Komatsu Bulldozer D65EXi-18E0 D65PXi-18E0 service & repair manual

Description Komatsu Bulldozer D65EXi-18E0 D65PXi-18E0 service & repair manual

Komatsu Bulldozer D65EXi-18E0, D65PXi-18E0 pdf workshop service repair manual

Serial numbers:
91845 and up
96001 and up

Specifications, maintenance, testing, technical documentation, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Discard Waste Materials
Procedures for Exhaust Gas Regulations
Precautions for DEF
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
Disconnect and Connect Connector with Lock to Pull
Disconnect and Connect Connector with Lock to Push
Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specification
Abbreviation List
Specification Drawing
Weight Table
Table of Fuel, Coolant, and Lubricants

Structure and Function
Abbreviation List
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Component Parts of Urea SCR System
Boot-up System
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal)
Layout Drawing of Boot-up System (Machine with Gateway Function Controller)
System Operating Lamp System
Battery Disconnect Switch
Engine System
Layout Drawing of Engine System
Engine Control System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Cooling Fan Control System
Component Parts of Cooling System
Control System
Layout Drawing of Control System (Machine with KOMTRAX Terminal)
Layout Drawing of Control System (Machine with Gateway Function Controller)
Machine Monitor System
KOMTRAX System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Operation of Power Train System
Transmission, Steering, and Brake Control
Palm Command Control System
HSS System
Centralized Pressure Pickup Port
Component Parts of Power Train System
Work Equipment System
Work Equipment Control
Layout of Tilt Dozer and Power Tilt Pitch Dozer Series
Layout of Power Angle Power Tilt Dozer Series
Layout Drawing of Fixed Multi-Shank Ripper
Component Parts of Work Equipment System
ICT System
Layout Drawing of ICT System
System Diagram of ICT Control System
Blade Control System
Smooth Start System
Slip Control System
Assist Control System
Component Parts of ICT System
Undercarriage and Frame
Main Frame
Suspension
Track Frame and Idler Cushion
Work Equipment
Structure of Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series)
Structure of Front Work Equipment (For Power Angle Power Tilt Dozer Series)
Structure of Fixed Multi-Shank Ripper
CAB Related Parts
ROPS CAB
CAB Mount

Standard Value Table
Abbreviation List
Standard Value Table for Engine
Standard Value Table for Machine
Machine Posture and Procedures to Measure Performance
Standard Value Table for Electricity

Testing and Adjusting
Precautions Before Work
Abbreviation List
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine Mass Air Flow and Temperature Sensor
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine EGR Valve and VGT Oil Pressure
Examine Fuel Pressure
Examine Fuel Discharge, Return and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Examine and Adjust Air Conditioner Compressor Belt Tension
Examine Alternator Belt
Examine Automatic Tensioner
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine SCR Related Functions
Clean DEF Tank
Clean DEF Tank Mounting Part
Clean DEF Pump
Adjust Decelerator Pedal
Power Train
Examine Power Train Oil Pressure
Adjust Transmission Output Shaft Speed Sensor
Examine Brake Performance Simply
Adjust Brake Pedal
Adjust Parking Brake Lever
Move Machine by Parking Brake Release When Machine Does Not Travel
Undercarriage and Frame
Adjust Idler Clearance
Examine and Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
Examine and Adjust Work Equipment and HSS Oil Pressure
Examine Oil Pressure of Control Circuit
Examine PPC Valve Outlet Pressure
Bleed Air from HSS Pump
Examine and Adjust Play of Work Equipment PPC Valve
Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
Bleed Air in Cooling Fan Pump
Examine Parts Which Cause Hydraulic Drift of Work Equipment
Examine Oil Leakage from Work Equipment Cylinder
Bleed Air from Work Equipment Cylinders
Work Equipment
Adjust Work Equipment Lock Lever
CAB Related Parts
Examine and Adjust Operator Cab
Electrical System
Set and Operate Machine Monitor
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)
Start Up KOMTRAX System (Machine with Gateway Function Controller)
Stop Use of KOMTRAX System (Machine with Gateway Function Controller)
Adjust When Power Train Controller is Replaced
Adjust Rearview Camera Angle
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal)
Handle Battery Disconnect Switch (Machine with Gateway Function Controller)
Examine Diodes
ICT System
Set and Operate Control Box
Calibrate Blade Edge Position (SIGMA Power Tilt Pitch Dozer)
Calibrate Blade Edge Position (SIGMADOZER, Straight Tilt Dozer, Power Angle Power Tilt Dozer)
Calibrate IMU Sensor
Reset Cylinder Stroke End (SIGMA Power Tilt Pitch Dozer, SIGMADOZER, Semi-U Dozer Straight Tilt Dozer)
Reset Cylinder Stroke End (Power Angle Power Tilt Dozer)
Set Standard Angle of Blade Edge
How to Input Wear Volume of Blade Edge and Track Shoes
Examine and Adjust Blade Elevation
Examine Stroke Sensor for Lift Cylinder
Examine Stroke Sensor for Tilt Cylinder
Examine Stroke Sensor for Angle Cylinder
Examine and Adjust Reset Sensor for Lift Cylinder
Adjust When ICT Sensor Controller is Replaced
Adjust When ICT Related Devices are Repaired or Replaced (SIGMA Power Tilt Pitch Dozer)
Adjust When ICT Related Devices are Repaired or Replaced (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)
Adjust When ICT Related Devices are Repaired or Replaced (Power Angle Power Tilt Dozer)
Pm Clinic
Pm Clinic Service

Troubleshooting
Precautions Before Work
Abbreviation List
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness
Connector List and Layout (Machine with KOMTRAX Terminal)
Connector List and Layout (Machine with Gateway Function Controller)
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table (Machine with KOMTRAX Terminal)
Fuse Location Table (Machine with Gateway Function Controller)
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Troubleshooting of Engine (S-Mode)

Disassembly and Assembly
Precautions Before Work
Abbreviation List
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Alternator Belt
Remove and Install Automatic Tensioner
Remove and Install Expansion Tank Assembly
Remove and Install Radiator Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
Remove and Install Power Train Oil Cooler Assembly
Remove and Install Cooling Fan Drive Assembly
Remove and Install Cooling Fan Motor Assembly
Remove and Install Engine Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
Remove and Install DEF Tank Strainer
Remove and Install KDPF Assembly
Disassemble and Assemble KDPF Assembly
Remove and Install SCR Assembly
Remove and Install KDPF and SCR Assembly
Remove and Install KCCV Assembly
Remove and Install DEF Mixing Tube
Remove and Install DEF Injector
Remove and Install DEF Pump
Remove and Install DEF Hose
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Remove and Install Damper Assembly
Remove and Install Power Train Unit Assembly
Disconnect and Connect Power Train Unit Assembly
Disassemble and Assemble PTO Assembly
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Disassemble and Assemble HSS Assembly
Remove and Install HSS Motor Assembly
Remove and Install Final Drive Assembly
Disassemble and Assemble Final Drive Assembly
Undercarriage and Frame
Remove and Install Track Frame Assembly
Remove and Install Idler Assembly
Disassemble and Assemble Idler Assembly
Remove and Install Recoil Spring Assembly
Disassemble and Assemble Recoil Spring Assembly
Remove and Install Track Roller Assembly
Disassemble and Assemble Track Roller Assembly
Remove and Install Carrier Roller Assembly
Disassemble and Assemble Carrier Roller Assembly
Remove and Install Pivot Shaft Assembly
Separate and Connect PLUS Type Track Assembly
Disassemble and Assemble Track Assembly Generally
Disassemble and Assemble PLUS Type Track Assembly Generally
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly)
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)
Remove and Install Equalizer Bar Assembly
Disassemble and Assemble Equalizer Bar Bushing
Hydraulic System
Remove and Install Hydraulic Tank Assembly
Remove and Install HSS Pump and Cooling Fan Pump Assembly
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly
Remove and Install Scavenging Pump Assembly
Remove and Install 5 Spool Control Valve Assembly
Remove and Install 4 Spool Control Valve Assembly
Disassemble and Assemble Blade PPC Valve
Disassemble and Assemble Ripper PPC Valve
Work Equipment
Remove and Install Straight Tilt Power Pitch Dozer Blade Assembly
Remove and Install Power Angle Power Tilt Dozer Blade Assembly
Remove and Install Ripper Assembly
Remove and Install Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series)
Remove and Install Stroke Sensing Blade Lift Cylinder Assembly (For Power Angle Power Tilt Dozer Series)
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly
Remove and Install Stroke Sensing Blade Tilt Cylinder Assembly
Disassemble and Assemble Stroke Sensing Blade Tilt Cylinder Assembly
Remove and Install Stroke Sensing Blade Angle Cylinder Assembly
Disassemble and Assemble Stroke Sensing Blade Angle Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
How to Remove and Install Seat Belt
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Power Train Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
Remove and Install SCR Temperature Sensor
Remove and Install Rearview Camera
Remove and Install KOMTRAX Terminal Assembly
Remove and Install Gateway Function Controller Assembly
Remove and Install Communication Terminal
Remove and Install ICT Sensor Controller Assembly
Remove and Install Control Box
Remove and Install GNSS Receiver
Remove and Install GNSS Antenna
Remove and Install IMU Sensor

Maintenance Standard
Abbreviation List
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Cooling System
Maintenance Standard for Cooling Fan Pump
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Universal Joint
Maintenance Standard for Power Train Mount
Maintenance Standard for Torque Converter and PTO
Maintenance Standard for Lockup Clutch ECMV
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve
Maintenance Standard for Transmission Lubrication Relief Valve
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake
Maintenance Standard for Brake Valve
Maintenance Standard for Final Drive
Maintenance Standard for Sprocket for Conventional Type Track Shoes
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes
Maintenance Standard for Sprocket for PLUS Type Track Shoes
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes
Undercarriage and Frame
Maintenance Standard for Main Frame
Maintenance Standard for Suspension
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type)
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type)
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes
Maintenance Standard for Conventional Type Track Shoes
Maintenance Standard for PLUS Type Track Shoes
Maintenance Standard for Single Shoes
Maintenance Standard for Swamp Shoes
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Scavenging Pump
Maintenance Standard for Steering Lubrication Pump and Power Train Pump
Maintenance Standard for Work Equipment and HSS Pump
Maintenance Standard for PC-EPC Valve
Maintenance Standard for HSS Motor
Maintenance Standard for Control Valve
Maintenance Standard for Blade PPC Valve
Maintenance Standard for Ripper PPC Valve
Maintenance Standard for Angle Control EPC Valve
Maintenance Standard for Quick Drop Valve
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Tilt Dozer Series)
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Tilt Pitch Dozer Series)
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Angle Power Tilt Dozer Series)
Work Equipment
Maintenance Standard for Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series)
Maintenance Standard for Front Work Equipment (For Power Angle Power Tilt Dozer Series)
Maintenance Standard for Cutting Edge and End Bit
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series)
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder (For Power Angle Power Tilt Dozer Series)
Maintenance Standard for Blade Tilt Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series)
Maintenance Standard for Stroke Sensing Blade Tilt Cylinder (For Power Angle Power Tilt Dozer Series)
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series)
Maintenance Standard for Stroke Sensing Blade Angle Cylinder (For Power Angle Power Tilt Dozer Series)
Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder (Tilt Dozer, Semi-U Dozer, Power Tilt Pitch Dozer Series)
Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder (For Power Angle Power Tilt Dozer Series)
Maintenance Standard for Stroke Sensor for Blade Tilt Cylinder (For Power Angle Power Tilt Dozer Series)
Maintenance Standard for Stroke Sensor for Blade Angle Cylinder (For Power Angle Power Tilt Dozer Series)
Maintenance Standard for Fixed Multi-Shank Ripper
Maintenance Standard for Ripper Lift Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount

Appendix
Precautions Before Work
Abbreviation List
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Explanation for Test of Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Dual) Pressure Switch
How to Examine Refrigerant (Dual) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting Table
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil

Circuit Diagrams
Abbreviation List
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (For Tilt Dozer Series)
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer Series)
Hydraulic Circuit Diagram (For Power Angle Power Tilt Dozer Series)
Power Train Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

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