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

Komatsu d65 EX 16 dozer bulldozer service repair manual sn 80001 and up,Table of Contents:
Comprehensive listing of topics including specifications, technical data, maintenance standards, operation procedures, and troubleshooting guides associated with the bulldozer.
Safety Notices and General Information:
Emphasizes the importance of safety during operation and maintenance, with warnings and precautions to prevent accidents.

1. BULLDOZER
SEN04887-05
D65EX
-16
D65PX
-16
D65WX
-16
SERIAL NUMBERS
D65EX- 80001
D65PX- 80001
D65WX-80001
and up
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2. SEN04931-05
00-100 4 D65EX, PX, WX-16
Table of contents
100 Index
Table of contents 1
00 Index and foreword
100 Index ..........................................................................................................................................SEN04931-05
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information .............................................................................................SEN04932-01
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code ...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 General
100 Specification and technical data.................................................................................................SEN04933-00
Specification dimension drawing ................................................................................................................... 2
Specifications ................................................................................................................................................ 6
Weight table .................................................................................................................................................. 18
Table of fuel, coolant and lubricants.............................................................................................................. 22
10 Structure, function and maintenance standard
100 Engine and cooling system ........................................................................................................SEN04963-00
Engine mount ................................................................................................................................................ 3
Cooling system.............................................................................................................................................. 4
Cooling fan pump .......................................................................................................................................... 6
Cooling fan motor.......................................................................................................................................... 20
201 Power train, Part 1 .....................................................................................................................SEN04964-00
Power train .................................................................................................................................................... 2
HSS system .................................................................................................................................................. 4
Overall view of power train unit ..................................................................................................................... 6
Power train hydraulic piping diagram ............................................................................................................ 10
Transmission, steering and brake control ..................................................................................................... 12
Damper ......................................................................................................................................................... 14
Universal joint................................................................................................................................................ 16
Torque converter and PTO............................................................................................................................ 17
Transmission ................................................................................................................................................. 24
Transmission control valve............................................................................................................................ 42
ECMV............................................................................................................................................................ 46
Main relief and torque converter relief valve ................................................................................................. 54
Transmission lubrication relief valve ............................................................................................................. 56
202 Power train, Part 2 .....................................................................................................................SEN04965-00
Bevel gear shaft, HSS and brake.................................................................................................................. 2
Brake valve ................................................................................................................................................... 24
Final drive...................................................................................................................................................... 30
300 Undercarriage and frame ...........................................................................................................SEN04966-01
Main frame .................................................................................................................................................... 2
Suspension ................................................................................................................................................... 4
Track frame and idler cushion ....................................................................................................................... 14
Idler ............................................................................................................................................................... 18
Track roller .................................................................................................................................................... 20
Carrier roller .................................................................................................................................................. 24
Sprocket ........................................................................................................................................................
26

3. SEN04931-05
D65EX, PX, WX-16 00-100 5
Table of contents
100 Index
Track shoe ..................................................................................................................................................... 30
401 Hydraulic system, Part 1 ........................................................................................................... SEN04967-00
Work equipment hydraulic system layout drawing ........................................................................................ 2
Work equipment control................................................................................................................................. 6
Hydraulic tank and filter ................................................................................................................................. 8
Scavenging pump.......................................................................................................................................... 10
Power train and steering lubrication pump .................................................................................................... 11
HSS pump ..................................................................................................................................................... 12
HSS motor ..................................................................................................................................................... 31
402 Hydraulic system, Part 2 ........................................................................................................... SEN04968-01
Control valve.................................................................................................................................................. 2
CLSS ............................................................................................................................................................. 11
Function and operation of each valve............................................................................................................ 14
403 Hydraulic system, Part 3 ........................................................................................................... SEN04969-00
PPC valve (blade lift, blade tilt)...................................................................................................................... 2
PPC valve (ripper) ......................................................................................................................................... 8
Electric lever (steering).................................................................................................................................. 12
Quick drop valve............................................................................................................................................ 16
Work equipment lock solenoid valve ............................................................................................................. 18
Pitch selector solenoid valve ......................................................................................................................... 22
Hydraulic oil cooler bypass valve .................................................................................................................. 23
Accumulator................................................................................................................................................... 24
500 Work equipment ........................................................................................................................ SEN04970-00
Blade ............................................................................................................................................................. 2
Cutting edge and end bit ............................................................................................................................... 8
Ripper ............................................................................................................................................................ 10
Hydraulic cylinder .......................................................................................................................................... 11
Piston valve ................................................................................................................................................... 14
600 Cab and its attachments............................................................................................................ SEN04971-00
Cab mount ..................................................................................................................................................... 2
Cab ................................................................................................................................................................ 3
700 Electrical system ....................................................................................................................... SEN04972-00
Monitor system .............................................................................................................................................. 2
Engine control system ................................................................................................................................... 18
Cooling system control system...................................................................................................................... 21
Electronic steering control system................................................................................................................. 23
KOMTRAX system ........................................................................................................................................ 26
System components ...................................................................................................................................... 28
Sensor ........................................................................................................................................................... 36
20 Standard value table
100 Standard service value table ..................................................................................................... SEN05118-01
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 4
30 Testing and adjusting
101 Testing and adjusting, Part 1 ..................................................................................................... SEN05119-02
Tools for testing, adjusting, and troubleshooting ........................................................................................... 2
Testing engine speed..................................................................................................................................... 5
Testing intake air pressure (boost pressure) ................................................................................................. 7
Testing exhaust temperature ......................................................................................................................... 9
Testing exhaust gas color .............................................................................................................................. 11
Adjusting valve clearance.............................................................................................................................. 12
Testing compression pressure....................................................................................................................... 14
Te
sting blow-by pressure............................................................................................................................... 18
Testing engine oil pressure............................................................................................................................ 19

4. SEN04931-05
00-100 6 D65EX, PX, WX-16
Table of contents
100 Index
Handling of fuel system devices.................................................................................................................... 20
Releasing residual pressure from fuel system .............................................................................................. 20
Testing fuel pressure ..................................................................................................................................... 21
Testing fuel return and leak amount .............................................................................................................. 26
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing fuel circuit for leakage....................................................................................................................... 29
Handling of reduced cylinder mode operation............................................................................................... 30
Handling of no injection cranking operation .................................................................................................. 30
Testing and adjusting air conditioner compressor belt tension...................................................................... 31
Replacing alternator belt ............................................................................................................................... 32
Adjusting fuel control dial and decelerator pedal .......................................................................................... 33
Handling controller high-voltage circuit ......................................................................................................... 34
102 Testing and adjusting, Part 2......................................................................................................SEN05120-01
Testing power train oil pressure .................................................................................................................... 3
Adjusting transmission output shaft speed sensor (replacement procedure) ............................................... 8
Simple test procedure for brake performance............................................................................................... 9
Adjusting brake pedal.................................................................................................................................... 10
Adjusting parking brake lever........................................................................................................................ 12
Emergency escape method when power train has trouble ...........................................................................14
Adjusting clearance of idler ........................................................................................................................... 17
Inspecting wear of sprocket .......................................................................................................................... 18
Testing and adjusting track shoe tension ...................................................................................................... 19
Testing and adjusting work equipment and HSS oil pressure .......................................................................20
Testing control circuit basic pressure ............................................................................................................ 23
Testing PPC valve output pressure ............................................................................................................... 24
Adjusting work equipment PPC valve play.................................................................................................... 26
Testing internal leakage of work equipment cylinder..................................................................................... 30
Bleeding air from work equipment cylinder ................................................................................................... 31
Releasing residual pressure from work equipment cylinder.......................................................................... 31
Checking parts which caused hydraulic drift of blade or ripper ..................................................................... 32
Adjusting work equipment lock lever............................................................................................................. 33
Testing fan speed .......................................................................................................................................... 34
Testing fan circuit oil pressure....................................................................................................................... 35
Bleeding air from fan pump ........................................................................................................................... 36
Bleeding air from HSS pump......................................................................................................................... 37
Adjusting straight tiltdozer ............................................................................................................................. 38
Adjusting play of blade center ball ................................................................................................................ 40
Adjusting operator’s cab................................................................................................................................ 41
103 Testing and adjusting, Part 3......................................................................................................SEN05121-02
Special functions of machine monitor (EMMS) ............................................................................................. 2
104 Testing and adjusting, Part 4......................................................................................................SEN05122-01
Handling of voltage circuit of engine controller ............................................................................................. 2
Adjustment method when controller has been replaced ............................................................................... 3
Preparation work for troubleshooting of electrical system............................................................................. 5
Inspection procedure of diode....................................................................................................................... 9
Pm-Clinic service .......................................................................................................................................... 10
40 Troubleshooting
100 Failure code table and fuse locations ........................................................................................SEN05029-01
Failure codes table........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 7
200 General information on troubleshooting.....................................................................................SEN05030-01
Points to remember when troubleshooting.................................................................................................... 2
How to proc
eed troubleshooting ................................................................................................................... 3
Checks before troubleshooting ..................................................................................................................... 4
Classification and procedures for troubleshooting ........................................................................................ 6
Symptom supposed to be failure and troubleshooting No. ........................................................................... 10

5. SEN04931-05
D65EX, PX, WX-16 00-100 7
Table of contents
100 Index
Information contained in troubleshooting table.............................................................................................. 12
Troubleshooting method for disconnecting wiring harness of pressure sensor system ................................ 14
Connector list and stereogram ...................................................................................................................... 16
Connection table for connector pin numbers................................................................................................. 30
T- branch box and T- branch adapter table ................................................................................................... 66
301 Troubleshooting by failure code (Display of code), Part 1......................................................... SEN05031-00
Failure code [1500L0] Transmission clutch: Abnormal.................................................................................. 3
Failure code [15SAL1] Forward clutch: Fill high ............................................................................................ 4
Failure code [15SALH] Forward clutch: Fill low............................................................................................. 6
Failure code [15SBL1] Reverse clutch: Fill high............................................................................................ 8
Failure code [15SBLH] Reverse clutch: Fill low............................................................................................. 10
Failure code [15SEL1] Speed 1st clutch: Fill high ......................................................................................... 12
Failure code [15SELH] Speed 1st clutch: Fill low .......................................................................................... 14
Failure code [15SFL1] Speed 2nd clutch: Fill high ........................................................................................ 16
Failure code [15SFLH] Speed 2nd clutch: Fill low ......................................................................................... 18
Failure code [15SGL1] Speed 3rd clutch: Fill high ........................................................................................ 20
Failure code [15SGLH] Speed 3rd clutch: Fill low ......................................................................................... 22
Failure code [15SJL1] L/U: Fill high............................................................................................................... 24
Failure code [15SJLH] L/U: Fill low ............................................................................................................... 26
Failure code [AB00MA] Battery Charge Abnormal ........................................................................................ 28
Failure code [B@BAZG] Eng Oil Press Low ................................................................................................. 30
Failure code [B@BCNS] Eng Water Overheat .............................................................................................. 30
Failure code [B@CENS] T/C Oil Overheat.................................................................................................... 31
Failure code [B@HANS] Hyd Oil Overheat ................................................................................................... 31
302 Troubleshooting by failure code (Display of code), Part 2......................................................... SEN05032-01
Failure code [CA111] ECM Critical Internal Failure ....................................................................................... 3
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ..........................................................................3
Failure code [CA122] Chg Air Press Sensor High Error................................................................................ 4
Failure code [CA123] Chg Air Press Sensor Low Error................................................................................. 6
Failure code [CA131] Throttle Sensor High Error.......................................................................................... 8
Failure code [CA132] Throttle Sensor Low Error........................................................................................... 10
Failure code [CA144] Coolant Temp Sens High Error ................................................................................... 12
Failure code [CA145] Coolant Temp Sens Low Error.................................................................................... 14
Failure code [CA153] Chg Air Temp Sensor High Error ................................................................................ 16
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................. 18
Failure code [CA155] Chg Air Temp High Speed Derate............................................................................... 20
Failure code [CA187] Sens Supply 2 Volt Low Error ..................................................................................... 22
Failure code [CA221] Ambient Press Sens High Error.................................................................................. 24
Failure code [CA222] Ambient Press Sens Low Error................................................................................... 26
Failure code [CA227] Sens Supply 2 Volt High Error .................................................................................... 28
Failure code [CA234] Eng Overspeed........................................................................................................... 28
Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................... 29
Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 30
Failure code [CA272] IMV/PCV1 Open Error ................................................................................................ 32
Failure code [CA281] Abnormal supply pump pressure balance .................................................................. 34
Failure code [CA322] Inj #1(L#1) Open/Short Error ...................................................................................... 36
Failure code [CA323] Inj #5(L#5) Open/Short Error ...................................................................................... 38
Failure code [CA324] Inj #3(L#3) Open/Short Error ...................................................................................... 40
Failure code [CA325] Inj #6(L#6) Open/Short Error ...................................................................................... 42
Failure code [CA331] Inj #2(L#2) Open/Short Error ...................................................................................... 44
Failure code [CA332] Inj #4(L#4) Open/Short Error ...................................................................................... 46
303 Troubleshooting by failure code (Display of code), Part 3......................................................... SEN05033-01
Failure code [CA342] Calibrati
on Code Incompatibility ................................................................................. 3
Failure code [CA351] Injectors Drive Circuit Error......................................................................................... 3
Failure code [CA352] Sens Supply 1 Volt Low Error ..................................................................................... 4
Failure code [CA386] Sens Supply 1 Volt High Error .................................................................................... 6
Failure code [CA428] Water in Fuel Sensor High Error................................................................................. 8
Failure code [CA429] Water in Fuel Sensor Low Error.................................................................................. 10

6. SEN04931-05
00-100 8 D65EX, PX, WX-16
Table of contents
100 Index
Failure code [CA435] Eng Oil Press Sw Error .............................................................................................. 12
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 14
Failure code [CA442] Battery Voltage High Error.......................................................................................... 16
Failure code [CA449] Rail Press Very High Error ......................................................................................... 18
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 20
Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 22
Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................. 24
Failure code [CA553] Rail Press High Error.................................................................................................. 25
Failure code [CA559] Rail Press Low Error .................................................................................................. 26
Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error ...........................................................................32
Failure code [CA757] All Continuous Data Lost Error................................................................................... 33
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 34
Failure code [CA1633] KOMNET Datalink Timeout Error .............................................................................37
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 38
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 40
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 42
Failure code [CA2265] Fuel Feed Pump Open Error .................................................................................... 44
Failure code [CA2266] Fuel Feed Pump Short Error .................................................................................... 46
Failure code [CA2311] IMV Solenoid Error ................................................................................................... 47
Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 48
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................................... 50
304 Troubleshooting by failure code (Display of code), Part 4 .........................................................SEN05034-01
Failure code [D110KB] Battery relay drive: Short circuit ............................................................................... 4
Failure code [D130KA] Neutral relay: Disconnection .................................................................................... 6
Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 8
Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................10
Failure code [D161KB] Back-up alarm relay: Short circuit ............................................................................ 12
Failure code [D862KA] GPS Antenna Open Circuit ...................................................................................... 14
Failure code [DAFRKR] CAN Disconnection ................................................................................................ 15
Failure code [DAFRMC] CAN Discon (Monitor Detected).............................................................................16
Failure code [DB2RKR] CAN Disconnection................................................................................................. 19
Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 24
Failure code [DBE1KK] Battery direct Source voltage reduction ..................................................................26
Failure code [DBE2KK] Solenoid Source voltage reduction .........................................................................28
Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction .............................................................. 30
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction.................................................................. 32
Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction .............................................................. 34
Failure code [DBE9KQ] PT controller: Type select signal............................................................................. 36
Failure code [DD12KA] Shift up Sw: Disconnection...................................................................................... 38
Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 40
Failure code [DD13KA] Shift down Sw: Disconnection ................................................................................. 42
Failure code [DD13KB] Shift down Sw: Short circuit..................................................................................... 44
Failure code [DD14KA] Parking lever Sw: Disconnection............................................................................. 46
Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 48
305 Troubleshooting by failure code (Display of code), Part 5 .........................................................SEN05035-00
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ................................................................... 4
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit....................................................................... 6
Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection........................................................................ 8
Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit ...........................................................................10
Failure code [DDNLKA] Weq lock Sw: Disconnection .................................................................................. 12
Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................... 14
Failure code [DGS1KX] Hyd oil temp sensor: Abnormal............................................................................... 16
Failure code [DGT
1KA] T/C oil temp sensor: Disconnection ........................................................................18
Failure code [DGT1KX] T/C oil temp sensor: Short circuit ............................................................................ 20
Failure code [DH21KA] Weq pressure sensor: Disconnection...................................................................... 22
Failure code [DH21KB] Weq pressure sensor: Short circuit ......................................................................... 24
Failure code [DHT5KA] T/C pressure sensor: Disconnection .......................................................................26

7. SEN04931-05
D65EX, PX, WX-16 00-100 9
Table of contents
100 Index
Failure code [DHT5KB] T/C pressure sensor: Short circuit ........................................................................... 28
Failure code [DK10KA] Fuel control Dial: Disconnection .............................................................................. 30
Failure code [DK10KB] Fuel control Dial: Short circuit .................................................................................. 32
Failure code [DK30KA] ST lever 1: Disconnection ........................................................................................ 34
Failure code [DK30KB] ST lever 1: Short circuit............................................................................................ 36
Failure code [DK30KX] ST lever: Out of normal range.................................................................................. 38
Failure code [DK30KZ] ST lever: Disconnection or short circuit.................................................................... 38
Failure code [DK30L8] ST lever: Signal mismatch ........................................................................................ 39
Failure code [DK31KA] ST lever 2: Disconnection ........................................................................................ 40
Failure code [DK31KB] ST lever 2: Short circuit............................................................................................ 42
Failure code [DK40KA] Brake potentiometer: Disconnection ........................................................................44
Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................ 46
Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 48
Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 48
Failure code [DK55L8] FR lever: Signal mismatch........................................................................................ 49
Failure code [DK56KA] FR lever 1: Disconnection........................................................................................ 50
Failure code [DK56KB] FR lever 1: Short circuit ........................................................................................... 52
Failure code [DK57KA] FR lever 2: Disconnection........................................................................................ 54
Failure code [DK57KB] FR lever 2: Short circuit ........................................................................................... 56
306 Troubleshooting by failure code (Display of code), Part 6......................................................... SEN05036-01
Failure code [DKH1KA] Pitch angle sensor: Disconnection .......................................................................... 4
Failure code [DKH1KB] Pitch angle sensor: Short circuit.............................................................................. 6
Failure code [DLT3KA] T/M out-speed sensor: Disconnection......................................................................8
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................. 9
Failure code [DW5AKA] Pitch selector Sol.: Disconnection .......................................................................... 10
Failure code [DW5AKB] Pitch selector Sol.: Short circuit.............................................................................. 11
Failure code [DW5AKY] Pitch selector Sol.: Short circuit.............................................................................. 12
Failure code [DW7BKA] Fan rev EPC: Disconnection .................................................................................. 14
Failure code [DW7BKB] Fan rev EPC: Short circuit ...................................................................................... 15
Failure code [DWN1KA] Hss EPC1: Disconnection ...................................................................................... 16
Failure code [DWN1KB] Hss EPC1: Short circuit.......................................................................................... 17
Failure code [DWN1KY] Hss EPC1: Short circuit.......................................................................................... 18
Failure code [DWN2KA] Hss EPC2: Disconnection ...................................................................................... 19
Failure code [DWN2KB] Hss EPC2: Short circuit.......................................................................................... 20
Failure code [DWN2KY] Hss EPC2: Short circuit.......................................................................................... 21
Failure code [DWN5KA] Fan pump solenoid: Disconnection ........................................................................ 22
Failure code [DWN5KB] Fan pump solenoid: Short circuit............................................................................ 23
Failure code [DWN5KY] Fan control solenoid: Short circuit .......................................................................... 24
Failure code [DXA0KA] TVC Sol.: Disconnection.......................................................................................... 26
Failure code [DXA0KB] TVC Sol.: Short circuit ............................................................................................. 27
Failure code [DXA0KY] TVC Sol.: Short circuit ............................................................................................. 28
Failure code [DXH1KA] Lock-up ECMV: Disconnection................................................................................ 29
Failure code [DXH1KB] Lock-up ECMV: Short circuit ................................................................................... 30
Failure code [DXH1KY] Lock-up ECMV: Short circ
uit ................................................................................... 32
Failure code [DXH4KA] 1st clutch ECMV: Disconnection ............................................................................. 34
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ................................................................................. 35
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ................................................................................. 36
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ............................................................................37
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit................................................................................ 38
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit................................................................................ 39
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ............................................................................. 40
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................. 41
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit................................................................................. 42
Failure code [DXH7KA] R clutch ECMV: Disconnection................................................................................ 43
Failure code [DXH7KB] R clutch ECMV: Short circuit ................................................................................... 44
Failure code [DXH7KY] R clutch ECMV: Short circuit ................................................................................... 46
Failure code [DXH8KA] F clutch ECMV: Disconnection ................................................................................ 48
Failure code [DXH8KB] F clutch ECMV: Short circuit.................................................................................... 49

8. SEN04931-05
00-100 10 D65EX, PX, WX-16
Table of contents
100 Index
Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................................... 50
Failure code [DXJ4KA] Weq lock Sol.: Disconnection .................................................................................. 52
Failure code [DXJ4KB] Weq lock Sol.: Short circuit...................................................................................... 53
400 Troubleshooting of electrical system (E-mode)..........................................................................SEN05037-01
Before troubleshooting of electrical system .................................................................................................. 3
Information in troubleshooting table .............................................................................................................. 5
E-1 Engine does not start (starting motor does not turn) .............................................................................. 7
E-2 Preheater does not operate.................................................................................................................... 10
E-3 When starting switch is turned ON, machine monitor displays nothing.................................................. 16
E-4 When starting switch is turned ON (before starting engine), basic check item lights up ........................ 18
E-5 Precaution item lights up while engine is running................................................................................... 20
E-6 Emergency stop item lights up while engine is running.......................................................................... 22
E-7 Engine coolant temperature gauge does not indicate normally.............................................................. 24
E-8 Fuel gauge does not indicate properly ................................................................................................... 26
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 29
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 30
E-11 Contents of display by machine monitor are different from applicable machine................................... 31
E-12 Machine monitor does not display some items..................................................................................... 31
E-13 Function switch does not work ............................................................................................................. 31
E-14 Operation mode does not change ........................................................................................................ 32
E-15 Gearshift mode does not change ......................................................................................................... 32
E-16 Customize function does not operate normally .................................................................................... 33
E-17 Customize memory function does not operate normally ...................................................................... 33
E-18 Alarm buzzer does not sound or does not stop .................................................................................... 34
E-19 When starting switch is turned OFF, service meter is not displayed .................................................... 34
E-20 Machine monitor cannot be set in service mode .................................................................................. 34
E-21 Horn does not sound or does not stop ................................................................................................. 35
E-22 Back-up alarm does not sound or does not stop .................................................................................. 36
E-23 Head lamp or rear lamp does not light up ............................................................................................ 38
E-24 Windshield wiper does not operate ...................................................................................................... 42
E-25 Window washer does not operate ........................................................................................................ 56
E-26 KOMTRAX system does not operate correctly..................................................................................... 61
500 Troubleshooting of hydraulic and mechanical system (H-mode) ...............................................SEN05038-00
Failure mode and cause table....................................................................................................................... 2
Contents of troubleshooting table ................................................................................................................. 4
H-1 There is no travel power (no drawbar pull)............................................................................................. 5
H-2 Machine does not move (at 2nd or 3rd speed)....................................................................................... 6
H-3 Machine does not move at any gear speed ........................................................................................... 7
H-4 Machine travels only in one direction, forward or in reverse .................................................................. 8
H-5 When gear is shifted or travel direction is changed, large time lag is made .......................................... 9
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) ........................................... 10
H-7 Steering speed or power is low .............................................................................................................. 10
H- 8 Brake does not work.............................................................................................................................. 11
H-9 Overheat of power train oil ..................................................................................................................... 12
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor................... 13
H-11 All work equipment speeds are slow .................................................................................................... 13
H-12 Work equipment does not move........................................................................................................... 14
H-13 Blade lift speed is slow or lacks power................................................................................................. 14
H-14 Blade tilt speed is slow or lacks power................................................................................................. 15
H-15 Ripper lift speed is slow or lacks power ............................................................................................... 15
H-16 Excessive hydraulic drift of blade lift..................................................................................................... 16
H-17 Excessive hydraulic drift of blade tilt .................................................................................................... 16
H-18 Excessive hydraulic drift of ripper lift .................................................................................................... 17
600 Troubleshooting of engine (S-mode)..........................................................................................SEN05039-00
Method of using troubleshooting charts ........................................................................................................ 3
S-1 Starting performance is poor................................................................................................................... 6
S-2 Engine does not start.............................................................................................................................. 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10

9. SEN04931-05
D65EX, PX, WX-16 00-100 11
Table of contents
100 Index
S-4 Engine stops during operations .............................................................................................................. 11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ...................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) .................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive ............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)................................................... 18
S-12 Oil pressure drops................................................................................................................................. 19
S-13 Oil level rises (water, fuel in oil) ............................................................................................................ 20
S-14 Coolant temperature becomes too high (overheating).......................................................................... 21
S-15 Abnormal noise is made ....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
50 Disassembly and assembly
100 General information on disassembly and assembly.................................................................. SEN05110-00
How to read this manual................................................................................................................................ 2
Coating materials list ..................................................................................................................................... 4
Special tool list............................................................................................................................................... 7
Sketches of special tools ............................................................................................................................... 16
200 Engine and cooling system ........................................................................................................SEN05111-00
Removal and installation of fuel supply pump assembly ............................................................................... 2
Removal and installation of fuel injector assembly........................................................................................ 7
Removal and installation of cylinder head assembly..................................................................................... 17
Removal and installation of radiator assembly .............................................................................................. 32
Removal and installation of aftercooler assembly ......................................................................................... 35
Removal and installation of hydraulic oil cooler assembly ............................................................................ 37
Removal and installation of power train oil cooler assembly ......................................................................... 39
Removal and installation of cooling fan drive assembly ................................................................................ 42
Removal and installation of cooling fan motor assembly............................................................................... 44
Removal and installation of engine assembly ............................................................................................... 46
Removal and installation of damper assembly .............................................................................................. 54
Removal and installation of engine front oil seal ........................................................................................... 57
Removal and installation of engine rear oil seal ............................................................................................ 61
Removal and installation of engine hood assembly ...................................................................................... 69
Removal and installation of fuel tank assembly............................................................................................. 71
300 Power train ................................................................................................................................ SEN05112-00
Removal and installation of power train unit assembly.................................................................................. 2
Separation and connection of power train unit assembly .............................................................................. 6
Disassembly and assembly of PTO assembly............................................................................................... 11
Disassembly and assembly of torque converter assembly............................................................................ 16
Disassembly and assembly of transmission assembly.................................................................................. 27
Disassembly and assembly of HSS assembly .............................................................................................. 54
Removal and installation of final drive assembly........................................................................................... 74
Disassembly and assembly of final drive assembly ...................................................................................... 76
400 Undercarriage and frame .......................................................................................................... SEN05113-01
Removal and installation of track frame assembly ........................................................................................ 2
Removal and installation of idler assembly ................................................................................................... 4
Disassembly and assembly of idler assembly ............................................................................................... 6
Removal and installation of recoil spring assembly....................................................................................... 10
Disassembly and assembly of recoil spring assembly .................................................................................. 11
Removal and installation of track roller assembly ......................................................................................... 15
Disassembly and assembly of track roller assembly ..................................................................................... 16
Removal and
installation of carrier roller assembly ....................................................................................... 20
Disassembly and assembly of carrier roller assembly................................................................................... 21
Expansion and installation of track shoe assembly (Conventional type track shoe) ..................................... 24
Expansion and installation of track shoe assembly (PLUS type track shoe) ................................................. 27

10. SEN04931-05
00-100 12 D65EX, PX, WX-16
Table of contents
100 Index
Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe) .............. 28
Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe).......................... 42
Field disassembly and assembly of one link (Conventional type track shoe) ............................................... 54
Field disassembly and assembly of one link (PLUS type track shoe)........................................................... 61
Removal and installation of pivot shaft assembly.......................................................................................... 66
Removal and installation of equalizer bar assembly ..................................................................................... 67
Disassembly and assembly of equalizer bar side bushing............................................................................ 69
500 Hydraulic system........................................................................................................................SEN05114-00
Removal and installation of hydraulic tank assembly.................................................................................... 2
Removal and installation of control valve assembly...................................................................................... 5
Disassembly and assembly of control valve assembly ................................................................................. 8
Disassembly and assembly of blade lift and tilt PPC valve assembly........................................................... 10
Disassembly and assembly of ripper PPC valve assembly ..........................................................................11
Removal and installation of HSS and cooling fan pump assembly ............................................................... 12
Removal and installation of power train and lubrication pump assembly...................................................... 14
Removal and installation of scavenging pump assembly.............................................................................. 16
Removal and installation of HSS motor assembly ........................................................................................ 17
Disassembly and assembly of hydraulic cylinder assembly.......................................................................... 20
600 Work equipment.........................................................................................................................SEN05115-00
Removal and installation of blade assembly (ST-TPP dozer) .......................................................................2
Removal and installation of blade assembly (PAT dozer) ............................................................................. 5
Removal and installation of ripper assembly................................................................................................. 7
700 Cab and its attachments ............................................................................................................SEN05116-00
Removal and installation of ROPS cab assembly......................................................................................... 2
Removal and installation of operator’s cab glass (Stuck glass) .................................................................... 9
Removal and installation of air conditioner unit assembly ............................................................................ 15
Removal and installation of air conditioner compressor assembly ............................................................... 19
800 Electrical system ........................................................................................................................SEN05117-00
Removal and installation of monitor panel assembly .................................................................................... 2
Removal and installation of engine controller assembly ............................................................................... 4
Removal and installation of power train controller assembly ........................................................................ 6
Removal and installation of KOMTRAX terminal assembly ..........................................................................8
80 Appendix
100 Air conditioner ............................................................................................................................SEN05041-00
Structure and function....................................................................................................................................... 4
Air conditioner component ............................................................................................................................ 4
Configuration and function of refrigerating cycle........................................................................................... 6
Outline of refrigerating cycle ......................................................................................................................... 7
Air conditioner unit ........................................................................................................................................ 10
Control plate.................................................................................................................................................. 14
Compressor................................................................................................................................................... 15
Condenser..................................................................................................................................................... 16
Receiver drier................................................................................................................................................ 17
Testing, adjusting and troubleshooting ............................................................................................................. 18
Caution about refrigerant .............................................................................................................................. 18
Troubleshooting procedure ........................................................................................................................... 19
Block diagram ............................................................................................................................................... 20
Circuit diagram and arrangement of connector pins ..................................................................................... 22
Detail of air conditioner unit........................................................................................................................... 24
Parts and connectors arrangement............................................................................................................... 26
Testing air leakage (duct) .............................................................................................................................. 32
Testing with self-diagnosis function............................................................................................................... 34
Testing temperature control........................................................................................................................... 37
Testing vent (mode) changeover................................................................................................................... 39
Testing Recirc/Fresh changeover.................................................................................................................. 42
Te
sting inner sensor ...................................................................................................................................... 43

11. SEN04931-05
D65EX, PX, WX-16 00-100 13
Table of contents
100 Index
Testing evaporator temperature sensor......................................................................................................... 44
Testing sunlight sensor .................................................................................................................................. 47
Testing (dual) pressure switch for refrigerant ................................................................................................ 48
Testing relays and diodes .............................................................................................................................. 50
Troubleshooting chart 1 ................................................................................................................................. 52
Troubleshooting chart 2 ................................................................................................................................. 53
Troubleshooting for electrical system (E mode) ............................................................................................ 56
E-1 Power supply system (Air conditioner does not operate).....................................................................57
E-2 Compressor and refrigerant system (Air is not cooled)........................................................................ 60
E-3 Blower motor system (No air comes out or air flow is abnormal)......................................................... 63
E-4 Temperature cannot be controlled ....................................................................................................... 66
E-5 Vent (mode) cannot be changed over.................................................................................................. 68
E-6 Recirc/Fresh air cannot be changed over ............................................................................................ 70
Troubleshooting with gauge pressure............................................................................................................ 72
Connection of service tool ............................................................................................................................. 75
Precautions for connecting air conditioner piping.......................................................................................... 76
Handling of compressor oil ............................................................................................................................ 77
1. Control of compressor oil (Denso: ND-OIL8: For R134a)..................................................................... 77
2. Adding of compressor oil ...................................................................................................................... 77
3. Compressor replacement ..................................................................................................................... 78
4. Applying compressor oil for O-ring ....................................................................................................... 78
90 Diagrams and drawings
100 Hydraulic diagrams and drawings .............................................................................................SEN04934-00
Power train hydraulic circuit diagram............................................................................................................. 3
Work equipment hydraulic circuit diagram..................................................................................................... 5
200 Electrical diagrams and drawings.............................................................................................. SEN04935-00
Electrical circuit diagram................................................................................................................................ 3

12. SEN04932-01
00-200 2 D65EX, PX, WX-16
200 Foreword and general information
Safety notice
Safety notice 1(Rev. 2008/08-a)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniqu
es recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol
k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
kMistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read al
l the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Main-
tenance Manual.
2) Decide a place in the repair workshop to
keep tools and re
moved parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety
shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
qAlways wear safety glasses when hit-
ting parts with a hammer.
qAlways wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers,
always agree on the oper-
ating procedure before starting. Always
inform your
fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require
license or
qualification.
6) Keep all tools in good condition, learn the
correct way to
use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
7) If welding repairs are needed, always
have a trained and ex
perienced welder
carry out the work. When carrying out
welding work, always wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
8) Before starting work, warm up your body
thoroughly to st
art work under good condi-
tion.
9) Avoid continuing work for long hours and
take rests at pro
per intervals to keep your
body in good condition. Take rests in
specified safe places.
Safety points
1Good arrangement
2Correct work clothes
3Following work standard
4Making and checking signs
5
Prohibition of operation and handling by
unlicensed wor
kers
6Safety check before starting work
7
Wearing protective goggles
(for cleaning or grinding work)
8
Wearing shielding goggles and protectors
(for welding
work)
9Good physical condition and preparation
10
Precautions against work which you are
not used to or yo
u are used to too much

13. SEN04932-01
D65EX, PX, WX-16 00-200 3
200 Foreword and general information
Safety notice
2. Preparations for work
1) Before adding oil or making any repairs,
park the machi
ne on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade,
ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, sup-
port the machine with blocks, jacks, or
stands before st
arting work.
4) Remove all mud and oil from the steps or
other places u
sed to get on and off the
machine. Always use the handrails, lad-
ders or steps when getting on or off the
machine. Never
jump on or off the
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
3. Precautions during work
1) Before disconnecting or removing compo-
nents of the oil, water, or air circuits, first
release the press
ure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine
is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on
or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. A
lways remove the lead
from the negative (–) terminal first.
5) When raising a heavy component (heavier
than 25 kg
), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pr
essure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the elec
trical wir-
ing. Damaged wiring may cause electrical
fires.
8) Whe
n removing piping, stop the fuel or oil
from spilling out. I
f any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
9) As a general rule, do not use gasoline to
wash parts.
Do not use it to clean electri-
cal parts, in particular.
10) Be sure to assemble all parts again in their
original place
s. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be dam-
aged by contact with other parts when the
machine is oper
ated.
11) When installing high pressure hoses,
make sure t
hat they are not twisted. Dam-
aged tubes are dangerous, so be
extremel
y careful when installing tubes for
high pressure circuits. In addition, check
that connecting parts are correctly
installed.
12) When assembling or installing parts,
always tighten them to the spe
cified
torques. When installing protective parts
such as guards, or parts which vibrate vio-
lently or rotate at high speed, be particu-
larly careful to check that they are
installed c
orrectly.
13) When aligning 2 holes, never insert your
fingers or
hand. Be careful not to get your
fingers caught in a hole.
14) When measuring hydraulic pressure,
check that the measur
ing tools are cor-
rectly assembled.
15) Take care when removing or installing the
tracks of tr
ack-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
16) If the engine is operated for a long time in
a place whi
ch is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.

14. SEN04932-01
00-200 4 D65EX, PX, WX-16
200 Foreword and general information
Safety notice
4. Precautions for sling work and making
signs
1) Only one appointed worker must make
signs and co-wor
kers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
qDo not stand under the load.
qDo not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting
on gloves during sling work.
(Put on leather gl
oves, if available.)
4) Measure the weight of the load by the eye
and check its ce
nter of gravity.
5) Use proper sling according to the weight
of the load and met
hod of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slun
g so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
kSlinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a da
ngerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjec
ted to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ro
pes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120°. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150°, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8) When installing wire ropes to an angular
load, apply pads to prot
ect the wire ropes.
If the load is slippery, apply proper mate-
rial to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them wi
th shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
qSlinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle por-
tion.
11) Do not use twisted or kinked wire ropes.
12) When lifting up a load, observe the follow-
ing.
qWind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
qAfter the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

15. SEN05111-00
50-200 2 D65EX, PX, WX-16
200 Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel
supply pump assembly
1
Special tools
Removal
kStop the machine on a level place and
apply the parking brake.
kLower the work equipment to the ground
and stop the engine.
kDisconnect the cable from the negative (–)
terminal of the battery.
1. Open fuel tank lower cover (1a).
2. Turn the fuel valve at the fuel tank bottom to
the “CLOSE” position.
3. Open left engine side cover (1) and lock it.
aLock the cover securely.
4. Remove cover (2).
5. Remove 2 air conditioner hose clamps (3).
6. Remove air hose clamp (4) and disconnect air
hose (5). [*1]
7. Remove 3 wiring harness clamps (6).
8. Disconnect wiring harness connectors CN-AC
(7) and CN-ACG (8) and ground cable (9).
9. Remove air conditioner compressor (10). For
details, see Testing and adjusting, “Testing and
adjusting air conditioner compressor belt ten-
sion”. [*2]
aFix air conditioner compressor (10) to the
machine with a rope.
10. Disconnect wiring harness connector (11) from
the fuel supply pump.
11. Remove hose clamp (12).
12. Disconnect overflow tube (13). [*3]
Symbol
Part No. Part name
Necessity
Q’ty
New/Remodel
Sketch
A
1795-799-1131 Gear t1
2795-799-1390 Remover t1

16. SEN05111-00
D65EX, PX, WX-16 50-200 3
200 Engine and cooling system
Removal and installation of fuel supply pump assembly
13. Remove the fuel scatter prevention caps at
both ends and disconnect fuel high-pressure
pipe (14). [*4]
14. Disconnect fuel hoses (15), (16) and (17)
according to the following procedure. [*5]
1) While pushing part (a) of fuel hose (15) in
the direction of the arrow, pull part (b) in
the direction of the arrow to disconnect the
fuel hose.
2) Disconnect fuel hoses (16) and (17) simi-
larly.
15. To remove the air conditioner hose clamp,
remove the following covers.
1) Remove cover (18).
2) Remove left step cover (19).
aRemove the cover in order to remove
air conditioner hose clamp.
16. Remove hose clamp (20).
17. Disconnect wiring harness connector CN-
AC05 (21).
18. Remove receiver drier and bracket assembly
(22).
aFix receiver drier and bracket assembly
(22) to the machine.

17. SEN05111-00
50-200 4 D65EX, PX, WX-16
200 Engine and cooling system
Removal and installation of fuel supply pump assembly
19. Remove cap (23) from the flywheel housing
and install engine cranking tool A1 (See the
special tool table).
aSee Testing and adjusting, “Adjusting
valve clearance”.
20. Loosen and remove cap (24).
aUse a filter wrench etc. to remove cap
(24).
21. Using tool A1, rotate the crankshaft forward
(counterclockwise seeing from the flywheel
side) and set stamp (M) of drive gear (GY) to
the TDC (Top Dead Center). (See the special
tool table)
aUse a mirror to check the stamp etc.
aSee Testing and adjusting, “Adjusting
valve clearance”.
22. Remove mounting nut (25) and washer (26)
from fuel supply pump shaft (SH).
aWhen removing mounting nut (25) and
washer (26), take care not to drip them
into the case.
23. Tighten tool A2 evenly to disconnect shaft (SH)
of the fuel supply pump from drive gear (GY).
24. Remove bracket (27).
25. Remove 4 mounting nuts (28) and fuel supply
pump assembly (29).

18. SEN05111-00
D65EX, PX, WX-16 50-200 5
200 Engine and cooling system
Removal and installation of fuel supply pump assembly
Installation
qInstall the fuel supply pump assembly accord-
ing to the following procedure.
1. Install fuel supply pump assembly (29) while
matching projection (P) of its shaft (SH) to
groove (G) of gear (GY).
2. Install bracket (27) to fuel supply pump assem-
bly (29).
3 Mounting bolt (27a):
65 ± 6 Nm {6.6 ± 0.6 kgm}
3 Mounting bolt (27b):
77 ± 12 Nm {7.9 ± 1.2 kgm}
3. Install 4 mounting nuts (28).
2 Mounting nut (28): Adhesive (LT-2)
3 Mounting nut (28):
43 ± 6 Nm {4.4 ± 0.6 kgm}
4. Install washer (26) and tighten mounting nut
(25).
aWhen installing mounting nut (25) and
washer (26), take care not to drip them
into the case.
3 Mounting nut (25):
180 ± 13 Nm {18.4 ± 1.3 kgm}
qCarry out the following installation in the
reverse order to removal.
[*1]
aPush in air hose (5) to the stopper of the tube
securely.
3 Air hose mounting clamp (4):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
aInstall the air conditioner compressor. For
detail, see Testing and adjusting, “Testing and
adjusting air conditioner compressor belt ten-
sion” and “Removal and installation of air con-
ditioner compressor”.
[*3]
3 Overflow tube (13) mounting joint bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}

19. SEN05111-00
50-200 6 D65EX, PX, WX-16
200 Engine and cooling system
Removal and installation of fuel supply pump assembly
[*4]
qInstall fuel high-pressure pipe (14) and install
the fuel scatter prevention caps to both ends.
aTighten the sleeve nut of fuel high-pressure
pipe (14) with the fingers at first, and then
tighten them permanently.
3 Fuel high-pressure pipe (14) sleeve nut:
37.3 ± 4 Nm {3.8 ± 0.4 kgm}
[*5]
kSince the internal parts of the installed por-
tions of fuel hoses (15), (16) and (17) may
have been damaged, replace those hoses
with new ones.
qChecking for fuel leakage (Fuel system)
Check the fuel system for leakage. For details,
see Testing and adjusting, “Checking fuel sys-
tem for leakage”.
qBleeding air (Fuel system)
Bleed air from the fuel circuit. For details, see
Testing and adjusting, “Bleeding air from fuel
circuit”.

20. SEN05111-00
D65EX, PX, WX-16 50-200 7
200 Engine and cooling system
Removal and installation of fuel injector assembly
Removal and installation of fuel
injector assembly
1
Special tools
Removal
kStop the machine on a level place and
apply the parking brake.
kLower the work equipment to the ground
and stop the engine.
kDisconnect the cable from the negative (–)
terminal of the battery.
1. Open cover (1) under the fuel tank.
2. Turn the fuel valve at the fuel tank bottom to
the “CLOSE” position.
3. Remove the engine hood assembly. For
details, see “Removal and installation of
engine hood assembly”.
4. Sling the muffler assembly temporarily.
5. Remove U-bolt (2) and mounting bolt (3). [*1]
6. Lift off muffler assembly (4).
4 Muffler assembly (4): 30 kg
7. Remove 3 air conditioner hose clamps (5).
Symbol
Part No. Part name
Necessity
Q’ty
New/Remodel
Sketch
A
1795-799-1131 Gear t1
3795-799-6700 Puller t1
4795-799-8150 Remover q1

21. SEN05111-00
50-200 8 D65EX, PX, WX-16
200 Engine and cooling system
Removal and installation of fuel injector assembly
8. Remove wiring harness clamp (6).
9. Disconnect wiring harness connectors CN-AC
(7) and CN-ACG (8) and ground cable (9).
10. Remove air conditioner compressor assembly
(10). For details, see Testing and adjusting,
“Testing and adjusting air conditioner compres-
sor belt tension”. [*2]
aFix air conditioner compressor assembly
(10) to the machine with a rope.
11. Remove tube clamp (11) and muffler water
drain tube (12).
12. Remove bracket (13).
13. Remove wiring harness clamps (14), (15) and
(16).
14. Disconnect the following wiring harness con-
nectors.
(17): CN-HTD (Disconnect from clamp)
(18): CN-WIF
(19): CN-HT/B
(20): CN-HT/A
(21): CN-HT/C
(22): Ground
15. Remove plate (23).
16. Remove hose clamp (24) and disconnect air
hose (25). [*3]
17. Disconnect wiring harness connectors CN-C8
(26) and CN-C17 (27).
18. Disconnect air tube (29). [*4]

22. SEN05111-00
D65EX, PX, WX-16 50-200 9
200 Engine and cooling system
Removal and installation of fuel injector assembly
19. Remove left step cover (30).
aRemove the left step cover to remove the
air conditioner hose clamp.
20. Remove hose clamp (31).
21. Disconnect wiring harness connector CN-
AC05 (32).
22. Remove receiver drier and bracket assembly
(33).
aFix receiver drier and bracket assembly
(33) to the machine.
23. Disconnect 2 heater hoses (34).
24. Disconnect 2 fuel hoses (35). [*5]
aWhile pushing part (c) of fuel hose (35) in
the direction of the arrow, pull part (d) in
the direction of the arrow to disconnect the
fuel hose.
25. Remove fuel filter and corrosion resistor
assembly (36).
26. Disconnect wiring harness connector CN-C4
(37).
aTo disconnect wiring harness connector
CN-C4 (37), slide lock (e) in the direction
of the arrow and pull the connector toward
you while pressing lock (f).
aEven if lock (f) is pressed, the connector
cannot be pulled out if part (g) does not
float. In this case, float part (g) with a flat-
head screwdriver while pressing lock (f)
and pull out the connector toward you to
disconnect.

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24. SEN05111-00
50-200 10 D65EX, PX, WX-16
200 Engine and cooling system
Removal and installation of fuel injector assembly
27. Remove bracket (38).
28. Remove wiring harness clamp (39).
29. Disconnect 3 fuel injector wiring harness con-
nectors CN-C9 (41).
30. Remove bracket (42).
31. Remove the fuel scatter prevention caps at
both ends and disconnect 6 fuel high-pressure
pipes (43). [*6]
32. Remove hose clamp (44) and disconnect 2
blow-by hoses (45).
33. Remove cylinder head cover (46). [*7]

25. SEN05111-00
D65EX, PX, WX-16 50-200 11
200 Engine and cooling system
Removal and installation of fuel injector assembly
34. Loosen 2 capture nuts (47) at the fuel injector
head and disconnect fuel injector wiring har-
ness (48).
aLoosen the capture nuts alternately.
aThe capture nuts are not removable from
the wiring harness.
aInstalled position of wiring harness
35. Loosen locknut (49) and loosen adjustment
screw (50) by 2 – 3 turns.
aLoosen the adjustment screw so that an
excessive force will not be applied to the
pushrod when the rocker arm is installed.
36. Remove mounting bolts (51) and rocker arm
and crosshead assembly (52).
aRecord the installed position and direction
(shapes of holes (a) and (b)) of the cross-
head. (Install the crosshead in the
recorded direction)
37. Remove retainer (53) and inlet connector (54).
aBefore removing retainer (53), remove all
dirt and sand sticking to and around the
retainer.
aTool A4 (remover) is set for removing inlet
connector (54). (See the special tool table)
38. Remove 2 fuel injector holder mounting bolts
(55).
39. Using tool A3 , remove fuel injector holder (56)
and fuel injector assembly (57) together.
aTake care that dirt and foreign matter will
not enter the mounting portion of fuel
injector assembly (57).
aNever hold the solenoid valve at the fuel
injector top with pliers etc.
Cable color Cylinder No.
pYellow
May be installed
reversely
1, 3, 5
q Orange
rRed
May be installed
reversely
2, 4, 6
sBrown

26. SEN05111-00
50-200 12 D65EX, PX, WX-16
200 Engine and cooling system
Removal and installation of fuel injector assembly
Installation
qFuel injector assembly
aCheck that the fuel injector installation hole is
free from flaw and dirt.
aWhen replacing the fuel injector assembly with
new one, be sure to replace the inlet connec-
tor, too.
aCheck the inlet connector visually for the fol-
lowing defects. If it has any of those defects,
replace it with new one.
(a): There are burrs or deformation at the inlet
or outlet of the inlet connector.
(b): The edge filter is clogged or dirty. If there is
sediment in it, it must not be reused.
(c): The O-ring is cracked or deteriorated.
(d): The outlet seal surface is worn or has a
trace of bad contact or leakage.
aIf high-pressure fuel leaks, the seat surface is
eroded and fine streaks or cracks are made. In
this case, replace the inlet connector and fuel
injector assembly with new ones.
1. Install gasket (58) and O-ring (59) to fuel injec-
tor assembly (57).
2 O-ring (59) and fuel injector mounting
hole: Engine oil (EO15W-40)
2. Install fuel injector holder (56) to fuel injector
assembly (57).
aMatch the convex (A) and concave (B)
parts.
3. Insert fuel injector assembly (57) in the cylin-
der head with its fuel inlet hole directed toward
the intake manifold.
4. Finger-tighten mounting bolts (55) of fuel injec-
tor holder (56) 3 – 4 turns.
5. Install inlet connector (54) with retainer (53)
temporarily.
2 O-ring of inlet connector (54) and
mounting hole on cylinder head side:
Engine oil (EO15W-40)
3 Retainer (53):
15 ± 5.0 Nm {1.5 ± 0.5 kgm}
6. Tighten mounting bolts (55) of fuel injector
holder (56) alternately.
3 Fuel injector holder mounting bolt (55):
10 ± 2 Nm {1.0 ± 0.2 kgm}
aThe top of fuel injector holder (56) must be
in parallel with the top of the cylinder
head.
Max. allowance: 2.4°