and adjusting "Bleeding air
[*3] from work equipment cylinder".
D65EX,PX,WX-17 50-301
Work equipment
Removal and installation of blade assembly (PAT dozer)

• PAT: Power angle and power tilt dozer

pressuree in the hydraulic tank.
Removal
1. Place blocks [1] under the right and left straight
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
procedure. 5. Disconnect three hydraulic hoses (6) from the
right side of the machine and three hydraulic
1) Remove pin(2) from blade lift cylinder rod (1).
hoses (7) from the left side of the machine.
2) Sling the blade lift cylinder assembly (3)

temporarily. Start the engine and retract
blade lift cylinder rod (1) fully.
3) Secure blade lift cylinder assembly (3) to the 6. Remove two mounting bolts (8) each from the
machine by using stay [2]. right and left side, and remove trunnion cap (9)
and shims (10).[*1]
a Secure blade lift cylinder rod (1) by using
wire etc. to prevent it from coming out. a Check and note the number and thickness of
3. Use the same procedure to separate the right the shims.
blade lift cylinder from the blade.
50-302 D65EX,PX,WX-17
Work equipment


water")
Bleed air from the work equipment cylinder. For
details, see Testing and adjusting "Bleeding air
from work equipment cylinder".
7. Start the engine and move the machine
backward slowly to separate work equipment
frame (11) from the trunnion.[*2 ]
Installation
removal.
[*1]
a Adjust trunnion cap (9) by using shims. 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 following
dimension.
• Height (a): 857 mm (D65EX-16)
857 mm (D65PX-16)
D65EX,PX,WX-17 50-303
Work equipment
Removal and installation of ripper assembly

a This section includes the disassembly and adjusting "Releasing remaining pressure in
assembly procedures for ripper. hydraulic circuit"
k Stop the machine on a level ground and 7. Disconnect two ripper hoses (3).
apply the parking brake. a Plug the disconnected hose to prevent oil
leakage.
Removal
1. Place stand [1] under the ripper assembly arm.
2. Set hydraulic jack [2] under the ripper assembly
beam center.
8. Sling ripper lift cylinder (4).

9. Remove the pin mounting bolts and two pins (5).
[*2]
10.Sling and remove ripper lift cylinder (4).
4 Ripper lift cylinder (4):

80 kg
3. Sling left link (1).

4. Remove the pin mounting bolts and two pins (2).
[*1]
5. Sling and remove link (1).
4 Link (1):
50 kg
6. Remove the right link according to the following
procedure.
11.Sling boom (6).

12.Remove the pin mounting bolts and two right
and left pins (7).[*3]
13.Sling and remove beam (6).
4 Beam (6) (including three shanks):

500 kg
k Release the remaining pressure inside the

piping, and loosen the oil filler cap of the
hydraulic tank to release the pressure in the
hydraulic tank. For details, see Testing and
50-304 D65EX,PX,WX-17
Work equipment
k After the operation, set the work

equipment lock lever to lock the ripper
control lever securely.
2) Sling the shank.
3) Remove lock pin (13) and remove pin (14).
[*6]
14.Sling arm (8).

15.Remove the pin mounting bolts and two right
and left pins (9).[*4]
16.Sling and remove arm (8).
4 Arm (8):
260 kg
4) Sling shank (15) and gradually lower it to
remove.
4 Shank (15):
90 kg
17.Sling support bracket (10).

18.Remove ten mounting bolts (11), six bolts (12)
then sling and remove support bracket (10).
[*5]
4 Support bracket (10): Installation

310 kg • Perform installation in the reverse order to
removal.
[*1], [*2], [*3], [*4]
k When aligning the mounting holes for the pin,
never insert your fingers in the holes.
2 Pin:
Grease (G2-LI)
[*5]
Adhesive (LT-2)
19.Remove the shank according to the following 3 Mounting bolt (11):

procedure. 785 to 980 Nm {80 to 100 kgm}
1) Start the engine, and raise the ripper 2 Mounting bolt (12):
assembly to the maximum. Adhesive (LT-2)
D65EX,PX,WX-17 50-305
Work equipment

1,960 to 2,450 Nm {200 to 250 kgm}
[*6]
a Install lock pin (13) securely.

water")
Bleed air from the work equipment cylinder. For
details, see Testing and adjusting "Bleeding air
from work equipment cylinder".
50-306 D65EX,PX,WX-17

Removal and installation of ROPS cab assembly



Removal 7. Sling and remove operator's seat assembly (2).

1. Collect the air conditioner refrigerant (R134a) For details, see "Removal and installation of
from the air conditioner circuit. [*1] operator seat assembly."
k If the refrigerant (air conditioner gas: R134a) 4 Operator's seat assembly (2):
gets in your eyes, you may lose your sight. 50 kg
may suffer from frostbite. Always wear safety a The crane cannot be used inside the ROPS
goggles, globes, and working suits with long cab. Sling and remove operator's seat
sleeves when collecting the refrigerant or assembly (2) by using a bar etc.
charging the air conditioner with the
refrigerant.
a Never release the refrigerant (R134a) to the
atmosphere.
a Ask a qualified person for collection, and
charge of the refrigerant (R134a).
6 Fuel tank:
415 l
3. Remove the fuel tank assembly. For details, see 8. Remove the floor plate assembly according to
"Removal and installation of fuel tank assembly". the following procedure.
4. Open the left side cover and lock the opened 1) Remove floor mat (3).
cover.
a Be sure to lock the opened cover securely.
5. Remove cover (1a).
6. Open right and left doors (1b) of the ROPS cab,
and fix them with the locks.
a Be sure to lock the opened doors securely.
D65EX,PX,WX-17 50-307
2) Remove inspection cover (4) of the floor

plate.
10.Open battery cover (9) on the left side of the

machine and fix it with the lock.
3) Disconnect harness connector CN-PAC (5) a Be sure to lock the opened cover securely.
from the bottom of the floor plate.
4) Disconnect the turnbuckle of brake rod (6). 11.Disconnect the parking brake cable (10). For
For details, see Testing and adjusting, details, see Testing and adjusting, "Adjusting
"Adjusting brake pedal".[*2] parking brake".
5) Sling and remove floor plate assembly (7). [*3]
4 Floor plate assembly (7):

30 kg
a The crane cannot be used inside the
ROPS cab. Sling and remove floor plate
assembly (7) by using a bar etc.
12.Disconnect wiring harness connectors CN-PL1

(11) and CN-FD1 (12).
a When disconnecting wiring harness
connectors CN-PL1 (11) and CN-FD1 (12),
loosen hexagonal socket head bolt (4 mm) at
the center of them.[*4]
9. Remove inspection cover (8) under the a How to disconnect wiring harness
operator's seat. connectors CN-PL1 (11) and CN-FD1 (12):
Disconnect the connector straight slowly and
50-308 D65EX,PX,WX-17
check for breakage and peeling of the seal

and sticking of foreign matter.
a If the seal is defective, replace it.
13.Disconnect fresh air duct (13) .[*5]
17.Remove hose clamp (18).

18.Disconnect air conditioner tubes (18a) and
(18b).
a Disconnect air conditioner tube (18b) from
the air conditioner compressor.
14.Remove hose clamp (14), and disconnect four
wiper liquid hoses (15).
19.Remove two pins (19).[*6]

15.Disconnect ground cable (16) from the rear of
the machine. a Remove all the wiring harness clamps under
the floor.
16.Disconnect two heater hoses (17) and remove

bracket (17a). 20.Remove covers (20), (22), and (23) inside the
ROPS cab.
21.Reverse cover (23) and disconnect connectors
CN-CBACC (24) and CN-CBCIG (24a) and AUX
terminal wiring connector MD1B (25).
D65EX,PX,WX-17 50-309
25.Disconnect the quick couplers of ripper PPC

hoses (31) and (32).
26.Disconnect the quick couplers of blade PPC
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 If hydraulic hoses (42) and (43) are not
disconnected, they interfere with the ROPS
cab.
22.Remove cover (26) from the right rear.
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 covers (30).
29.Sling the ROPS cab assembly.

30.Remove four ROPS cab front mounting bolts
(44) on each of the right and left sides.[*7]
50-310 D65EX,PX,WX-17

deterioration.
k Screw size (M16 x 1.5) (width across flats:
19):
12–15 Nm {1.2–1.5 kgm}
31.Remove four ROPS cab rear mounting bolts k Screw size (M22 x 1.5) (width across flats:
(45) on each of the right and left sides.[*8] 24):
20–25 Nm {2.0–2.6 kgm}
k Screw size (M24 x 1.5) (width across flats:

27):
29–34 Nm {3.0–3.5 kgm}
k Receiver tank refrigerant tube mounting bolt

3.9–6.9 Nm {0.4–0.7 kgm}
k Air conditioner compressor refrigerant tube

32.Sling and remove ROPS cab assembly (46). 10):
8–12 Nm {0.8–1.2 kgm}
4 ROPS cab assembly (46):
1,000 kg
cab assembly.
[*2]
Install the turnbuckle of brake rod (6). For details,
see Testing and adjusting, "Adjusting brake pedal".
[*3]
Install parking brake cable (10). For details, see
Testing and adjusting, "Adjusting parking brake".
Installation
[*4]
removal. a How to install wiring harness connectors CN-
[*1] PL1 (11) and CN-FD1 (12)
1. Check that the seal is installed to the plug
correctly.
2. Check that the key is fitted to the groove on the
receptacle.
D65EX,PX,WX-17 50-311
3. Match the connector on the plug side straight

with the receptacle (since the seal is projected),
and connect the connector lightly while checking Only necessary quantity
that the seal does not roll up. (For details, see "List of lubricant and
4. Tighten the hexagonal socket head bolt at the water")
center of the connector by two to three turns. • Refilling of fuel (fuel tank)
5. Connect the connector on the plug side fully and
adjust it so that the clearance between it and 5 Fuel tank (diesel fuel):
receptacle will be even when viewed from each 415 l
direction.
6. Tighten the lock bolt to the specified torque.
water")
3 Hexagon socket head bolt (4 mm): • Checking for fuel leakage (fuel system)
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm} Check the fuel system for leakage. For details,
a If this bolt is tightened too strongly, the lock system for leakage".
may be broken and the connector cannot be • Bleeding air (fuel system)
locked. Bleed air from the fuel circuit. For details, see
circuit".
[*5]
a Install heater air duct (13) with the bolt of the
mounting clamp down so that it can be tightened
from the rear of the machine.
[*6]
3 Mounting bolt of Pin (19):
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}
50-312 D65EX,PX,WX-17
Removal and installation of operator's cab glass (adhesion glass)
a Make holes in the adhesive and both-sided

adhesive tape using a drill, and pass a fine
wire (piano wire, etc.) [2] through the holes.
Grip 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
a Among the window glasses of operator's cab, adhesive tape.
window glasses (3), (4), (5), and (6) are Since the wire may be broken by the
adhesion type. In this section, the procedure for frictional heat, apply lubricant to it.
replacing the adhered glasses is explained. (The figure shows the operator's cab of a
(1) : Trim seal wheel loader.)
(2) : Both-sided adhesive tape
(3) : Front window glass
(4) : Rear window glass
(5) : Right door window glass
(6) : Left door window glass
Special tools
Sy-
mb- Part number Part name
ol Q'ty
Necessity
New/redesign
Sketch
793-498- Lifter (Suction cup)

X1 2
1210 t
Removal a If the window glass is broken in small pieces,
it may be removed with knife [4] and a flat-
a Remove the window glass to be replaced blade screwdriver.
a Widening the cut using a flat-blade
1. Using seal cutter [1], cut the adhesive between
screwdriver, cut the adhesive and dam
broken window glass (6) and operator's cab
rubber using knife [4].
(metal sheet) (7).
(The following figure shows the operator's
cab of a wheel loader.)
D65EX,PX,WX-17 50-313
2. Remove the window glass. 3. Adhere dam rubber (3) along the inside edge of
the glass bonding section of the front window
Installation glass and right and left door window glasses.
1. Using a knife and scraper [5], remove the
a Do not remove the release tape of dam
remaining adhesive and dam rubber from the
rubber on the glass sticking side before
sheet metal (adhesion surfaces) of the
sticking the glass.
operator's cab.
a When sticking the dam rubber, do not touch
a Remove the adhesive and dam rubber to a
the cleaned surface to the utmost.
degree that they will not affect adhesion of
the new adhesive. Take care not to scratch a Care should be taken not to float the dam
the painted surfaces. rubber of each sticking corner.
(If the painted surfaces are scratched, a Take care not to overlap the beginning and
adhesion will be lowered.) end portions of dam rubber (3).
(The following figure shows the operator's Contact mating ends (a) with each other.
cab of a wheel loader.)
2. Remove oil, dust, dirt, etc. from the bonding

surfaces on operator's cab (7) and window glass
(8) using 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 lease five minutes to dry.
4. Position the new window glass.

1) Using tool X1, check the clearances between
the window glass and the operator's cab on
the right, left, upper, and lower sides, and
50-314 D65EX,PX,WX-17
then position the window glass with the 1) Break aluminum dehumidification membrane
clearance evenly. (11) at the mouth of adhesive cartridge (10)
and attach there the dedicated nozzle.
a Adjust the position of front window glass
(1) from the inside of operator's cab (7).
Adjust the front window glass so that the
difference between the black coating
portion (black ceramic) and the metal
sheet of operator's cab (7) becomes even
at the right and left and top and bottom
positions.
a Adjust the position of right and left door
window glasses (2) so that the clearance
becomes even between glasses and
metal plate of the door.
2) After the positioning, stick tape [6] between
front window glass (1) and operator's cab (7), 2) Cut the tip of the adhesive cartridge nozzle
and between right and left door window glass (12) to dimensions (f) and (g).
(2) and the right , left and bottom portions of • (Dimensions f): 10 mm
right and left doors (9). Then, mark line (e) on • (Dimensions g): 15 mm
these tapes for positioning.
3) Cut the tape between window glasses (1)
and (2) and operator's cab (7) using a utility
knife or others, and remove the window
glasses.
a Do not remove the tapes left on the
window glass and the operator's cab
before installing the window glass.
3) Set adhesive cartridge (10) to caulking gun

[7].
a An electric caulking gun is more efficient.
5. Apply adhesive.
2 Adhesive: Manufactured by Sika Ltd.
Sikaflex 256HV
a Do not use a primer.
a The use limit of adhesive is six months after
its production. Do not use the adhesive after
this limit. 4) Remove tape (3a) on glass adhesion side of
a Keep the adhesive in a dark place where the the dam rubber.
temperature is below 25 °C .
a Never heat the adhesive higher than 30 °C .
a When reusing the adhesive, remove the all
hardened part form the nozzle tip.
D65EX,PX,WX-17 50-315
5) Apply adhesive (13) to the outside of dam 6. Install the front window glass.
rubber (3) on the operator's cab. 1) Using tool X1, install front window glass (1)
to operator's cab (7) while aligning lines (e)
of positioning tapes [6] attached in Step 5.
a Since the window glass cannot be
removed and stuck again, stick it with
utmost caution.
a Stick the glass within five minutes after
applying the adhesive.
2) After installation of the window glass, press
its periphery until it bonds to the dam rubber.
a Press the corners of the window glass
firmly.
7. Install right and left door window glasses.

a Apply adhesive (13) with dimensions (h) 1) Using tool X1, install right and left door
and (j) relative to dam rubber (3) attached window glasses (2) to doors (9) while
on operator's cab (7). aligning lines (e) of positioning tapes [6]
• (Dimensions h): 10 mm attached in Step 5.
• (Dimensions j): 15 mm
a Since it is not allowed to remove and
a Apply adhesive (13) with the height bond the window glasses again, bond
higher than dam rubber (3). them very carefully.
a Apply the adhesive evenly with same a Stick the glass within five minutes after
height level. applying the adhesive.
2) After installation of the window glass, press
its periphery until it bonds to the dam rubber.
50-316 D65EX,PX,WX-17
a Press the corners of the window glass

firmly.
8. Fix window glass (9).

1) Using styrene foam blocks [10] and rubber
bands [11], fix the front window glass
securely to cure it.
a Or secure it using adhesive tapes.
(The figure shows the operator's cab of a
hydraulic excavator.)
9. Clean the remaining primer and adhesive on the

window glass and operator's cab after
completing the installation of the window glass.
a By using the white gasoline, wipe off the
adhesive before it dries off.
a When cleaning the glass, do not give an
impact to it.
10.Protect the stuck window glass.
1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours of curing period.
(Ambient temperature 20 °C /humidity 65%)
2) After applying adhesives, cure the windows
for 24 hours. Then, start the machine.
D65EX,PX,WX-17 50-317
Removal and installation of operator's sea


stop the engine.

Removal
1. Disconnect wiring connectors (1) and (2).
a Pull connector (1a) out of the clip.
(When removing only upper seat assembly)
In Step 2, remove four mounting bolts (5) of upper
seat assembly (6), and remove upper seat
assembly (6).
•
cab. Sling and remove operator's seat
assembly (4) by two persons.
4 Upper seat assembly (6):

25 kg
2. Disconnect wiring connector (7) and wiring

clamp (8).
Installation
removal.
3. Remove four mounting bolts (3) of operator's
seat assembly (4).
4. Remove operator's seat assembly (4).
4 Operator's seat assembly (4):

50 kg
50-318 D65EX,PX,WX-17
Removal and installation of seat belt


stop the engine.

Removal
1. Remove the operator's seat assembly. For
operator's seat assembly."
2. Remove mounting bolts (2) of seat belt (1) (one
on each side) to remove seat belt (1). [*1]
Installation
removal.
[*1] [*2]
3 Seat belt assembly mounting bolt:
19.8–29.4 Nm {2.0–3.0 km}
D65EX,PX,WX-17 50-319
Removal and installation of air conditioner unit assembly

k Place the machine on a level ground and 4 Operator seat assembly:
50 kg
k Lower the work equipment to the ground and 5. Remove IB unit (7) according to the following
stop the engine. procedure. (if equipped)
1) Disconnect wiring connectors (2) to (5).
k Set the disconnect switch to the OFF 2) Disconnect wiring clamp (6).
position and remove the key. 3) Disconnect IB unit (7).

k If the refrigerant (air conditioner gas: R134a)

gets in your eyes, you may lose your sight.
may suffer from frostbite.
Always wear safety glasses, globes, and
long sleeve cloth when collecting the
refrigerant or charging the air conditioner
with the refrigerant.
4) Disconnect wiring clamp (8a).
a Never release the refrigerant (R134a) to the 5) Remove covers (8) and (9).
atmosphere.
a Ask a qualified person for collection and charge
of the refrigerant (R134a).
a Note connector numbers and installed positions
before disconnecting wiring and hoses.
Removal
undercover.
6. Remove covers (10) and (11).

7. Remove covers (12) and (13).
6 Radiator:
54 l
4. Remove the operator's seat assembly. For
50-320 D65EX,PX,WX-17
a This is for prevention of damage of the filter

during work.
8. When removing cover (12), reverse it and

disconnect wiring connectors CBACC (14),
CBCIG (15), and AUX terminal wiring MD1B
11.Remove ducts (22), (23), and (24) according to
(16).
1) Remove mounting bolts of ducts (22) and
(24).
2) Remove two mounting clips of duct (23).
3) Remove ducts (22), (23), and (24) in this
order.
9. Remove covers (18) to (20).
10.Remove filter (21).
12.Disconnect wiring connectors (25), AC01 (26),

and AC02 (27).
13.Disconnect three wiring clamps (28) and four
bands (29).
14.Remove cover (30).
D65EX,PX,WX-17 50-321
15.Remove battery cover (31) on the left side of the

machine. 19.Disconnect heater hoses (34).
20.Disconnect air conditioner hose (35).[*2]
21.Disconnect drain hose (36).
16.Remove bolts (33) and (33a) of fresh air duct.

17.Remove fresh air ducts (34) and (35). 22.Remove six mounting bolts (37), then remove
air conditioner unit (38).
18.Remove inspection cover (41) under the

operator's seat.
50-322 D65EX,PX,WX-17
Installation
removal.
[*1][*2]
that O-ring is fitted to each fitting.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, apply
(DENSO: ND-OIL8) to the O-rings.
• Screw size (M16 x 1.5) (width across flats:
19):
12–15 Nm {1.2–1.5 kgm}
24):
20–25 Nm {2.0–2.6 kgm}
27):
29–34 Nm {3.0–3.5 kgm}
Receiver tank refrigerant tube mounting bolt (M6
x 1.0) (width across flats: 10): 3.9 to 6.9 Nm {0.4
to 0.7 kgm}
• Air conditioner compressor refrigerant tube
mounting bolt (M6 x 1.0) (width across flats: 10):
8–12 Nm {0.8–1.2 kgm}
6 Radiator:
54 l
D65EX,PX,WX-17 50-323
Removal and installation of air conditioner compressor assembly

a In this section, only the precautions for installing
the air conditioner compressor are described.
Installation
1. Install air conditioner compressor assembly (1)
to bracket (3) with four mounting bolts (2).
24.5–29.4 Nm {2.5–3.0 kgm}
k If mounting bolts (2) are overtightened, the

air conditioner compressor may be damaged
at its inside. Strictly observe the specified
tightening torque.
50-324 D65EX,PX,WX-17
Electric system
Electric system
Removal and installation of machine monitor assembly

stop the engine.

Removal
1. Remove lower cover (1).
2. Remove top cover (2).
3. Disconnect wiring connectors FLSW (3) and

RLSW (4).
installation
4. Disconnect wiring connectors SESW (5), CM01 • Carry out installation in the reverse order to
(6), and CM02 (7). removal.
a Since the wiring of connectors SESW (5),
CM01 (6), and CM02 (7) is so short that you
have to disconnect them where they are not
seen, take care not to damage them.
5. Remove the monitory assembly.
D65EX,PX,WX-17 50-325
Electric system
Removal and installation of engine controller assembly


k Disconnect the cable from the negative (-)

terminal of the battery.
Removal
1. Open the engine left side cover (1) and lock the
opened cover.
a Be sure to lock the opened cover securely.
7. Remove mounting bolts (7), (7a), and (8), and
remove engine controller assembly (9).
a Mounting bolt (7a) is also used to tighten
ground cable (8).
3. Disconnect air conditioner hose clamps (3a) and

(3b).
4. Remove two receiver mounting bolts (3c).
5. Disconnect receiver assembly (3). Installation
removal.
a Remove all dirt from the wiring harness
connectors of engine controller assembly before
installation.
3 Hexagonal socket head bolt (4 mm) at
center of wiring harness connector CN-
CE01 (5) and CN-CE02 (6):
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
6. Disconnect wiring harness connectors CN-CE03

(4), CN-CE01 (5), and CN-CE02 (6).
a Remove wiring harness connectors CN-
CE01 (5) and CN-CE02 (6) as one unit by
loosening the hexagonal socket head bolts
(4 mm) at their centers.[*1]
50-326 D65EX,PX,WX-17
Electric system
Removal and installation of power train controller assembly



Removal
and lock the opened doors.
4. Disconnect wiring harness connectors CN-STC3
(4), CN-STC2 (5), and CN-STC1 (6).
a When disconnecting wiring harness
connectors CN-STC3 (4), CN-STC2 (5), and
CN-STC1 (6), loosen hexagonal socket head
bolt (4 mm) at the center of them.[*1]
5. Remove the four mounting bolts to remove
power train controller assembly (7).
2. Remove operator's seat assembly (2). For


50 kg
cab. Remove operator's seat assembly (2)
by two persons.
Installation
3. Remove cover (3) on the left side in the ROPS removal.
cab.
a Remove all dirt from wiring harness connectors
of power train controller assembly before
installation.
[*1]
D65EX,PX,WX-17 50-327
Electric system
3 Hexagonal socket head bolt (4 mm) at

center of wiring harness connector CN-
STC3 (4), CN-STC2 (5), and CNSTC1 (6):
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
50-328 D65EX,PX,WX-17
Electric system
Removal and installation of mass air flow and temperature sensor


stop the engine.

Removal
cover.
a Check that the opened door is locked
securely. Installation
removal.
[*1]
3 Mounting screw of mass air flow and
temperature sensor assembly:
0.98–1.27 Nm {0.1–0.13 km}

3. Remove the mass air flow and temperature
sensor assembly.[*1]
a Be careful about dust from entering into air
cleaner.
D65EX,PX,WX-17 50-329
Electric system
Removal and installation of KOMTRAX terminal



Removal
and lock the opened doors.
5. Remove covers (8), (9), (10), and (11).
2. Remove operator's seat assembly (2). For

operator seat assembly."

50 kg
6. Disconnect harness connectors CN-CK02 (14),

CN-CK01 (15), GPS cable connector (16), and
ORBCOM cable connector (16a).
7. Remove four mounting bolts (12) and remove
KOMTRAX terminal assembly (13).
3. Remove covers (3), (4), and (5) from the ROPS

cab.
4. Reverse cover (5), disconnect wiring harness
connectors CN-CBACC (6) and CN-CBCIG (7),
and unplug AUX terminal connector CN-MC1B
(7a).
50-330 D65EX,PX,WX-17
Electric system
Installation
removal.
a Remove all dirt from the wiring harness
connectors of KOMTRAX terminal assembly,
and then install the assembly.
D65EX,PX,WX-17 50-331
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
60 Maintenance standard
D65EX,PX,WX-17 60-1
Table Of Contents
60 Maintenance standard................................................................................................................... 60-2
Engine mount ...................................................................................................................... 60-3
Damper ............................................................................................................................... 60-4
Cooling system .................................................................................................................... 60-6
Cooling fan pump ................................................................................................................. 60-7
Power train............................................................................................................................... 60-12
Universal joint .................................................................................................................... 60-14
Transmission ..................................................................................................................... 60-18
Forward-reverse clutch ECMV and gear shift clutch ECMV .................................................... 60-23
Brake valve ....................................................................................................................... 60-32
Final drive ......................................................................................................................... 60-33
Sprocket............................................................................................................................ 60-36
Main frame ........................................................................................................................ 60-41
Suspension ....................................................................................................................... 60-43
Track frame and idler cushion ............................................................................................. 60-45
Idler .................................................................................................................................. 60-47
Track roller ........................................................................................................................ 60-49
Carrier roller ...................................................................................................................... 60-53
Track shoe ........................................................................................................................ 60-55
Hydraulic tank.................................................................................................................... 60-60
Scavenging pump .............................................................................................................. 60-61
Steering lubricating pump and power train pump................................................................... 60-62
HSS pump......................................................................................................................... 60-63
HSS motor ........................................................................................................................ 60-65
Control valve ..................................................................................................................... 60-67
Blade PPC valve ................................................................................................................ 60-74
Ripper PPC valve............................................................................................................... 60-76
Quick drop valve ................................................................................................................ 60-78
Work equipment lock solenoid valve .................................................................................... 60-80
Angle control EPC valve ..................................................................................................... 60-83
Work equipment ....................................................................................................................... 60-84
Work equipment................................................................................................................. 60-84
Cutting edge and end bit ..................................................................................................... 60-92
Ripper ............................................................................................................................... 60-94
Lift cylinder ........................................................................................................................ 60-95
Tilt cylinder ........................................................................................................................ 60-96
Pitch cylinder ..................................................................................................................... 60-97
Angle cylinder .................................................................................................................... 60-98
Ripper cylinder................................................................................................................... 60-99
Cab mount ...................................................................................................................... 60-100
1 60 Maintenance standard
60-2 D65EX,PX,WX-17
Engine mount

Engine mount
D65EX,PX,WX-17 60-3
Damper
Damper
60-4 D65EX,PX,WX-17
Damper
Unit: mm
Standard Repair limit
Tolerance Repair by hard
Outside diameter of coupling dimension
1 chrome-plating
oil seal contact surface 0
85 84.8 or replace
-0.087
Facial runout: Max. 1.0 (at f 148.38), radial runout:
Max.1.5
– Coupling facial runout and Adjust
radial runout [When damper shaft and transmission input shaft are
rotated simultaneously]
D65EX,PX,WX-17 60-5
Cooling system
Cooling system
60-6 D65EX,PX,WX-17
Cooling fan pump
Cooling fan pump
D65EX,PX,WX-17 60-7
Cooling fan pump
Servo valve
60-8 D65EX,PX,WX-17
Cooling fan pump
D65EX,PX,WX-17 60-9
Cooling fan motor
Cooling fan motor
60-10 D65EX,PX,WX-17
Cooling fan motor
Unit: mm
Standard dimension Repair limit
Load at Load at
Free length Installed installed Free installed
x Outside length length of length length of If damaged or
1 Spool return spring diameter spring spring deformed,
58.8 N 47.1 N replace spring
44.84 x 12 33 –
{6 kg} {4.8 kg}
3.43 N 2.75 N
2 Check valve spring 13.0 x 6.5 7 –
{0.35 kg} {0.28 kg}
D65EX,PX,WX-17 60-11
Power train mount
Power train
Power train mount
*1: Other than power angle power tilt dozer is shown.

*2: Power angle power tilt dozer is shown.
Unit: mm
Clearance between steering dimension Shaft Hole clearance clearance
1 case cover and bushing Replace
+0.096 +0.046 -0.096 to
204 Max. 0
+0.050 0 -0.004
60-12 D65EX,PX,WX-17
Power train mount
Unit: mm
Free height of rear cab Standard dimension Repair limit
2
mount rubber 43 41
D65EX,PX,WX-17 60-13
Universal joint
Universal joint
60-14 D65EX,PX,WX-17

a PTO: Abbreviation for Power Take Off
D65EX,PX,WX-17 60-15
60-16 D65EX,PX,WX-17
Unit: mm
Outside diameter of input Tolerance
dimension
1 coupling oil seal contact 0 Repair by hard
surface 95 94.8 chrome-plating
-0.087 or replace
Inner diameter of seal ring +0.040
2 140 140.5
contact surface of retainer 0
Backlash between PTO drive
3 gear and PTO idler gear 0.17 to 0.46
Backlash between PTO idler
gear and HSS pump, cooling
4 fan pump, power train, and 0.16 to 0.42 Replace
steering lubrication pump
drive gear
Backlash between PTO drive
5 gear and scavenging pump 0.17 to 0.46
drive gear
Tolerance
Standard dimension
Shaft Hole
Fit tolerance for Outside 0 -0.024

6 PTO idler gear diame- 110
-0.015 -0.049
bearing ter
Inner 0 0
diame- 60
ter -0.019 -0.015
Outside
diame-
ter +0.035
(cover 0
Fit tolerance for –
HSS pump, cooling side) 0
fan pump, steering Outside 120
-0.015
7 lubrication pump, diame-
and power train ter +0.022
pump drive gear (case -0.013
bearing side)
Inner +0.030 0
diame- 55
ter +0.011 -0.015
Outside 0 +0.030
Fit tolerance for diame- 72
ter -0.013 0
8 scavenging pump
drive gear bearing Inner +0.025 0
diame- 35
ter +0.009 -0.010
D65EX,PX,WX-17 60-17
Transmission
Transmission
60-18 D65EX,PX,WX-17
Transmission
D65EX,PX,WX-17 60-19
Transmission
Unit: mm
Load at Load at
Free Installed installed Free installed
1 R clutch spring (5 pcs.) length length length of length length of
spring spring
190.2 N 161.7 N
69.5 60.7 65.3
{19.4 kg} {16.5 kg}
95.2 N 81 N Replace
2 F clutch spring (5 pcs.) 77.0 63.6 72.4
{9.7 kg} {8.2 kg}
141.2 N 120.0 N
3 3rd clutch spring (5 pcs.) 59.0 44.6 55.5
{14.4 kg} {12.2 kg}
141.2 N 120.0 N
4 2nd clutch spring (5 pcs.) 59.0 44.6 55.5
{14.4 kg} {12.2 kg}
114.7 N 97.5 N
5 1st clutch spring (5 pcs.) 59.0 47.3 55.5
{11.7 kg} {9.9 kg}
60-20 D65EX,PX,WX-17
Transmission
Unit: mm
Total thickness of R clutch Standard Repair limit
Tolerance
6 consisting of five discs and dimension
six plates 36.2 ±0.33 32.2
Total thickness of F clutch
7 consisting of seven discs 49.4 ±0.39 43.8
and eight plates
Total thickness of 3rd clutch
8 consisting of four discs and 29.6 ±0.30 26.4
five plates
Total thickness of 2nd clutch
five plates
Total thickness of 1st clutch
five 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 of 3rd carrier Width 4 3.6
13 and 1st carrier -0.03
cover seal ring Thick-
5 ±0.15 4.85
ness
Backlash between R, F, 3rd,
14 1st clutch sun gear and 0.11 to 0.30
planetary pinion
Backlash between 2nd cluch
15 sun gear and planetary 0.12 to 0.33
pinion
Backlash between R clutch
16 planetary pinion and ring 0.13 to 0.41
gear teeth
Backlash between F, 3rd,
17 and 1st clutch planetary 0.12 to 0.33
pinion and ring gear teeth
Backlash between 2nd
18 clutch planetary pinion and 0.13 to 0.36
ring gear teeth
Backlash between R clutch
19 carrier and ring gear teeth 0.14 to 0.44
Backlash between F clutch
Backlash between 1st clutch
D65EX,PX,WX-17 60-21
60-22 D65EX,PX,WX-17
Forward-reverse clutch ECMV and gear shift clutch
ECMV
Forward-reverse clutch ECMV and gear shift clutch ECMV

D65EX,PX,WX-17 60-23
Lockup clutch ECMV
Lockup clutch ECMV

60-24 D65EX,PX,WX-17
Unit: mm
Standard Tolerance Standard
Allowable
dimen- clear-
Clearance between main Shaft Hole clearance
1 relief valve and valve body sion ance
-0.035 +0.013 0.035 to
28 0.078
-0.045 0 0.058
Clearance between torque -0.035 +0.013 0.035 to
2 converter relief valve and 22 0.078
valve body -0.045 0 0.058
Load at Load at Replace
Main relief valve spring length length length of length length of
3 (outside)
spring spring
479.1 N 456 N
128 78.3 124.2
{48.9 kg} {46.5 kg}
Main relief valve spring 365.5 N 347 N
4 (inside) 108 78.3 104.8
{37.3 kg} {35.4 kg}
Torque converter relief valve 162.5 N 154 N
5 spring 50 41.5 48.5
{16.5 kg} {15.7 kg}
D65EX,PX,WX-17 60-25
Unit: mm
Load at Load at
Transmission lubricating oil length length length of length length of
1 relief valve spring Replace
spring spring
12.0 N 11.4 N
26 23.7 25.2
{1.22 kg} {1.16 kg}
60-26 D65EX,PX,WX-17

D65EX,PX,WX-17 60-27
60-28 D65EX,PX,WX-17
Unit: mm
Tolerance
dimension Replace
Thick-
1 Brake plate ness
5.0 ±0.1 4.7
Repair or
Strain – 0.15 or less 0.3 replace
Thick- Replace
5.2 ±0.1 4.7
ness
2 Brake disc Repair or
Strain – Max. 0.25 0.4 replace
Total thickness of assembly
3 containing four brake plates 46.0 ±0.3 43.3
and five discs
Backlash between gear A Standard clearance Allowable clearance
4 and gear B
0.06 to 0.65 – Replace
Backlash between gear A
5 and planetary pinion 0.14 to 0.35 –
Backlash between planetary
6 pinion and ring gear 0.15 to 0.38 –
Adjust the preload if the starting torque is less than 9.8
Preload of bevel gear shaft Nm {1.0 kgm}
7 taper roller bearing Adjust
Starting torque after adjustment: 10.3 to 14.7 Nm {1.05
to 1.50 kgm}
D65EX,PX,WX-17 60-29
60-30 D65EX,PX,WX-17
Unit: mm
Backlash between gear A Standard clearance Allowable clearance
1 and gear D 0.09 to 0.64 –
Backlash between gear C Replace
2 0.15 to 0.49 –
and gear D
Backlash between gear D
3 0.10 to 0.40 –
and HSS motor drive gear
Backlash between bevel
4 0.20 to 0.28 – Adjust
pinion and bevel gear
D65EX,PX,WX-17 60-31
Brake valve
Brake valve
Unit: mm
dimen-
Clearance between main Shaft Hole clearance clearance
1 brake valve and body sion
-0.020 +0.013 0.020 to
19 0.07
-0.030 0 0.043
Clearance between main -0.030 +0.015 0.030 to
2 brake valve and piston 9 0.08
-0.040 0 0.055
Clearance between parking -0.034 +0.013 0.034 to
3 brake valve and body 19 0.08
-0.043 0 0.056
Load at Load at Replace
Main brake modulation length length length of length length of
4 spring
spring spring
75.3 N 71.6 N
48 36 46.6
{7.68 kg} {7.3 kg}
Main brake valve return 157.9 N 150 N
5 spring 52 38 50.4
{16.11 kg} {15.3 kg}
Parking brake valve return 16.7 N 15.7 N
6 spring 36.5 28.5 35.4
{1.7 kg} {1.6 kg}
60-32 D65EX,PX,WX-17
Final drive
Final drive
a The figure shows D65EX-17.
D65EX,PX,WX-17 60-33
Final drive
Unit: mm
Backlash between pinion Standard clearance Allowable clearance
1 and gear
0.23 to 0.70 1.0
Backlash between sun gear
2 and planetary gear 0.17 to 0.47 1.0
Backlash between planetary
3 gear and ring gear 0.20 to 0.66 1.0
Tolerance Replace
Outside diameter of oil seal dimension
4 contact surface of pinion 0
80 79.9
-0.074
Tolerance Standard Allowable
Standard
Interference between interfer- interfer-
dimension Shaft Hole
5 planetary gear shaft and ence ence
carrier +0.059 +0.035 0.002 to
84 0.002
+0.037 0 0.059
60-34 D65EX,PX,WX-17
Final drive
Unit: mm
Axial clearance of pinion
6 bearing 0 to 0.1
Adjust
Standard shim thickness of
7 pinion bearing cage 1.5
8 Pinion cover ball projection Replace
5.2 1.5
Build-up
welding for
9 Wear of sprocket teeth 317 299 rebuilding or
replace
D65EX,PX,WX-17 60-35
Sprocket
Sprocket
For conventional type track shoes
Unit: mm
Standard dimension Repair limit Build-up
1 Width of tooth bottom welding for
87 77 rebuilding or
replace
2 Thickness of tooth bottom 26 17
60-36 D65EX,PX,WX-17
Sprocket
Full-scale drawing of sprocket tooth shape

a Duplicate the full-scale drawing onto an OHP sheet.
D65EX,PX,WX-17 60-37
Sprocket
For PLUS type track shoes

Unit: mm
1 Width of tooth bottom welding for
87 78
rebuilding or
2 Thickness of tooth bottom 26 17 replace
60-38 D65EX,PX,WX-17
Sprocket
Full-scale drawing of sprocket tooth shape

a Duplicate the full-scale drawing onto an OHP sheet.
D65EX,PX,WX-17 60-39
60-40 D65EX,PX,WX-17
Main frame
Main frame
a The drawing shows other than power angle power tilt dozer.
D65EX,PX,WX-17 60-41
Main frame
Unit: mm
Clearance between cylinder dimension Shaft Hole clearance clearance
1 yoke and bushing (large)
-0.036 +0.207 0.156 to Replace
85 0.5 bushing
-0.090 +0.120 0.297
Clearance between cylinder -0.030 +0.174 0.130 to
2 yoke and bushing (small) 65 0.5
-0.076 +0.100 0.250
60-42 D65EX,PX,WX-17
Suspension
Suspension
D65EX,PX,WX-17 60-43
Suspension
Unit: mm
Clearance between pivot dimension Shaft Hole clearance clearance
1 shaft and bushing (large)
-0.145 +0.063 0.145 to
148 1.0
-0.208 0 0.271
Clearance between pivot -0.120 +0.054 0.120 to Replace
2 shaft and bushing (small) 105 1.0 bushing
-0.174 0 0.228
Clearance between center -0.100 +0.174 0.200 to
-0.146 +0.100 0.320
Clearance between side pin -0.030 +0.010 0.010 to
4 and bushing 60 0.5
-0.060 -0.020 0.070
Press fit force of pivot shaft
5 ring (large) 0.98 to 22.6 kN {0.1 to 2.3 ton}
Press fit force of pivot shaft –
6 ring (small) 0.98 to 36.3 kN {0.1 to 3.7 ton}
– Oil quantity at pivot shaft 4.5 l (power line oil: TO30)
60-44 D65EX,PX,WX-17

a The drawing shows D65PX-17.
*1: Machine with conventional type track shoes is shown.

*2: Machine with PLUS type track shoes is shown.
D65EX,PX,WX-17 60-45
Unit: mm
Item Repair limit
Straightness 7 (per length 3,000)
1 Deformation of track frame Correct
Torsion 3 (per length 300)
Opening at idler 5
Load at Load at
x Outside length length of length length of
2 Recoil spring diameter spring spring Replace
193.2 kN
171.9 kN
723 x 239 580 {19,700 705
{17,533 kg}
kg}
Tolerance Standard
Standard Allowable
clear-
Clearance between piston dimension Shaft Hole clearance Replace
3 and bushing ance
bushing
-0.036 +0.270 0.097 to
90 1.0
-0.090 +0.061 0.360
4 Press fit force of idler yoke 392 kN {40 ton} Adjust
Track roller guard guide welding for
5 height rebuilding or
27 16
replace
– Amount of filled grease 140 cc (grease: G2-LI) –
60-46 D65EX,PX,WX-17
Idler
Idler
D65EX,PX,WX-17 60-47
Idler
Unit: mm
Outside diameter of Standard dimension Repair limit
1 protrusion
630 –
2 Outside diameter of tread 590 570 Build-up
welding for
3 Depth of tread 20 30 rebuilding or
4 Thickness of tread 15 5 replace
5 Width of tread 44.5 48.5
6 Overall width 190 –
Clearance between shaft dimension Shaft Hole clearance clearance
7 and bushing
-0.250 +0.142 0.242 to
65 –
-0.350 -0.008 0.492
Replace
Clearance between shaft -0.250 +0.090 0.250 to
8 and support 64.7 –
-0.350 0 0.440
Standard clearance Allowable clearance
9 Axial play of idler
0.26 to 0.66 –
Clearance between guide
10 plate and side plate 0.9 –
Adjust shims or
Standard shim thickness for replace plate
11 side plate mount 4.0
60-48 D65EX,PX,WX-17
Track roller
Track roller
For conventional type track shoes (single flange type)
Unit: mm
Outer diameter of flange Standard dimension Repair limit
1 (outside flange)
240 –
welding for
3 Thickness of tread 69 51 rebuilding or
4 Width of flange (outer) 19.5 13.5 replace
5 Width of tread 47 –
7 and bushing
-0.250 +0.143 0.243 to
65 –
-0.350 -0.007 0.493
Replace
Clearance between shaft -0.250 -0.100 0.100 to
8 64.7 –
and collar -0.350 -0.150 0.250
9 Axial play of roller
0.26 to 0.66 –
D65EX,PX,WX-17 60-49
Track roller
For conventional type track shoes (double flange type)
Unit: mm
1 (outside flange) 240 –
Outer diameter of flange
2 236 –
(inside flange) Build-up
3 Outside diameter of tread 210 174 welding for
6 Width of flange (inner) 19.5 13.5
7 Width of tread 47.7 –
9 and bushing -0.250 +0.143 0.243 to
65 –
-0.350 -0.007 0.493
Replace
10 64.7 –
and collar -0.350 -0.150 0.250
0.26 to 0.66 –
60-50 D65EX,PX,WX-17
Track roller
For PLUS type track shoes (single flange type)

Unit: mm
1 (outside flange)
250 –
welding for
4 Width of flange (outer) 24 13.5 replace
5 Width of tread 47 –
7 and bushing
-0.250 +0.143 0.243 to
65 –
-0.350 -0.007 0.493
Replace
8 64.7 –
and collar -0.350 -0.150 0.250
0.26 to 0.66 –
D65EX,PX,WX-17 60-51
Track roller
For PLUS type track shoes (double flange type)

Unit: mm
1 (outside flange) 240 –
Outer diameter of flange
2 236 –
(inside flange) Build-up
6 Width of flange (inner) 19.5 13.5
7 Width of tread 47.7 –
9 and bushing
-0.250 +0.143 0.243 to
65 –
-0.350 -0.007 0.493
Replace
10 64.7 –
and collar -0.350 -0.150 0.250
0.26 to 0.66 –
60-52 D65EX,PX,WX-17
Carrier roller
Carrier roller
For conventional type track shoes
Unit: mm
1 Outside diameter of flange
215 – Build-up
3 Thickness of tread 37.5 26.5 rebuilding or
4 Width of tread 49.5 – replace
5 Width of flange 21 15
6 and support
-0.100 +0.300 0.100 to
61 –
-0.200 0 0.500
Standard Replace
interfer- interfer-
Interference between shaft dimension Shaft Hole
7 and seal guard ence ence
+0.150 +0.030 0.100 to
61.5 –
+0.130 0 0.150
0 to 0.32 –
D65EX,PX,WX-17 60-53
Carrier roller
For PLUS type track shoes

Unit: mm
1 Outside diameter of flange
224 – Build-up
4 Width of tread 49.5 55.5 replace
5 Width of flange 21 15
6 and support
-0.100 +0.300 0.100 to
61 –
-0.200 0 0.500
Standard Replace
interfer- interfer-
Interference between shaft dimension Shaft Hole
7 and seal guard ence ence
+0.150 +0.030 0.100 to
61.5 –
+0.130 0 0.150
0 to 0.32 –
60-54 D65EX,PX,WX-17
Track shoe
Track shoe
Conventional type track shoe
*1. Single grouser shoe

*2. Swamp shoe
a Part P is the link on the bushing press-fitting side.
Unit: mm
Standard dimension Repair limit Turn 180 deg.
1 Link pitch or replace
203.45 206.45
D65EX,PX,WX-17 60-55
Track shoe
Unit: mm
Reverse
Standard dimension
2 Outside diameter of bushing Light load Heavy load
73 62.8 65.4
3 Thickness of bushing 13.9 3.7 6.3
Standard dimension Repair limit Repair or
4 Link height replace
132 119.5
Thickness of link (bushing
5 press-fit part) 44.8 32.3 Replace
a. Tightening torque Retightening angle
Regular (Nm {kgm}) (deg.)
link 539 ± 49 {55 ± 5} 120 ± 10
Tightening Retightening
6 Shoe bolt Lower limit torque Retighten
b. torque angle
(Nm {kgm})
Master (Nm {kgm}) (deg.)
link 343 ± 39
180 (0/-20) 784 {80}
{35 ± 4}
Interference between dimension Shaft Hole interference
7 bushing and link
+0.404 +0.074
66.5 0.230 to 0.404
+0.304 0
Interference between regular +0.435 +0.086 Adjust or
8 pin and link 44.4 0.199 to 0.411 replace
+0.285 +0.024
Clearance between regular dimension Shaft Hole clearance
9 pin and bushing
+0.235 +0.915
44.6 0.180 to 0.830
+0.085 +0.415
60-56 D65EX,PX,WX-17
Track shoe
PLUS type track shoe

a Part P is the link on the bushing press-fitting side.

Unit: mm
1 Link pitch
203.45 206.45 Turn 180 deg.
2 Outside diameter of bushing 73 64 or replace
3 Thickness of bushing 13 8.5
D65EX,PX,WX-17 60-57
Track shoe
Unit: mm
Standard dimension Repair limit Repair or
4 Link height replace
137 119
Thickness of link (bushing
5 press-fit part) 56.5 38.5 Replace
a. Tightening torque Retightening angle
Regular (Nm {kgm}) (deg.)
link 343 ± 39 {35 ± 4} 120 ± 10
6 Shoe bolt Retighten
b. Tightening torque Retightening angle
Master (Nm {kgm}) (deg.)
link 343 ± 39 {35 ± 4} 120 ± 10
Interference between regular dimension Shaft Hole interference
7 pin and link
+0.235 -0.114
44.6 0.289 to 0.411 Adjust or
+0.175 -0.176 replace
Standard clearance
8 Clearance between links One side Both side
1.4 2.8
Single grouser shoe
Unit: mm
1 Height of grouser welding for
65 25
rebuilding or
2 Thickness of grouser 77 37 replace
Swamp shoe
60-58 D65EX,PX,WX-17
Track shoe
Unit: mm
1 Height of grouser welding for
109.5 94.5
rebuilding or
2 Thickness of grouser 20 5 replace
D65EX,PX,WX-17 60-59
Hydraulic tank
Hydraulic system
Hydraulic tank
60-60 D65EX,PX,WX-17
Scavenging pump
Scavenging pump
D65EX,PX,WX-17 60-61
Steering lubricating pump and power train pump
Steering lubricating pump and power train pump
Unit: mm
Type Standard clearance Allowable clearance
1 Side clearance
SAL(2)45 0.10 to 0.15 0.19
Clearance between plain
2 bearing inside diameter and SAL(2)45 0.067 to 0.125 0.20
gear shaft outside diameter
Replace
Type Standard Repair
Allowance
dimension limit
3 Pin driving depth 0
SAL(2)45 12 –
-0.5
4 Torque of splined shaft 5.8 to 13.8 Nm {0.6 to 1.4 kgm}
Delivery
Pump Standard Allowable
Delivery pressure
Type speed delivery delivery
– Engine oil: SAE10W (MPa {kg/ –
(rpm) (l/min) (l/min)
Oil temperature: 45 – 55 cm2})
SAL(2)45 3,000 20.6 {210} 119 110
60-62 D65EX,PX,WX-17
HSS pump
HSS pump
D65EX,PX,WX-17 60-63
HSS pump
LS(PC)-EPC valve
a EPC: Abbreviation for Electromagnetic Proportional Control
60-64 D65EX,PX,WX-17
HSS motor
HSS motor
D65EX,PX,WX-17 60-65
HSS motor
Unit: mm
Load at Load at
x Outside length length of length length of If damaged or
1 Spool return spring diameter spring spring deformed,
192 N 154 N replace spring
42.7 x 30.0 40.5 –
{19.6 kg} {15.7 kg}
1.27 N 0.98 N
2 Check valve spring 43 x 13.8 32.9 –
{0.13 kg} {0.10 kg}
60-66 D65EX,PX,WX-17
Control valve
Control valve
a In this section, only the 5-spool valve (straight tilt power pitch dozer + ripper) is shown.
D65EX,PX,WX-17 60-67
Control valve
Unit: mm
Free length Load at Load at
Suction valve spring x Outside Installed installed Free installed
1 diameter length length of length length of
spring spring
5.49 N 4.41 N If damaged or
46.8 x 7.5 40.6 – deformed,
{0.56 kg} {0.45 kg} replace spring
Back pressure valve spring 67.7 N 54.1 N
2 67.7 x 20 42.5 –
{6.9 kg} {5.52 kg}
5.10 N 4.12 N
3 Suction valve spring 39.2 x 4.45 33.5 –
{0.52 kg} {0.42 kg}
4 Spool return spring 45.7 x 28 45.0 55.9 N – 44.7 N
60-68 D65EX,PX,WX-17
Control valve
Unit: mm
(steering) {5.70 kg} {4.56 kg}
Spool return spring 55.3 N 44.2 N
5 41.1 x 19.3 40.5 –
(lift ripper) {5.43 kg} {4.34 kg}
6 37.3 x 19.4 17.0 –
(tilt pitch) {6.70 kg} {5.36 kg}
7 (lift) 40.5x 24.6 39.0 –
{3.50 kg} {2.80 kg}
8 (lift) 41.9 x 18.6 40.5 –
{5.39 kg} {4.31 kg}
D65EX,PX,WX-17 60-69
Control valve
Unit: mm
Pressure compensation x Outside Installed installed Free installed
1 diameter length length of length length of
valve F
spring spring
29.4 N 23.5 N
36.2 x 5.3 23.5 –
{3.0 kg} {2.4 kg}
Pressure compensation 12.9 N 10.3 N
2 valve R spring 27.5 x 14.2 20.5 –
{1.32 kg} {1.06 kg}
Steering priority valve spring 472.7 N 378.2 N
3 106.5 x 20 82.0 – If damaged or
{48.2 kg} {38.9 kg} deformed,
Pressure reducing valve 159.8 N 127.8 N replace spring
4 spring 51.6 x 10.5 42.5 –
{16.3 kg} {13.0 kg}
5 valve F spring 30.85 x 5.2 20.0 –
{2.82 kg} {2.26 kg}
6 valve R spring 31.9 x 14.4 21.5 –
{3.5 kg} {2.8 kg}
7 valve R spring 33.4 x 14.4 21.5 –
{5.7 kg} {4.56 kg}
3.92 N 3.14 N
8 Check valve spring 27.2 x 6.9 22.0 –
{0.4 kg} {0.32 kg}
60-70 D65EX,PX,WX-17
Control valve
D65EX,PX,WX-17 60-71
Control valve
60-72 D65EX,PX,WX-17
Control valve
D65EX,PX,WX-17 60-73
Blade PPC valve
Blade PPC valve

60-74 D65EX,PX,WX-17
Blade PPC valve
D65EX,PX,WX-17 60-75
Ripper PPC valve
Ripper PPC valve

(if equipped)
60-76 D65EX,PX,WX-17
Ripper PPC valve
Unit: mm
Centering spring x Outside Installed installed Free installed
1 diameter length length of length length of If damaged or
spring spring deformed,
125 N 100 N replace spring
33.9 x 15.3 28.4 –
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0 –
{1.70 kg} {1.36 kg}
D65EX,PX,WX-17 60-77
Quick drop valve
Quick drop valve
Unit: mm
Piston spring x Outside Installed installed Free installed If damaged or
1 diameter length length of length length of deformed,
spring spring replace spring
4.8 N 3.48 N
27.3 x 12 25.9 –
{0.49 kg} {0.39 kg}
60-78 D65EX,PX,WX-17
Quick drop valve
Unit: mm
53.24 x 46.1 N 36.9 N
2 Valve spring 18 –
34.8 {4.7 kg} {3.76 kg}
52.7 N 42.2 N
3 Valve spring 26.35 x 23 25 –
{5.37 kg} {4.30 kg}
D65EX,PX,WX-17 60-79

Tilt dozer and angle dozer series
60-80 D65EX,PX,WX-17
D65EX,PX,WX-17 60-81
60-82 D65EX,PX,WX-17
Unit: mm
Load at Load at If damaged or

Free Installed installed Free installed deformed,
1 Metering spring length length length of length length of replace EPC
spring spring valve
assembly.
3.1 kN 2.5 kN
9.5 8.4 –
{0.32 kg} {0.26 kg}
D65EX,PX,WX-17 60-83
Work equipment
Work equipment
Work equipment
Tilt dozer and power tilt pitch dozer series
*1: Sigma dozer and sigma power pitch dozer are shown.
60-84 D65EX,PX,WX-17
Work equipment
Unit: mm
Tolerance Standard
Standard Allowable
clear-
Clearance between dimension clearance Adjust shims or
Shaft Hole ance
1 spherical surfaces of
trunnion and cap replace
-0.1 +1.5
S140 0.1 to 2.0 5.0
-0.5 0
Clearance between brace -0.2 +0.2
2 mounting pin and bracket 50 0.2 to 0.6 2.0
-0.4 0 Replace
3 mounting pin and brace 50 0.2 to 0.6 2.0
-0.4 0
Clearance between S90 (shaft) Adjust shims or
-0.1 +1.0
4 spherical surfaces of bracket S91 (hole) 1.1 to 2.3 2.0 replace
and brace -0.3 0
Clearance between
-0.1 +0.5
5 spherical surfaces of S90 0.1 to 1.0 2.0
bearing and bushing -0.5 0
Clearance between frame 0 +0.6
-0.3 +0.2
Clearance between frame 0 +0.5
7 mounting pin and bearing 55 0.2 to 0.8 2.0 Replace
-0.3 +0.2
Clearance between center -0.2 +0.2
8 brace mounting pin and 50 0.2 to 0.6 2.0
bracket -0.4 0
9 brace mounting pin and 50 0.2 to 0.6 2.0
brace -0.4 0
-0.1 +1.0
10 spherical surfaces of bracket S91 (hole) 1.1 to 2.3 2.0 replace
and center brace -0.3 0
D65EX,PX,WX-17 60-85
Work equipment
60-86 D65EX,PX,WX-17
Work equipment
Unit: mm
Tolerance Standard
Standard Allowable
clear-
Clearance between dimension clearance Adjust shims or
Shaft Hole ance
trunnion and cap replace
-0.1 +1.5
S140 0.1 to 2.0 5.0
-0.5 0
Clearance between angle -0.025 +0.3 0.125 to
2 cylinder bottom pin and U- 50 1.0
-0.064 +0.1 0.364
frame bracket Replace
Clearance between angle -0.025 +0.3 0.125 to
3 cylinder head pin and blade 50 1.0
-0.064 +0.1 0.364
bracket
Clearance between U-frame Adjust shims or
-0.25 +0.5 0.25 to
4 center spherical surface and S177.5 5.0 replace
blade cap -0.75 0 1.25
Clearance between pitch rod -0.030 +0.004 0.011 to
-0.076 -0.019 0.080
Clearance between tilt -0.025 +0.3 0.125 to
6 cylinder bottom pin and U- 50 1.0 Replace
-0.064 +0.1 0.364
frame bracket
Clearance between tilt -0.025 +0.3 0.125 to
7 cylinder head pin and blade 50 1.0
-0.064 +0.1 0.364
bracket
D65EX,PX,WX-17 60-87
Work equipment
Unit: mm
Standard shim thickness Adjust shims or
8 between U-frame spherical 8.0 replace
surface and blade cap
60-88 D65EX,PX,WX-17
Work equipment
Angle dozer series
D65EX,PX,WX-17 60-89
Work equipment
60-90 D65EX,PX,WX-17
Work equipment
Unit: mm
Tolerance Standard
Standard Allowable
clear-
Clearance between dimension clearance
Shaft Hole ance
trunnion and cap
-0.1 +1.5
S140 0.1 to 2.0 8.0
-0.5 0
Clearance between arm
-0.6 +1.5
(large) -1.0 +1.0
Clearance between arm
-0.6 +1.5
(small) -1.0 +1.0
4 mounting pin and arm 50 0.3 to 1.3 2.0
bracket -0.6 0
5 mounting pin and brace 50 0.3 to 0.8 2.0
-0.6 0
Clearance between brace 0 +0.2 Replace
6 mounting pin and joint 50 0 to 0.5 2.0
-0.3 0
Clearance between brace 0 +0.5
7 mounting pin and bearing 50 0 to 0.8 2.0
-0.3 0
Clearance between joint -0.1 +0.3
-0.3 0
Clearance between joint -0.1 +0.2
9 mounting pin and joint 50 0.1 to 0.5 2.0
-0.3 0
79.5
Clearance between center (shaft) -0.2 +0.5
10 0.2 to 1.5 2.0
shaft and frame 80 (hole) -0.5 -0.5

11 shaft mounting pin and 55 0.1 to 0.6 2.0
bracket -0.3 0
Clearance between center 55 (shaft)
-0.1 +0.5
12 shaft mounting pin and 60 (hole) 5.2 to 5.8 7.0
center shaft -0.3 +0.1
D65EX,PX,WX-17 60-91
Cutting edge and end bit
Unit: mm
ST-T(EX)
ST-TPP 242 187
(EX)
ST-T(PX)
ST-TPP 204 187
(PX)
1
Height of end bit
(outside) SGM(EX,
WX)
SGM-PP 225 198
(EX,WX)
A(EX) 242 187

PAT(EX,
PX,WX) 242 187
ST-T(EX)
ST-TPP 330 300
(EX)
Replace
ST-T(PX)
ST-TPP 325 300
(PX)
Width of end bit
2 SGM(EX,
WX)
SGM-PP 511 440
(EX,WX)
A(EX) 330 300

PAT(EX,
PX,WX) 330 300
ST-T(EX)
ST-TPP 204 187
(EX)
Height of end bit
3 (inside) ST-T(PX)
ST-TPP 204 187
(PX)
205 198
60-92 D65EX,PX,WX-17
Unit: mm
SGM(EX,
WX)
SGM-PP
(EX,WX)
A(EX) 204 187

PAT(EX,
PX,WX) 204 187
ST-T(EX)
ST-TPP 102 85
(EX)
ST-T(PX)
Height of cutting ST-TPP 102 85
edge (PX)
Replace or turn
4 (bolt mounting 180 deg.
SGM(EX,
hole center to WX)
end surface)
SGM-PP 102 85
(EX,WX)
A(EX) 102 85
PAT(EX,
PX,WX) 102 85
ST-T(EX)
ST-TPP 392 to 530 Nm {40 to 54 kgm}
(EX)
ST-T(PX)
ST-TPP 392 to 530 Nm {40 to 54 kgm}
(PX)
Tightening
5 torque of end bit Retighten
SGM(EX,
and cutting edge
WX)
SGM-PP 392 to 530 Nm {40 to 54 kgm}
(EX,WX)
A(EX) 392 to 490 Nm {40 to 50 kgm}

PAT(EX,
392 to 530 Nm {40 to 54 kgm}
PX,WX)
ST-T: For straight tilt dozer is shown.
ST-TPP: For straight tilt power pitch dozer is shown.
SGM: For sigma dozer is shown.
SGM-PP: For sigma power pitch dozer is shown.
PAT: For power angle power tilt dozer is shown.
A: For angle dozer is shown.
D65EX,PX,WX-17 60-93
Ripper
Ripper
(if equipped)
D65EX-17, D65WX-17
Unit: mm
dimension Shaft Hole clearance clearance
Clearance between pin and -0.030 +0.299 0.199 to
1 bushing 56 -0.076 +0.169 0.375 1.0 Replace
2 Wear of point 222 152
60-94 D65EX,PX,WX-17
Lift cylinder
Lift cylinder
For other than power angle power tilt dozer
For power angle power tilt dozer
Unit: mm
Specifi- Standard Tolerance Standard Allowable
cations dimension clearance clearance
Shaft Hole
Clearance Replace
1 between piston rod -0.030 +0.151 0.024– bushing
(*1) 60 0.527
and bushing -0.076 -0.006 0.227
-0.030 +0.151 0.024–
(*2) 60 0.527
-0.076 -0.006 0.227
Clearance Adjust shims or
between spherical -0.2 +0.3
(*1) S85 0.2 to 0.5 1.0 replace
surfaces of piston -0.3 0
rod and trunnion
2 Clearance
between piston rod -0.025 +0.003 0.010 to Replace
(*2) 50 1.0
support shaft and -0.064 -0.015 0.067 bushing
bushing
-0.100 +0.116 0.100 to
Clearance (*1) 55 1.0
-0.174 0 0.290 Replace pin or
3 between cylinder bushing
boss and bushing -0.100 +0.118 0.100 to
(*2) 55 1.0
-0.174 0 0.292
*1: For other than power angle power tilt dozer is shown.
*2: For power angle power tilt dozer is shown.
D65EX,PX,WX-17 60-95
Tilt cylinder
Tilt cylinder
For other than power angle power tilt dozer
Unit: mm
Specifi- Standard Tolerance Standard Allowable
cations dimension clearance clearance
Shaft Hole
Clearance Replace
1 between piston rod -0.030 +0.259 0.093 to bushing
(*1) 70 0.635
and bushing -0.076 +0.063 0.335
-0.030 +0.259 0.093 to
(*2) 70 0.635
-0.076 +0.063 0.335
Clearance S90 (shaft) Adjust shims or
between spherical -0.1 +1.0
(*1) S91 (hole) 0.2 to 0.5 2.0 replace
surfaces of piston -0.3 0
rod and bracket
2 Clearance
between piston rod -0.025 +0.039 0.025 to
(*2) 50 1.0
support shaft and -0.064 0 0.103
bushing Replace pin or
Clearance -0.200 +0.142 0.280 to bushing
(*1) 50 1.0
between cylinder -0.400 +0.080 0.542
3 bottom support
-0.025 +0.039 0.025 to
shaft and bushing (*2) 50 1.0
-0.064 0 0.103
*1: For other than power angle power tilt dozer is shown.
*2: For power angle power tilt dozer is shown.
60-96 D65EX,PX,WX-17
Pitch cylinder
Pitch cylinder
For straight tilt power pitch dozer
Unit: mm
dimension clearance clearance Replace
Clearance between piston Shaft Hole
1 rod and bushing bushing
-0.030 +0.259 0.093 to
70 0.635
-0.076 +0.063 0.335
-0.1 +1.0
2 spherical surfaces of piston S91 (hole) 0.2 to 0.5 2.0 replace
rod and bracket -0.3 0
Clearance between cylinder -0.200 +0.142 0.280 to Replace pin or
3 bottom support shaft and 50 1.0 bushing
bushing -0.400 +0.080 0.542
D65EX,PX,WX-17 60-97
Angle cylinder
Angle cylinder
Unit: mm
-0.030 +0.250 0.085 to
65 0.626
-0.076 +0.055 0.326
Clearance between piston
-0.025 +0.039 0.025 to
2 rod support shaft and 50 1.0
bushing -0.064 0 0.103
Replace pin or
Clearance between cylinder bushing
-0.025 +0.039 0.025 to
3 bottom support shaft and 50 1.0
bushing -0.064 0 0.103
60-98 D65EX,PX,WX-17
Ripper cylinder
Ripper cylinder
D65EX-17, D65WX-17
Unit: mm
-0.030 +0.259 0.093 to
70 0.635
-0.076 +0.063 0.335
Clearance between piston
-0.030 +0.174 0.130 to
2 rod support shaft and 75 1.0
bushing -0.076 +0.100 0.250
Replace pin or
Clearance between cylinder bushing
-0.030 +0.174 0.130 to
3 bottom support shaft and 75 1.0
bushing -0.076 +0.100 0.250
D65EX,PX,WX-17 60-99
Cab mount
Cab mount
60-100 D65EX,PX,WX-17
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
80 Appendix
D65EX,PX,WX-17 80-1
80 Appendix
Table Of Contents
80 Appendix...................................................................................................................................... 80-2
Air conditioner ............................................................................................................................ 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-16
Air conditioner controller ..................................................................................................... 80-17
Air conditioner compressor ................................................................................................. 80-18
Condenser ........................................................................................................................ 80-19
Receiver drier .................................................................................................................... 80-20
Sunlight sensor .................................................................................................................. 80-21
Outside air temperature sensor ........................................................................................... 80-22
Procedure for testing and troubleshooting ............................................................................ 80-23
Circuit diagram and arrangement of connector pins............................................................... 80-25
System diagram................................................................................................................. 80-27
Input and output signals of the air conditioner controller ......................................................... 80-28
Layout of air conditioner related parts and connectors ........................................................... 80-30
Testing air leakage (duct) .................................................................................................... 80-39
Testing with self-diagnosis function ...................................................................................... 80-42
How to enter the electrical system abnormality record screen in service mode of machine
monitor ................................................................................................................ 80-43
Testing vent (mode) changeover.......................................................................................... 80-45
Testing FRESH/RECIRC air changeover.............................................................................. 80-46
Testing sunlight sensor ....................................................................................................... 80-47
Testing (dual) pressure switch for refrigerant......................................................................... 80-48
Testing relays .................................................................................................................... 80-49
Failure code list related to air conditioner.............................................................................. 80-55
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-56
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-57
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-58
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-60
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-62
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-63
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-64
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-66
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-67
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-68
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-69
A-2 Troubleshooting for compressor system (Air is not cooled)............................................... 80-71
A-3 Troubleshooting for blower motor system (Air does not come out or air flow is
abnormal) ............................................................................................................ 80-74
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-76
Troubleshooting with gauge pressure................................................................................... 80-78
Connection of service tool................................................................................................... 80-81
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-82
Handling of compressor oil.................................................................................................. 80-84
1 80 Appendix
80-2 D65EX,PX,WX-17
80 Appendix
Precautions for refrigerant
Air conditioner
Precautions for refrigerant
k Although the refrigerant (refrigerant gas: R134a) used on the machine's air conditioner is less
destructive to the ozone layer for environmentally friendliness, it is not allowed to be released into
the atmosphere as is. Whenever disconnecting the air conditioner gas circuit, be sure to recover
the refrigerant gas to reuse it.
a Ask a qualified person for collection and charge of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k Wear safety glasses, gloves and a working suit with long sleeves when you collect or fill
refrigerant gas (R134a). Otherwise, you may lose your sight if the gas gets in your eyes, or you
may suffer from frostbite if your skin is exposed to the gas.
D65EX,PX,WX-17 80-3
80 Appendix
Air conditioner component
80-4 D65EX,PX,WX-17
80 Appendix
1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Air conditioner controller
10. Air conditioner unit
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
A. Front window and door window defroster vents
B. Face level air vents
C. Center air vents
D. Rear air vents
E. Foot level air vents
D65EX,PX,WX-17 80-5
80 Appendix
Specifications
Refrigerant R134a
Refrigerant refilling level (g) 900 ± 50
80-6 D65EX,PX,WX-17
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle

Cycle Compression Condensation Expansion Evaporation
(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator cab In operator cab
Engine
Location compartment Front of radiator (Built in air conditioner (Built in air conditioner
unit) unit)
Circulates
refrigerant gas and Condenses
Lowers temperature and Evaporates refrigerant
increases its refrigerant to
pressure of refrigerant to absorb heat from air
temperature and discharge heat
liquid and gas for easy around evaporator,
Function pressure so that it absorbed in
evaporation with throttle. and cool the air.
can be liquefied evaporator.
Controls flow rate, too. (Evaporation of
easily in condenser. (condensation of
(Throttle of refrigerant) refrigerant)
(Compression of refrigerant)
refrigerant)
Gas o Gas Gas o Liquid Liquid and gas o Gas
State of Liquid o Liquid and gas
refrigerant Adiabatic Constant pressure Constant pressure
Adiabatic expansion
compression change change
D65EX,PX,WX-17 80-7
80 Appendix
Outline of refrigeration cycle

• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
Compression (Compressor)
• The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
• The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
• The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
• The heat released to the outside from the condenser is called condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency.
• In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
(The condensation pressure varies depending on the condensation temperature of the refrigerant)
Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
• The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
*1: Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
• The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
• The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
Relationship between refrigerant and defective air conditioning

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
80-8 D65EX,PX,WX-17
80 Appendix
• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
• If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.
D65EX,PX,WX-17 80-9
80 Appendix
Air conditioner unit

a This air conditioner unit is auto temperature control type.
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
80-10 D65EX,PX,WX-17
80 Appendix
C: Hot water inlet

D: Hot water outlet
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan, blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor (MODES)
Vent (mode) changeover door
8. Rear door
9. Foot door
10. Defroster door
11. FRESH/RECIRC air changeover servomotor (R/FS)
12. FRESH/RECIRC air changeover door
13. Power transistor
14. Evaporator temperature sensor
15. Insidel air temperature sensor
Function
• The air conditioner unit consists of the evaporator (1) and heater core (2), and is used to cool down or
warm up the air in the cab.
Temperature control
• Whenever a temperature control switch is operated on the machine monitor, temperature setting data is
sent to the air conditioner controller, which is located behind the operator seat. The air conditioner
controller controls the air mix servomotor (5) and changes the angle of the air mix door (6) in order to
adjust the temperature.
Over-cooling (Freezing) prevention

• Evaporator temperature sensor (14) varies its electrical resistance according to temperature.
• The air conditioner controller detects the temperature of the evaporator (1) by converting the changes in
the resistance of the evaporator temperature sensor (14) into voltage changes.
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: See "Parts and connectors layout" for details regarding the compressor clutch relay.
Air flow adjustment

• Whenever an air flow control switch is operated on the machine monitor, air flow setting data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) using power transistor
(13) in order to adjust the air flow.
Vent (mode) changeover

• Whenever a vent switch is operated on the machine monitor, mode data is sent to the air conditioner
controller. The air conditioner controller controls mode changeover servomotor (7) to adjust the opening
angle of mode changeover doors (8) to (10) and thus perform vent changeover.
FRESH/RECIRC air changeover

• Whenever a FRESH/RECIRC air changeover switch is operated on the machine monitor, FRESH/
RECIRC air changeover setting data is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (11) to open and close FRESH/RECIRC air
changeover door (12).
D65EX,PX,WX-17 80-11
80 Appendix
Automatic air conditioner

• Inside air temperature sensor (15) detects the internal temperature based on changes in resistance. The
air conditioner controller detects the internal temperature by converting the changes in the resistance of
inside air temperature sensor (15) into voltage changes.
The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the
internal temperature so that it matches the setting made on the machine monitor.
Data from the sunlight sensor and the outside air temperature sensor is also taken into consideration
when adjusting the internal temperature.
a The door is the same as the damper.
Changeover pattern of the vent (mode) changeover door
Rear door (8) Foot door (9) Defroster door (10)
Opening Opening Opening
and closing Angle and closing Angle and closing Angle
door door door
Front Close 0 Close 0 Close 0
Front and rear Open 25 Close 0 Close 0
Front, rear and Open Open
25 35 Close 0
Air vent foot
mode Foot Open 25 Open 53 Close 0
Foot and Open Open Open
25 23 38
defroster
Defroster Open 25 Open 0 Open 38
Selection pattern of air mix door (6)
Set temperature Opening and closing door Angle
Max. Cool Close 0
Max. Hot Open 80
80-12 D65EX,PX,WX-17
80 Appendix
Functions of major components

Evaporator
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3). Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.
Heater core
• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through the heater core fins.
Evaporator temperature sensor

• Evaporator temperature sensor (12) is installed on evaporator (1) with the holder. Its resistance changes
in response to the temperature change of the evaporator. The air conditioner controller monitors the
evaporator temperature to prevent its from freezing.
Servomotors
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.
• Whenever a switch on the machine monitor is operated, the air conditioner controller delivers power to the
servomotor by raising the voltage between terminals (6) and (7) to 24 V. (The rotation direction changes
based on the supply polarity.)
• The servomotor contains a variable resistance, and its resistance value changes as the motor turns.
• The air conditioner controller delivers voltage at 5 V to the variable resistance and detects motor rotation
angle based on the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the potential difference fails to reach a predefined voltage for control of the servomotor, the air
conditioner controller notifies the machine monitor of an abnormality. [879EMC] or [879FMC] is displayed
on the "Electrical Systems" screen of the electrical system on the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
a When attempting to operate a servomotor during inspecting, do not supply power directly between
servomotor terminals (6) and (7).
D65EX,PX,WX-17 80-13
80 Appendix
Expansion valve
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Outline
• The expansion valve converts high-pressure and high-temperature liquid refrigerant from the receiver drier
to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).
Structure
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).
• The opening level of needle valve (1a) is determined based on the balance between the reaction force
exerted by spring (1b) in a rightward direction, and force (Fg) of refrigerant gas (2) pushing needle valve
(1a) through diaphragm (1a-1) in a leftward direction.
80-14 D65EX,PX,WX-17
80 Appendix
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).
Operation
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve
(1a) is moved rightward by the reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)
D65EX,PX,WX-17 80-15
80 Appendix
Dual pressure switch
Dual pressure switch

a The dual pressure switch is mounted on the air conditioner hose under the floor.
• The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay "OFF". As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
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 }
80-16 D65EX,PX,WX-17
80 Appendix
Air conditioner controller
Air conditioner controller
a See "System Diagrams" for details regarding input/output signals.
D65EX,PX,WX-17 80-17
80 Appendix
Air conditioner compressor
Air conditioner compressor
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Specification
Number of cylinder – Bore × Stroke (mm) 10 – 32 × 20.8
Piston capacity (cc/rev) 157.3
Allowable maximum speed (rpm) 6,000
Compressor oil Denso: ND-OIL8 (for R134a)
Compressor oil refill capacity (cc) 180
Function
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When the magnetic clutch is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.
80-18 D65EX,PX,WX-17
80 Appendix
Condenser
Condenser
1. Condenser
A: Refrigerant inlet (from compressor)
B: Refrigerant outlet (to receiver drier)
Specifications
Fin pitch (mm) 4.0
Height x Width x Thickness (mm) 350 x 570 x 16
Max. working pressure (MPa {kg/cm2} 3.6 {36}
Function
• The condenser cools and liquefies the high pressure and high temperature misty refrigerant sent from the
compressor.
a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction
of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pressure in the refrigerant circulation circuit will be increased,
applying extra load to the engine or reducing the cooling effect. Take extreme care not to crush or damage
the fins when hangling it or performing daily inspection.
D65EX,PX,WX-17 80-19
80 Appendix
Receiver drier
Receiver drier
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to air conditioner unit)
Function
• The receiver drier temporarily stores the high pressure and high temperature liquid refrigerant from the
condenser so that it can be supplied to the evaporator according to the need of cooling.
• It sends the stored refrigerant from its bottom to the evaporator, allowing the refrigerant to be liquefied
completely ever when it contains bubbles due to the lowered heat dissipation of the condenser.
• The built-in filter and desiccating agent eliminate foreign substances in the circulation circuit and water
content in the refrigerant.
Specification
Effective volume (cc) 370
Weight of desiccating agent (g) 290
80-20 D65EX,PX,WX-17
80 Appendix
Sunlight sensor
Sunlight sensor
1. Connector
2. Sensor
Outline
• The sunlight sensor is mounted on top of the machine monitor.
• It detects the strength of incident sunlight and sends signals to the air conditioner controller.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
D65EX,PX,WX-17 80-21
80 Appendix
Outside air temperature sensor
Outside air temperature sensor
1. Connector
2. Sensor
Outline
• The outside air temperature sensor is installed in the battery room at the rear left of the machine.
• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller detects the ambient temperature by converting the changes in the resistance
of the outside air temperature sensor into voltage changes.
• Only when performing automatic air conditioning, the air conditioner controller controls the blower motor
and the air mix servomotor in order to adjust the temperature and air flow based on the data from the
outside air temperature sensor.
80-22 D65EX,PX,WX-17
80 Appendix
Procedure for testing and troubleshooting

The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
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. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air
conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air
conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with
the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
D65EX,PX,WX-17 80-23
80 Appendix
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no
refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
80-24 D65EX,PX,WX-17
80 Appendix
Circuit diagram and arrangement of connector pins
D65EX,PX,WX-17 80-25
80 Appendix
a Diffuser servomotor means vent (mode) changeover servomotor.

a FRESH/RECIRC servomotor means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.
80-26 D65EX,PX,WX-17
80 Appendix
System diagram
System diagram
a This air conditioner unit is auto temperature control type.
D65EX,PX,WX-17 80-27
80 Appendix
Input and output signals of the air conditioner controller

Controller side connector: AMP 025 - 32PM
Harness side connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply(5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA FRESH/RECIRC servomotor terminal A Output
14 MRFB FRESH/RECIRC servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
Function
• Operation of air conditioner controller
1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.
80-28 D65EX,PX,WX-17
80 Appendix
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the air conditioner controller controls the inside air
temperature to the set temperature and regulates the blower speed based on data from the sunlight
sensor, the outside air temperature sensor, and the inside air temperature sensor.
8. The controller has a self-diagnosis function. If any abnormality is detected, the control notifies it to the
machine monitor by the CAN communication. Then, failure code [879***] is displayed on the electrical
system abnormality record screen of the machine monitor.
D65EX,PX,WX-17 80-29
80 Appendix
Layout of air conditioner related parts and connectors

a There are two fuses. One is in the fuse box, and the other is wound onto the wiring harness between the
air conditioner unit and control amplifier.
a The air conditioner unit is under the rear of the operator seat.
1. Remove cover (1) from the lower left side of the operator's seat.
2. Remove fuse box cover (2).
• FS12-3(5 A):
Air conditioner controller power supply and compressor relay primary power supply
• FS12-6(20 A):
Air conditioner controller continuous power supply and FRESH/RECIRC air changeover servomotor
power supply
• FS21-2(20 A):
For power supply to blower (fan) and air conditioner compressor
3. Remove operator's seat (3).

4. Remove leveller controller (4). (option)
6. At the rear of cover (5), disconnect connectors CBCIG, CBACC1, and CBACC2.
80-30 D65EX,PX,WX-17
80 Appendix

8. Remove armrest (7).

a Condition with cover (9) removed

• (10): Air conditioner controller
• A/C U: Air conditioner unit
• ACECU: Air conditioner controller connector
• AC01: Connector to air conditioner unit for GND, compressor relay, pressure switch, and sunlight
sensor
• AC02: Connector to air conditioner unit for 24 V power supply and CAN communication with the
machine monitor (communication lines shared with engine controller and power train controller)
D65EX,PX,WX-17 80-31
80 Appendix
a Connectors at the air conditioner unit side cannot be checked on-board.
a Back side of air conditioner unit

[ACFS]: Evaporator temperature sensor connector
[ACIS]: FRESH/RECIRC air changeover servomotor connector
[ACPS]: Inside air temperature sensor connector
[ACPT]: Power transistor (PTR) connector
PTR: Power transistor
• Pressure switch
11.Remove foot duct (11).
80-32 D65EX,PX,WX-17
80 Appendix
From bottom of the cab

• AC05: Pressure switch connector
• Relay
• AC04: Compressor clutch relay connector ... air conditioner compressor (clutch) ON/OFF
• (13): Compressor clutch relay
13.Sunlight sensor connector SLS and machine monitor connector CM02 (CAN communication connector)
D65EX,PX,WX-17 80-33
80 Appendix
a If machine monitor connector CM02 is disconnected, CAN communication with the engine controller,
power train controller, and air conditioner controller will be lost. Failure codes [DAZQKR], [DB2QKR],
[DB2RKR], [DBEIKK], and [D19JKZ] will be issued.
1) Remove machine monitor assembly (14).
a Since the wiring harness is connected, pull out slowly.
2) Check connector (SLS) for sunlight sensor (S) from the inside.
14.Air conditioner compressor

Open the engine left cover.
• ACC: Air conditioner compressor
• A/C: Air conditioner compressor connector
• ACS: Air conditioner compressor diode connector
• GND09: Diode ground
80-34 D65EX,PX,WX-17
80 Appendix
Open the engine right cover.

• EG2: Air conditioner compressor intermediate connector
15.Open cover (15).
• TOA: Outside air temperature sensor connector

• (16): Outside air temperature sensor
16.Intermediate connector
1) Disconnect the battery ground cable.
2) Check connector FD1.
D65EX,PX,WX-17 80-35
80 Appendix
a Connector FD1 is DRC16-70, and it must be handled with care.

[*1]
3) Open the engine hood.

• DSH: Machine monitor intermediate connector (outside)
a Connector DSH is DRC16-40, and it must be handled with care.[*1]
4) Remove covers (17) and (18).

• DSH: Machine monitor intermediate connector (inside)
a Connector DSH is DRC16-40, and it must be handled with care.[*1]
17.Ground
GND12: Air conditioner components grounding
80-36 D65EX,PX,WX-17
80 Appendix
[*1]
• How to disconnect connectors DSH and FD1
Remove the connector straight slowly and check it for breakage and coming off of the seal and sticking of
foreign matter.
a If the seal is defective, replace it.
• How to install connectors DSH and FD1
1. Check that the seal is installed to the plug correctly.
2. Check that the key is fitted to the receptacle side (it must be in the correct direction).
3. Match the connector on the plug side 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 head bolt 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 head bolt:
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
a Tightening too strongly can break the lock bolt. So be careful.
• DSH, 40-pin
• FD1, 70-pin
D65EX,PX,WX-17 80-37
80 Appendix
80-38 D65EX,PX,WX-17
80 Appendix
Testing air leakage (duct)

Testing
1. Referring to items 3 to 10 of "Parts and connectors layout", remove the operator's seat rear cover.
3. Check the following for disconnection.

1) Front right duct (2)
2) Front left ducts (3) to (5)

3) Front right duct (6)
4) Rear duct (7)
5) Defroster ducts (8) and (9)
• A/C U: Air conditioner unit
D65EX,PX,WX-17 80-39
80 Appendix
4. If air does not flow out from the ceiling louvers in defroster mode
1) Remove defroster duct (8). (See figure above)
2) Check if air flows out from defroster duct (8) joint.
a If air does not flow out from defroster duct (8) in defroster mode, see "Testing vent (mode)
changeover".
a Since the ceiling duct is very hard to remove, the ceiling removal procedure is shown below for
reference.
Reference: How to remove the ceiling
1) Remove garnish (10).
2) Remove handle (11).

3) Remove clip bolts and garnish (12).
4) Remove mirror stay (13).

5) Remove louver (14).
6) Remove room lamp (15).
7) Remove radio (16).
8) Remove switch panel (17).
9) Remove speaker cover (18).
10)Remove clip bolts and covers (19) and (20).
80-40 D65EX,PX,WX-17
80 Appendix
5. Open the left fender and check outside air duct (21).
D65EX,PX,WX-17 80-41
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function

Outline
On the air conditioner operation screen of the machine monitor, the system performs self-diagnosis for the
communication with the air conditioner unit, inside air temperature sensor, outside air temperature sensor,
evaporator temperature sensor, temperature control, vent (mode) changeover, and refrigerant pressure with
the pressure switch. If a problem is detected, the "Air conditioner system status monitor" is displayed.
a Even if the cause of a detected problem is restored to normal, the self-diagnosis failure condition will not
automatically be reset. To reset the failure condition, the starter switch must be set to OFF.
a The electrical system abnormality record screen of the machine monitor in service mode displays the
results of self-diagnosis and indicates any abnormalities if found.
a FRESH/RECIRC air changeover servomotor is not checked with self-diagnosis function.
80-42 D65EX,PX,WX-17
80 Appendix
How to enter the electrical system abnormality record
screen in service mode of machine monitor
How to enter the electrical system abnormality record screen in service

mode of machine monitor
• Overview of machine monitor operating procedure
Normal screen
O While pressing [4], press [1], [2], and [3] in this order.
Service menu (Mode)
O Press [F3] twice. Press [F6].
03 Abnormality Record
O Press [F3] once. Press [F6].
02 Electrical System Abnormality Record Screen
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. On the service menu screen, press [F3] (R) twice, and then select "03 Abnormality Record".
3. Press [F6] to confirm.
4. On the Abnormality Record screen, press [F3] (R) once, and then select "02 Electrical System
Abnormality Record".
5. Press [F6] to confirm.
D65EX,PX,WX-17 80-43
80 Appendix
How to enter the electrical system abnormality record
screen in service mode of machine monitor
a For details, see the failure code list for the air conditioner system.
Failure code Failure (Displayed on screen) Remarks
879AKA A/C Inner Sensor Open Circuit
*
879AKB A/C Inner Sensor Short Circuit
879BKA A/C Outer Sensor Open Circuit
879BKB A/C Outer Sensor Short Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
879DKZ Sunlight Sensor Open or Short Circuit
879EMC Ventilation Dumper Abnormality *
879FMC Air Mix Dumper Abnormality *
879GKX Refrigerant Abnormality
DAZ9KQ A/C Model Selection Abnormality See Chapter 40
"Troubleshooting by failure
DAZQKR CAN2 Discon (Aircon ECU) code".
**
*: Troubleshooting is not possible because the connector cannot be tested when it is mounted on the machine.
**: Troubleshooting is done by the machine monitor, not by the air conditioner unit.
a Air conditioner inner sensor means inside air temperature sensor.
a Air conditioner outer sensor means outside air temperature sensor.
a Ventilating sensor means evaporator temperature sensor (frost sensor).
a Ventilation means vent (mode) changeover damper (door).
a A/M damper meands temperature control (air mix) damper (door).
80-44 D65EX,PX,WX-17
80 Appendix
Testing vent (mode) changeover
Testing vent (mode) changeover

Outline
The vents (mode) are switched by changing the angle of the three doors (dampers) at the inside. Door
(damper) angles are changed by servomotors via internal linkages. These cannot be seen from the outside.
Visually check the opening and closing of the defroster and rear face door (damper).
a To reset the self-diagnosis (clear the air conditioner related failure codes displayed on the electrical
system abnormality record screen of the machine monitor), the starting switch must be turned OFF (while
abnormality is detected by self-diagnosis, no signals are output to the servomotor).
Testing
1. Referring to items 3 to 10 of "Parts and connectors layout", remove the operator's seat rear cover.
2. Remove defroster duct (1).
3. Start the engine and turn the air conditioner power ON.
4. Press the vent changeover switch on the air conditioner operation screen of the machine monitor and
visually check that rear door (damper) (2) and defroster door (damper) (3) move smoothly.
5. Stop the engine.
6.
D65EX,PX,WX-17 80-45
80 Appendix
Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover

Outline
FRESH/RECIRC air is selected by changing the door (damper) angle in the air conditioner unit with the servo
motor. Check the opening and closing operations of the door (damper) visually.
a The system does not have self-diagnosis function for FRESH/RECIRC air changeover servo motor.
Testing
1. Remove recirculation air filter (1) from behind the operator's seat.
2. Start the engine and turn the air conditioner power ON.
3. Press FRESH/RECIRC air selector switch on the machine monitor's air conditioner control screen, and
then visually check the opening and closing operation of FRESH/RECIRC air changeover door (damper)
(2).
a The connector for FRESH/RECIRC air changeover door (damper) (2) servomotor cannot be checked on-
board for its connection condition.
80-46 D65EX,PX,WX-17
80 Appendix
Testing sunlight sensor
Testing sunlight sensor

• If [879DKZ] "Sunlight Sensor Open or Short Circuit" is displayed by the self-diagnosis (on the air
conditioner system abnormality record screen of the machine monitor), test the sunlight sensor connector
SLS.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
a If sunlight sensor (S) is mesured with resistance range of tester, sunlight sensor may be destroyed, so do
not measure with resistance range of tester.
Testing
1. Referring to item 13 of "Parts and connectors layout", remove the machine monitor.
2. Check connector SLS located behind sunlight sensor (S). (whether it is partially disconnected or not)
3. Disconnect connector SLS, remove sunlight sensor (S), and using a tester set to the voltage range,
measure the voltage between the sensor side terminals.
• Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
D65EX,PX,WX-17 80-47
80 Appendix
Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant

• If [879GKX] "Refrigerant Abnormality" is displayed by the self-diagnosis (on the electrical system
abnormality record screen of the machine monitor), test the pressure switch connector AC05.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
• The dual pressure switch is ON when the refrigerant pressure is normal and OFF when it is abnormal.
a As the refrigerant pressure will drop when the ambient temperature is below 0 °C , there is a possibility
that the dual pressure switch is OFF. In such a case, the dual pressure switch is actually normal (I.e.,
not defective).
Testing
1. Referring to item 11 of "Parts and connectors layout", remove the foot duct.
2. Disconnect pressure switch connector AC05.
3. Check if the resistance between the switch-side terminals of connector AC05 are shorted (ON). (If not
shorted (OFF), pressure switch is detecting an abnormal refrigerant pressure.)
a When the pressure switch is OFF, connect a pressure gauge to the high pressure side of the air
conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and
"Troubleshooting with gauge pressure."
a If refrigerant pressure is normal, the pressure switch is defective.
• (Dual) pressure switch
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, refrigerant must be collected in advance.
• If resistance between the switch-side terminals of connector AC05 is shorted (ON): (See circuit diagram in
"Troubleshooting for the compressor and refrigerant system".)
80-48 D65EX,PX,WX-17
80 Appendix
Testing relays
Testing relays
a If the air conditioner compressor is normal (air is cooled), the relays are normal. Accordingly, the test can
be omitted.
a Listen closely to the relay to check whether or not it is defective.
• Compressor clutch relay AC04:
Used to turn the air conditioner compressor (clutch) ON/OFF
Testing
1. Referring to item 12 of "Parts and connectors layout", remove the cover.
2. Check the condition of contact of connector AC04. (whether it is partially disconnected or not)
3. Turn the starting switch ON (do not start the engine) and turn the main power of the air conditioner ON.
When the air conditioner is turned ON, the compressor relay will activate if it is normal. Check the clicking
sound.
4.
a The air conditioner controller will not turn on the compressor relay (CCRL) 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 abnormality (it is turned OFF).
• Checking relay unit

a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil
actually.
Compressor clutch relay (CCRL), connector (AC04)
1. The coil resistance between terminals (1) and (2) is 300–500 z .
2. While voltage (20 to 30 VDC) is not applied between terminals (1) (+) and (2), terminals between (3) and
(4) are closed.
3. While voltage (20 to 30 VDC) is applied between terminals (1) (+) and (2), terminals between (3) and (5)
are closed.
D65EX,PX,WX-17 80-49
80 Appendix
Troubleshooting chart 1
The numbers in the boxes are the item numbers in the troubleshooting table.
1. Cooling trouble
2. Heating trouble
80-50 D65EX,PX,WX-17
80 Appendix
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check connector for disconnection. Repair broken
Wire breakage or defective parts and connect
connection See "Parts and connectors layout". correctly
Operate the fan switch to each position and check the fan
Defective blower fan motor Replace
speed. See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check the duct joints by referring to
Air leakage through duct joints Repair
"Testing air leakage (duct)."
Remove
Obstruction at evaporator inlet Check evaporator for stain and obstruction obstruction and
clean
Defective evaporator Evaporator is frozen.
temperature sensor, defective Sensor fixing clip inspection, sensor contaminated
contact of evaporator Inspect the air conditioner hose around the pressure Repair or replace
temperature sensor, defective switch for frost.
expansion valve* (when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Repair leaking
part, then charge
Insufficient refrigerant with proper
Check the refrigerant volume through sight glass. quantity of
Specifically, perform checking with the gauge manifold refrigerant again
connected. Collect refrigerant,
then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2 } See
Judgment by pressure at Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 - 1.7 MPa {15 – 17 kg/cm2 } with gauge
Temperature in operator's cab: 30 to 35 °C , Engine pressure
speed: Approx. 1,500 rpm
D65EX,PX,WX-17 80-51
80 Appendix
4. During cooling, the compressor does not operate easily or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
part
Compressor Deflection of belt is large. Adjust tension
Slack of belt
belt
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 - 20 z ) Replace
Magnet
Check the grounding and connections.
clutch Wire breakage or defective
See "Troubleshooting for compressor Repair
connection of ground wire
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing (dual) pressure switch for
refrigerant".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging
engine coolant Bleed air and correct
(hoses, pipes, cores)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
See "Testing and adjusting of Air conditioner compressor
Fan speed is low belt tension" in the "Testing and adjusting" of Chapter 30 Correct
of the shop manual.
80-52 D65EX,PX,WX-17
80 Appendix
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Try to change the temperature setting in manual mode.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible. and heating
FRESH/RECIRC air
See "Testing FRESH/RECIRC air changeover".
cannot be changed over
Excessive compressor oil See "Handling compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
D65EX,PX,WX-17 80-53
80 Appendix

Information in troubleshooting table
a The following information is summarized in the troubleshooting table and the related circuit diagram.
Before performing troubleshooting, understand that information fully.
Failure Problem on machine
Related information Information related to the detected failure or troubleshooting
[Contents of description]
• Procedure
• Measuring location
1
a "Between A and B" means "Measure voltage or resistance and so
Probable causes for on between A and B".
trouble
• Criteria to judge probable causes
(Perform troubleshooting • Remarks required for judgement
according to these.)
[Notes on troubleshooting]
2 (1) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the plus (+) and minus (–) tester leads
as shown below unless otherwise 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.
3 Defective component
(2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time “ - " defective shown at left is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
• Short circuit
An independent wire in the harness contacts with other wire. (poor insulation at connector and others)
Circuit diagram related

This is the excerpted circuit diagram related to failure.
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location.
• 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 two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
• N.C.: Normally closed (Normally ON)
• [1], [2], ··· are numbers of unlabeled connectors.
• Arrow (io): Roughly indicates their mounting place on the machine.
80-54 D65EX,PX,WX-17
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner

Compo-
Failure Failure (Displayed on screen) nent in Action Category
Remarks
code charge level of record
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON –
Circuit system performed while the controller
is mounted on the machine
A/C Inner Sensor Short Electrical
879AKB MON – since the connector cannot
Circuit system
be checked.
A/C Outer Sensor Open Electrical
879BKA MON –
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON –
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot
Circuit system
be checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Short Circuit system
Ventilation Dumper Electrical Troubleshooting cannot be
879EMC Abnormality MON L01 system performed while the controller
Electrical
879FMC Air Mix Dumper Abnormality MON L01 since the connector cannot
system
be checked.
Electrical
879GKX Refrigerant Abnormality MON L01 system
A/C Model Selection Electrical
DAZ9KQ Abnormality MON –
system See Chapter 40,
"Troubleshooting by failure
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01 code"
system
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The vent damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes is explained after failure code
[879GKX].
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover
D65EX,PX,WX-17 80-55
80 Appendix
Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKA] A/C Inner sensor Open Circuit

Action Air conditioner inside air temperature sensor disconnection
Failure code
level Failure
— (Machine monitor system)
879AKA
Details of • Air conditioner controller detected disconnection in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a disconnection in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
controller (Since this is an internal defect, troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
80-56 D65EX,PX,WX-17
80 Appendix
Failure code [879AKB] A/C Inner sensor Short Circuit
Failure code [879AKB] A/C Inner sensor Short Circuit

Action Air conditioner inside air temperature sensor short circuit
Failure code
level Failure
879AKB
Details of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
2
conditioner unit
D65EX,PX,WX-17 80-57
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit

Action Open circuit in air conditioner outside air temperature
Failure code sensor
level Failure
– 879BKA (Machine monitor system)
Detail of • An open circuit is detected in the air conditioner controller outside air temperature sensor
failure
• The air conditioner controller informs of the open circuit in the outside air temperature
Action of sensor to the machine monitor via CAN communication.
controller • In automatic air conditioning mode, data from the outside air temperature sensor is
ignored while maintaining control of the air conditioner.
• Since there is an open circuit in the air conditioner outside air temperature sensor, outside
Problem on air temperature data is not used for automatic air conditioning.
machine (does not have any effect to the air conditioner in manual mode)
electrical system in the service mode of the machine monitor.
• For connectors etc., see "Parts and connector locations".
Related • Since a T-adapter is not provided for connector ACECU of the air conditioner controller
information and the pins are small, use the intermediate connector for troubleshooting (the
intermediate connector is not provided with a T-adapter either, but the pins are large).
• To replace the air conditioner harness between air conditioner controller connector
ACECU and intermediate controller, the air conditioner unit must be replaced.
Defective outside air 2. Disconnect connector TOA.
1 temperature sensor Resis- Between TOA (male) (1) and (2) Approx.
25 °C
tance 1.7 Kz
2. Disconnect connector AC01.
2 a Same resistance as above if normal
harness
Resis- Between AC01 (female) (3) and (4) 25 °C Approx.
tance 1.7 Kz
a If no failure is found by check for cause 2, this check is not required.
Open circuit in wiring harness 2. Disconnect connectors TOA and AC01.
3 (wire breakage or defective Between AC01 (female) (3) and TOA (female)
contact of connector) (1) Max. 1 z
Resis-
tance Between AC01 (female) (4) and TOA (female)
(2) Max. 1 z
If no failures are found by the above checks, the air conditioner
Defective air conditioner controller may be defective. (Since this is an internal defect,
4
controller troubleshooting cannot be performed.)
If no failure is found by above checks, air conditioner unit may be
5 Defective air conditioner unit
defective.
80-58 D65EX,PX,WX-17
80 Appendix
Circuit diagram related to air conditioner outside air temperature sensor
D65EX,PX,WX-17 80-59
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit

Action Short circuit in air conditioner outside air temperature
Failure code sensor
level Failure
– 879BKB (Machine monitor system)
Detail of • A short circuit is detected in the air conditioner controller outside air temperature sensor
failure
• The air conditioner controller informs of the short circuit in the outside air temperature
Action of sensor to the machine monitor via CAN communication.
controller • In automatic air conditioning mode, data from the outside air temperature sensor is
ignored while maintaining control of the air conditioner.
• Since there is a short circuit in the air conditioner outside air temperature sensor, outside
Problem on air temperature data is not used for automatic air conditioning.
machine (does not have any effect to the air conditioner in manual mode)
Defective outside air 2. Disconnect connector TOA.
1 temperature sensor Resis- Between TOA (male) (1) and (2) Approx.
25 °C
tance 1.7 Kz
2 a Same resistance as above if normal
harness
Resis- Between AC01 (female) (3) and (4) 25 °C Approx.
tance 1.7 Kz
a If no failure is found by check for cause 2, this check is not required.
3 Short circuit in wiring harness 2. Disconnect connectors TOA and AC01.
Resis- Between AC01 (female) (3) and (4), or between
TOA (female) (1) and (2) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors TOA and AC01.
4
(contact with ground circuit) Resis- Between ground and AC01 (female) (3) or TOA
tance
5
defective.
80-60 D65EX,PX,WX-17
80 Appendix
Circuit diagram related to air conditioner outside air temperature sensor
D65EX,PX,WX-17 80-61
80 Appendix
Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKA] Ventilating sensor Open Circuit

Action Evaporator temperature (frost) sensor disconnection
Failure code
level Failure
879CKA
Details of • Air conditioner controller detected disconnection in evaporator temperature (frost) sensor.
failure
• Th air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a disconnection in the evaporator
machine temperature (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
2
conditioner unit
80-62 D65EX,PX,WX-17
80 Appendix
Failure code [879CKB] Ventilating sensor Short Circuit
Failure code [879CKB] Ventilating sensor Short Circuit

Action Evaporator temperature (frost) sensor short circuit
Failure code
level Failure
879CKB
Details of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
2
conditioner unit
D65EX,PX,WX-17 80-63
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit

Action
Failure code Sunlight sensor open or short circuit
level Failure
(Machine monitor system)
– 879DKZ
Detail of • An open or short circuit is detected in the air conditioner controller sunlight sensor
failure
• The air conditioner controller informs of the open or short circuit in the sunlight sensor to
Action of the machine monitor via CAN communication.
controller • In automatic air conditioning mode, data from the sunlight sensor is ignored while
maintaining control of the air conditioner.
• Since there is an open or short circuit in the air conditioner sunlight sensor, sunlight data
Problem on is not used for automatic air conditioning (does not have any effect to the air conditioner in
machine manual mode).
1. See "Testing sunlight sensor".
Direct Approx.
Between sunlight sensor terminals
sunlight 0.55 V
1 Defective sunlight sensor Approx.
Voltage Between sunlight sensor terminals Cloudy
0.45 V
Between sunlight sensor terminals Indoors Approx.
0.4 V
2. Disconnect connector SLS.
Open circuit in wiring harness a See "Testing sunlight sensor".
2 (wire breakage or defective Between SLS (female) (1) and AC01 (female)
contact of connector) (1) Max. 1 z
Resis-
tance Between SLS (female) (2) and AC01 (female)
(2) Max. 1 z
3
defective.
80-64 D65EX,PX,WX-17
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
D65EX,PX,WX-17 80-65
80 Appendix
Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879EMC] Ventilating Damper Abnormality

Action Abnormality in vent (mode) changeover damper servomotor
Failure code
level Failure
L01 879EMC
Details of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
2
conditioner unit
80-66 D65EX,PX,WX-17
80 Appendix
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality

Action Abnormality in air mix (temperature regulation) damper
Failure code
level Failure servomotor
L01 879FMC (Machine monitor power train control system)
Details of • The air conditioner controller judged from the potentiometer voltage of the servomotor
failure that the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
• Method of reproducing failure code: Turn starting switch ON position.
Related
information
• Troubleshooting cannot be performed since the connector part of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
2
conditioner unit
D65EX,PX,WX-17 80-67
80 Appendix

Action
Failure code Abnormal refrigerant (dual) pressure switch
level Failure
L01 879GKX
Detail of • The air conditioner controller detected that the dual pressure switch has been OFF
failure (abnormal).
• The air conditioner controller informs of the abnormality in the refrigerant pressure to the
Action of machine monitor via CAN communication.
controller • Due to abnormal refrigerant pressure, the compressor clutch relay will be turned OFF.
(air conditioner compressor stops)
Problem on • Air conditioner (cooling) does not work
machine
Defective refrigerant (dual) 1. See "Testing (dual) pressure switch for refrigerant".
1 pressure switch If the dual pressure switch is to be replaced, refrigerant must be
collected in advance. See "Precautions for refrigerant".
2. Disconnect connectors AC01 and AC05.
Between AC05 (female) (1) and AC01 (female)
2 (wire breakage or defective (5) Max. 1 z
tance Between AC05 (female) (2) and ground
Max. 1 z
a Loose or rusted GND12
3
defective.
Circuit diagram related to refrigerant (dual) pressure switch
80-68 D65EX,PX,WX-17
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)
A-1 Troubleshooting for power supply system (Air conditioner does not
operate)
Failure Air conditioner does not operate due to power supply system failure.
Problem on • [DAZQKR] is displayed on the operation screen of machine monitor.
machine • No air blows out (Blower motor does not rotate).
• If failure code [DAZQKR] is displayed on the machine monitor, carry out this
troubleshooting first.
a The machine monitor, engine controller, power train controller, and air conditioner
controller are connected via CAN communication.
• [DAZQKR]is displayed on the operation screen of machine monitor in the following cases.
The following description deals with items 1) and 2).
1. The air conditioner controller is receiving no power.
2. The air conditioner controller is malfunctioning.
3. No communication is possible between the air conditioner controller and the machine
monitor.
a See failure code [DAZQKR] for item 3).
• Turn the starting switch to the ON position and make sure if failure code [DAZQKR] is
Related displayed on the machine monitor and CAN communication is abnormal. A CAN status
information error means that the air conditioner controller on the air conditioner unit cannot
communicate with the machine monitor via CAN.
• Referring to "Parts and connectors layout", check fuse No. 3 (5 A) in fuse box FS12 for
breakage.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• For each connector, see "Parts and connectors layout".
• In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system."
• Since a T-adapter is not provided for connector ACECU of the air conditioner controller
and the pins are small, use the intermediate connector for troubleshooting (the
Defective wiring harness 2. Turn battery disconnect swith to OFF position.
1 (ground) 3. Disconnect connector AC02.
Between (1) (black) on the harness side of
Resistance connector AC02 and chassis ground Max. 1 z

2 Blown fuse 2. Referring to "Parts and connectors layout", check fuse No. 3 (5 A) in
fuse box FS12.
a If fuse described in related information is blown, replace it.
2. Turn battery disconnect swith to OFF position.
3 Defective harness 3. Disconnect connector AC02.
Between connector AC02 (female) (4) (brown)
Voltage 20 – 30 V
and (1) (black)
a If fuse is blown again in the above test, perform the following
procedure.
4 2. Turn battery disconnect swith to OFF position.
(contact with ground circuit) 3. Disconnect connector AC02.
Between connector AC02 (female) (4) (brown) Min. 1
Resistance or FS12-3 and ground
Mz
D65EX,PX,WX-17 80-69
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

1.
Turn starting switch to OFF position.
2.
Turn battery disconnect swith to OFF position.
5 Open circuit in wiring harness 3.
Disconnect connector AC02.
4.
Remove fuse No. 3 of fuse box FS12.
Between connector AC02 (female) (4) (brown) Min. 1
Resistance
and FS12-3 Mz
Defective air conditioner Replace the air conditioner controller as a trial.
6
controller
defective.
8 Defective machine monitor If no failure is found by above checks, machine monitor is defective.
Electrical diagram related to power supply
80-70 D65EX,PX,WX-17
80 Appendix
A-2 Troubleshooting for compressor system (Air is not
cooled)
A-2 Troubleshooting for compressor system (Air is not cooled)

Failure Air is not cooled due to compressor or refrigerant system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine
Problem on monitor, air is not cooled as displayed on screen.
machine • Air conditioner compressor does not operate.
• Referring to "Testing with self-diagnosis function", display the electrical system abnormality
record screen on the machine monitor and check if failure code [879GKX] (abnormal
refrigerant pressure) is present. If refrigerant pressure is abnormal, air is not cooled
because the compressor is not turned ON.
a Abnormal refrigerant pressure indicates that "Signal from pressure switch (connector
ACECU (21)) is not grounded".
• In certain cases, the air conditioner will not turn on at 3 °C or lower (normal).
Related • If air does not come out, see "Troubleshooting of blower motor system".
information • For each connector and fuse, see "Parts and connectors layout".
a T-adapter is not prepared for connectors other than A/C and ACS.
• Since a T-adapter is not provided for connector ACECU of the air conditioner controller and
the pins are small, use the intermediate connector for troubleshooting (the intermediate
connector is not provided with a T-adapter either, but the pins are large).
• To replace the air conditioner harness between air conditioner controller connector ACECU
and intermediate controller, the air conditioner unit must be replaced.

a If failure code [879GKX] is displayed on the electrical system abnormality
record screen of the machine monitor, perform following procedure.
See failure code [879GKX].
Defective dual pressure a The dual pressure switch may be OFF even when it is operating normally.
1 switch system Therefore, if a failure (i.e., switch OFF) is detected, attach a pressure
gauge to the air conditioner compressor and check the refrigerant
pressure. (See "Troubleshooting with gauge pressure.")
k Before replacing pressure switch, collect refrigerant.
2. Disconnect connector A/C from the air conditioner compressor and
connect the T-adapter to the male side.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2 compressor (See "Parts and connectors layout".)
Between connector A/C (male) (1) and chassis
Resistance ground (i.e., air conditioner compressor coil Approx. 15 z
resistance)
• Referring to "Testing relays", check sound when compressor clutch relay
is turned ON.
A click is heard. ... A
a If A above and B below are abnormal and C is normal (relay is normal), go
to the next cause.
Defective compressor 2. Disconnect connector AC04.
3 clutch relay (does not 3. Use a wire to short-circuit (3) (blue) and (5) (red line on green base) of
turn ON) connector AC04 (wiring harness side). (This forces the compressor to
operate without using the relay.)
Air is cooled. ... B
2. Disconnect connector AC04 and troubleshoot in that condition.
Between (1) and (2) of connector 300 –
Resistance AC04 (male) (i.e., coil resistance) C
530 z
D65EX,PX,WX-17 80-71
80 Appendix
cooled)

2. Remove diode ACS and connect T-adapter to male side.
4 Defective diode ACS a Measure in diode range of tester.
Continuity Continuity between ACS (male) (2) (+) and (1) (-) Continuity
Continuity Continuity between ACS (male) (1) (+) and (2) (-) No continuity
2. Disconnect connector AC04 and carryout troubleshooting in that OFF
condition.
a Ensure that test result for cause 2 is normal (air conditioner compressor is
normal).
Between connector AC04 (female) (5) and FS22-
Open circuit in wiring 2 Max. 1 z
5
harness (Pressure switch is turned ON)
Between connector AC04 (female) (3) and
Resistance chassis ground Approx. 15 z
(Air conditioner compressor coil resistance)
Between FS12-3 and AC01 (female) (7)
300 – 530 z
a Relay coil resistance
Ground fault in wiring a If the fuse is not blown, skip troubleshooting.

harness 1. Turn starting switch to OFF position.
6 2. Disconnect connectors A/C, ACS, and AC04, and connect T-adapter to
(contact with ground
circuit) female side of A/C.
Resistance Between A/C (female) (1) and chassis ground Min. 1 Mz
2. Disconnect connectors AC01, AC02, and AC04.
7 a Ensure that test result for cause 2 is normal.
harness
Between connector AC04 (harness side) (2) and
Resistance AC02 (female) (2), (3), (4) Min. 1 Mz

Defective air conditioner 3. Turn starting switch to ON position.
8 4. Display the air conditioner operation screen on the machine monitor and
controller
press the A/C switch.
Voltage Between connector AC04 (female) (2) and ground Max. 1 V
Defective machine 1. Turn starting switch to ON position.
9 monitor 2. Display the air conditioner operation screen on the machine monitor.
(defective switch) Press A/C switch. "A/C ON" is displayed
Defective air conditioner If no failure is found by above checks, air conditioner unit may be defective.
10
unit
80-72 D65EX,PX,WX-17
80 Appendix
cooled)
Circuit diagram related to compressor and refrigerant system
D65EX,PX,WX-17 80-73
80 Appendix
A-3 Troubleshooting for blower motor system (Air does
not come out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (Air does not come out or
air flow is abnormal)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
• LCD of machine monitor on air conditioner operation screen lights up normally but air does
Problem on not come out.
machine • Air flow does not match fan switch setting on air conditioner operation screen.
• This failure is not checked with self-diagnosis function.
• In cases where the blown-air volume begins to behave in an unpredictable manner after a
certain while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1. Defective compressor clutch relay (i.e., stuck in ON position) (see item 3 A of
"Troubleshooting for compressor and refrigerant system")
2. Detachment of the evaporator temperature sensor's mounting holder (replace air
conditioner unit)
3. Incorrect adjustment of the expansion valve (replace air conditioner unit)
• If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
• For each connector and power transistor, see "Parts and connectors layout".
Related a Since the power transistor is located at the rear of the air conditioner unit, its
information troubleshooting or troubleshooting by disconnecting connector (2) is not available as long
as it is installed on the machine.
• In cases where air is discharged but with unpredictable volumes even during heating, the
power transistor has failed, and therefore, the air conditioner unit must be replaced.
a The power transistor and blower motor cannot be replaced unless the air conditioner unit is
once removed.
and the pins are small, use the intermediate connector for troubleshooting (the
Defective fuse No. 2 in When a fuse is blown, a short circuit to ground is suspected.
1
fuse box FS22
harness 2. Disconnect connector AC02.
2 (wire breakage or 3. Remove fuse No. 2 of fuse box FS22.
defective contact of
connector) Resistance Between AC02 (female) (2) and FS22-2 Max. 1 z
harness 2. Disconnect connectors AC02 and AC04.
3
(contact with ground 3. Remove fuse No. 2 of fuse box FS22.
circuit) Resistance Between ground and AC02 (female) (2) or FS22-2 Max. 1 z
If no failures are found by the above checks, the air conditioner controller
Defective air conditioner may be defective. (Since this is an internal defect, troubleshooting cannot be
4
Defective air conditioner If no failure is found by above checks, air conditioner unit may be defective.
5
unit
80-74 D65EX,PX,WX-17
80 Appendix
A-3 Troubleshooting for blower motor system (Air does
not come out or air flow is abnormal)
Circuit diagram related to blower motor system
D65EX,PX,WX-17 80-75
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover

Failure FRESH/RECIRC air cannot be changed over
• When FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or
Problem on fresh air does not change over.
machine (FRESH/RECIRC air changeover door (damper) does not rotate)
• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air
selector switch and confirm the operation of the FRESH/RECIRC air changeover door
(damper).
• For each connector, see "Parts and connectors layout".
a T-adapter is not available for the connector.
Related and the pins are small, use the intermediate connector for troubleshooting (the
information intermediate connector is not provided with a T-adapter either, but the pins are large).
• Troubleshooting of the sevomotor cannot be done because the servomotor connector
cannot be checked on-board.
Defective fuse No. 6 in fuse box When a fuse is blown, a short circuit to ground is suspected.
1
FS12
a Since connector [5] is located at the rear of the air conditioner unit, it
cannot be disconnected on-board.
2 (wire breakage or defective 2. Disconnect connector AC02.
contact of connector) 3. Remove fuse No. 6 of fuse box FS12.
Resis- Between FS12-6 and AC02 (female) (3) Max. 1 z
tance
Ground fault in wiring harness 2. Disconnect connector AC02.
3 3. Remove fuse No. 6 of fuse box FS12.
Resis- Between ground and FS12-6 or AC02 (female)
(3) Max. 1 z
tance
4
If no failures are found by the above checks, the air conditioner unit
5 Defective air conditioner unit may be defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
Defective machine monitor 2. Display the air conditioner operation screen on the machine
6 monitor.
(defective switch)
Display of Recirc/
Press FRESH/RECIRC air selector switch. Fresh changes.
80-76 D65EX,PX,WX-17
80 Appendix
Circuit diagram related to FRESH/RECIRC air changeover
D65EX,PX,WX-17 80-77
80 Appendix
Troubleshooting with gauge pressure

Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• High-pressure line pressure is too high: Above approx. 2.5 MPa {25 kg/cm 2}
• High-pressure line pressure is too low: Below approx. 1 MPa {10 kg/cm 2}
• Low-pressure line pressure is too high: Above approx. 0.3 MPa {3 kg/cm2}
• Low-pressure line pressure is too low: Below approx. 0.05 MPa {0.5 kg/cm2}
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-perssure line is abnormal.
<Measurement condition for pressure>
Item Condition value
Ambient temperature 25 – 50 °C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Full cool
• Dual pressure switch
a The swiths is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.
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}
80-78 D65EX,PX,WX-17
80 Appendix
Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is operating normally.
Pressure is If there is any trouble (cooling trouble), there is another cause.
–
normal 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 up with
Bubble can be seen through sight
Insufficient refrigerant proper quantity of
glass. *1, *3
refrigerant again
*2
There is a temperature difference
between inlet and outlet pipes of Replace
Clogging of receiver drier receiver drier. *2
Tank is frosty
Both high- Clean or replace
Clogging of expansion valve Expansion valve is frosted
pressure and *2
low-pressure Gas leakage at thermoprobe of Low-pressure gauge reads Replace
are too low> expansion valve vacuum *2
Low-pressure Repair or replace
gauge reads Evaporator is frozen Replace receiver
vacuum Defective evaporator temperature drier
Flow rate of refrigerant is reduced
sensor or defective contact of Collect refrigerant,
due to freezing.
sensor (coming off of mounting then fill up with
clip) (At Cool Max. and HI speed of fan, proper quantity of
later it becomes not to cold.)
refrigerant again
*2
Piping between receiver drier and
compressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low- *2
pressure gauge reads vacuum
Collect refrigerant,
then fill up with
Filling too much with refrigerant Connect gauge manifold proper quantity of
refrigerant again
*2
Clean, repair fins,
Dirty condenser, clogging or
or repair or replace
<Both high- Defective cooling of condenser crushing of fins, or defective
condenser
pressure and rotation of cooling fan
low-pressure *2
are too high> Improper adjustment of
Bubble can be seen through sight Replace
expansion valve (Valve is opened
glass. *3 *2
too wide)
Evacuate and then
fill up with proper
Bubble can be seen through sight quantity of
Air in cycle parts
glass. *3
refrigerant again
*2
<High-pressure Clean inside of
Clogged or crushed piping There is a remarkable temperature
is too high and cycle or replace
between compressor and difference across clogged part
low-pressure is
condenser *2
too low>
Both high-pressure and low-
<High-pressure pressure are balanced while
Defective compressor Replace
is too low and compressor is in operation.
(Compression trouble of
low-pressure is *2
compressor) Compressor has seized and is
too high>
extremely hot.
D65EX,PX,WX-17 80-79
80 Appendix
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*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.
*3: Sight glass is on the receiver drier.
80-80 D65EX,PX,WX-17
80 Appendix
Connection of service tool
Connection of service tool

Symbol Part number Part name
X 799 - 703 - 1200 Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): High-pressure charging hose (red)
(3): Low pressure charging hose (blue)
(4): Quick joint for HI side (large diameter)
(5): Quick joint for LO side (small diameter)
(a): As the thread is coarse, care should be taken with regard to loosening.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure valve (6) and low-pressure valve (7) of gauge manifold (1).
2. Connect the red charging hose (2) to the HI side of the gauge manifold and the blue charging hose (3) to
the LO side.
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
A: From Cab
B: To Condenser
D65EX,PX,WX-17 80-81
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
Precautions for disconnecting and connecting air conditioner piping

k Collect the refrigerant (Air conditioner gas: 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 person 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 skin,
you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working cloth
with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
• When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches.
Use one wrench to fix and use the other one to loosen the nuts.
Precautions for connecting
• When connecting piping, apply compressor oil (ND-OIL8) for R134a to its O-rings. (See item 4 of
"Handling compressor oil")
Do not apply oil to the threads of a bolt, nut or union, however.
• 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 damaged.
• Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers.
• Be sure to use two wrenches to tighten each nut. Use one wrench to fix and tighten the nut with the other
wrench to the specified torque (Use a torque wrench for tightening).
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
3.9 - 6.9 {0.4 - 0.7} (Receiver drier)
M6 x 1.0
8 - 12 {0.8 - 1.2} (Air conditioner unit and compressor)
M16 x 1.5 12–15(1.2–1.5)
M22 x 1.5 20–25 {2.0–2.5}
M24 x 1.5 30–35 {3.1–3.6}
80-82 D65EX,PX,WX-17
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
5. Air conditioner unit
D65EX,PX,WX-17 80-83
80 Appendix
Handling of compressor oil

1. Compressor oil management (DENSO: ND-OIL8 for R134a)
Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following
types of problem can occur if the amount in the system is too high or too low.
Condition Content
Insufficiency of oil Lubrication trouble and seizure of compressor
Cooling trouble
Excess of oil
(Excessive oil stick to parts and lower heat exchange performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2. Filling compressor oil

k Refrigerant is potentially hazardous to health and to the environment. Before disconnecting air
conditioner hoses, therefore, refrigerant should be collected in accordance with "Precautions for
connecting air conditioner piping."
a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized.
Be sure to use an oil suitable for R134a (DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic, and therefore, the cap must be immediately closed after
use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (except
a baked finish) as it may dissolve these plastics.
Check compressor oil in the following cases, and then add new oil if necessary.
• When much refrigerant is discharged because of leakage.
• When the compressor is troubled and replaced.
(See 3 below)
• When a cycle parts such as condenser, receiver drier, evaporator unit, etc. is replaced.
• Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (M24 joint to cab) Approx. 20
Hose (compressor to M24 joint) Approx. 10
Hose
Approx. 10
(Condenser – Receiver dryer)
Hose (Cab – Receiver drier) Approx. 10
80-84 D65EX,PX,WX-17
80 Appendix
3. Replacement of compressor
• In case of compressor seizure or breakage.
Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
In this case, flush the air conditioner circuit and replace the compressor and receiver drier.
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.
• Other cases
a New compressor contains compressor oil of 180 cc in it.
1.
1) Prepare an oil container and drain oil from the old compressor.
2) Measure the quantity of the drained oil with a measuring cylinder, and note the quantity or mark the
level.
3) Drain below-mentioned quantity of oil from the new compressor.

Quantity to be drained= 180 cc - "Noted quantity"
Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new
compressor would be 150 cc (i.e., 180 - 30 cc).
4. Applying compressor oil to O-rings

Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in order to
prevent the leakage of refrigerant.
D65EX,PX,WX-17 80-85
Shop Manual
Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65PX-17
D65WX-17
D65EX,PX,WX-17 90-1
Table Of Contents
90 Diagrams and drawings................................................................................................................. 90-2
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Power train hydraulic circuit diagram...................................................................................... 90-7
Hydraulic circuit diagram....................................................................................................... 90-9
Electric circuit diagram .............................................................................................................. 90-21
Symbols in electric circuit diagram ....................................................................................... 90-21
Electric circuit diagram........................................................................................................ 90-25
Electric circuit diagram for air conditioner unit ....................................................................... 90-51
1 90 Diagrams and drawings
90-2 D65EX,PX,WX-17
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram

(Rev. 2010/03)
D65EX,PX,WX-17 90-3
90-4 D65EX,PX,WX-17
D65EX,PX,WX-17 90-5
90-6 D65EX,PX,WX-17
Power train hydraulic circuit diagram Power train hydraulic circuit diagram
D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
D65EX, PX, WX-17 90-7

Hydraulic circuit diagram Hydraulic circuit diagram
D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
Straight tilt dozer, Sigma dozer
D65EX, PX, WX-17 90-9

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
Straight tilt power pitch dozer
D65EX, PX, WX-17 90-11

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
Power angle power tilt dozer
D65EX, PX, WX-17 90-13

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
(3 Dimensional machine control system specification)
D65EX, PX, WX-17 90-15

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-17

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-19

Symbols in electric circuit diagram
Electric circuit diagram

(Rev. 2010/03)
D65EX,PX,WX-17 90-21
90-22 D65EX,PX,WX-17
D65EX,PX,WX-17 90-23
90-24 D65EX,PX,WX-17
Electrical circuit diagram (1/13) Electrical circuit diagram (1/13)
D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-25

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-27

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-29

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-31

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-33

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
a The air conditioner section in the drawing is same as the "Air conditioner unit electrical circuit diagram".
D65EX, PX, WX-17 90-35

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-37

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-39

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-41

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-43

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-45

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-47

D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
D65EX, PX, WX-17 90-49

Air conditioner electrical circuit diagram Air conditioner electrical circuit diagram
D65EX-17, D65PX-17, D65WX-17
D65EX-17, D65PX-17, D65WX-17
a In the drawing, full line shows air conditioner wiring harness, same as the air conditioner section of the "Electrical circuit diagram (6/13)".
a In the drawing, dashed lines show the cab harness and chassis wiring harness, whose wiring may differ by the machine model. (For the details of cab harness and chassis harness, see "Electrical circuit diagram".)
a In the drawing, dot and dash line shows machine monitor wiring, which consists of twisted lines (AVS 0.5 x 2, pitch 45 mm or less).
D65EX, PX, WX-17 90-51

Index
Index
A Coating materials list....................................... 50-6

Condenser ................................................... 80-19
A-1 Troubleshooting for power supply system
Configuration and function of refrigeration
(Air conditioner does not operate) ................. 80-69
cycle ............................................................ 80-7
A-2 Troubleshooting for compressor system
Connection of service tool ............................. 80-81
(Air is not cooled) ........................................ 80-71
Connector contact identification ..................... 40-45
A-3 Troubleshooting for blower motor system
Connector list and layout ............................... 40-32
(Air does not come out or air flow is abnormal)...80-
Control valve .................................... 10-159, 60-67
74
Conversion table .......................................... 00-53
A-4 Troubleshooting for FRESH/RECIRC air
Cooling fan motor ............................... 10-24, 60-10
changeover ................................................ 80-76
Cooling fan pump .................................10-10, 60-7
Adjusting brake pedal.................................... 30-50
Cooling system.......................................10-8, 60-6
Adjusting fuel dial and decelerator pedal......... 30-41
Cooling system control system..................... 10-226
Adjusting idler clearance ............................... 30-57
Cutting edge and end bit................................ 60-92
Adjusting operator's cab ................................ 30-79
Adjusting parking brake lever ......................... 30-52
Adjusting play of blade center ball .................. 30-82 D
Adjusting play of work equipment PPC valve... 30-68
Damper .................................................10-6, 60-4
Adjusting transmission output shaft speed
Disassembly and assembly of blade PPC
sensor (replacement procedure)................... 30-48
valve ........................................................ 50-285
Adjusting work equipment lock lever............... 30-76
Disassembly and assembly of carrier roller ... 50-229
Adjustment method when controller has been
Disassembly and assembly of control valve .. 50-284
replaced ................................................... 30-144
Disassembly and assembly of equalizer bar
Adjustment of straight tilt dozer ...................... 30-77
side bushing ............................................. 50-276
Air conditioner component ............................... 80-4
Disassembly and assembly of final drive....... 50-198
Air conditioner compressor ............................ 80-18
Disassembly and assembly of HSS .............. 50-177
Air conditioner controller ................................ 80-17
Disassembly and assembly of hydraulic
Air conditioner unit ........................................ 80-10
cylinder .................................................... 50-294
Angle control EPC valve.................... 10-207, 60-83
Disassembly and assembly of idler............... 50-215
Angle cylinder............................................... 60-98
Disassembly and assembly of KDPF ............ 50-117
Disassembly and assembly of one link in field
B (PLUS type track shoe).............................. 50-268
Disassembly and assembly of one link in field
Bevel gear shaft, HSS, and brake......... 10-81, 60-27
(standard type track shoe) ......................... 50-261
Blade PPC valve .............................. 10-186, 60-74
Disassembly and assembly of PTO .............. 50-140
Bleeding air from fuel system ......................... 30-37
Disassembly and assembly of recoil spring ... 50-220
Bleeding air from hydraulic circuit ................... 30-74
Disassembly and assembly of ripper PPC
Brake valve ...................................... 10-102, 60-32
valve ........................................................ 50-286
Disassembly and assembly of TORQFLOW
C transmission ............................................. 50-153
Disassembly and assembly of torque converter ...50-
Cab mount ................................................. 60-100
144
Carrier roller ................................................. 60-53
Disassembly and assembly of track roller ..... 50-225
Check before troubleshooting ........................ 40-12
Disc clutch ................................................... 10-55
Checking and adjusting track shoe tension ..... 30-59
Disconnecting and connecting of power train
Checking fan speed ...................................... 30-72
unit assembly ........................................... 50-135
Checking fuel circuit for leakage..................... 30-38
Checking sprocket wear ................................ 30-58
Circuit diagram and arrangement of connector E
pins ........................................................... 80-25
E-1 Engine does not start (Engine does not
Classification and procedure for
crank) ...................................................... 40-594
troubleshooting ........................................... 40-23
E-2 Manual preheating does not work........... 40-600
Classification and procedures for
E-3 Automatic preheating does not work....... 40-603
troubleshooting numbers ............................. 40-25
E-4 While preheating is working, preheating
CLSS......................................................... 10-124
monitor does not light up............................ 40-605
D65EX,PX,WX-17 1
Index
E-5 When starting switch is turned to ON E-35 Right door wiper does not operate
position, machine monitor displays nothing.. 40-607 (Failure of both continuous and intermittent
E-6 When starting switch is turned to ON operations) ............................................... 40-653
position (with engine stopped), basic check E-36 KOMTRAX system does not operate
monitor lights up........................................ 40-610 properly.................................................... 40-656
E-7 Air cleaner clogging monitor lights up in Electric circuit diagram .................................. 90-25
yellow while engine is running .................... 40-611 Electric circuit diagram for air conditioner unit .. 90-51
E-8 Charge level monitor lights up while engine Engine control system ................................. 10-223
is running ................................................. 40-612 Engine mount ................................................. 60-3
E-9 Engine coolant temperature monitor lights Engine related parts ........................................ 10-4
up while engine is running.......................... 40-614 Explanation of terms for maintenance standard ...00-
E-10 Engine oil pressure monitor lights up 22
while engine is running .............................. 40-615
E-11 Power train oil temperature monitor lights
up while engine is running.......................... 40-616
F
E-12 Hydraulic oil temperature monitor lights Failure code [15SEL1] Speed 1st clutch:Fill
up while engine is running.......................... 40-617 High......................................................... 40-113
E-13 Engine coolant temperature gauge does Failure code [15SFL1] Speed 2nd clutch:Fill
not indicate correct temparature ................. 40-618 High......................................................... 40-117
E-14 Fuel level gauge does not indicate correct Failure code [15SFLH] Speed 2nd clutch:Fill
level......................................................... 40-619 Low ......................................................... 40-119
E-15 Power train oil temperature gauge (multi- Failure code [15SGLH] Speed 3rd clutch:Fill
gauge) does not indicate correct temperature ....40- Low ......................................................... 40-123
621 Failure code [879AKA] Air Conditioner Inner
E-16 Hydraulic oil temperature gauge (multi- Sensor Disconnection ............................... 40-130
gauge) does not indicate correct temperature ....40- Failure code [879AKB] Air Conditioner Inner
622 Sensor Disconnection ............................... 40-131
E-17 Operation mode does not change......... 40-623 Failure code [879BKA] A/C Outer sensor Open
E-18 Gearshift mode does not change.......... 40-624 Circuit ........................................................ 80-58
E-19 Operating customize switch does not Failure code [879BKA] Air Conditioner Outside
display customize screen........................... 40-625 Air Sensor Disconnection........................... 40-132
E-20 Modifying setting on customize screen Failure code [879BKB] A/C Outer sensor Short
does not change setting of machine............ 40-626 Circuit ........................................................ 80-60
E-21 Reverse slow mode does not function Failure code [879BKB] Air Conditioner Outside
properly.................................................... 40-627 Air Sensor Disconnection........................... 40-133
E-22 Alarm buzzer does not sound or does not Failure code [879CKA] Ventilating Sensor
stop sounding ........................................... 40-628 Disconnection........................................... 40-134
E-23 While starting switch is in OFF position, Failure code [879CKB] Ventilating Sensor
service meter is not displayed .................... 40-629 Short Circuit ............................................. 40-135
E-24 Service mode cannot be selected......... 40-630 Failure code [879DKZ] Sunlight sensor Open
E-25 Horn does not sound ........................... 40-631 or Short Circuit............................................ 80-64
E-26 Horn does not stop sounding ............... 40-632 Failure code [879DKZ] Sunlight Sensor Open
E-27 Backup alarm does not sound .............. 40-633 Or Short Circuit ......................................... 40-136
E-28 Backup alarm does not stop sounding .. 40-635 Failure code [879EMC] Ventilation Abnormal 40-137
E-29 Headlamp does not light up ................. 40-636 Failure code [879FMC] A/M Damper Abnormal ...40-
E-30 Rear lamp does not light up ................. 40-639 138
E-31 No wiper operates continuously or Failure code [879FMC] Air Mix Damper
intermittently ............................................. 40-641 Abnormality ................................................ 80-67
E-32 Front wiper does not operate (Failure in Failure code [879GKX] Refrigerant
both continuous and intermittent operations) .....40- Abnormality .................................... 40-139, 80-68
644 Failure code [989L00] Engine Controller Lock
E-33 Rear wiper does not operate (Failure in Caution 1 ................................................. 40-140
both continuous and intermittent operations) .....40- Failure code [989M00] Engine Controller Lock
647 Caution 2 ................................................. 40-141
E-34 Left door wiper does not operate (Failure Failure code [989N00] Engine Controller Lock
of both continuous and intermittent Caution 3 ................................................. 40-142
operations) ............................................... 40-650 Failure code [A1U0N3]: KDPF Dry Request
(HC Release)............................................ 40-143
2 D65EX,PX,WX-17
Index
Failure code [A1U0N4] KDPF Dry Request Failure code [CA221] Ambient Press Sens
(HC Release)............................................ 40-145 High Error................................................. 40-174
Failure code [B@BAZG] Engine Oil Pressure Failure code [CA222] Ambient Press Sens Low
Low ......................................................... 40-150 Error ........................................................ 40-176
Failure code [B@BCNS] Eng Water Overheat .....40- Failure code [CA2249] Rail Press Very Low
151 Error ........................................................ 40-287
Failure code [B@HANS] Hyd Oil Overheat.... 40-153 Failure code [CA2265] Fuel Feed Pump Open
Failure code [CA1117] Engine Controller Error ........................................................ 40-288
Partial Data Lost Error ............................... 40-255 Failure code [CA2266] Fuel Feed Pump Short
Failure code [CA115] Eng Ne and Bkup Speed Error ........................................................ 40-290
Sens Error ................................................ 40-154 Failure code [CA227] Sens Supply 2 Volt High
Failure code [CA122] Chg Air Press Sensor Error ........................................................ 40-178
High Error................................................. 40-155 Failure code [CA2271] EGR Valve Pos Sens
Failure code [CA123] Chg Air Press Sensor High Error................................................. 40-292
Low Error ................................................. 40-157 Failure code [CA2272] EGR Valve Pos Sens
Failure code [CA131] Throttle Sensor High Low Error ................................................. 40-294
Error ........................................................ 40-159 Failure code [CA2288] Turbo Speed High Error
Failure code [CA132] Throttle Sensor Low 1.............................................................. 40-297
Error ........................................................ 40-161 Failure code [CA2311] lMV Solenoid Error .... 40-298
Failure code [CA144] Coolant Temp Sens High Failure code [CA234] Eng Overspeed........... 40-173
Error ........................................................ 40-163 Failure code [CA2349] EGR Valve Solenoid
Failure code [CA145] Coolant Temp Sens Low Open Error ............................................... 40-299
Error ........................................................ 40-165 Failure code [CA2353] EGR Valve Solenoid
Failure code [CA153] Chg Air Temp Sensor Short Error................................................ 40-301
High Error................................................. 40-167 Failure code [CA2357] EGR Valve Servo Error ....40-
Failure code [CA154] Chg Air Temp Sensor 303
Low Error ................................................. 40-169 Failure code [CA2373] Exhaust Manifold Press
Failure code [CA1664] KDOC Malfunction .... 40-256 Sens High error......................................... 40-304
Failure code [CA1691] Regeneration Failure code [CA2374] Exhaust Manifold Press
Ineffective................................................. 40-258 Sens Low error ......................................... 40-306
Failure code [CA1695] Sensor 5 Supply Volt Failure code [CA2375] EGR Orifice Temp Sens
High Error................................................. 40-261 High Error................................................. 40-308
Failure code [CA1696] Sensor 5 Supply Volt Failure code [CA2376] EGR Orifice Temp Sens
Low Error ................................................. 40-262 Low Error ................................................. 40-310
Failure code [CA1843] Crankcase Press Sens Failure code [CA238] Ne Speed Sens Supply
High Error................................................. 40-264 Volt Error .................................................. 40-179
Failure code [CA1844] Crankcase Press Sens Failure code [CA2381] KVGT Pos Sens High
Low Error ................................................. 40-266 Error ........................................................ 40-312
Failure code [CA187] Sensor 2 Supply Volt Failure code [CA2382] KVGT Pos Sens Low
Low Error ................................................. 40-171 Error ........................................................ 40-314
Failure code [CA1879] KDPF Delta P Sensor Failure code [CA2383] KVGT Solenoid Open
High Error................................................. 40-268 Error ........................................................ 40-316
Failure code [CA1881] KDPF Delta P Sensor Failure code [CA2386] KVGT Solenoid Short
Low Error ................................................. 40-270 Error ........................................................ 40-318
Failure code [CA1883] KDPF Delta P Sens In Failure code [CA2387] KVGT Valve Servo
Range Error.............................................. 40-272 Error ........................................................ 40-320
Failure code [CA1921] KDPF Soot Level High Failure code [CA239] Ne Speed Sens Supply
Error 1...................................................... 40-275 Volt High Error .......................................... 40-180
Failure code [CA1922] KDPF Soot Level High Failure code [CA2554] Exh Manifold Press
Error 2...................................................... 40-277 Sens In Range error .................................. 40-321
Failure code [CA1942] Crankcase Press Failure code [CA2555] Grid Htr Relay Volt Low
Sensor In Range Error............................... 40-281 Error ........................................................ 40-322
Failure code [CA1993] KDPF Delta Pressure Failure code [CA2556] Grid Htr Relay Volt High
Low Error ................................................. 40-282 Error ........................................................ 40-324
Failure code [CA2185] Throt Sensor Sup Volt Failure code [CA2637] KDOC Blocked ......... 40-326
High Error................................................. 40-283 Failure code [CA2639] Manual Stationary
Failure code [CA2186] Throt Sensor Sup Volt Regeneration Request............................... 40-328
Low Error ................................................. 40-285 Failure code [CA271] IMV/PCV1 Short Error . 40-182
Failure code [CA272] IMV/PCV1 Open Error . 40-184
D65EX,PX,WX-17 3
Index
Failure code [CA281] Pump Press Balance Failure code [CA352] Sensor 1 Supply Volt
Error ........................................................ 40-186 Low Error ................................................. 40-202
Failure code [CA295] Ambient Pressure Failure code [CA356] Mass Air Flow Sensor
Sensor In Range Error............................... 40-187 High Error................................................. 40-204
Failure code [CA2961] EGR Orifice Temp High Failure code [CA357] Mass Air Flow Sensor
Error 1...................................................... 40-331 Low Error ................................................. 40-206
Failure code [CA2973] Chg Air Press Sensor Failure code [CA3741] Rail Press Valve Trip
In Range Error .......................................... 40-332 Error ........................................................ 40-390
Failure code [CA3133] KDPF Outlet Press Failure code [CA386] Sens Supply 1 Volt High
Sens High Error ........................................ 40-333 Error ........................................................ 40-208
Failure code [CA3134] KDPF Outlet Press Failure code [CA428] Water in Fuel Sensor
Sens Low Error ......................................... 40-335 High Error................................................. 40-209
Failure code [CA3135] KDPF Outlet Press Failure code [CA429] Water in Fuel Sensor
Sens In Range Error.................................. 40-337 Low Error ................................................. 40-211
Failure code [CA322] Inj #1(L#1) Open/Short Failure code [CA435] Eng Oil Press SW Error .....40-
Error ........................................................ 40-188 213
Failure code [CA323] Inj #5 (L#5) Open/Short Failure code [CA441] Battery Voltage Low
Error ........................................................ 40-190 Error ........................................................ 40-214
Failure code [CA324] Inj #3(L#3) Open/Short Failure code [CA442] Battery Voltage High
Error ........................................................ 40-192 Error ........................................................ 40-216
Failure code [CA325] Inj #6 (L#6) Open/Short Failure code [CA449] Rail Press Very High
Error ........................................................ 40-194 Error ........................................................ 40-217
Failure code [CA3251] KDOC Inlet Temp High Failure code [CA451] Rail Press Sensor High
Error ........................................................ 40-340 Error ........................................................ 40-219
Failure code [CA3254] KDOC Outlet Temp Failure code [CA452] Rail Press Sensor Low
High Error 1 .............................................. 40-344 Error ........................................................ 40-221
Failure code [CA331] Inj #2(L#2) Open/Short Failure code [CA488] Chg Air Temp High
Error ........................................................ 40-196 Torque Derate........................................... 40-223
Failure code [CA3312] KDPF Outlet Temp Failure code [CA515] Rail Press Sens Sup Volt
High Error 2 .............................................. 40-350 High Error................................................. 40-224
Failure code [CA3313] KDOC Inlet Temp Failure code [CA516] Rail Press Sens Sup Volt
Sensor Low Error ...................................... 40-353 Low Error ................................................. 40-226
Failure code [CA3314] KDOC Inlet Temp Sens Failure code [CA553] Rail Press High Error... 40-228
High Error................................................. 40-356 Failure code [CA555] Crankcase Press High
Failure code [CA3315] KDOC Inlet Temp Sens Error 2...................................................... 40-229
In Range Error .......................................... 40-360 Failure code [CA556] Crankcase Pressure
Failure code [CA3316] KDOC Outlet Temp High Error 3 .............................................. 40-230
Sens Low Error ......................................... 40-364 Failure code [CA559] Rail Pump Press Low
Failure code [CA3317] KDOC Outlet Temp Error ........................................................ 40-231
Sens High Error ........................................ 40-367 Failure code [CA595] Turbocharger Speed
Failure code [CA3318] KDOC Outlet Temp High Error 2 .............................................. 40-235
Sens In Range Error.................................. 40-371 Failure code [CA687] Turbo Speed Low Error .....40-
Failure code [CA3319] KDPF Outlet Temp 236
Sens High Error ........................................ 40-375 Failure code [CA689] Eng Ne Speed Sensor
Failure code [CA332] Inj #4 (L#4) Open/Short Error ........................................................ 40-238
Error ........................................................ 40-198 Failure code [CA691] Intake Air Temp Sens
Failure code [CA3321] KDPF Outlet Temp High Error................................................. 40-242
Sens Low Error ......................................... 40-379 Failure code [CA692] Intake Air Temp Sens
Failure code [CA3322] KDPF Outlet Temp Low Error ................................................. 40-244
Sens In Range Error.................................. 40-382 Failure code [CA697] ECM Internal Temp
Failure code [CA3419] Mass Air Flow Sensor Sensor High Error ..................................... 40-246
Sup Volt High Error.................................... 40-386 Failure code [CA698] ECM Internal Temp
Failure code [CA3421] Mass Air Flow Sensor Sensor Low Error ...................................... 40-247
Sup Volt Low Error .................................... 40-388 Failure code [CA731] Eng Bkup Speed Sens
Failure code [CA343] ECM Critical Internal Phase Error .............................................. 40-248
Failure ..................................................... 40-200 Failure code [CA778] Eng Bkup Speed Sensor
Failure code [CA351] Injectors Drive Circuit Error ........................................................ 40-250
Error ........................................................ 40-201 Failure code [D130KA] Neutral relay:Open.... 40-391
4 D65EX,PX,WX-17
Index
Failure code [D130KB] Neutral relay:Short Failure code [DBERKR] CAN1 Discon (PT
circuit ....................................................... 40-393 Con) ........................................................ 40-449
Failure code [D19DKA] Amber light relay:Open ...40- Failure code [DD12KA] Shift up Sw:Open ..... 40-450
395 Failure code [DD12KB] Shift up Sw:Short
Failure code [D19DKB] Amber light relay:Short circuit ....................................................... 40-452
circuit ....................................................... 40-397 Failure code [DD13KA] Shift down Sw:Open . 40-454
Failure code [D19JKZ] Personal Code Relay Failure code [DD13KB] Shift down Sw:Short
Abnormality .............................................. 40-399 circuit ....................................................... 40-456
Failure code [D811MC] KOMTRAX Error ...... 40-402 Failure code [DD14KA] Parking lever Sw:Open ...40-
Failure code [D862KA] GPS Antenna Open 458
Circuit ...................................................... 40-403 Failure code [DD14KB] Parking lever Sw:Short
Failure code [D8ALKA] Operating Lamp Open circuit ....................................................... 40-460
Circuit(KOMTRAX).................................... 40-404 Failure code [DDKFL4] Left Angle Sw:Signal
Failure code [D8ALKB] Operating Lamp Short mismatch ................................................. 40-462
Circuit(KOMTRAX).................................... 40-406 Failure code [DDKGL4] Right Angle Sw:Signal
Failure code [D8AQKR] CAN2 Discon mismatch ................................................. 40-464
(KOMTRAX) ............................................. 40-407 Failure code [DDKHKA] iB Sw:Open ............ 40-466
Failure code [DAF0MB] Monitor Memory Error ....40- Failure code [DDKHKB] iB Sw:Short circuit ... 40-468
408 Failure code [DDN7KA] Weq pitch SW: Open......40-
Failure code [DAF0MC] Monitor Malfunction . 40-409 470
Failure code [DAF8KB] Camera Power Supply Failure code [DDN7KB] Pitch select solenoid:
Short Circuit ............................................. 40-410 Short circuit .............................................. 40-472
Failure code [DAF9KQ] Model Selection Failure code [DDNLKA] Weq lock Sw:Open .. 40-474
Abnormality .............................................. 40-412 Failure code [DDNLKB] Weq lock Sw:Short
Failure code [DAFGMC] GPS Module Error .. 40-413 circuit ....................................................... 40-476
Failure code [DAFLKA] Operating Lamp Open Failure code [DGS1KA] Hyd oil temp sensor:
Circuit(Monitor) ......................................... 40-414 Open ....................................................... 40-478
Failure code [DAFLKB] Operating Lamp Short Failure code [DGS1KX] Hyd oil temp: signal
Circuit(Monitor) ......................................... 40-416 abnormal.................................................. 40-479
Failure code [DAFQKR] CAN2 Discon .......... 40-417 Failure code [DGT1KA] T/C oil temp sensor:
Failure code [DAZ9KQ] A/C Model Selection Open ....................................................... 40-481
Abnormality .............................................. 40-418 Failure code [DGT1KX] T/C oil temp sensor:
Failure code [DAZQKR] CAN2 Discon (Aircon Out of normal range .................................. 40-482
ECU) ....................................................... 40-419 Failure code [DH21KA] Weq pressure sensor:
Failure code [DB2QKR] CAN2 Discon (Engine Open ....................................................... 40-484
Con) ........................................................ 40-423 Failure code [DH21KB] Work equipment
Failure code [DB2RKR] CAN1 Discon (Engine pressure sensor:Hot Short ......................... 40-486
Con) ........................................................ 40-428 Failure code [DHA4KA] Air Cleaner Clogging
Failure code [DBE0KT] PT controller: Sensor Open Circuit .................................. 40-488
Abnormality in controller ............................ 40-433 Failure code [DHTDKA] T/C pressure sensor:
Failure code [DBE1KK] PT controller:Source Open ....................................................... 40-489
voltage low ............................................... 40-434 Failure code [DHTDKB] T/C pressure sensor:
Failure code [DBE2KK] PT controller:Output Hot Short.................................................. 40-491
voltage low ............................................... 40-436 Failure code [DK10KA] Fuel control Dial:Open ....40-
Failure code [DBE5KK] PT:Sensor volt 5V (0) 493
Out of normal range .................................. 40-438 Failure code [DK10KB] Fuel control Dial:Short
Failure code [DBE6KK] PT:Sensor volt 24V circuit ....................................................... 40-495
Out of normal range .................................. 40-440 Failure code [DK30KA] ST lever1:Open........ 40-497
Failure code [DBE7KK] PT:Sensor volt 5V (1) Failure code [DK30KB] ST lever:Hot Short .... 40-499
Out of normal range .................................. 40-442 Failure code [DK30KX] ST lever:Main and Sub
Failure code [DBE9KQ] PT controller:Type Error ........................................................ 40-501
select signal ............................................. 40-444 Failure code [DK30KZ] ST lever:Main and Sub
Failure code [DBELKA] Operating Lamp Open Error ........................................................ 40-502
Circuit(PT Con) ......................................... 40-445 Failure code [DK30L8] ST lever:Signal
Failure code [DBELKB] Operating Lamp Short mismatch ................................................. 40-503
Circuit(PT Con) ......................................... 40-447 Failure code [DK31KA] ST lever2:Open........ 40-504
Failure code [DBEQKR] CAN2 Discon (PT Failure code [DK31KB] ST lever2:Hot Short .. 40-506
Con) ........................................................ 40-448 Failure code [DK40KA] Brake potentiometer:
Open ....................................................... 40-508
D65EX,PX,WX-17 5
Index
Failure code [DK40KB] Brake potentiometer: Failure code [DXH1KA] Lock-up ECMV:Open .....40-
Hot Short.................................................. 40-510 558
Failure code [DK55KX] FR lever:Main and Sub Failure code [DXH1KB] Lock-up ECMV: Short
Error ........................................................ 40-512 circuit ....................................................... 40-560
Failure code [DK55KZ] FR lever:Main and Sub Failure code [DXH1KY] Lock-up ECMV: Hot
Error ........................................................ 40-513 short ........................................................ 40-561
Failure code [DK55L8] FR lever:Signal Failure code [DXH4KA] 1st clutch ECMV:Open ...40-
mismatch ................................................. 40-514 563
Failure code [DK56KA] FR lever1:Open........ 40-515 Failure code [DXH4KB] 1st clutch ECMV:Short
Failure code [DK56KB] FR lever1:Hot Short .. 40-517 circuit ....................................................... 40-564
Failure code [DK57KA] FR lever2:Open........ 40-519 Failure code [DXH4KY] 1st clutch ECMV:Hot
Failure code [DK57KB] FR lever2:Hot Short .. 40-521 short ........................................................ 40-565
Failure code [DKH1KA] Pitch angle sensor: Failure code [DXH5KA] 2nd clutch ECMV:
Open ....................................................... 40-523 Open ....................................................... 40-567
Failure code [DKH1KB] Pitch angle sensor:Hot Failure code [DXH5KB] 2nd clutch ECMV:
Short........................................................ 40-525 Short circuit .............................................. 40-568
Failure code [DLM3KA] Fan rev. sensor:Open.....40- Failure code [DXH5KY] 2nd clutch ECMV:Hot
527 short ........................................................ 40-569
Failure code [DLM3MB] Fan control:Mismatch ....40- Failure code [DXH6KA] 3rd clutch ECMV:Open...40-
529 571
Failure code [DLT3KA] T/M out-speed sensor: Failure code [DXH6KB] 3rd clutch ECMV:Short
Open ....................................................... 40-530 circuit ....................................................... 40-572
Failure code [DLT3KB] T/M out-speed sensor: Failure code [DXH6KY] 3rd clutch ECMV:Hot
Short circuit .............................................. 40-532 short ........................................................ 40-573
Failure code [DV20KB] Back-up alarm :Short Failure code [DXH7KA] R clutch ECMV:Open .....40-
Circuit ...................................................... 40-533 575
Failure code [DW5AKA] Pitch select solenoid: Failure code [DXH7KB] R clutch ECMV:Short
Disconnection........................................... 40-535 circuit ....................................................... 40-576
Failure code [DW5AKB] Pitch select solenoid: Failure code [DXH7KY] R clutch ECMV:Hot
Failure code [DW5AKY] Pitch select solenoid: Failure code [DXH8KA] F clutch ECMV:Open .....40-
Hot short .................................................. 40-537 579
Failure code [DW7BKA] Fan reverse solenoid: Failure code [DXH8KB] F clutch ECMV:Short
Open ....................................................... 40-539 circuit ....................................................... 40-580
Failure code [DW7BKB] Fan reverse solenoid: Failure code [DXH8KY] F clutch ECMV:Hot
Failure code [DWN1KA] Hss EPC RH:Open . 40-542 Failure code [DXJ4KA] Weq lock Sol.:Open .. 40-583
Failure code [DWN1KB] Hss EPC RH:Short Failure code [DXJ4KB] Weq lock Sol.:Short
circuit ....................................................... 40-543 circuit ....................................................... 40-585
Failure code [DWN1KY] Hss EPC RH:Hot Failure code [DXJCKA] Blade angle left EPC:
short ........................................................ 40-544 Open ....................................................... 40-586
Failure code [DWN2KA] Hss EPC LH:Open .. 40-546 Failure code [DXJCKB] Blade angle left EPC:
Failure code [DWN2KB] Hss EPC LH:Short Short circuit .............................................. 40-587
circuit ....................................................... 40-547 Failure code [DXJCKY] Blade angle left EPC:
Failure code [DWN2KY] Hss EPC LH:Hot short...40- Hot short .................................................. 40-588
548 Failure code [DXJDKA] Blade angle right EPC:
Failure code [DWN5KA] Fan pump solenoid 1 : Open ....................................................... 40-590
Open ....................................................... 40-550 Failure code [DXJDKB] Blade angle right EPC:
Failure code [DWN5KB] Fan pump solenoid 1 : Short circuit .............................................. 40-591
Short circuit .............................................. 40-551 Failure code [DXJDKY] Blade angle right EPC:
Failure code [DWN5KY] Fan pump solenoid 1: Hot short .................................................. 40-592
Hot short .................................................. 40-552 Failure code [1500L0] Transmission clutch:
Failure code [DXA2KA] TVC solenoid 1: Open ....40- Abnormal ................................................. 40-104
554 Failure code [15SAL1] Forward clutch:Fill High ...40-
Failure code [DXA2KB] TVC solenoid 1: Short 105
circuit ....................................................... 40-555 Failure code [15SALH] Forward clutch:Fill Low....40-
Failure code [DXA2KY] TVC solenoid 1: Hot 107
short ........................................................ 40-556 Failure code [15SBL1] Reverse clutch:Fill High ...40-
109
6 D65EX,PX,WX-17
Index
Failure code [15SBLH] Reverse clutch:Fill Low ...40- H-16 Blade angle speed or power is low ....... 40-680
111 H-17 Ripper lift speed or power is low ........... 40-681
Failure code [15SELH] Speed 1st clutch:Fill H-18 Hydraulic drift of lifted blade is large ..... 40-682
Low ......................................................... 40-115 H-19 Hydraulic drift of tilted blade is large ..... 40-683
Failure code [15SGL1] Speed 3rd clutch:Fill H-2 Machine cannot travel (at 2nd or 3rd
High......................................................... 40-121 speed) ..................................................... 40-666
Failure code [15SJL1] L/U :Fill Hihg.............. 40-125 H-20 Hydraulic drift of lifted ripper is large ..... 40-684
Failure code [15SJLH] L/U :Fill low ............... 40-127 H-21 Fans speed is abnormal (high, low, or no
Failure code [1800MW] P/L clutch:Slip ......... 40-129 rotation).................................................... 40-685
Failure code [879AKA] A/C Inner sensor Open H-22 Unusual noise is heard from around fan......40-
Circuit ........................................................ 80-56 687
Failure code [879AKB] A/C Inner sensor Short H-3 Machine does not start at all gear speeds .....40-
Circuit ........................................................ 80-57 667
Failure code [879CKA] Ventilating sensor H-4 Machine travels only in one direction,
Open Circuit ............................................... 80-62 either forward or in reverse ........................ 40-668
Failure code [879CKB] Ventilating sensor H-5 Large time lag at gear shifting or
Short Circuit ............................................... 80-63 directional selection................................... 40-669
Failure code [879EMC] Ventilating Damper H-6 Machine cannot be steered (machine does
Abnormality ................................................ 80-66 not turn left or right) ................................... 40-670
Failure code [AA10NX] Air Cleaner Clogging. 40-147 H-7 Steering speed or power is insufficient.... 40-671
Failure code [AB00KE] Battery Charge Voltage H-8 Brake does not operate ......................... 40-672
Low ......................................................... 40-148 H-9 Torque converter does not lock up.......... 40-673
Failure code [B@CENS] P/L Oil Overheat..... 40-152 Handling cylinder cutout mode operation ........ 30-35
Failure code [CA3253] KDOC Temp Error - Handling no injection cranking operation......... 30-36
Non Regeneration ..................................... 40-343 Handling of compressor oil ............................ 80-84
Failure code [CA3255] KDPF Temp Error - Non Handling of electrical equipment .................... 00-31
Regeneration............................................ 40-347 Handling of fuel system devices ..................... 00-24
Failure code [CA3256] KDPF Outlet Temp Handling of hydraulic equipment .................... 00-26
High Error 1 .............................................. 40-348 Handling of intake system parts ..................... 00-25
Failure code [CA3311] KDOC Outlet Temp Handling voltage circuit of engine controller .. 30-143
High Error 2 .............................................. 40-349 How to proceed troubleshooting..................... 40-11
Failure code list related to air conditioner ........ 80-55 How to read electric wire code ....................... 00-39
Failure codes table ....................................... 40-93 How to read the shop manual ........................ 00-20
Final drive .................................................... 60-33 How to read this manual .................................. 50-4
Forward and reverse clutch ECMV and gear HSS motor ....................................... 10-150, 60-65
shift clutch ECMV........................................ 10-66 HSS pump ................................................... 60-63
Forward-reverse clutch ECMV and gear shift HSS system ................................................. 10-35
clutch ECMV .............................................. 60-23 Hydraulic circuit diagram ................................. 90-9
Fuel level sensor ........................................ 10-283 Hydraulic motor ............................................ 10-26
Function. 10-5, 10-7, 10-13, 10-16, 10-19, 10-26, 10- Hydraulic oil cooler bypass valve ................. 10-212
36, 10-39, 10-42, 10-44, 10-65–10-66, 10-73, 10- Hydraulic piping drawing ............................. 10-116
213 Hydraulic tank .................................. 10-122, 60-60
Fuse locations table ...................................... 40-88
I
G Idler ............................................................. 60-47
General information on testing and adjusting..... 30-4 Important safety notice .................................. 00-15
Information contained in troubleshooting table
(S mode) .................................................. 40-688
H Information mentioned in troubleshooting table....40-
H-1 Machine lacks power (insufficient drawbar 28, 80-54
pull) ......................................................... 40-664 Information mentioned in troubleshooting table
H-10 Power train oil overheats ..................... 40-674 (H mode) .................................................. 40-658
H-11 Unusual noise is heard from around HSS Instruction on troubleshooting .......................... 40-9
and work equipment pump or HSS motor .... 40-675 Isolating the parts causing hydraulic drift in
H-12 All work equipment operates slowly ...... 40-676 blade and ripper .......................................... 30-70
H-13 All work equipment does not operate .... 40-677
H-14 Blade lift speed or power is low ............ 40-678
H-15 Blade tilt speed or power is low ............ 40-679
D65EX,PX,WX-17 7
Index
K Posture of machine for measuring

performance and measurement procedure .... 20-25
KOMTRAX system ..................................... 10-252
Power train................................................... 10-32
Power train hydraulic circuit diagram ................ 90-7
L Power train hydraulic piping drawing .............. 10-40
Power train mount............................... 10-39, 60-12
Layout of air conditioner related parts and
Power transmitting route...................... 10-48, 10-56
connectors ................................................. 80-30
Precautions for cleaning and replacing KDPF
Lift cylinder................................................... 60-95
(KCSF, KDOC)............................................ 40-91
List of abbreviation........................................ 00-49
Precautions for disconnecting and connecting
List of Failure Mode and Cause.................... 40-661
air conditioner piping ................................... 80-82
Lockup clutch ECMV........................... 10-73, 60-24
Precautions for refrigerant ............................... 80-3
Precautions when performing operation.......... 00-42
M Principle of operation .................................... 10-26
Procedure for testing and troubleshooting ....... 80-23
Machine monitor system.............................. 10-232
Main frame ....................................... 10-110, 60-41
Main relief valve............................................ 10-77 Q
Main relief valve and torque converter relief
valve ................................................ 10-77, 60-25 Quick drop valve............................... 10-198, 60-78
Measure internal oil leakage of work
equipment cylinder ...................................... 30-71 R
Measuring and adjusting valve clearance........ 30-15
Measuring and adjusting work equipment and Receiver drier............................................... 80-20
HSS oil pressure ......................................... 30-61 Releasing remaining pressure from fuel
Measuring blowby pressure ........................... 30-19 system ....................................................... 30-23
Measuring boost pressure ............................. 30-10 Releasing remaining pressure in work
Measuring compression pressure .................. 30-17 equipment cylinder ...................................... 30-60
Measuring EGR valve and KVGT oil pressure . 30-22 Removal and installation of aftercooler and
Measuring engine oil pressure ....................... 30-21 assembly.................................................... 50-77
Measuring exhaust gas color ......................... 30-13 Removal and installation of air cleaner
Measuring exhaust gas temperature............... 30-11 assembly.................................................. 50-129
Measuring fan circuit oil pressure ................... 30-73 Removal and installation of air conditioner
Measuring fuel delivery, return rate and compressor assembly ............................... 50-324
leakage ...................................................... 30-31 Removal and installation of air conditioner unit
Measuring fuel pressure ................................ 30-24 assembly.................................................. 50-320
Measuring power train oil pressure ................. 30-43 Removal and installation of blade assembly
Measuring PPC valve output pressure............ 30-65 (PAT dozer) .............................................. 50-302
Measuring source pressure of control circuit.... 30-64 Removal and installation of blade assembly
Method of disconnecting and connecting push- (ST-TPP dozer)......................................... 50-300
pull type coupler.......................................... 00-28 Removal and installation of carrier roller
assembly.................................................. 50-228
Removal and installation of control valve
O assembly.................................................. 50-280
Removal and installation of cooling fan drive
Oil flow......................................................... 10-50
assembly.................................................... 50-84
Operation.. 10-13, 10-17, 10-20, 10-55, 10-74, 10-78
Removal and installation of cooling fan motor
Operation of ECMV....................................... 10-68
assembly.................................................... 50-86
Outline of refrigeration cycle ............................ 80-8
Removal and installation of cooling scavenging
Overall disassembly and assembly of track
pump assembly ........................................ 50-291
shoe (PLUS type track shoe)...................... 50-249
Removal and installation of cylinder head
Overall drawing of power train unit.................. 10-37
assembly.................................................... 50-54
Removal and installation of damper assembly . 50-95
P Removal and installation of engine assembly .. 50-88
Removal and installation of engine controller
Palm command control system .................... 10-228
assembly.................................................. 50-326
Piston valve ............................................... 10-218
Removal and installation of engine front seal... 50-98
Pitch cylinder................................................ 60-97
Removal and installation of engine hood
Pitch selector solenoid valve........................ 10-206
assembly.................................................. 50-109
Pm clinic .................................................... 30-147
8 D65EX,PX,WX-17
Index
Removal and installation of engine rear seal . 50-101 ROPS cab.................................................. 10-220
Removal and installation of equalizer bar
assembly.................................................. 50-274
Removal and installation of final drive
S
assembly.................................................. 50-196 S-1 When starting switch is turned to START
Removal and installation of fuel injector position, engine is not cranked ................... 40-689
assembly.................................................... 50-40 S-10 Engine oil consumption is excessive..... 40-703
Removal and installation of fuel tank assembly....50- S-11 Engine oil becomes contaminated early 40-704
111 S-12 Fuel consumption is excessive............. 40-705
Removal and installation of HSS motor S-13 Oil is in coolant (or coolant spurts or
assembly.................................................. 50-292 coolant level goes down) ........................... 40-706
Removal and installation of HSS pump and S-14 Oil pressure drops............................... 40-707
cooling fan pump assembly........................ 50-287 S-15 Fuel mixes into engine oil .................... 40-708
Removal and installation of hydraulic oil cooler S-16 Water mixes into engine oil (milky)........ 40-709
assembly.................................................... 50-80 S-17 Coolant temperature rises too high
Removal and installation of hydraulic tank (overheating) ............................................ 40-710
assembly.................................................. 50-277 S-18 Unusual noise is made ........................ 40-711
Removal and installation of idler assembly .... 50-213 S-19 Vibration is excessive.......................... 40-712
Removal and installation of KCCV assembly . 50-125 S-2 The engine cranks but exhaust smoke
Removal and installation of KDPF assembly . 50-113 does not come out..................................... 40-690
Removal and installation of KOMTRAX S-20 Air cannot be bled from fuel circuit ........ 40-713
terminal .................................................... 50-330 S-21 Frequent active regeneration ............... 40-714
Removal and installation of machine monitor S-22 Active regeneration is long................... 40-715
assembly.................................................. 50-325 S-23 White smoke is exhausted during active
Removal and installation of mass air flow and regeneration ............................................. 40-716
temperature sensor ................................... 50-329 S-3 Fuel is being injected but engine does not
Removal and installation of operator's cab start (incomplete combustion: engine cranks
glass (adhesion glass)............................... 50-313 but does not start) ..................................... 40-691
Removal and installation of operator's sea .... 50-318 S-4 Startability is poor ................................. 40-692
Removal and installation of pivot shaft S-5 Engine does not pick up smoothly .......... 40-694
assembly.................................................. 50-273 S-6 Engine stops during operation................ 40-696
Removal and installation of power train S-7 Engine runs rough or is unstable ............ 40-698
controller assembly ................................... 50-327 S-8 Engine lacks power............................... 40-699
Removal and installation of power train oil S-9 Exhaust gas is black (KDPF gets clogged
cooler assembly.......................................... 50-82 in a short time) .......................................... 40-701
Removal and installation of power train unit Safety valve ................................................. 10-31
assembly.................................................. 50-130 Scavenging pump............................. 10-127, 60-61
Removal and installation of radiator assembly . 50-72 Self-pressure reducing valve ......................... 10-18
Removal and installation of recoil spring Sensors ..................................................... 10-270
assembly.................................................. 50-219 Separation and connection of track shoe
Removal and installation of ripper assembly.. 50-304 assembly (PLUS type track shoe)............... 50-235
Removal and installation of ROPS cab Separation and connection of track shoe
assembly.................................................. 50-307 assembly (Standard type track shoe) .......... 50-232
Removal and installation of seat belt............. 50-319 Servo valve .................................................. 10-15
Removal and installation of steering lubrication Simple test procedure for brake performance .. 30-49
pump and power train pump assembly ........ 50-289 Sketches of special tools ............................... 50-20
Removal and installation of supply pump Special functions of machine monitor.............. 30-83
assembly.................................................... 50-35 Special tool list ............................................. 50-10
Removal and installation of track frame Specification drawing ...................................... 01-3
assembly.................................................. 50-211 Specifications ............01-6, 10-7, 10-9, 10-12, 10-25
Removal and installation of track roller Sprocket ...................................................... 60-36
assembly.................................................. 50-224 Standard tightening torque table .................... 00-45
Replacing alternator belt................................ 30-40 Standard value table for engine........................ 20-3
Retrieval of disabled machine using brake Standard value table for machine ..................... 20-5
release device ............................................ 30-54 Steering lubricating oil pump and power train
Reversible valve ........................................... 10-29 pump ....................................................... 10-128
Ripper.............................................. 10-217, 60-94 Steering lubricating pump and power train
Ripper cylinder ............................................. 60-99 pump ......................................................... 60-62
Ripper PPC valve ............................. 10-194, 60-76 Suction valve................................................ 10-27
D65EX,PX,WX-17 9
Index
Sunlight sensor............................................. 80-21

Suspension ...................................... 10-112, 60-43
Symbols in electric circuit diagram.................. 90-21
Symbols in hydraulic circuit diagram................. 90-3
System component part .............................. 10-255
System diagram ........................................... 80-27
System diagram of hydraulic and mechanical
system ..................................................... 40-659
T
Table of fuel, coolant and lubricants ................ 01-38
Testing (dual) pressure switch for refrigerant ... 80-48
Testing air leakage (duct)............................... 80-39
Testing and adjusting air conditioner
compressor belt tension............................... 30-39
Testing diodes ............................................ 30-146
Testing engine speed ...................................... 30-8
Testing FRESH/RECIRC air changeover ........ 80-46
Testing procedure before troubleshooting ....... 40-14
Testing relays ............................................... 80-49
Testing sunlight sensor.................................. 80-47
Testing vent (mode) changeover .................... 80-45
Testing with self-diagnosis function................. 80-42
Tilt cylinder................................................... 60-96
Tools for testing, adjusting, and
troubleshooting ............................................. 30-4
Torque converter and PTO................... 10-45, 60-15
Torque converter relief valve .......................... 10-78
Track frame and idler cushion ............ 10-114, 60-45
Track roller ................................................... 60-49
Track shoe ................................................... 60-55
Transmission...................................... 10-51, 60-18
Transmission control valve .................. 10-64, 60-22
Transmission lubricating oil relief valve . 10-80, 60-26
Transmission, steering, and brake control ....... 10-42
Troubleshooting chart 1................................. 80-50
Troubleshooting chart 2................................. 80-51
Troubleshooting method for open circuit in
wiring harness of pressure sensor system ..... 40-30
Troubleshooting with gauge pressure ............. 80-78
T-branch box and T-branch adapter table........ 40-82
U
Universal joint..................................... 10-44, 60-14
W
Weight table ................................................. 01-30
Work equipment ............................... 10-214, 60-84
Work equipment control............................... 10-120
Work equipment lock solenoid valve... 10-201, 60-80
10 D65EX,PX,WX-17
D65EX-17,D65PX-17,D65WX-17 Bulldozer
Form No. SEN05536–01
©2011KOMATSU
ALL Rights Reserved

Printed in Japan 04–11

17355274-Komatsu D65ex-17 D65px-17 D65wx-17 Dozer Bulldozer Service Repair Workshop Manual Download SN 1001 and Up

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17355274-Komatsu D65ex-17 D65px-17 D65wx-17 Dozer Bulldozer Service Repair Workshop Manual Download SN 1001 and Up

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SEN05536-01

BULLDOZER D65EX -17

D65EX-17 1001 and up

00 Index and foreword

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

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

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

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

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

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

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

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

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

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

Foreword, safety and general information

General precautions wear welding gloves, apron, shielding goggles,

winding position on the load, which can result

• Before starting work, inspect the wire ropes,

the other wrench to the specified torque (Use a

a For tightening torques, see "Others",

How to read the shop manual

Composition of shop manual

Revision and distribution

Explanation of terms for maintenance standard

Standard dimension and tolerance

• The performance and function of products

Handling of fuel system devices

Be careful of the work environment

Cleaning off dusts

Precautions for replacing fuel filter cartridge

Handling of intake system parts

Be careful of the work environment

Handling of hydraulic equipment

Be careful of the work environment

Disassembly and maintenance work in the field

Method of disconnecting and connecting push-pull type coupler

Handling of electrical equipment

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

dry cloth or blow it with compressed air and

High-pressure water entering connector

Entry of water or mud or dirt when disconnecting a

• Check that connector pins are free from

3. Action to take after removing connectors

Deutsch connector (DT8-pin, DT12-pin)

2. Dry the inside of the connector with a dryer.

3. Perform a continuity test on the connector.

Drying wiring harness

a After completely drying the connector,

Slide, lock type (Type 2) (FRAMATOME-24)

Connection • 107 series

Pull lock type (PACKARD-2)

Push lock type (1)

Push lock type (3) Turn-housing type (Round green connector)

Example) Injection pressure control valve of

Example) Speed sensor of supply pump: G

connected to the controller.Fit an arc welding

Precautions for troubleshooting electrical

• Cover the control connectors with tape or a vinyl

• Precautions when performing arc welding

How to read electric wire code

Type, symbol, and material