Shop Manual D65ex-16 PDF

SEN04887-07
BULLDOZER D65EX -16

D65PX -16
D65WX -16
D65EX- 80001
SERIAL NUMBERS D65PX- 80001 and up
D65WX- 80001
SEN04931-07
BULLDOZER
D65EX-16
D65PX-16
D65WX-16
Machine model Serial number

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

100 Index
SEN04931-07 Composition of shop manual
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04887-07
00 Index and foreword .................................................................................................................... SEN04923-07

100 Index .................................................................................................................................. SEN04931-07 q
200 Foreword and general information ..................................................................................... SEN04932-01
01 General ...................................................................................................................................... SEN04924-01

100 Specification and technical data......................................................................................... SEN04933-01
10 Structure, function and maintenance standard........................................................................... SEN04925-03

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

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

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

100 Index
Composition of shop manual SEN04931-07
305 Troubleshooting by failure code (Display of code), Part 5..................................................SEN05035-00

306 Troubleshooting by failure code (Display of code), Part 6..................................................SEN05036-01
400 Troubleshooting of electrical system (E-mode) ..................................................................SEN05037-01
500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN05038-00
600 Troubleshooting of engine (S-mode) ..................................................................................SEN05039-00
50 Disassembly and assembly ........................................................................................................SEN04929-03

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

100 Hydraulic diagrams and drawings ......................................................................................SEN04934-00
200 Electrical diagrams and drawings.......................................................................................SEN04935-02 q
D65EX, PX, WX-16 00-100 3

100 Index
SEN04931-07 Table of contents
Table of contents 1
00 Index and foreword

100 Index ..........................................................................................................................................SEN04931-07
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.................................................................................................SEN04933-01
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 .....................................................................................................................SEN04965-01
Bevel gear shaft, HSS and brake.................................................................................................................. 2
Brake valve ................................................................................................................................................... 24
Final drive...................................................................................................................................................... 30
Final drive (Planetary gear installed inside of sprocket type) ........................................................................ 36
300 Undercarriage and frame ...........................................................................................................SEN04966-02
Main frame .................................................................................................................................................... 2
Suspension ................................................................................................................................................... 4
Track frame and idler cushion ....................................................................................................................... 14
Idler ............................................................................................................................................................... 18
Idler (Without idler support automatic thrust adjustment).............................................................................. 20
Carrier roller .................................................................................................................................................. 26
00-100 4 D65EX, PX, WX-16

100 Index
Table of contents SEN04931-07
Sprocket......................................................................................................................................................... 28
Track shoe ..................................................................................................................................................... 32
401 Hydraulic system, Part 1 ........................................................................................................... SEN04967-00
Work equipment hydraulic system layout drawing ........................................................................................ 2
Work equipment control................................................................................................................................. 6
Hydraulic tank and filter ................................................................................................................................. 8
Scavenging pump.......................................................................................................................................... 10
Power train and steering lubrication pump .................................................................................................... 11
HSS pump ..................................................................................................................................................... 12
HSS motor ..................................................................................................................................................... 31
Control valve.................................................................................................................................................. 2
CLSS ............................................................................................................................................................. 11
Function and operation of each valve............................................................................................................ 14
PPC valve (blade lift, blade tilt)...................................................................................................................... 2
PPC valve (ripper) ......................................................................................................................................... 8
Electric lever (steering).................................................................................................................................. 12
Quick drop valve............................................................................................................................................ 16
Work equipment lock solenoid valve ............................................................................................................. 18
Pitch selector solenoid valve ......................................................................................................................... 22
Hydraulic oil cooler bypass valve .................................................................................................................. 23
Accumulator................................................................................................................................................... 24
500 Work equipment ........................................................................................................................ SEN04970-00
Blade ............................................................................................................................................................. 2
Cutting edge and end bit ............................................................................................................................... 8
Ripper ............................................................................................................................................................ 10
Hydraulic cylinder .......................................................................................................................................... 11
Piston valve ................................................................................................................................................... 14
600 Cab and its attachments............................................................................................................ SEN04971-01
Cab mount ..................................................................................................................................................... 2
Cab ................................................................................................................................................................ 3
FRP canopy mount........................................................................................................................................ 4
FRP canopy................................................................................................................................................... 5
700 Electrical system ....................................................................................................................... SEN04972-01
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
D65EX, PX, WX-16 00-100 5

100 Index
Testing compression pressure ...................................................................................................................... 14

Testing blow-by pressure .............................................................................................................................. 18
Testing engine oil pressure ........................................................................................................................... 19
Handling of fuel system devices.................................................................................................................... 20
Releasing residual pressure from fuel system .............................................................................................. 20
Testing fuel pressure ..................................................................................................................................... 21
Testing fuel return and leak amount .............................................................................................................. 26
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing fuel circuit for leakage....................................................................................................................... 29
Handling of reduced cylinder mode operation............................................................................................... 30
Handling of no injection cranking operation .................................................................................................. 30
Testing and adjusting air conditioner compressor belt tension...................................................................... 31
Replacing alternator belt ............................................................................................................................... 32
Adjusting fuel control dial and decelerator pedal .......................................................................................... 33
Handling controller high-voltage circuit ......................................................................................................... 34
102 Testing and adjusting, Part 2......................................................................................................SEN05120-02
Testing power train oil pressure .................................................................................................................... 3
Adjusting transmission output shaft speed sensor (replacement procedure) ............................................... 8
Simple test procedure for brake performance............................................................................................... 9
Adjusting brake pedal.................................................................................................................................... 10
Adjusting parking brake lever........................................................................................................................ 12
Emergency escape method when power train has trouble ........................................................................... 14
Adjusting clearance of idler ........................................................................................................................... 17
Adjusting clearance of idler (without idler support automatic thrust adjustment) .......................................... 18
Inspecting wear of sprocket .......................................................................................................................... 19
Testing and adjusting track shoe tension ...................................................................................................... 20
Testing and adjusting work equipment and HSS oil pressure ....................................................................... 21
Testing control circuit basic pressure ............................................................................................................ 24
Testing PPC valve output pressure ............................................................................................................... 25
Adjusting work equipment PPC valve play.................................................................................................... 27
Testing internal leakage of work equipment cylinder..................................................................................... 31
Bleeding air from work equipment cylinder ................................................................................................... 32
Releasing residual pressure from work equipment cylinder.......................................................................... 32
Checking parts which caused hydraulic drift of blade or ripper ..................................................................... 33
Adjusting work equipment lock lever............................................................................................................. 34
Adjusting work equipment lock lever (FRP canopy specification)................................................................. 35
Testing fan speed .......................................................................................................................................... 37
Testing fan circuit oil pressure....................................................................................................................... 38
Bleeding air from fan pump ........................................................................................................................... 39
Bleeding air from HSS pump......................................................................................................................... 40
Adjusting straight tiltdozer ............................................................................................................................. 41
Adjusting play of blade center ball ................................................................................................................ 43
Adjusting operator's cab................................................................................................................................ 44
Special functions of machine monitor (EMMS) ............................................................................................. 2
Handling of voltage circuit of engine controller ............................................................................................. 2
Adjustment method when controller has been replaced ............................................................................... 3
Preparation work for troubleshooting of electrical system............................................................................. 5
Inspection procedure of diode....................................................................................................................... 9
Pm-Clinic service .......................................................................................................................................... 10
40 Troubleshooting
100 Failure code table and fuse locations ........................................................................................SEN05029-01
Failure codes table........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 7
00-100 6 D65EX, PX, WX-16

100 Index
200General information on troubleshootingSEN05030-01

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

100 Index
303Troubleshooting by failure code (Display of code), Part 3SEN05033-01

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

100 Index
Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................... 14

Failure code [DGS1KX] Hyd oil temp sensor: Abnormal ............................................................................... 16
Failure code [DGT1KA] T/C oil temp sensor: Disconnection ......................................................................... 18
Failure code [DGT1KX] T/C oil temp sensor: Short circuit ............................................................................ 20
Failure code [DH21KA] Weq pressure sensor: Disconnection ...................................................................... 22
Failure code [DH21KB] Weq pressure sensor: Short circuit.......................................................................... 24
Failure code [DHT5KA] T/C pressure sensor: Disconnection ....................................................................... 26
Failure code [DHT5KB] T/C pressure sensor: Short circuit ........................................................................... 28
Failure code [DK10KA] Fuel control Dial: Disconnection .............................................................................. 30
Failure code [DK10KB] Fuel control Dial: Short circuit .................................................................................. 32
Failure code [DK30KA] ST lever 1: Disconnection ........................................................................................ 34
Failure code [DK30KB] ST lever 1: Short circuit............................................................................................ 36
Failure code [DK30KX] ST lever: Out of normal range.................................................................................. 38
Failure code [DK30KZ] ST lever: Disconnection or short circuit.................................................................... 38
Failure code [DK30L8] ST lever: Signal mismatch ........................................................................................ 39
Failure code [DK31KA] ST lever 2: Disconnection ........................................................................................ 40
Failure code [DK31KB] ST lever 2: Short circuit............................................................................................ 42
Failure code [DK40KA] Brake potentiometer: Disconnection ........................................................................ 44
Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................ 46
Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 48
Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 48
Failure code [DK55L8] FR lever: Signal mismatch........................................................................................ 49
Failure code [DK56KA] FR lever 1: Disconnection........................................................................................ 50
Failure code [DK56KB] FR lever 1: Short circuit ........................................................................................... 52
Failure code [DK57KA] FR lever 2: Disconnection........................................................................................ 54
Failure code [DK57KB] FR lever 2: Short circuit ........................................................................................... 56
Failure code [DKH1KA] Pitch angle sensor: Disconnection .......................................................................... 4
Failure code [DKH1KB] Pitch angle sensor: Short circuit.............................................................................. 6
Failure code [DLT3KA] T/M out-speed sensor: Disconnection ...................................................................... 8
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................. 9
Failure code [DW5AKA] Pitch selector Sol.: Disconnection .......................................................................... 10
Failure code [DW5AKB] Pitch selector Sol.: Short circuit.............................................................................. 11
Failure code [DW5AKY] Pitch selector Sol.: Short circuit.............................................................................. 12
Failure code [DW7BKA] Fan rev EPC: Disconnection .................................................................................. 14
Failure code [DW7BKB] Fan rev EPC: Short circuit ...................................................................................... 15
Failure code [DWN1KA] Hss EPC1: Disconnection ...................................................................................... 16
Failure code [DWN1KB] Hss EPC1: Short circuit.......................................................................................... 17
Failure code [DWN1KY] Hss EPC1: Short circuit.......................................................................................... 18
Failure code [DWN2KA] Hss EPC2: Disconnection ...................................................................................... 19
Failure code [DWN2KB] Hss EPC2: Short circuit.......................................................................................... 20
Failure code [DWN2KY] Hss EPC2: Short circuit.......................................................................................... 21
Failure code [DWN5KA] Fan pump solenoid: Disconnection ........................................................................ 22
Failure code [DWN5KB] Fan pump solenoid: Short circuit............................................................................ 23
Failure code [DWN5KY] Fan control solenoid: Short circuit .......................................................................... 24
Failure code [DXA0KA] TVC Sol.: Disconnection.......................................................................................... 26
Failure code [DXA0KB] TVC Sol.: Short circuit ............................................................................................. 27
Failure code [DXA0KY] TVC Sol.: Short circuit ............................................................................................. 28
Failure code [DXH1KA] Lock-up ECMV: Disconnection................................................................................ 29
Failure code [DXH1KB] Lock-up ECMV: Short circuit ................................................................................... 30
Failure code [DXH1KY] Lock-up ECMV: Short circuit ................................................................................... 32
Failure code [DXH4KA] 1st clutch ECMV: Disconnection ............................................................................. 34
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ................................................................................. 35
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
D65EX, PX, WX-16 00-100 9

100 Index
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 41

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

100 Index
H-17 Excessive hydraulic drift of blade tilt..................................................................................................... 16

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

100 General information on disassembly and assembly.................................................................. SEN05110-01
How to read this manual................................................................................................................................ 2
Coating materials list ..................................................................................................................................... 4
Special tool list............................................................................................................................................... 7
Sketches of special tools ............................................................................................................................... 17
200 Engine and cooling system ........................................................................................................SEN05111-00
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 ................................................................................................................................ SEN05112-01
Removal and installation of power train unit assembly.................................................................................. 2
Separation and connection of power train unit assembly .............................................................................. 6
Disassembly and assembly of PTO assembly............................................................................................... 11
Disassembly and assembly of torque converter assembly............................................................................ 16
Disassembly and assembly of transmission assembly.................................................................................. 27
Disassembly and assembly of HSS assembly .............................................................................................. 54
Removal and installation of final drive assembly ........................................................................................... 74
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type) ............. 76
Disassembly and assembly of final drive assembly ...................................................................................... 78
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type)......... 86
400 Undercarriage and frame .......................................................................................................... SEN05113-02
Removal and installation of track frame assembly ........................................................................................ 2
Removal and installation of idler assembly ................................................................................................... 4
D65EX, PX, WX-16 00-100 11

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

100 Index
Testing, adjusting and troubleshooting.............................................................................................................. 18

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

100 Hydraulic diagrams and drawings ............................................................................................. SEN04934-00
Power train hydraulic circuit diagram............................................................................................................. 3
Work equipment hydraulic circuit diagram..................................................................................................... 5
200 Electrical diagrams and drawings.............................................................................................. SEN04935-02
Electrical circuit diagram................................................................................................................................ 3
Electrical circuit diagram (sand terrain specification) .................................................................................... 23
Electrical circuit diagram (FRP canopy specification).................................................................................... 29
D65EX, PX, WX-16 00-100 13

SEN04931-07
D65EX-16, D65PX-16, D65WX-16 Bulldozer

Form No. SEN04931-07
©2011 KOMATSU
All Rights Reserved
Printed in Japan 09-11
00-100 14
SEN04965-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

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

maintenance standard 10
202 Power train, Part 2

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

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

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

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

10-202 4 D65EX, PX, WX-16

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

10-202 6 D65EX, PX, WX-16

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Replace
Thickness 5.0 ± 0.1 4.7
1 Brake plate
Strain — Max 0.15 0.3 Repair or replace
Thickness 5.2 ± 0.1 4.7 Replace

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

10-202 8 D65EX, PX, WX-16

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

Outline
Bevel gear shaft Brake

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

D65EX, PX, WX-16 10-202 11

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

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

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

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

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

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

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

When steered to "LEFT TURN" (reverse)

*C: Combined output

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

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

When steered to "RIGHT TURN" (forward)

*C: Combined output

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

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

When steered to "RIGHT TURN" (reverse)

*C: Combined output

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

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

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

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

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

D65EX, PX, WX-16 10-202 23

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

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

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

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

depressed], parking brake valve (1) opens port
(P) and chamber (A) by the reaction force of
return spring (2).
q Main brake valve (3) opens chamber (B) and
port (Br) by the reaction force of return spring
(4).
q The oil pressure from the power train pump is
regulated at the main relief valve, flows from
port (P) through chambers (A) and (B) and port
(Br) to the brake piston back pressure port.
q The brake piston moves to the left and com-
presses the brake spring to "RELEASE" the
brake.
q At this time, the oil pressure is balanced at
2.84 MPa {29.0 kg/cm2}. Its measurement is
available at pressure detection port (Q).
10-202 26 D65EX, PX, WX-16

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

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

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

D65EX, PX, WX-16 10-202 29

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

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

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

10-202 32 D65EX, PX, WX-16

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

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

Power transmitting route

10-202 34 D65EX, PX, WX-16

The power from HSS

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

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

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

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

10-202 38 D65EX, PX, WX-16

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

Power transmitting route
10-202 40 D65EX, PX, WX-16

The power from HSS

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

SEN04965-01

©2011 KOMATSU
All Rights Reserved
10-202 42
SEN04972-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

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

maintenance standard 10
700 Electrical system

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
D65EX, PX, WX-16 10-700 1

SEN04972-01 Monitor system
Monitor system 1
1. Machine monitor Outline

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

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

Monitor system SEN04972-01
Processing on machine monitor (common to all specifications)
Display of machine monitor

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

Machine monitor 1
Outline Precautions on the machine monitor display

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

Input and output signals

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

Display 1
A: Check before starting screen

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

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

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

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

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

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

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

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


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

For the non air conditioner specification

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

D65EX, PX, WX-16 10-700 13

Guidance icon and function switch

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

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

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

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

SEN04972-01 Engine control system
Engine control system 1
10-700 18 D65EX, PX, WX-16

Engine control system SEN04972-01
1. Battery
2. Starting switch
3. Engine controller
4. Power train controller
5. Machine monitor
6. Fuel control dial
7. Decelerator pedal
8. Parking limit switch
9. Parking brake lever
10. Work equipment lock limit switch
11. Work equipment lock lever
12. Electric lever
13. Steering, directional, gear shift lever (PCCS lever)
14. Neutral safety relay
15. Engine
16. Starting motor
17. Engine speed sensor
18. Coolant temperature sensor
19. Engine oil pressure switch
20. Injector
21. Fuel supply pump valve

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

SEN04972-01 Engine control system
Engine start mechanism Engine stop mechanism

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

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

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

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

Cooling system control system SEN04972-01
Cooling system control system 1
1. Battery Input and output signals

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

SEN04972-01 Cooling system control system
Outline Selection of fan rotation mode

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

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

Electronic steering control system SEN04972-01
Electronic steering control system 1
1. Machine monitor 8. Engine

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

SEN04972-01 Electronic steering control system
Gear shift mode function 1
Outline Screen display

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

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

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

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

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

Electronic steering control system SEN04972-01
Setting preset with shift switch operation at Shifting speed range by operating shift switch
NEUTRAL when traveling
q Set the preset (gear speed at start) and the q While the machine is traveling, operating UP
maximum gear speed during travel (for only switch and DOWN switch allows changing the
the auto gear shift mode) with the gear shift maximum gear speed when the auto gear shift
switches in neutral. mode is turned on and changing the gear
speed currently used when the manual gear
Auto gear shift mode shift mode is turned on.
Setting the preset (gear speed at start) and the
maximum gear speed during travel Auto gear shift mode
Changing maximum gear speed during travel
During The maximum gear speed can be set to
forward travel
F1–F3.
reverse travel
R1–R3.
Each time operator presses this switch,
UP switch the maximum gear speed is sequentially
increased to the next higher range.
DOWN switch the maximum gear speed is sequentially
decreased to the next lower range.

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

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

SEN04972-01 KOMTRAX system
KOMTRAX system 1
q The KOMTRAX system consists of the

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

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

KOMTRAX system SEN04972-01
KOMTRAX terminal 1
Model: TH300
q The KOMTRAX system uses satellite communication technology.
1. Communication antenna connection Input and output signals

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

SEN04972-01 System components
System components 1
Engine controller

q The following is the list of the symbols used for signal classification in the input/output signal chart.
A: Power supply
B: Input
C: Ground/shield/return
D: Output
E: Communication
DTP06-4P [CN-CE03]
Signal
Pin No. Signal name classification
1 GND C
2 GND C
3 Constant power supply (+24 V) A
4 Constant power supply (+24 V) A
10-700 28 D65EX, PX, WX-16

System components SEN04972-01
DRC26-60P [CN-CE01]
Pin Signal name Signal Pin Signal name Signal
No. classification No. classification
1 Fuel electrical lift pump (+) D 31 NC —
2 Inlet metering valve (+) D 32 Inlet metering valve (–) C
3 Atmospheric pressure sensor B 33 Atmospheric pressure sensor power supply (+5V) A
4 NC — 34 NC —
5 NC — 35 NC —
6 CAN_L E 36 NC —
7 NC — 37 Sensor power supply (+5 V) A
8 CAN_H E 38 Sensor GND C
9 NC — 39 NC —
10 NC — 40 NC —
11 Fuel electrical lift pump (–) C 41 NC —
12 NC — 42 NC —
13 NC — 43 NC —
14 Water-in-fuel sensor (+) B 44 Boost pressure sensor B
15 Coolant temperature sensor B 45 Injector #1 (+) D
16 Crank shaft angle sensor power supply (+5V) A 46 Injector #5 (+) D
17 Engine oil pressure switch B 47 Sensor GND C
18 NC — 48 Crankshaft angle sensor GND C
19 NC — 49 NC —
20 NC — 50 NC —
21 NC — 51 Injector #2 (–) C
22 NC — 52 Injector #3 (–) C
23 Boost temperature sensor B 53 Injector #1 (–) C
24 NC — 54 Injector #2 (+) D
25 Common rail pressure sensor B 55 Injector #3 (+) D
26 Camshaft speed sensor (+) B 56 Injector #4 (+) D
27 Crankshaft angle sensor (+) B 57 Injector #6 (+) D
28 NC — 58 Injector #4 (–) C
29 NC — 59 Injector #6 (–) C
30 NC — 60 Injector #5 (–) C
DRC26-50P [CN-CE02]
Pin Signal Pin Signal
No. Signal name classification No. Signal name classification
1 NC — 26 NC —
2 NC — 27 NC —
3 NC — 28 NC —
4 NC — 29 NC —
5 NC — 30 NC —
6 NC — 31 NC —
7 NC — 32 NC —
8 NC — 33 NC —
9 Decelerator potentiometer signal B 34 NC —
10 NC — 35 NC —
11 NC — 36 NC —
12 NC — 37 NC —
13 NC — 38 NC —
14 NC — 39 Starting switch ACC signal B
15 NC — 40 Intake air heater drive signal D
16 NC — 41 NC —
17 NC — 42 NC —
18 NC — 43 NC —
19 NC — 44 NC —
20 NC — 45 NC —
21 NC — 46 CAN_H E
Decelerator potentiometer power supply
22 (+5 V) A 47 CAN_L E
23 Decelerator potentiometer (–) C 48 NC —
24 NC — 49 Engine power supply relay drive signal D
25 NC — 50 NC —
D65EX, PX, WX-16 10-700 29

Power train controller
10-700 30 D65EX, PX, WX-16


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

Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Coolant temperature sensor
1. Connector
2. Sensor
3. O-ring
10-700 32 D65EX, PX, WX-16

Crankshaft angle sensor (Ne sensor)
1. Connector
2. Sensor
3. O-ring
Boost pressure, temperature sensor
1. Connector
2. Sensor
3. O-ring
D65EX, PX, WX-16 10-700 33

Fuel control dial
1. Knob Function
2. Dial q The fuel control dial is installed to the left side
3. Spring of the operator's seat.
4. Ball q If knob (1) is turned, the shaft of potentiometer
5. Potentiometer (5) is turned to change the resistance of the
6. Connector variable resistor and send a throttle signal to
the engine controller.
q The hatched areas in the following graph is the
abnormality detection areas. In those areas,
the engine speed is reduced to a half.
10-700 34 D65EX, PX, WX-16

Decelerator pedal potentiometer

Brake pedal potentiometer
1. Element Output characteristics

2. Contact
3. Shaft
4. Connector
Function
q The decelerator pedal potentiometer is
installed at the bottom of the front part of the
floor and directly connected to the decelerator
pedal.
q The brake pedal potentiometer is installed at
the bottom of the front part of the floor and
directly connected to the brake pedal.
q Potentiometer shaft (3) starts rotation when the
pedal is operated. It outputs the signal voltage
after converting the power supply voltage to
signal voltage according to the angle of pedal
operation based on the resistance value of the
variable resistor.
D65EX, PX, WX-16 10-700 35

SEN04972-01 Sensor
Sensor 1
Power train oil temperature sensor

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

2. Sensor
3. Connector
Function
q This sensor is installed in the discharge side
block of the HSS pump.
q This sensor detects pressure of hydraulic oil. It
converts the pressure to an electric signal and
then outputs that signal.
10-700 36 D65EX, PX, WX-16

Sensor SEN04972-01
Torque converter oil pressure sensor
1. O-ring Output characteristics

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

SEN04972-01 Sensor
Transmission output speed sensor
1. Pole piece 4. Magnet 7. Connector

2. Magnet wire 5. Housing
3. Bobbin 6. Grommet
Function
q This sensor is installed on the bevel gear area situated in the rear side of the steering case.
q These sensors detect the gear shift speed. It converts speed to the corresponding pulse signals and
then outputs the signals.
Pitch angle sensor
1. Body 4. Ring
2. Tube 5. Wire
3. Tube 6. Connector
Function
q This sensor is installed in the engine room on the right side of the machine body.
q There are multiple electrodes and oil in this sensor. The changes of the oil level made by inclination of
the machine are sensed by the differences in electrostatic capacity between the electrodes, and then
those differences are converted into voltage signals.
10-700 38 D65EX, PX, WX-16

Sensor SEN04972-01
Fuel level sensor
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
Function
q This sensor is installed on the front of the fuel tank.
q This sensor senses the fuel level and converts it into an electric signal and then outputs that signal.
q The float moves up and down according to the fuel level.
q The movement of the float operates the variable resistor through the arm.
D65EX, PX, WX-16 10-700 39

SEN04972-01 Sensor
Water-in-fuel sensor
1. Connector 3. Sensor
2. Tube 4. O-ring
Function
q This sensor is installed in the cup of the fuel pre-filter.
q This sensor outputs the signal upon sensing water in fuel.
10-700 40 D65EX, PX, WX-16

Sensor SEN04972-01
Air cleaner clogging sensor (sand terrain specification)
1. Adapter
2. Hood
3. Indicator
4. Connector
Function
q The air cleaner clogging sensor is installed to
the air cleaner outlet. If the air cleaner is
clogged and the pressure reaches the speci-
fied level (negative pressure), caution lamp on
the machine monitor lights up to output a warn-
ing.
D65EX, PX, WX-16 10-700 41

SEN04972-01

©2011 KOMATSU
All Rights Reserved
10-700 42
SEN05110-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
50 Disassembly and assembly 50
100 General information on disassembly

and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 17
D65EX, PX, WX-16 50-100 1

100 General information on disassembly and assembly
SEN05110-01 How to read this manual
How to read this manual (Rev. 2009.01)1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
6 : Amount of oil or coolant to be drained
model. They have a new part num-
ber respectively.
4: Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each Installation
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
for the following.
79 T-
* *** ****
- :
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
50-100 2 D65EX, PX, WX-16

How to read this manual SEN05110-01
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
6 : Amount of oil or coolant drained
2) Distinction of new and existing special
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively.
q In “Assembly” section, the work procedures,
R: Tools made available by redesign-
precautions and know-how to do the work, and
ing the existing tools which were
the amount of oil and coolant to be replenished
developed for other models. Each
are described.
of them has a new part number
q Common tools that are necessary for assem-
assigned by setting forward the
bly are described as [1], [2]••• etc. and their
part number of the existing tool.
part numbers, part names and quantities are
Blank : Tools already available for other
not described.
models. They can be used without
q The meanings of the symbols used in “Assem-
any modification.
bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre-
: Precautions related to work safety
sented in the section of “Sketches of
a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
* *** ****
79 T- - :
means that they are not available 5 : Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
D65EX, PX, WX-16 50-100 3

SEN05110-01 Coating materials list
Coating materials list (Rev. 2009.02)1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060 • Used to stick and seal metal, glass, and plas-
Adhesive: 1 kg
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8 tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
50-100 4 D65EX, PX, WX-16

Coating materials list SEN05110-01
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
disulfide lubricant
Molybdenum
• Used to lubricate linkages, bearings, etc.

• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A • Feature: Lithium grease with extreme pressure
G0-LI SYG2-160LI
Various Various lubrication performance.
*: For cold dis- SYGA-160CNLI
trict SYG0-400LI-A (*) • General purpose type.
SYG0-160CNLI
(*)
• Used for parts under heavy load.
400 g x • Caution:
Bellows- • Do not apply grease to rolling bearings like
Molybdenum SYG2-400M 10
type con-
disulfide grease SYG2-400M-A 400 g x swing circle bearings, etc. and spline.
tainer
LM-G (G2-M) SYGA-16CNM 20
Grease
Can • The grease should be applied to work equipment

16 kg pins at their assembly only, not applied for
greasing afterwards.
Hyper White • Seizure resistance, heat resistance and water

SYG2-400T-A Bellows- resistance higher than molybdenum disulfide
Grease G2-T, 400 g
SYG2-16CNT type con-
G0-T (*) grease.
SYG0-400T-A (*) tainer
*: For cold dis- 16 kg • Not conspicuous on machine since color is
SYG0-16CNT (*) Can
trict white.
Biogrease
SYG2-400B
G2-B, G2-BT (*) Bellows- • Since this grease is decomposed by natural bac-
SYGA-16CNB 400 g
*: For use at type con-
SYG2-400BT (*) teria in short period, it has less effects on micro-
high tempera- tainer
SYGA-16CNBT 16 kg organisms, animals, and plants.
ture and under Can
(*)
high load
D65EX, PX, WX-16 50-100 5

SEN05110-01 Coating materials list
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
• Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass con-
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
tainer
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass con-
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 tainer
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR side.
Glass con-
PAINT PRIMER 22M-54-27230 20 ml
Primer
tainer (Using limit: 4 months after date of manu-

435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
435-41 (Using limit: 4 months after date of manu-
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass con-
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
tainer
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season

PENGUINE Polyethyl- and “W” for low-temperature season as
SEAL 580 417-926-3910 320 ml ene con- adhesive for glass.
SUPER “S” or tainer (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
Polyethyl- • Used as adhesive for glass.

Sika Japan,
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manu-
Sikaflex 256HV
tainer
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Polyethyl- • Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manu-
SEAL No. 2505 tainer facture)
Caulking material
SEKISUI Polyethyl- • Used to seal front window.

SILICONE 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manu-
SEALANT tainer facture)
• Used to seal joint of glasses.
GE TOSHIBA Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
TOSSEAL 381 (Using limit: 12 months after date of manu-
facture)
50-100 6 D65EX, PX, WX-16

Special tool list SEN05110-01
Special tool list 1
a Tools with part number 79 T-

tools to be made locally).
* *** **** - means that they are not available from Komatsu Ltd. (i.e.
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”)
New/remodel
Necessity
Sketch
Q'ty
Item Symbol Part No. Part name Nature of work, remarks
Removal and
installation of fuel supply
pump assembly, fuel
1 795-799-1131 Gear t 1 Cranking
injector assembly, engine
front oil seal, and cylinder
head assembly
Removal and installation Removal, installation of
of fuel supply pump 2 795-799-1390 Remover t 1 fuel supply pump drive
assembly gear
Removal and 3 795-799-6700 Puller t 1
installation of fuel injector Removal of fuel injector
assembly and cylinder A assembly
head assembly 4 795-799-8150 Remover q 1
Removal and
Installation of engine front
installation of engine front 5 795-799-8120 Oil seal driver q 1 N
oil seal
oil seal
Removal and 795-799-1150 Repair stand q 1
installation of engine rear 6 Fitting of engine assembly
oil seal 795-799-2280 Adapter q 1
Removal and
Tightening of cylinder head
installation of cylinder 7 790-331-1120 Wrench (angle) q 1
bolt
head assembly
790-101-5401 Push tool kit (C) t 1
Disconnection and 790-101-5431 • Plate 1
connection of power train 1 Installation of oil seal
unit assembly 790-101-5421 • Grip 1
01010-51240 • Bolt 1
2 790-201-2720 Spacer t 1 Installation of bearing
790-101-5201 Push tool kit (B) t 1
790-101-5231 • Plate 1
D 3
790-101-5221 • Grip 1
Disassembly and assem- 01010-51225 • Bolt 1
bly of PTO assembly 790-101-5201 Push tool kit (B) t 1 Press fitting of bearing
790-101-5331 • Plate 1
4
790-101-5221 • Grip 1
01010-51225 • Bolt 1
5 796-430-1110 Push tool t 1
D65EX, PX, WX-16 50-100 7

SEN05110-01 Special tool list
New/remodel
Necessity
Sketch
Q'ty
6 794T-422-1110 Push tool t 1 Q

7 794T-413-1120 Push tool t 1 Q
790-101-5401 Push tool kit (C) t 1
Disassembly and assem- Press fitting of bearing
790-101-5491 • Plate 1
bly of torque converter 8
assembly 790-101-5421 • Grip 1
01010-51240 • Bolt 1
Wrench Removal and installation of
9 792-213-1110 t 1
assembly nut
791T-415-5300 Puller assembly t 1 Q
10 791T-415-5310 • Plate 1 Q Installation of snap ring
01010-82040 • Bolt 1
Operation check of clutch
11 799-301-1600 Oil leak tester kit t 1
piston
790-101-5201 Push tool kit (B) t 1
790-101-5311 • Plate 1
12
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5401 Push tool kit (C) t 1
D 790-101-5461 • Plate 1
13
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5201 Push tool kit (B) t 1
Disassembly and
assembly of transmission 790-101-5281 • Plate 1
assembly 14
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Press fitting of bearing
790-101-5001 Push tool kit (A) t 1
790-101-5081 • Plate 1
15
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5471 • Plate 1
16
790-101-5421 • Grip 1
01010-51240 • Bolt 1
17 790-201-2760 Spacer t 1
18 793T-615-1170 Push tool t 1 Q
19 790-201-2830 Spacer t 1
20 791T-415-5210 Push tool t 1 Q
50-100 8 D65EX, PX, WX-16

New/remodel
Necessity
Sketch
Q'ty
Removal, installation of
1 791T-422-1320 Hanger q 1 Q
brake and carrier assembly
Removal, installation of
2 790-302-1500 Wrench kit q 1
bevel pinion nut
Wrench
3 796-730-2300 q 1
assembly
Commercially
Torque wrench
available or q 1
set Adjustment of preload on
795-630-1803
bevel gear shaft and bevel
• Torque gear assembly
4 795-630-1810 1
wrench
795-630-1830 • Adapter 1
790-101-5201 Push tool kit (B) t 1

790-101-5261 • Plate 1
5 Removal of bevel pinion
790-101-5221 • Grip 1
01010-51225 • Bolt 1
6 794T-422-1110 Push tool t 1 Q
Disassembly and 790-101-5401 Push tool kit (C) t 1
assembly of HSS E
assembly 790-101-5481 • Plate 1
7
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5491 • Plate 1
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
9 793T-659-1110 Push tool t 1 Q
10 796T-467-2160 Push tool t 1 Q Press fitting of bearing
11 790-201-2730 Push tool t 1
790-101-5201 Push tool kit (B) t 1
790-101-5221 • Grip 1
12 01010-51225 • Bolt 1
790-101-5271 • Plate 1
790-101-5311 • Plate 1
790-101-5001 Push tool kit (A) t 1
790-101-5091 • Plate 1
13
790-101-5021 • Grip 1
01010-50816 • Bolt 1
D65EX, PX, WX-16 50-100 9

New/remodel
Necessity
Sketch
Q'ty
790-337-1032 Lifting tool t 1

Removal and
Lifting up of final drive
installation of final drive 1 791-427-1090 Plate t 1
assembly
assembly
01010-51635 Bolt t 2
Remover
791-427-1100 t 1
assembly
Separation of sprocket hub
2
790-101-2102 Puller t 1 assembly and bearing
790-101-1102 Pump t 1
3 792-520-2121 Installer t 1 Installation of floating seal
Installer
791-427-1200 t 1
assembly
Press fitting of sprocket
4
Disassembly and 790-101-2102 Puller t 1 hub bearing
assembly of final drive 790-101-1102 Pump t 1
assembly
790-101-5201 Push tool kit (B) t 1
790-101-5321 • Plate 1
5 Installation of oil seal
790-101-5221 • Grip 1
01010-51225 • Bolt 1
6 790-201-2330 Plate t 1
7 790-201-2460 Plate t 1 Press fitting of bearing
8 790-101-5431 Plate t 1
Removal and installation J
of final drive assembly 791T-527-1110 Plate t 1 Slinging of final drive
9
(Planetary gear installed 01010-81680 Bolt t 2 assembly
inside of sprocket type)
01643-31645 Washer t 6
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
Separation of sprocket hub
10 790-101-2470 Adapter (M20) t 2
assembly and bearing
790-101-2450 Adapter (M12) t 2
790-201-2680 Plate t 1
Disassembly and assem-
bly of final drive (Plane- 790-101-2102 Puller t 1
tary gear installed inside 790-101-1102 Hydraulic pump t 1
of sprocket type)
791-520-4140 Screw t 1
791-112-1180 Nut t 1
01643-22460 Washer t 1
11 790-101-2420 Adapter (M16) t 1 Installation of bearing
790-201-2840 Spacer t 1
790-101-2102 Puller t 1
790-101-1102 Hydraulic pump t 1
50-100 10 D65EX, PX, WX-16

New/remodel
Necessity
Sketch
Q'ty
790-431-1031 Block t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
01643-22460 Washer t 2 Press fitting of sprocket
12
791T-527-1130 Plate t 1 N Q hub bearing
791T-527-1120 Push tool t 1 N Q
790-101-2102 Puller t 1
13 791-580-8110 Installer t 1 Installation of floating seal
790-101-5201 Push tool kit t 1
Disassembly and assem-
bly of final drive (Plane- 790-101-5321 • Plate t 1
J
tary gear installed inside 14 790-101-5311 • Plate t 1
of sprocket type)
790-101-5221 • Grip t 1
01010-51225 • Bolt t 1
Installation of oil seal,
790-101-5441 • Plate t 1
Press fitting of bearing
15 790-101-5431 • Plate t 1
790-101-5421 • Grip t 1
01010-51240 • Bolt t 1
790-101-5630 Plate t 1 N
16 790-101-5421 Grip t 1
01010-51240 Bolt t 1
Disassembly and
assembly of idler 1 791-515-1520 Installer t 1
assembly
Disassembly and
assembly of track roller 2 791-530-1520 Installer t 1 Installation of floating seal
assembly
Disassembly and L
assembly of carrier roller 3 796-230-1110 Installer t 1
assembly
Disassembly and
assembly of idler
4 791-601-1000 Oil pump t 1 Supply of oil
assembly and track roller
assembly
Compressor of
791-685-8005 t 1
type B
791-635-3160 Extension t 1
Disassembly and
790-201-2780 Spacer t 1 Disassembly, assembly of
assembly of recoil spring M
recoil spring assembly
assembly 790-201-2790 Spacer t 1
790-101-1102 Pump t 1
790-101-1600 Cylinder t 1
Remover
791-450-1100 t 1
assembly
Removal and installation
N Pulling out of center pin
of equalizer bar assembly 790-101-2102 Puller t 1
790-101-1102 Pump t 1
D65EX, PX, WX-16 50-100 11

New/remodel
Necessity
Sketch
Q'ty
Installer
791-430-1200 t 1
assembly
Removal and installation
P Press fit ring
of pivot shaft assembly 790-101-2102 Puller t 1
790-101-1102 Pump t 1
Removal of pin plug of
1 790-646-7531 Remover t 1
track link
2 791-660-7460 Brush t 1 Cleaning of pin of track link
791-432-1110 Push tool t 1
Installation of pin of track
3 791-646-7550 Bar t 1
link (for large plug)
Whole disassembly and 791-646-7560 Guide t 1
whole
assembly of track shoe 791-932-1110 Push tool t 1
R
assembly Installation of pin of track
4 791-646-7523 Bar t 1
(Conventional type track link (for small plug)
shoe) 791-646-7590 Guide t 1
Check of track link for
5 790-701-3000 Checker t 1
airtightness
Installation of seal of track
6 791-432-1120 Installer t 1
link
7 791-601-1000 Oil pump t 1 Supply of track link oil
791-932-1110 Push tool t 1
Installation of pin of track
4 791-646-7523 Bar t 1
link (for small plug)
791-646-7590 Guide t 1
Check of track link for air-
5 790-701-3000 Checker t 1
tightness
Push tool
791T-532-1100 t 1 Q
assembly
Whole disassembly and 791T-532-1110 • Adapter 1 Q
whole assembly of track 791T-532-1130 • Ring 1 Q
R
shoe assembly 791T-532-1140 • Plate 1 Q
(PLUS type track shoe)
791T-532-1150 • Ring 1 Q
791T-532-1160 • Push tool 1 Q Installation of wedge ring
18
791T-532-1170 • Adapter 1 Q (For large plug side)
791T-532-1180 • Spring 1 Q
791T-532-1190 • Spring 1 Q
791T-532-1210 • Bolt 1 Q
791T-632-5730 • Bar 1 Q
01580-11210 • Nut 1
01252-60610 • Bolt 4
50-100 12 D65EX, PX, WX-16

New/remodel
Necessity
Sketch
Q'ty
Push tool
791T-532-1200 t 1 Q
assembly
791T-532-1120 • Adapter 1 Q
791T-532-1130 • Ring 1 Q
791T-532-1140 • Plate 1 Q
791T-532-1150 • Ring 1 Q
791T-532-1160 • Push tool 1 Q Installation of wedge ring
R 19
791T-532-1170 • Adapter 1 Q (For small plug side)
791T-532-1180 • Spring 1 Q
Whole disassembly and 791T-532-1190 • Spring 1 Q
assembly of one link
(PLUS type track shoe) 791T-532-1220 • Bolt 1 Q
791T-632-5730 • Bar 1 Q
01580-11210 • Nut 1
01252-60610 • Bolt 4
Push tool
791T-532-1300 t 2 Q
assembly
20 791T-532-1310 • Push tool 2 Q Press fitting of wedge ring
R
791T-632-5730 • Bar 2 Q
01580-11210 • Nut 2
21 791T-432-1130 Push tool t 1 Q Press fitting of oil seal
791-432-1110 Push tool t 1
Installation of pin plug of
3 791-646-7550 Bar t 1
track link (for large plug)
791-646-7560 Guide t 1
791-932-1110 Push tool t 1
Installation of pin plug of
4 791-646-7523 Bar t 1
track link (for small plug)
791-646-7590 Guide t 1
Installation of seal of track
6 791-432-1120 Installer t 1
link
791-635-3110 Frame t 1
Field disassembly and 791-635-3160 Extension t 1
assembly of one link
R 791-635-3170 Nut t 4
(Conventional type track
shoe) 8 791-635-3180 Screw t 2
791-635-3190 Screw t 1 Pulling out of pin
791-645-3510 Adapter t 1
791-646-3260 Pusher t 1
790-101-1102 Pump t 1
9
790-101-1300 Cylinder t 1
Jack
790-105-2300 t 1
10 (196 kN {20 ton} Connection of link
790-101-1102 Pump t 1
791-645-3520 Adapter t 1
11 Press fitting of bushing
791-432-1210 Spacer t 1
D65EX, PX, WX-16 50-100 13

New/remodel
Necessity
Sketch
Q'ty
12 791-645-3540 Guide t 1
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
791-635-3190 Screw t 1 Press fitting of pin
13
791-645-3510 Adapter t 1
791-645-3520 Adapter t 1
791-645-3530 Pusher t 1
791-432-1210 Spacer t 1
791-432-1220 Spacer t 1
791-635-3110 Frame t 1
Field disassembly and
assembly of one link 791-635-3160 Extension t 1
R
(Conventional type track 791-635-3170 Nut t 4
shoe)
791-635-3180 Screw t 2
14 Press fitting of bushing
791-635-3190 Screw t 1
791-645-3520 Adapter t 1
791-645-3540 Guide t 1
791-645-3550 Pusher t 1
15 791-646-3270 Guide t 1 Connection of link
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
16 Press fitting of pin
791-635-3180 Screw t 2
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
50-100 14 D65EX, PX, WX-16

New/remodel
Necessity
Sketch
Q'ty
1 790-101-1102 Pump assembly t 1

Jack (196 kN {20 Expansion of
2 790-105-2300 t 1
ton}) link
Remover &
1 791-532-2201 t 1
installer
• Cylinder (980
2 790-101-1300 1
kN {100 ton})
3 791-532-2210 • Plate 1
4 791-532-2220 • Plate 1
5 791-532-2230 • Block 1
6 791-532-2240 • Stud bolt 2
Field disassembly and Disassembly
assembly of one link 7 791-532-2390 • Rod 2 and
R 17
(PLUS type 8 791-532-2260 • Plate 1 assembly of
track shoe) link
3 9 791-532-2270 • Boss 2
10 791-532-2280 • Boss 2
11 791-532-2290 • Plate 1
12 01582-12722 • Nut 4
13 791-532-2380 • Washer 2
14 01252-61645 • Bolt 4
15 02205-12437 • Nut 4
16 791-532-2370 • Plate 1
Press fitting
17 791-532-2340 • Push tool 2 of wedge
ring
790-502-1003 Repair stand t 1 Disassembly and assembly
1 hydraulic cylinder
790-101-1102 Pump t 1 assembly
Wrench Removal and installation of
2 790-330-1100 t 1
assembly cylinder head
Socket (Width
790-302-1270 across flats: 50 t 1
mm)
Socket (Width
Removal and installation of
3 790-102-1330 across flats: 75 t 1
nut
mm)
Socket (Width
Disassembly and 790-302-1340 across flats: 80 t 1
assembly of hydraulic U mm)
cylinder assembly
4 790-720-1000 Expander t 1 Expansion of piston ring
796-720-1650 Ring t 1 For blade lift
07281-01029 Clamp t 1 cylinder
796-720-1660 Ring t 1 For blade
angle
07281-01159 Clamp t 1 cylinder Installation of
5
796-720-1670 Ring t 1 For blade tilt piston ring
cylinder,
blade pitch
07281-01279 Clamp t 1 cylinder,
ripper lift
cylinder
D65EX, PX, WX-16 50-100 15

New/remodel
Necessity
Sketch
Q'ty

790-101-5021 • Grip 1
01010-50816 • Bolt 1
For blade lift
790-201-1781 • Push tool 1
cylinder
For blade tilt Press fitting
6 cylinder, of bushing
blade pitch
790-201-1811 • Push tool 1
cylinder,
ripper lift
cylinder
For blade
790-201-1791 • Push tool 1 angle
Disassembly and cylinder
assembly of hydraulic U
cylinder assembly 790-201-1500 Push tool kit 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
For blade lift
790-201-1590 • Plate 1
cylinder
For blade tilt Press fitting
7 cylinder, of dust seal
blade pitch
790-201-1620 • Plate 1
cylinder,
ripper lift
cylinder
For blade
790-201-1610 • Plate 1 angle
cylinder
Removal and
installation of Lifter (Suction
X 1 793-498-1210 t 2 Installation of window glass
operator’s cab glass cup)
(Stuck glass)
50-100 16 D65EX, PX, WX-16

Sketches of special tools SEN05110-01
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D6 Push tool
D7 Push tool
D65EX, PX, WX-16 50-100 17

SEN05110-01 Sketches of special tools
D10 Puller assembly
D10 Plate
50-100 18 D65EX, PX, WX-16

D18 Push tool
D20 Push tool
D65EX, PX, WX-16 50-100 19

E1 Hanger
E6 Push tool
50-100 20 D65EX, PX, WX-16

E9 Push tool
E10 Push tool
D65EX, PX, WX-16 50-100 21

J9 Plate (Planetary gear installed inside of sprocket type)
J12 Push tool (Planetary gear installed inside of sprocket type)
50-100 22 D65EX, PX, WX-16

J12 Plate (Planetary gear installed inside of sprocket type)
R18 Push tool assembly
D65EX, PX, WX-16 50-100 23

R18 Adapter
R18, R19 Ring
50-100 24 D65EX, PX, WX-16

R18, R19 Plate
R18, R19 Ring
D65EX, PX, WX-16 50-100 25

R18, R19 Push tool
R18, R19 Adapter
50-100 26 D65EX, PX, WX-16

R18, R19 Spring
R18, R19 Spring
D65EX, PX, WX-16 50-100 27

R18 Bolt
R18, R19, R20 Bar
50-100 28 D65EX, PX, WX-16

R19 Adapter
D65EX, PX, WX-16 50-100 29

R19 Bolt
50-100 30 D65EX, PX, WX-16

R20 Push tool
R21 Push tool
D65EX, PX, WX-16 50-100 31

SEN05110-01
D65EX, PX, WX-16 Bulldozer

©2011 KOMATSU
All Rights Reserved
50-100 32
SEN05112-01
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
50 Disassembly and assembly 50
300 Power train

Removal and installation of power train unit assembly ................................................................................... 2
Separation and connection of power train unit assembly ............................................................................... 6
Disassembly and assembly of PTO assembly ...............................................................................................11
Disassembly and assembly of torque converter assembly ........................................................................... 16
Disassembly and assembly of transmission assembly ................................................................................. 27
Disassembly and assembly of HSS assembly .............................................................................................. 54
Removal and installation of final drive assembly .......................................................................................... 74
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)............. 76
Disassembly and assembly of final drive assembly...................................................................................... 78
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type) ........ 86
D65EX, PX, WX-16 50-300 1

300 Power train
SEN05112-01 Removal and installation of power train unit assembly
Removal and installation of power

train unit assembly 1
Removal
k Stop the machine on a level place and
apply the parking brake.
k Lower the work equipment to the ground,
stop the engine, and loosen the hydraulic
tank cap gradually to release the pressure
inside the hydraulic tank.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If the radiator coolant temperature is high,
wait until it decreases to avoid getting
scalded and then drain the coolant. 6. Remove the ROPS cab assembly. For details,
q Precautions for handling refrigerant see “Removal and installation of ROPS cab
k Collect refrigerant (R134a) beforehand. assembly”.
a Ask professional traders for collecting and
filling the refrigerant (R134a). 7. Remove the HSS motor assembly. For details,
a Never release the refrigerant (R134a) to see “Removal and installation of HSS motor
the atmosphere. assembly”.
k If the refrigerant (R134a) gets inside a Remove the HSS motor to remove the
ones eyes, it may cause blindness. HSS case bevel gear shaft cover and cap
Therefore, make sure to wear protec- on the right side.
tive glasses when collecting or filling
the refrigerant. Collecting and filling 8. Remove undercover (1) under the power train.
work must be conducted by a qualified
person.
1. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit. [*1]
q Quantity of refrigerant: 900 ± 50 g
2. Drain the fuel through the fuel valve at the fuel

tank bottom.
6 Fuel tank: 415 l
3. Remove the fuel tank assembly. For details,

see “Removal and installation of fuel tank
assembly”.
9. Sling the drive shaft assembly.
4. Remove cover (1b) under the hydraulic tank.
10. Remove all drive shaft mounting bolts (2) from
5. Drain the hydraulic oil from the hydraulic tank. the underside of the power train. [*2]
6 Hydraulic tank: 82 l
50-300 2 D65EX, PX, WX-16

300 Power train
Removal and installation of power train unit assembly SEN05112-01
11. Lift off drive shaft assembly (3). 18. Disconnect 2 power train oil filter hoses (12).
a Plug the hoses and adapters to prevent
4 Drive shaft assembly (3): 25 kg
the oil from flowing out.
12. Disconnect pressure pickup pilot hose (4).

19. Remove 5 wiring harness clamps (13).
13. Disconnect wiring harness connector CN-RFD
20. Remove 2 hose clamps (14).
(5).
a Fix wiring harness (15) to the machine.
14. Disconnect HSS case oil feed pipe (6). [*3]

21. Remove hose clamp (16) from the left side of
the transmission.
15. Remove 2 hose clamps (7).
22. Disconnect 2 hydraulic hoses (17).
16. Disconnect suction hose (8). [*4]
17. Disconnect hydraulic hoses (9), (10) and (11).
D65EX, PX, WX-16 50-300 3

300 Power train
SEN05112-01 Removal and installation of power train unit assembly
23. Remove right and left covers (18) from the 26. Loosen right and left clamps (22) and move
inside of the sprocket. [*5] seals (23) out. [*6]
24. Using forcing screws [1], pull out right and left 27. Sling the power train unit assembly.
drive shafts (19) until their spline portions
come off. 28. Remove right and left power train front mount-
a If drive shafts (19) do not come off, apply a ing bolts (24). [*7]
hydraulic jack etc. to the track shoe
grouser and adjust the grouser position
finely.
29. Lift off power train unit assembly (25). [*8]

a Ensure that all the wiring and piping are
disconnected before lifting off the engine
25. Remove right and left HSS case bevel gear assembly.
4
shaft cap covers (20) and caps (21).
Power train unit assembly (25):
1,700 kg
50-300 4 D65EX, PX, WX-16

300 Power train
Removal and installation of power train unit assembly SEN05112-01
Installation [*6]
q Carry out installation in the reverse order to a Install seal (23) with the stamp (UP) up.
removal. a Ensure that clamp (22) is clamping all periph-
ery of the coupling securely.
[*1] 3 Seal mounting clamp (22):
a When installing the air conditioner hoses, take 4.9 – 8.3 Nm {0.50 – 0.85 kgm}
care that dirt, dust, water, etc. will not enter
them.
a When installing each joint of the air conditioner
hose, check that O-ring (70) is fitted to it.
a Check that O-ring (70) is free from flaw and
deterioration.
a When connecting the refrigerant piping, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8) to O-ring (70).
3 Thread size (M16 x 1.5) (Width across flats:
19 mm): 12 – 15 Nm {1.2 – 1.5 kgm}
24 mm): 20 – 25 Nm {2.0 – 2.6 kgm}
27 mm): 29 – 34 Nm {3.0 – 3.5 kgm} [*7]
3 Receiver tank refrigerant tube mounting bolt 2 Power train mounting bolt (24):
(M6 x 1.0) (Width across flats: 10 mm): Adhesive (LT-1A)
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
3 Air conditioner compressor refrigerant tube
[*8]
a Install seals (23) of the right and left bevel gear
mounting bolt (M6 x 1.0) (Width across flats:
shafts, taking care not to damage them.
10 mm): 8 – 12 Nm {0.8 – 1.2 kgm}
q Charging with refrigerant (R134a)
Charge the air conditioner circuit with refriger-
ant (R134a).
a Quantity of refrigerant: 900 ± 50 g
q Adding of compressor oil

For details, see Air conditioner, “Handling of
compressor oil”.
q Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5
[*2]
Hydraulic tank (Hydraulic oil): 82 l (For
2 Drive shaft mounting bolt (2):
details, see “Table of fuel, coolant and
Adhesive (LT-2)
3
lubricants”.)
Drive shaft mounting bolt (2):
98 – 123 Nm {10.0 – 12.5 kgm} q Refilling with fuel (Fuel tank)
Fuel tank (Diesel fuel): 415 l (For details, see
[*3] “Table of fuel, coolant and lubricants”.)
3 HSS case oil feed pipe (6) mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} q Checking for fuel leakage (Fuel system)
Check the fuel system for leakage. For details,
[*4] see Testing and adjusting, “Checking fuel sys-
3 Suction hose (8) mounting clamp: tem for leakage”.
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
q Bleeding air (Fuel system)
[*5] Bleed air from the fuel circuit. For details, see
3 Cover (18) mounting bolt: Testing and adjusting, “Bleeding air from fuel
98 – 123 Nm {10.0 – 12.5 kgm} circuit”.
D65EX, PX, WX-16 50-300 5

300 Power train
SEN05112-01 Separation and connection of power train unit assembly
Separation and connection of 4. Disconnect brake rod (2).

power train unit assembly 1
5. Disconnect parking brake cable (3). [*1]
Special tools a Check and record the installed dimen-
sions of parking brake cable (3).
New/Remodel
Necessity
6. Remove the hose clamps and disconnect
Symbol
Sketch
Q’ty
Part No. Part name hydraulic hoses (4), (5), (6) and (7).
7. Remove plate (8).

790-101-5401 Push tool kit (C) t 1
790-101-5431 • Plate 1
D 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Separation
1. Set the power train unit assembly horizontally
with blocks etc.
2. Drain the oil from the power train case.

6 Power train case: 53 l
3. Remove the mounting bolts and HSS and cool- 8. Remove the hose clamp and disconnect
ing fan pump assembly (1). hydraulic hose (9).
a Check and record the installed dimen-
4 HSS and cooling fan pump assembly sions of each branched hose.
(1): 130 kg
9. Remove the wiring harness clamp and discon-
nect wiring harness (10).
a Check and record the installed dimen-
sions of each branched wiring harness.
q Locations of wiring harness connectors
(See figure below)
(10a): CN-FAC
(10b): CN-TVC
(10c): CN-RFD
(10d): CN-L SOL
(10e): CN-L SW
(10f): CN-HHP
(10g): CN-R SW
(10h): CN-R SOL
(10j): CN-3 SOL
(10k): CN-3 SW
(10m): CN-1 SW
(10n): CN-1 SOL
(10p): CN-BVRV
(10q): CN-2 SW
(10r): CN-2 SOL
(10s): CN-F SW
(10t): CN-F SOL
(10u): CN-TCT
(10v): CN-TIP
50-300 6 D65EX, PX, WX-16

300 Power train
Separation and connection of power train unit assembly SEN05112-01
11. Sling HSS assembly (12).

a Ensure that all the wiring and piping are
disconnected.
12. Remove all transmission mounting bolts (13).

[*2]
13. Using 2 forcing screws [1], separate the trans-

mission assembly and HSS assembly (12).
a Use transmission mounting bolts (13)
described above as forcing screws [1].
10. Disconnect hydraulic hose (11).
14. Lift off HSS assembly (12).

4 HSS assembly (12): 750 kg
D65EX, PX, WX-16 50-300 7

300 Power train
15. Remove 2 brackets (13). 21. Set the transmission assembly on block [2]
with PTO assembly (19) up.
16. Disconnect PTO lubrication tube (14). [*3]
22. Remove oil strainer assembly (20).
23. Remove coupling (21). [*6]
24. Remove side block (22) for the torque con-

verter.
17. Disconnect hydraulic tube (15). [*4]
18. Remove the mounting bolts and lift off power

train and lubrication pump assembly (16). [*5]
4 Power train and lubrication pump
assembly (16): 20 kg
25. Remove 2 sleeves (25).
a Hook a wire etc. to the hole of sleeve (25)
19. Remove the mounting bolts and scavenging
to pull out.
pump assembly (17).
20. Remove right and left transmission mounting

brackets (18).
a Set a block etc. under the transmission
assembly to stabilize before removal.
50-300 8 D65EX, PX, WX-16

300 Power train
Separation and connection of power train unit assembly SEN05112-01
26. Using forcing screw [3], remove retainer 29. Lift off PTO assembly (27). [*8]
assembly (23). a The torque converter assembly is left on
the transmission side.
27. Remove oil seal (24) from retainer assembly 4 PTO assembly (27): 210 kg
(23). [*7]
30. Remove 9 mounting bolts (28) and lift off

torque converter assembly (29). [*9]
4 Torque converter assembly (29): 140 kg
28. Remove all mounting bolts (26).
31. Sling transmission assembly (30) and remove

it.
4 Transmission assembly (30): 380 kg
D65EX, PX, WX-16 50-300 9

300 Power train
Connection [*8]
q Carry out connection in the reverse order to 3 PTO assembly mounting bolt (26):
separation. 98 – 123 Nm {10.0 – 12.5 kgm}
[*1] [*9]
a If parking brake cable (3) was disconnected, 2 Torque converter assembly mounting bolt
adjust it. For details, see Testing and adjusting, (28): Adhesive (LT-2)
“Testing and adjusting parking brake cable”. 3 Torque converter assembly mounting bolt
(28): 98 – 123 Nm {10.0 – 12.5 kgm}
[*2]
3 Transmission mounting bolt (13):
245 – 309 Nm {25.0 ± 31.5 kgm} q Refilling with oil (Power train case)
Add oil through the oil filler to the specified
[*3] level.
3
5
PTO lubrication tube (14) joint bolt: Power train case (Power train oil): 53 l
19.6 – 29.4 Nm {2.0 – 3.0 kgm} (For details, see “Table of fuel, cool-
ant and lubricants”.)
[*4]
3 Hydraulic tube (15) hose mounting clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
3 Power train and lubrication pump assembly
(16) mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
[*6]
2 O-ring between coupling (21) and shaft end:
Grease (G2-LI)
2 Coupling (21) mounting bolt:
Adhesive (LT-2)
3 Coupling (21) mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
[*7]
a Using tool D1, press fit oil seal (24) to retainer
(23).
2 Oil seal (24) lip: Grease (G2-LI)
2 Outside of oil seal (24) press fitting face
and inside of hole on retainer (23) side:
Gasket sealant (LG-5)
a Wipe off projected gasket sealant.
50-300 10 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of PTO assembly SEN05112-01
Disassembly and assembly of 2) Drive gear assembly (2) out of cover

PTO assembly 1
assembly (1).
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
2 790-201-2720 Spacer t 1
790-101-5201 Push tool kit (B) t 1
790-101-5231 • Plate 1
3
790-101-5221 • Grip 1
01010-51225 • Bolt 1
D
790-101-5201 Push tool kit (B) t 1 3) Remove bearings (3a) and (3b) from gear
(2a).
790-101-5331 • Plate 1
4
790-101-5221 • Grip 1
01010-51225 • Bolt 1
5 796-430-1110 Push tool kit t 1
Disassembly
1. Cover assembly
1) Remove the mounting bolts and then
remove cover assembly (1) by using forc-
ing screws [1].
2. Idle gear
1) Remove mounting bolt (4) and plate (5).
D65EX, PX, WX-16 50-300 11

300 Power train
SEN05112-01 Disassembly and assembly of PTO assembly
2) Remove the mounting bolts and then 3) Remove bearing (14).

remove shaft (6) by using forcing screws
[2].
a Support gear (7) which may fall.
4. Input shaft bearing

Remove bearing (15).
3) Remove bearings (8a) and (8b) from gear

(7).
4) Remove outer races (10a) and (10b).
a When reusing bearings and outer
races (10a) and (10b), keep them
without changing their combinations.
3. Scavenging pump drive gear

1) Remove snap rings (11) and (12).
2) Drive gear (13) from the snap ring side.
50-300 12 D65EX, PX, WX-16

300 Power train
Assembly 2) Using tool D2, support the inner race of

q Precautions for assembly bearing (14).
a Clean each part thoroughly and check it is free 3) Press fit gear (13).
from dirt and flaw.
a Apply power train oil (For details, see “Table of
fuel, coolant and lubricants”) to the sliding sur-
faces of each part before installing.
a After press fitting each bearing, drip power
train oil (For details, see “Table of fuel, coolant
and lubricants”) onto its rotating parts and
rotate it about 10 turns.
a Confirm that the snap ring is securely in the
groove.
1. Input shaft bearing

Press fit bearing (15).
4) Install snap rings (12) and (11).
2. Scavenging pump drive gear

1) Using tool D3, press fit bearing (14).
3. Idle gear
1) Fit the O-ring to shaft (6) and install them
to the case.
2 O-ring: Grease (G2-LI)
D65EX, PX, WX-16 50-300 13

300 Power train
SEN05112-01 Disassembly and assembly of PTO assembly
2) Reverse the case and install bearing (8a). 5) Install plate (5) and mounting bolt (4).
2 Mounting bolt (4): Adhesive (LT-2)
3 Mounting bolt (4):
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
3) Using tool D4, press fit outer races (10a)

and (10b) to gear (7).
4. Cover assembly
1) Using tool D5, install bearings (3a) and
(3b) to gear (2a).
4) Install gear (7) and bearing (8b).

a When reusing bearings and outer
races (10a) and (10b), do not change
their combinations. (See the above)
a Press fit the inner race side of bearing 2) Fit the O-ring to cover (1a).
2 O-ring: Grease (G2-LI)
(8b).
3) Install gear assembly (2) to cover (1a).
50-300 14 D65EX, PX, WX-16

300 Power train
4) While meshing the idle gear and the PTO

gear, install cover assembly (1)
D65EX, PX, WX-16 50-300 15

300 Power train
SEN05112-01 Disassembly and assembly of torque converter assembly
Disassembly and assembly of 3) Sling and remove housing and turbine

torque converter assembly assembly (3).
4 Housing and turbine assembly (3):
1
Special tools 85 kg
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
6 794T-422-1110 Push tool t 1 Q

7 792T-413-1120 Push tool t 1 Q
790-101-5401 Push tool kit (C) t 1
D 790-101-5491 • Plate 1
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
9 792-213-1110 Wrench assembly t 1
2. Gear and input shaft assembly
1) Remove 20 mounting bolts (4).
Disassembly
1. Housing and turbine assembly
1) Sling and set torque converter assembly
(1).
4 Torque converter assembly (1):
140 kg
2) Remove 24 mounting bolts (2) from the
lower section.
2) Using forcing screws [1], remove gear and

input shaft assembly (5).
50-300 16 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of torque converter assembly SEN05112-01
3) Remove inner race (6) from gear and 2) Using puller [2], remove clutch housing
input shaft assembly (5). assembly (10) from turbine and gear
assembly (9).
3. Housing assembly
1) Remove snap ring (7) and spacer (8). 3) Remove turbine and gear assembly (9).
4) Remove 36 mounting bolts (39a).
D65EX, PX, WX-16 50-300 17

300 Power train
5) Sling and remove clutch housing (11). 8) Remove 2 seal rings (15) from clutch
housing (11).
6) Remove piston (12) from clutch housing

(11). 9) Remove 2 seal rings (16) from piston (12).
7) Remove bearing (13) from clutch housing 10) Remove 1 disc (18) from housing (17).
(11).
a Snap ring (14) is attached to bearing
(13).
50-300 18 D65EX, PX, WX-16

300 Power train
4. Stator assembly 5. Pump and stator shaft assembly

1) Remove stator assembly (20) from pump 1) Using tool D9, remove nut (27) from pump
and stator shaft assembly (19). and stator shaft assembly (19).
a Using a bar or others, lock housing
(28).
2) Remove snap ring (21) from stator (20a)

and remove freewheel assembly (22).
3) Remove outer race (23), 2 bushings (24),
2 balls (25), and freewheel (26) from free-
wheel assembly (22).
a Take care not to lose balls (25).
2) Reverse pump and stator shaft assembly

(19) and set it to block [3].
3) Remove the mounting bolts and then
remove stator shaft (29) by using forcing
screws [4].
4) Remove housing (28).
5) Remove inner races (30a) and (30b) from
stator shaft (29).
D65EX, PX, WX-16 50-300 19

300 Power train
8) Remove snap ring (34) from bearing cage

assembly (33) and remove bearing (35).
6) Remove seal ring (31) from housing (28).
7) Remove the mounting bolts and remove

bearing cage assembly (33) from pump
assembly (32).
50-300 20 D65EX, PX, WX-16

300 Power train
Assembly 3) Install bearing cage assembly (33) to

q Precautions for assembly pump (32).
a Clean each part thoroughly and confirm that it 2 Bearing cage assembly (33)
is free from dirt and flaw. mounting bolt: Adhesive (LT-2)
a Apply power train oil (For details, see “Table of 3 Bearing cage assembly (33)
fuel, coolant and lubricants”) to the sliding sur- mounting bolt:
faces of each part before installing. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Confirm that the snap ring is securely in the
groove.
1. Pump and stator shaft assembly

1) Using tool D8, press fit bearing (35) to
bearing cage (33).
2) Install snap ring (34).
4) Install seal ring (31) to housing (28).

a When installing seal ring (31), take
care not to open its abutment joint too
wide.
3 Seal ring (31): Grease (G2-LI)
D65EX, PX, WX-16 50-300 21

300 Power train
5) Install stator shaft (29) to housing (28). 9) Install nut (27) to pump and stator shaft
2 Stator shaft (29) mounting bolt: assembly (19) and tighten it with tool D9.
Adhesive (LT-2) 3 Nut (27):
3 Stator shaft (29) mounting bolt: 441.3 – 490.3 Nm {45 – 50 kgm}
98 – 123 Nm {10.0 – 12.5 kgm} a Using a bar or others, lock housing
(28).
6) Reverse housing (28) and install inner

race (30b) to stator shaft (29).
7) Install pump (32) and inner race (30a) to
stator shaft (29).
8) Using tool D6, press fit inner race (30a).
2. Stator assembly
1) Install freewheel (26), 2 balls (25) and 2
bushings (24) to outer race (23).
a When installing freewheel (one-way
clutch) (26), set arrow (b) on the front
face of the bearing cage toward the
input side and confirm the rotation
direction of the stator.
Clockwise direction: Free rotation
Counterclockwise direction: Lock
a Do not remove sprag (d).
a When inserting, take care that drag
clips (c) on the periphery of freewheel
(26) will not be hitched in the ball
grooves of the outer race.
2) Install freewheel assembly (22) to stator
(20a) and install snap ring (21).
50-300 22 D65EX, PX, WX-16

300 Power train
2 Freewheel assembly (22): 3) Install stator assembly (20) to pump and

Power train oil (For details, see stator shaft assembly (19).
“Table of fuel, coolant and lubri-
cants”)
3. Housing assembly
1) Set turbine and gear assembly (9) to cylin-
der [5].
2) Install housing (17) and 1 disc (18) to tur-

bine and gear assembly (9).
D65EX, PX, WX-16 50-300 23

300 Power train
3) Install 2 seal rings (15) to clutch housing 6) Sling and install clutch housing (11).
(11). a When installing the clutch housing,
4) Install 2 seal rings (16) to clutch housing match the holes (3 places) on the pis-
(12). ton top to the projections on the
2 Seal rings (15) and (16): clutch housing.
Grease (G2-LI) 4 Clutch housing (11): 25 kg
a Install seal rings (15) and (16) in the 2 Mounting bolt (39a):
direction shown below. Adhesive (LT-2)
3 Mounting bolt (39a):
59 – 74 Nm {6.0 – 7.5 kgm}
5) Install piston (12).

clutch housing (11).
a Snap ring (14) is attached to bearing
(13).
50-300 24 D65EX, PX, WX-16

300 Power train
8) Install spacer (8) and snap ring (7). 2) Install gear and input shaft assembly (5)
and install mounting bolts (4).
98 – 123 Nm {10.0 – 12.5 kgm}
5. Housing and turbine assembly

1) Sling and install housing and turbine
assembly (3).
a Match the drain plug mounting hole to
the oil groove of the housing.
4 Housing and turbine assembly (3):
85 kg
4. Gear and input shaft assembly

1) Press fit inner race (6) to gear and input
shaft assembly (5).
D65EX, PX, WX-16 50-300 25

300 Power train
2) Install mounting bolts (2) to torque con-

verter assembly (1) from below.
49.0 – 58.8 Nm {5.0 – 6.0 kgm}
3 2 drain plugs:
5.9 – 8.8 Nm {0.6 – 0.9 kgm}
50-300 26 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of transmission assembly SEN05112-01
Disassembly and assembly of Disassembly

transmission assembly 1 a Keep the removed discs and plates on a flat
place so that they will not distort.
Special tools
1. Related parts
New/Remodel
1) Sling and set transmission assembly (1) to
Necessity
Symbol
Sketch
block [1].
Q’ty
4 Transmission assembly (1): 380kg
Part No. Part name
791T-415-5300 Puller assembly t 1 Q

10 791T-415-5310 • Plate 1 Q
01010-82040 • Bolt 1
Oil leak tester kit
11 799-301-1600 t 1
(A)
790-101-5201 Push tool kit (B) t 1
790-101-5311 • Plate 1
12
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5461 • Plate 1
13 2) Remove the mounting bolts then sling and
790-101-5421 • Grip 1 remove transmission control valve assem-
01010-51240 • Bolt 1 bly (2).
790-101-5201 Push tool kit (B) t 1 4 Transmission control valve assem-
bly (2): 25 kg
D 790-101-5281 • Plate 1
14
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-101-5001 Push tool kit (A) t 1
790-101-5081 • Plate 1
15
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5471 • Plate 1
16
790-101-5421 • Grip 1
01010-51240 • Bolt 1
17 790-201-2760 Spacer t 1
18 793T-615-1170 Push tool t 1 Q 3) Using tool [2], remove 5 sleeves (3).
19 790-201-2830 Spacer t 1
20 791T-415-5210 Push tool t 1 Q
D65EX, PX, WX-16 50-300 27

300 Power train
SEN05112-01 Disassembly and assembly of transmission assembly
4) Remove main relief valve assembly (4) 3. Transmission case

and plate (5). 1) Sling and set transmission assembly (9)
5) Remove sleeve (6). vertically to block [3].
a Hook a wire or others to the hole of 4 Transmission assembly (9): 350 kg
sleeve (6) to pull out.
2) Sling transmission case (10) temporarily

and remove 11 through bolts (11).
a When loosening through bolts (11),
do not use an impact wrench which
can damage the vibration control
sleeve.
2. Snap ring
Remove snap ring (8) from output shaft (7).
a This is preparatory work for removing out-
put shaft (7).
3) Sling and remove transmission case (10).

4 Transmission case (10): 120 kg
50-300 28 D65EX, PX, WX-16

300 Power train
4. Input shaft, front cover and No. 1 carrier 5. Disassembly of input shaft, front cover and
assembly No. 1 carrier assembly
1) Remove remaining 3 through bolts (12). 1) Remove snap ring (14), No. 2 sun gear
a When loosening through bolts (12), (15) and snap ring (16).
do not use an impact wrench which 2) Remove snap ring (17) and No. 1 sun
can damage the vibration control gear (18).
sleeve.
3) Remove snap ring (19).

2) Sling and remove input shaft, front cover,
and No. 1 carrier assembly (13).
4 Input shaft, front cover, and No. 1
carrier assembly (13): 35 kg
4) Set front cover (20) to blocks [4].

5) Using tool D20, remove input shaft and
No. 1 carrier assembly (21) and spacer
(21a).
D65EX, PX, WX-16 50-300 29

300 Power train
6) Remove snap ring (22) and remove No. 1 6. Disassembly of No. 1 carrier assembly
carrier assembly (24) from input shaft Remove 4 shafts (28), ball (29), 2 thrust wash-
(23). ers (30), bearing (31) and planetary gear (32)
from No. 1 carrier assembly (24).
a Take care not to lose ball (29).
7) Remove 2 seal rings (35) and (36) each,

snap rings (37) and (38a) and bearing (38)
from input shaft (23). 7. Disassembly of front cover
1) Remove snap ring (33) from front cover
(20) and remove bearing (34).
2) Remove seal ring (34a).
8) Remove snap ring (25) from No. 1 carrier

assembly (24) and remove No. 1 ring gear
(26).
8. No. 1 disc, plate and spring
1) Remove 5 springs (39).
2) Remove the following alternately.
Plate (40): 6 pieces
Disc (41): 5 pieces
3) Remove 5 guide pins (42).
50-300 30 D65EX, PX, WX-16

300 Power train
9. No. 1 piston 2) Remove seal rings (46) and (47) from No.
1) Remove No. 1 piston (43). 1 housing (45).
2) Remove seal ring (44) from No. 1 piston 11. No. 2 piston
(43). 1) Remove No. 2 piston (48).
10. No. 1 housing 2) Remove seal ring (49) from No. 2 piston
1) Sling and remove No. 1 housing (45). (48).
4 No. 1 housing (45): 25 kg
D65EX, PX, WX-16 50-300 31

300 Power train
12. No. 2 disc, plate and spring 13. No. 2 housing and No. 2 carrier assembly
1) Remove 5 springs (50). 1) Remove snap ring (58).
Disc (52): 7 pieces
2) Sling and remove No. 2 housing and No. 2

carrier assembly (59).
4 No. 2 housing and No. 2 carrier
assembly (59): 45 kg
4) Remove 14 through bolt vibration control
sleeves (55) from No. 2 housing (54).
a Confirm and record slit position (a) of
each vibration control sleeve (55)
5) Remove lubricating oil relief valve (56)
and spring (57).
3) Set No. 2 housing and No. 2 carrier

assembly to blocks [5].
4) Remove snap ring (60) and remove No. 2
carrier assembly (61) from No. 2 housing
(62).
50-300 32 D65EX, PX, WX-16

300 Power train
5) Remove spacer (61a) and No. 2 ring gear

(61b) from No. 2 carrier assembly (61).
14. Disassembly of No. 2 housing

Remove snap ring (71), bearing (72) and seal
ring (73) from No. 2 housing (62).

Disc (76): 4 pieces
15. Disassembly of No. 2 carrier and No. 1 ring
gear assembly
1) Remove 5 shafts (64), ball (65), 2 thrust
washers (66), bearing (67) and planetary
gear (68) from No. 2 carrier assembly
(61).
2) Using pins [6], push out snap ring (69) and
remove No. 1 ring gear (70).
a Insert 2 pins [6] in 2 of the 4 holes at
the diagonal positions on the periph-
ery of No. 1 ring gear (70).
D65EX, PX, WX-16 50-300 33

300 Power train
17. Output shaft and No. 3 carrier assembly 18. Disassembly of No. 3 carrier assembly
1) Remove No. 3 carrier assembly (78). 1) Remove 3 seal rings (83) from No. 3 car-
rier assembly (79).
2) Remove snap ring (84) and bearing (85).
gear (90) from No. 3 carrier assembly
(79).
2) Remove output shaft (80).
19. No. 3 ring gear and No. 4 carrier assembly

Sling and remove No. 3 ring gear and No. 4
carrier assembly (91).
3) Remove snap ring (81) from output shaft

(80).
20. Disassembly of No. 3 ring gear and No. 4

carrier assembly
1) Using pins [7], push out snap ring (92) and
remove No. 3 ring gear (93).
a Insert 2 pins [7] in 2 of the 4 holes at
the diagonal positions on the periph-
ery of No. 3 ring gear (93).
50-300 34 D65EX, PX, WX-16

300 Power train
2) Remove seal ring (104) from No. 3 piston

(103).
2) Remove 4 shafts (95), pin (96), 2 thrust

gear (99) from No. 4 carrier assembly 22. No. 3 housing
(91). 1) Sling and remove No. 3 housing (105).
a Take care not to lose pin (96).
3) Remove snap ring (100) and remove
bearing (101) and spacer (102) as an
assembly.
4) Remove bearing (101) from spacer (102).
2) Remove seal ring (106) from No. 3 hous-

ing (105).
21. No. 3 piston

1) Remove No. 3 piston (103).
D65EX, PX, WX-16 50-300 35

300 Power train
23. No. 4 disc, plate, and spring

Disc (109): 4 pieces
2) Remove snap ring (118) from No. 5 carrier

assembly (112) and remove No. 4 ring
gear (119).
a If the above No. 5 carrier assembly is
not removed first, snap ring (118) pre-
24. No. 5 carrier and No. 4 ring gear assembly vents it from being removed.
1) Remove 4 hexagon socket head bolts
(110).
2) Remove No. 5 carrier and No. 4 ring gear
assembly (111).
26. No. 4 piston

25. Disassembly of No. 5 carrier and No. 4 ring

gear assembly
washers (115), bearing (116), and plane-
tary gear (117) from No. 5 carrier assem-
bly (112).
50-300 36 D65EX, PX, WX-16

300 Power train
2) Remove seal ring (121) from No. 4 piston 28. No. 5 disc, plate and spring
(120). 1) Remove 5 springs (124).
27. No. 4 housing

1) Sling and remove No. 4 housing (122).
29. No. 5 piston


ing (122).
2) Remove seal ring (129) from No. 5 piston

(128).
D65EX, PX, WX-16 50-300 37

300 Power train
30. No. 5 ring gear and No. 5 sun gear 3) Remove seal rings (137) and (138) from
1) Remove No. 5 ring gear (130) and No. 5 bearing cage (135).
sun gear (131).
4) Remove bearing (136) from bearing cage

31. Disassembly of No. 5 housing assembly (135).
1) Remove snap ring (133) and spacer (134)
from No. 5 housing assembly (132).
5) Reverse No. 5 housing assembly (132)

and remove snap ring (139).
2) Using puller [8], remove bearing cage 4 No. 5 housing assembly (132):
(135) and bearing (136) as an assembly. 30 kg
50-300 38 D65EX, PX, WX-16

300 Power train
6) Using push tool [9], remove spacer (140) Assembly

and bearing (141) as an assembly from q Precautions for assembly
No. 5 housing assembly (132). a Clean each part thoroughly and confirm that it
is free from dirt and flaw.
a Apply power train oil (For details, see “Table of
fuel, coolant and lubricants”) to the sliding sur-
faces of each part before installing.
a Check that the snap ring is securely in the
groove.
a When installing piston seal ring (a), set pres-
sure receiving side (b) toward housing (c) as
shown in the figure.
a When installing the metallic seal ring, apply
7) Remove bearing (141) from spacer (140). grease (G2-LI) to it and install evenly, taking
care not to shift it in any direction.

ing (132). 1. Assembly of No. 5 housing assembly
1) Set No. 5 housing (132) to blocks [10].
4 No. 5 housing (132): 30 kg
D65EX, PX, WX-16 50-300 39

300 Power train
2) Using tool D12, press fit bearing (141) to 7) Using tool D18, press fit bearing cage
spacer (140). assembly (135) to No. 5 housing (132).
a Press fit the inner race side of the
bearing.
3) Using the push tool, press fit spacer (140)

and bearing (141) as an assembly to No. 5
housing (132). 8) Set spacer (134) to No. 5 housing assem-
4) Install snap ring (139). bly (132) and install snap ring (133).
5) Using tool D13, press fit bearing (136) to 9) Install seal ring (142) to No. 5 housing
bearing cage (135). (132).
6) Install seal rings (137) and (138) to bear- 2 Seal ring (142): Grease (G2-LI)
ing cage (135). a When Installing the seal ring, confirm
2 Seal rings (137) and (138): its pressure receiving side.
Grease (G2-LI) (See “• Precautions for assembly”)
50-300 40 D65EX, PX, WX-16

300 Power train
2. No. 5 piston 4. No. 4 Housing

1) Install seal ring (129) to No. 5 piston (128). 1) Install seal ring (123) to No. 4 housing
2 Seal ring (129): Grease (G2-LI) (122).
a When installing the seal ring, confirm 2 Seal ring (123): Grease (G2-LI)
its pressure receiving side. a When installing the seal ring, confirm
(See “• Precautions for assembly”) its pressure receiving side.
(See “• Precautions for assembly”)
2) Install No. 5 piston (128) and No. 5 ring

gear (130). 2) Sling and install No. 4 housing (122).
a Check that the spring is securely in
the piston groove.

1) Install 5 guide pins (127).
2) Install the following alternately.
3) Install 5 springs (124).
a Spring free length: 59 mm
D65EX, PX, WX-16 50-300 41

300 Power train
5. No. 4 piston 2) Install bearing (116) to planetary gear

1) Install seal ring (121) to No. 4 piston (120). (117), set thrust washers (115) on its both
2 Seal ring (121): Grease (G2-LI) sides, and set it to No. 5 carrier (112).
a When installing the seal ring, confirm 3) Set ball (114) to shaft (113) and install it to
its pressure receiving side. No. 5 carrier (112). (4 places)
7. No. 5 carrier and No. 4 ring gear assembly

2) Install No. 4 piston (120). 1) Using guide bolts [11], install No. 5 carrier
and No. 4 ring gear assembly (111).
2) Tighten 4 hexagon socket head bolts
(110).
2 Hexagon socket head bolt (110):
Adhesive (LT-2)
3 Hexagon socket head bolt (110):
27– 34 Nm {2.8 – 3.5 kgm}
6. Assembly of No. 5 carrier and No. 4 ring

gear assembly
1) Set No. 4 ring gear (119) to No. 5 carrier
(112) and install snap ring (118).
8. No. 5 sun gear

Install No. 5 sun gear (131).
50-300 42 D65EX, PX, WX-16

300 Power train
9. No. 4 disc, plate and spring 11. No. 3 piston

1) Install the following alternately. 1) Install seal ring (104) to No. 3 piston (103).
Plate (108): 5 pieces 2 Seal ring (103): Grease (G2-LI)
Disc (109): 4 pieces a When installing the seal ring, confirm
2) Install 5 springs (107). its pressure receiving side.
a Spring free length: 59 mm (See “• Precautions for assembly”)
10. No. 3 housing 2) Install No. 3 piston (103).

1) Install seal ring (106) to No. 3 housing
(105).
a When installing the seal ring, confirm
its pressure receiving side.
12. Assembly of No. 3 ring gear and No. 4 car-

rier assembly
spacer (102).
2) Sling and install No. 3 housing (105).

a Confirm that the spring is securely in
the piston groove.
D65EX, PX, WX-16 50-300 43

300 Power train
2) Using the push tool, press fit bearing (101) 14. Output shaft
and spacer (102) as an assembly to No. 4 1) Install snap ring (81) to output shaft (80).
carrier (91). 2 Splined section of output shaft (80):
3) Install snap ring (100). Grease (LM-G) or molybdenum
4) Install bearing (98) to planetary gear (99), disulfide lubricant (LM-P)
set thrust washers (97) on its both sides,
and set it to No. 4 carrier (91).
5) Install shaft (95) to No. 4 carrier (91) and
drive pin (96). (4 places)
(91) and install snap ring (92).
2) Install output shaft (80) to No. 3 ring gear

and No.4 carrier assembly (91).
13. No. 3 ring gear and No. 4 carrier assembly

Sling and install No. 3 ring gear and No. 4 car-
rier assembly (91).
50-300 44 D65EX, PX, WX-16

300 Power train
15. Assembly of No. 3 carrier assembly 17. No. 3 disc, plate and spring
1) Install bearing (89) to planetary gear (90), 1) Install 5 guide pins (53).
set thrust washers (88) on its both sides, 2) Install the following alternately.
and set it to No. 3 carrier (79). Plate (75): 5 pieces
2) Set ball (87) to shaft (86) and install it to Disc (76): 4 pieces
No. 3 carrier (79). (4 places) 3) Install 5 springs (74).
3) Using tool D15, press fit bearing (85). a Spring free length: 59 mm
5) Install 3 seal rings (83) to No. 3 carrier
assembly (79).
18. Assembly of No. 2 housing

No. 2 housing (62).
2) Install seal ring (73).
16. No. 3 carrier assembly

Install No. 3 carrier assembly (78). 3) Install snap ring (71).
D65EX, PX, WX-16 50-300 45

300 Power train
19. Assembly of No. 2 carrier and No. 1 ring 2) Set No. 2 carrier assembly (61) to cylinder
gear assembly [12].
1) Set No. 1 ring gear (70) to No. 2 carrier 3) Install No. 2 housing assembly (62).
(61) and install snap ring (69). 4) Using tool D17, press No. 2 housing
2) Install bearing (67) to planetary gear (68), assembly (62).
set thrust washers (66) on its both sides, a Press fit the inner race side of the
and set it to No. 2 carrier (61). bearing.
3) Set ball (65) to shaft (64) and install it to
No. 2 carrier (61). (4 places)
21. No. 2 housing and No. 2 carrier assembly

20. Assembly of No. 2 housing and No. 2 car- 1) Sling and install No. 2 housing and No. 2
rier assembly carrier assembly (59).
1) Install spacer (61a) and No. 2 ring gear 4 No. 2 housing and No. 2 carrier
(61b) to No. 2 carrier assembly (61). assembly (59): 45 kg
a Check that the spring is securely in
the piston groove.
50-300 46 D65EX, PX, WX-16

300 Power train
2) Put tool D10 in groove (b) of No. 2 carrier 4) Install 14 through bolt vibration control
assembly (78) and rotate it about 90° to sleeves (55) to No. 2 housing (54).
part (c). a Set slit (a) of vibration control sleeve
a Set tool D10 so that its both ends will (55) to the position recorded when
be securely fixed in groove (d) on the removed.
inside wall of No. 2 carrier assembly 5) Install spring (57) and lubricating oil relief
(78). valve (56).
3) Tighten the bolt of tool D10 to pull up No.
2 carrier assembly (78), and then install
snap ring (58).

Disc (52): 7 pieces
a Spring free length: 77 mm
D65EX, PX, WX-16 50-300 47

300 Power train
23. No. 2 piston 2) Sling and install No. 1 housing (45).

1) Install seal ring (49) to No. 2 piston (48). 4 No. 1 housing (45): 25 kg
2 Seal ring (49): Grease (G2-LI) a Confirm that the spring is fitted to pis-
a When installing the seal ring, confirm ton groove securely.
25. No. 1 piston

1) Install seal ring (44) to No. 1 piston (43).
2) Install No. 2 piston (48). 2 Seal ring (44): Grease (G2-LI)
24. No. 1 housing

1) Install seal rings (46) and (47) to No. 1
housing (45).
2 Seal rings (46) and (47): 2) Install No. 1 piston (43).
Grease (G2-LI)
50-300 48 D65EX, PX, WX-16

300 Power train
26. Assembly of No. 1 carrier assembly

1) Install bearing (31) to planetary gear (32),
set thrust washers (30) on its both sides,
and set it to No. 1 carrier (24).
2) Set ball (29) to shaft (28) and install it to
No. 1 carrier (24). (4 places)
4) Install input shaft (23) to No. 1 carrier

assembly (24) and install snap ring (22).
27. Assembly of input shaft and No. 1 carrier

assembly
assembly (24) and install snap ring (25).
5) Install No. 1 sun gear (18) and snap ring

(17) to input shaft (23).
6) Install snap ring (16), No. 2 sun gear (15)
and snap ring (14).
2) Install bearing (38) to input shaft (23).

3) Install 2 seal rings (35) and (36) each and
snap rings (38a) and (37).
2 Seal rings (35) and (36):
Grease (G2-LI)
2 Transmission side spline portion
(e):
Grease (LM-G) or molybdenum
disulfide lubricant (LM-P)
a Do not coat grease to the torque con-
verter side spline portion (f).
D65EX, PX, WX-16 50-300 49

300 Power train
28. Input shaft and No. 1 carrier assembly 30. Assembly of front cover
Install input shaft and No. 1 carrier assembly 1) Using tool D19, press fit bearing (34) to
(21). front cover (20).
2) Install snap ring (33) to front cover (20).
3) Install seal ring (34a).
2 Seal ring (34a): Grease (G2-LI)

Disc (41): 5 pieces
a Spring free length: 69.5mm
31. Front cover

1) Install spacer (21a).
50-300 50 D65EX, PX, WX-16

300 Power train
2) Install front cover (20).

a Confirm that the spring is securely in
the piston groove.
3) Install 3 through bolts (12).
a Push in through bolts (12) with the
hand until they reach the tap hole so
that they will not damage the vibration
control sleeves.
a Use an impact wrench only after the
threads are engaged completely.
3 Through bolt (12):
157 – 177 Nm {16 – 18 kgm}
32. Operation check of piston

Using tool D11, check the operating condition
and stroke of the piston.
Piston Stroke (mm)
No.1 5
No.2 7
No.3 4
No.4 4
No.5 4
4) Install snap ring (19) according to the fol-

lowing procedure.
1] Using tool [13], sling input shaft (23)
slightly.
a At this time, ensure that the
mounting groove of snap ring
(19) is out completely.
2] Install snap ring (19).
33. Transmission case

1) Sling and install transmission case (10).
4 Transmission case (10): 120 kg
D65EX, PX, WX-16 50-300 51

300 Power train
2) Install 11 through bolts (11) to transmis- 35. Related parts

sion case (10). 1) Install sleeve (6).
a Push in through bolts (11) with the 2) Install the O-ring to the groove and install
hand until they reach the tap hole so plate (5) and main relief valve assembly
that they will not damage the vibration (4).
control sleeves. 3 Main relief valve assembly (4)
a Use an impact wrench only after the mounting bolt:
threads are engaged completely. 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
3 Through bolt (11):
157 – 177 Nm {16 – 18 kgm}
34. Snap ring

1) Sling and set transmission assembly hori-
zontally.
4 Transmission assembly: 350 kg
2) Install snap ring (8) to output shaft (7).
3) Using tool [2], install 5 sleeves (3).
50-300 52 D65EX, PX, WX-16

300 Power train
4) Install the O-ring to the groove and sling

and install transmission control valve
assembly (2).
4 Transmission control valve assem-
bly (2): 25 kg
D65EX, PX, WX-16 50-300 53

300 Power train
SEN05112-01 Disassembly and assembly of HSS assembly
Disassembly and assembly of Disassembly

HSS assembly 1 1. Transmission speed sensor
Remove transmission speed sensor cover (1),
Special tools and then pull out and remove transmission
speed sensor (2).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
1 791T-422-1320 Hanger q 1 Q
2 790-302-1500 Wrench kit q 1
3 796-730-2300 Wrench assembly q 1
Commercially
Torque wrench
available or q 1
set
4 795-630-1803
795-630-1810 • Torque wrench 1
795-630-1830 • Adapter 1
790-101-5201 Push tool kit (B) t 1
2. Brake valve assembly
790-101-5261 • Plate 1 Remove brake valve assembly (4).
5
790-101-5221 • Grip 1
01010-51225 • Bolt 1
6 794T-422-1110 Push tool t 1 Q
790-101-5401 Push tool kit (C) t 1
790-101-5481 • Plate 1
7
790-101-5421 • Grip 1
E 01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) t 1
790-101-5491 • Plate 1
8
790-101-5421 • Grip 1
01010-51240 • Bolt 1
9 793T-659-1110 Push tool t 1 Q
3. Cover assembly
10 796T-467-2160 Push tool t 1 Q 1) Using eyebolts [1], remove cover assem-
11 790-201-2730 Push tool t 1 bly (5).
790-101-5201 Push tool kit (B) t 1
790-101-5221 • Grip 1
12 01010-51225 • Bolt 1
790-101-5271 • Plate 1
790-101-5311 • Plate 1
790-101-5001 Push tool kit (A) t 1
790-101-5091 • Plate 1
13
790-101-5021 • Grip 1
01010-50816 • Bolt 1
50-300 54 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of HSS assembly SEN05112-01
2) Remove 5 sleeves (24) and 2 pieces of 3] Remove bearing (10) from gear (9).
(25) from the HSS case.
2) Intermediate gear
4. Disassembly of cover assembly 1] Remove tube (11).
1) Input gear assembly
1] Remove snap ring (12).
2] Remove the bolt and holder (13).

3] Drive out shaft (14) from the bolt side
2] Using puller [2], pull out gear assem- and remove gear (15).
bly (6) and cage (7) together, and a Take care not to lose the ball.
then remove gear assembly (6) from
cage (7).
D65EX, PX, WX-16 50-300 55

300 Power train
4] Remove bearing (17) and spacer 4] Remove snap ring (23), then remove
(17a) from gear (15). bearing (28) from cover (32).
5] Remove outer race (29) from cover
(32).
3) Left carrier driver gear

1] Remove bolt (19) and holder (20).
2] Remove gear (22). 6] Remove bearing (26) from shaft (21).
3] Using gear puller [3], push out shaft 4) Remove the plug, spring (30), and valve
(21). (31).
50-300 56 D65EX, PX, WX-16

300 Power train
5. Removal of brake and carrier assembly 4) Remove bearing (60) from cover (41).
Remove the mounting bolt, then remove brake
and carrier assembly (34) with tool E1.
a Do not remove 4 hexagon socket head
bolts.
5) Remove spring (42).

6) Using eyebolts [5], remove piston (43).
6. Disassembly of brake assembly

1) Remove flange (36).
2) Remove snap ring (37) and spacer (38).
7) Push up and remove cage (51), taking

care not to damage the disc.
8) Remove seal rings (53) and (27) from
cage (51).
9) Using eyebolts [7], remove drum (45),
3) Set puller [4] and loosen 4 hexagon discs, and plates as a unit.
socket head bolts and remove cover (41).
a The inner race side of the bearing
comes out.
a Do not remove bolts (40) until cover
(41) comes off.
D65EX, PX, WX-16 50-300 57

300 Power train
10) Remove discs (46), plates (47), and 13) Remove bushing (60) from hub (39).
springs (48) from drum (45). 14) Remove snap ring (58), then remove stop-
per (56) from the hub.
11) Remove snap ring (59) and bearing (57).

a Pry up the bearing from the cut of the 7. Disassembly of carrier assembly
hub. 1) Turn over the hub and carrier assembly
and remove bolts (89), then remove car-
rier assembly (64) from hub (54).
12) Remove 18 mounting bolts, then remove

hub (39) from hub (54).
2) Remove hub (92) from carrier assembly
(64), then remove snap ring (50) and gear
(52).
50-300 58 D65EX, PX, WX-16

300 Power train
3) Drive roll pin (65) into the shaft. 3) Using the bearing race puller, remove
4) Pull out shaft (66) and remove gear (52), bearing (74).
thrust washer (67), and bearing (69). 4) Remove collar (71).
a Pull roll pin (65) out of the shaft. 5) Remove snap ring (93).
a Only the right side of the machine.
5) Remove bushing (91) from carrier (90).

9. Bevel pinion assembly
8. Sun gear 1) Remove the mounting bolts.
1) Remove snap ring (70) and collar (73). 2) Using guide bolts [9] and forcing screws
[10], remove bevel pinion assembly (95)
and shim (96).
a Check and record the quantity and
thickness of the shims.
2) Using gear puller [8], remove sun gear

(72) and bearing (98).
3) Disassembly of bevel pinion assembly

1] Remove bolt (97), plate (99), and pin
(100).
D65EX, PX, WX-16 50-300 59

300 Power train
2] Secure the pinion with a press and 10. Bevel gear shaft and bevel gear
remove nut (101) with tool E2. 1) Sling bevel gear and shaft assembly (75)
3] Using tool E5, remove bevel pinion temporarily.
(102) from cage (103). 2) Remove cage assemblies (76) and (86).
a Check and record the thickness,
quantity, and positions of shims (77).
a Since both cages are different from
each other, make marks on them.
4] Remove bearing (104).

5] Remove outer races (105) and (107)
from cage (103).
3) Move bevel gear and shaft assembly (75)

to the left end and remove bearing (78)
with puller [12].
a Remove only the bearing on the left
side of the machine.
6] Remove bearing (106) and spacer

(108) from bevel pinion (102).
50-300 60 D65EX, PX, WX-16

300 Power train
4) Sling bevel gear (79) and remove mount- Assembly

ing nut (80) and pull out bevel gear shaft q Precautions for assembly
assembly (81) to the right side of the a Clean the all parts and check them for dirt
machine. or damage before installing.
a Drop power train oil (refer to the section
“Fuel, coolant and lubricants” for detail)
onto the rotating parts of each bearing and
rotate it several turns.
a Coat the sliding parts with power train oil
(refer to the section “Fuel, coolant and
lubricants” for detail) before installing.
a Apply grease (G2-LI) to each piston seal
ring and install it evenly with the pressure
receiving side directed to the housing.
2 Rotary seal ring:
Fix each seal ring with grease (G2-
LI) and install it very carefully not to
catch it in the parts.
5) Remove bearing (78) from bevel gear a Check that the snap rings are fitted
shaft (82). securely in the grooves.
6) Remove bolts (83).
7) Remove outer race (84) from cage (76).
1. Suction tube
Install suction tube (55).
8) Remove seal rings (85) from bevel gear
shaft (81).
D65EX, PX, WX-16 50-300 61

300 Power train
2. Bevel gear shaft and bevel gear assembly 5) Insert bevel gear shaft (81) in bevel gear
1) Install bolt (83) to bevel gear shaft (82). (79) slung at the center of the case from
2) Heat bearing (78) with a bearing heater, the right side of the machine.
etc. and install it to the right side of the a Tighten mounting nut (80) temporarily
bevel gear shaft by shrink fit. in advance.
a If the bearing temperature is raised
too high, the hardness of the heat-
treated part lowers. Accordingly, do
not raise the bearing temperature
more than 120ºC.
a After installing the bearing, drop
power train oil (refer to the section
“Fuel, coolant and lubricants” for
detail) onto its rotating parts and
a Check that the clearance at the bear-
ing end is 0.03 mm or less.
3) Install outer race (84) to cages (76) and (86).
6) Heat bearing (78) with a bearing heater,

etc. and install it to the left side of the
bevel gear shaft by shrink fit.
a If the bearing temperature is raised
too high, the hardness of the heat-
treated part lowers. Accordingly, do
not raise the bearing temperature
more than 120ºC.
a After installing the bearing, drop
power train oil (refer to the section
detail) onto its rotating parts and
4) Install seal rings (85) to bevel gear shaft a Check that the clearance at the bear-
(81). ing end is 0.03 mm or less.
50-300 62 D65EX, PX, WX-16

300 Power train
7) Install cages (76) and (86) to bevel gear

and shaft assembly (75).
a Since both cages are different from each
other, take care not to mistake them.
a Install shims (77) of the thickness and
quantity recorded when removed.
q Standard shim thickness: 1.5 mm
q Varieties of shim thickness:
0.2 mm, 0.3 mm, 0.5 mm
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
8) Tighten the bevel gear mounting nut
securely.
a Place a plastic hammer, etc. between
the bevel gear. 3. Bevel pinion assembly
3 Mounting nut: 1) Assembly of bevel pinion
245 – 309 Nm {25.0 – 31.5 kgm} 1] Using tool E6, press fit bearing (106)
to bevel pinion (102) and install
spacer (108).
9) Adjusting pre-load
a Adjust the pre-load with the bevel pin-
ion assembly removed.
1] Rotate the bevel gear and shaft
assembly several turns to fit the bear-
ing.
2] Install tool E3 to the end of bevel gear
shaft (81) and measure the rotation
torque with tool E4 (torque wrench).
q Standard rotation torque:
10.3 – 14.7 Nm {1.05 – 1.50 kgm}
a If the rotation torque is lower than the
standard value, reduce the quantity of
shims (77) in step 7). If the former is
higher, increase the latter.
D65EX, PX, WX-16 50-300 63

300 Power train
2] Using tools E7 and E8, press fit outer 4] Using tool E9, press fit bearing (104)
races (105) and (107) to cage (103). to cage (103).
3] Place bevel pinion (102) on the press 5] Secure the pinion with the press and
stand and set cage (103). tighten locknut (101) with tool E2.
2 Locknut: Adhesive (LT-2)
3 Locknut:
392 – 441 Nm {40 – 45 kgm}
6] After tightening the nut, return it until
1 of its pin holes (8 places) is
matched to 1 of the pin holes of the
pinion shaft (5 places).
a Return the nut by 0 – 9°.
a Tighten the nut, turning the cage.
a After tightening the nut, check
that the bevel pinion rotates
smoothly.
7] Install pin (100), plate (99), then

tighten bolt (97).
3 Bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
50-300 64 D65EX, PX, WX-16

300 Power train
2) Using guide bolt [9], install shims (96) and a Adjust the backlash by increasing or
bevel pinion assembly (95). decreasing the thickness of both
a Install shims of the thickness and shims. Do not change the total thick-
quantity recorded when removed. ness of both shims so that the pre-
q Standard shim thickness: 2 mm load will not change. (If the thickness
q Varieties of shim thickness: of the shim on one side is increased,
0.2 mm, 0.3 mm, 1.0 mm decrease the thickness of the other
side, and vice versa.)
q When backlash is insufficient
Decrease the thickness of the shim
on the right side of the machine body
and increase the thickness on the left
side by the same quantity. (Move the
bevel gear in direction (A).)
4. Adjusting backlash and tooth contact

1) Adjusting backlash
Apply the probe of dial gauge [13] to the
tooth tip at the end of the bevel gear at
right angles. Fix the bevel pinion and
move the bevel gear forward and back-
ward, and read the value at this time.
a Standard backlash: 0.2 – 0.28 mm q When backlash is too large
a Measure the backlash diagonally at 3 Decrease the thickness of the shim
or more places. on the left side of the machine body
and increase the thickness on the
q If the measured backlash is out of the right side by the same quantity. (Move
standard range, adjust it according to the bevel gear in direction (B).)
the following procedure.
D65EX, PX, WX-16 50-300 65

300 Power train
2) Adjusting tooth contact Adjusting

Testing If the tooth contact pattern is not proper,
Apply red lead thinly to the tooth surfaces adjust the tooth contact according to the
of the bevel gear and turn the bevel gear following procedure.
in the forward and reverse directions, then 1] If the bevel pinion is too far from the
check the tooth contact pattern on the center line of the bevel gear, the con-
bevel gear. tact is at the small end of the bevel
1] Check that tooth tip (A), bottom (B), gear tooth faces curved outward and
small end (C), and large end (D) of at the large end of the bevel gear
the teeth do not have any strong tooth tooth faces curved inward.
contact. q In this case, adjust the tooth contact
according to the following procedure.
Adjust the thickness of the shims on
the bevel pinion side to move the
bevel pinion in direction (A). Move the
bevel gear in direction (B), then check
the tooth contact pattern and back-
lash again.
2] The tooth contact must be as follows.

(The standard distance is measured
from the tooth tip of the bevel pinion.)
a) Center of tooth contact (a):
20 – 40% of face width
b) Width of tooth contact (b):
30 – 50% of face width
c) Center of tooth contact (c): 2] If the bevel pinion is too close to the
35 – 65% of tooth depth center line of the bevel gear, contact
d) Width of tooth contact (d): is at the large end of the bevel gear
60 – 80% of tooth depth tooth faces curved outward and the
a If the bevel gear and bevel pinion are small end of the bevel gear tooth
adjusted in this way, their teeth come faces curved inward.
in contact with each other correctly q In this case, adjust the tooth contact
when they are loaded. according to the following procedure.
a (C) shows the small end and (D) Adjust the thickness of the shims on
shows the large end. the bevel pinion side to move the
bevel pinion in direction (A). Move the
bevel gear in direction (B), then check
the tooth contact pattern and back-
lash again.
a Do not change the total thickness of
the shims on both sides.
50-300 66 D65EX, PX, WX-16

300 Power train
3] When adjustment is finished, tighten 4) Install sun gear (72).

the mounting bolts of the cage and 5) Using tool E11, press fit bearing (98).
bevel pinion assembly to the speci- a Press fit the inner race and outer race
fied torque. simultaneously.
3 Mounting bolts of cage and
bevel pinion assembly:
98 – 123 Nm {10.0 – 12.5 kgm}
5. Sun gear
1) Install snap ring (93) to the shaft.
a Perform this work for only right side of
the machine.
2) Install collar (71).
3) Using tool E10, install bearing (74).
6) Install collar (73) and snap ring (70).
6. Assembly of carrier assembly

1) Install bushing (91) to carrier (90).
2) Install bearing (69) to gear (52). Fit thrust

washers (67) to top and bottom of the
bearing, then set them to the carrier.
3) Install shaft (66), matching the inside of
the thrust washers and bearing to the
shaft hole of the carrier.
a Match the roll pin hole accurately.
D65EX, PX, WX-16 50-300 67

300 Power train
4) Install roll pin (65). 7. Assembly of brake assembly

1) Install stopper (56) to the hub, then install
snap ring (58).
2) Install bushing (60) to hub (39).
5) Set hub (92) to ring gear (52) and install

snap ring (50).
6) Install hub (92) to carrier assembly (64).
3) Install hub (39) to hub (54) with 18 mount-
ing bolts.
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
7) Install hub and carrier assembly (64) to

hub (54) and tighten bolts (89).
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
4) Install bearing (57) to hub (39).
50-300 68 D65EX, PX, WX-16

300 Power train
6) Set brake drum (45) to hub (39).

7) Install discs (46), plates (47), and springs
(48).
11) Install spring (42).

12) Install guide bolt [14] to cage (51).
13) Install bearing (60) to cover (41).
8) Install seal rings (27) and (53) and cage
(51).
a Roughly match the oil holes on the
cage to the 4 oil holes on the drum.
a Press fit the cage to the outer race
side of the bearing.
14) Using eyebolts [15] and matching to the

guide bolt, set cover (41).
a Check that the spring is fitted securely
to both of the piston and case.
15) Compressing the spring with forcing
screws [17] and nuts [16], press fit the
9) Install the seal ring to piston (43). inner race side of the bearing to the hub
10) Install piston (43) to the drum, while set- assembly.
ting match mark (a) of the former to the
center of 13.5 mm hole (c) of the latter.
(b): Spot facing of piston
(d): Opposite side to side hole of drum
D65EX, PX, WX-16 50-300 69

300 Power train
16) Install spacer (38) and snap ring (37). 9. Assembly of cover assembly
17) Install flange (36). 1) Install valve (31) and spring (30) to the
cover, then install the plug.
18) Remove the bolts and nuts used to com-

press the spring, then install 4 bolts (40). 2) Left carrier drive gear
1] Using tool E11, press fit bearing (26)
to shaft (21).
8. Installation of brake and carrier assembly

1) Set the seal rings on the carrier side to
equalize the projection from the shaft.
2) Using tool E1, install brake and carrier
assembly (34).
50-300 70 D65EX, PX, WX-16

300 Power train
2] Using tool E12, press outer race (29) 5] Install gear (22).
to cover (32). 6] Install holders (20) and tighten bolts
3] Using tool E12, press fit bearing (28) (19).
to cover (32), then install snap ring 3 Mounting bolt:
(23). 98 – 123 Nm {10.0 – 12.5 kgm}
3) Intermediate gear assembly

1] Using tool E12, press fit bearing (17)
to gear (15) and install spacer (17a).
4] Press fit shaft (21) to the inner race

side of bearing (28).
D65EX, PX, WX-16 50-300 71

300 Power train
2] Using tool E13, press fit shaft (14) to 4] Install tube (11).
the inner race side of bearing (17). Fit
ball (16) halfway and press fit com-
pletely.
a Before the shaft enters the cover,
position the ball accurately.
4) Input gear assembly

1] Install bearings (10) to gear (9).
2] Install gear assembly (6).

3] Install cage (7) and ball (8), matching
them to the hole for ball (8).
3] Install holder (13) and tighten bolt 4] Install snap ring (12).
(12).
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
50-300 72 D65EX, PX, WX-16

300 Power train
10. Installation of cover assembly 12. Transmission speed sensor

1) Install 2 sleeves (25) and 5 sleeves (24) to Install transmission speed sensor (2) and
the HSS case. cover (1). For details, see Testing and adjust-
ing, “Adjusting transmission output shaft speed
sensor (Replacement procedure)”.
2) Using eyebolts [1], install cover assembly

(5).
2 Mating face of cover:
Gasket sealant (LG-6)
a Apply gasket sealant to both mating
faces of the case and cover.
a Apply gasket sealant to each mating
face without breakage.
11. Brake valve assembly

Install brake valve assembly (4).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
D65EX, PX, WX-16 50-300 73

300 Power train
SEN05112-01 Removal and installation of final drive assembly
Removal and installation of final 5. Remove cover (2). [*2]

drive assembly 1
6. Use extraction bolt [3] to pull drive shaft (3) out
Special tools to a position where spline portion comes out.
a If drive shaft (3) cannot be pulled out,
New/Remodel
apply a jack etc. to the track shoe grouser
Necessity
Symbol
Sketch
and pull out the drive shaft while adjusting
Q’ty
Part No. Part name
its position finely.
7. Leave 2 or 3 of 11 inside mounting bolts (4)

and 9 outside mounting bolts in position at top,
J 1 791-427-1090 Plate t 1 and remove remaining mounting bolts. [*3]
01010-51635 Bolt t 2
Removal
1. Remove track shoe assembly. For details,
“Removal and installation of track shoe assem-
bly”.
2. Using jack, jack up chassis, then set stands [1]
and [2] under front frame and steering case.
k Set the stands in position securely.
3. Drain oil from final drive case.

6 Final drive case: D65EX-16: 24 l
D65EX-16 PAT: 27 l
D65PX-16: 27 l
D65WX-16: 27 l
4. Remove bracket (1). [*1]
50-300 74 D65EX, PX, WX-16

300 Power train
Removal and installation of final drive assembly SEN05112-01
8. Remove 2 cover mounting bolts from final drive Installation

case, then set tool J1 and lever block in posi- q Carry out installation in the reverse order to
tion, and sling final drive assembly (5). [*4] removal.
9. Remove the remaining bolts and move the [*1]

final drive assembly outward to remove it from 2 Thread of bracket (1) mounting bolt:
the case. Adhesive (LT-2)
a While operating the lever block and keep-
ing the clearance between the final drive [*2]
case assembly and the case even, pry off a Be careful not to damage the seal when install-
the final drive assembly with a bar, etc. ing.
3 Cover (2) mounting bolt:
4 Final drive assembly: 850 kg
98 – 123 Nm {10.0 – 12.5 kgm}
10. Remove sprocket (6).

[*3]
3 Final drive assembly mounting bolt:
490.3 – 608.0 Nm {50 – 62 kgm}
[*4]
3 Cover mounting bolt:
245.2 – 308.9 Nm {25.0 – 31.5 kgm}
q Refilling with oil

5 Final drive case:
Power train oil (refer to the section
detail)
D65EX-16: 24 l
D65EX-16 PAT: 27 l
D65PX-16: 27 l
D65WX-16: 27 l
D65EX, PX, WX-16 50-300 75

300 Power train
SEN05112-01 Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)
Removal and installation of final drive assembly (Planetary gear

installed inside of sprocket type) 1
a special tools 4. Remove bracket (1). [*1]
New/Redesign
Necessity
Sketch
Sym
Q'ty
Part number Part name
bol

791T-527-1110 Plate t 1 N Q
J 9
01010-81680 Bolt t 2
01010-31645 Bolt t 2
Removal
1. Separate track shoe assembly. For details,
see "Separation and connection of track
shoe assembly". 5. Remove cover (2). [*2]
2. Using jacks, lift up the machine body and set 6. Using forcing screws [3], draw out drive shaft
stands [1] and [2] under the front frame and (3) until the spline portion is pull out.
steering case. a If drive shaft (3) cannot be pulled out,
k Set the stand securely. push up the track shoe grouser by using a
jack etc. and fine-adjust the position
where the shaft can be pulled out easily.
7. Remove eleven inner mounting bolts (4) and
nine outer mounting bolts, but leave two to
three upper bolts installed. [*3]
3. Drain oil from the final drive case.

6 Final drive case
D65EX-16: 21 l(*1)
D65EX-16 PAT,D65PX-16,D65WX-16: 25l
*1: Indicates the oil level except for power
angle and power tilt dozer.
50-300 76 D65EX, PX, WX-16

300 Power train
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type) SEN05112-01
8. Remove three cover mounting bolts (4a) of Installation

the final drive case. Set tool J9 and the lever q Carry out installation in the reverse order to
block onto sling tap (P), and sling final drive removal.
assembly (5). [*4] 1)
[*1]
2 Threaded portion of mounting bolt for
bracket (1):
Adhesive (LT-2)
[*2]
3 Cover (2) mounting bolt:
98 - 123 Nm {10.0 - 12.5 kgm}
[*3]
3 Final drive assembly mounting bolt :
490.3 - 608.0 Nm {50 - 62 kgm}
[*4]
3 Cover mounting bolt:
245.2 - 308.9 Nm {25.0 - 31.5 kgm}
q Refilling of oil
5 Final drive case: Power train oil (For details,
see "List of lubricant and water")
D65EX-16: 21 l(*1)
D65EX-16 PAT,D65PX-16,D65WX-16: 25l
*1: Indicates the oil level except for power
angle and power tilt dozer.
9. Remove the remaining bolts, and slide

outward to remove from the case.
a Set guide bolt [1], and use forcing taps [2]
(set at two places diagonally) to remove
the final drive case assembly.
4 Final drive assembly:
850 kg
D65EX, PX, WX-16 50-300 77

300 Power train
SEN05112-01 Disassembly and assembly of final drive assembly
Disassembly and assembly of 2. Disassembly of carrier assembly

final drive assembly 1
1) Remove lock plates (2).
2) Using forcing screws [2], remove plate (3)
Special tools together with gear assembly (4).
3) Remove gear assembly (4) from plate (3).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part name
791-427-1100 Remover assembly t 1

2 790-101-2102 Puller t 1
790-101-1102 Pump t 1
3 792-520-2121 Installer t 1
791-427-1200 Installer assembly t 1
4 790-101-2102 Puller t 1
790-101-1102 Pump t 1
J
790-101-5201 Push tool kit (B) t 1
a If gear assembly (4) remains in posi-
790-101-5321 • Plate 1 tion when the plate remains, use
5
790-101-5221 • Grip 1 puller [3] to remove it.
01010-51225 • Bolt 1
6 790-201-2330 Plate t 1
7 790-201-2460 Plate t 1
8 790-101-5431 Plate t 1
Disassembly
1. Carrier assembly
1) Remove cover.
2) Remove mounting bolts, and using eye-
bolts [1], remove carrier assembly (1).
4) Support gear (5), then push shaft (6) and

remove bearing (7).
50-300 78 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of final drive assembly SEN05112-01
5) Remove bearing (7) from shaft (6). 5. Sprocket, hub assembly

6) Remove outer race (8) from gear (5). 1) Fit eyebolts, pull out sprocket and hub
assembly (15) with tool J2, and remove.
a Bearing (19) will come out at the
same time.
3. Shaft
Using eyebolt [4], remove shaft (9).
4. Ring gear, housing assembly

1) Remove holder (10).
2) Remove floating seal (16).

a If it is to be used again, be careful not
to damage the seal surface and keep
2) Using eyebolts [5], remove ring gear and
it in a safe place.
hub assembly (11).
3) Remove outer race (18).
3) Remove snap ring (12), then remove ring
gear (14) from hub (13).
D65EX, PX, WX-16 50-300 79

300 Power train
6. Cover assembly 7. Gear assembly

1) Tighten forcing screws [6] to pull cover 1) Using eyebolts [9], remove gear assembly
assembly (21) out of case (22). Then, (24) from case.
using eyebolts [7], remove cover assem- 2) Using puller [10], remove bearing (26)
bly (21). from gear assembly (25).
a Although the cover assemblies of
D65EX-16, D65PX-16 and D65WX-
16 have different shapes, they can be
removed similarly.
8. Output shaft
Remove output shaft (27).
9. Pinion assembly
1) Using forcing screws [11], remove cage
a If it is to be used again, be careful not
(28).
to damage the seal surface and keep
a Check and record the number and
it in a safe place.
thickness of the shims.
3) Using forcing screw [8], remove spacer
(20) and bearing (19) from cover.
2) Remove pinion assembly (29).

3) Remove bearing (31) from pinion (30).
50-300 80 D65EX, PX, WX-16

300 Power train
4) Remove outer race (32) and oil seal (33) Assembly

from cage (28). a Clean all parts, and check for dirt or damage.
5) Remove outer race (34) from case. Coat the sliding surfaces of all parts with power
train oil (refer to the section “Fuel, coolant and
lubricants” for detail) before installing.
1. Pinion assembly
1) Using tool J5, press fit oil seal (33) to cage
(28).
2 Lip of oil seal: Grease (G2-LI)
2) Install outer race (32) to cage (28).

3) Install outer race (34) to case.
D65EX, PX, WX-16 50-300 81

300 Power train
4) Install bearings (31) to pinion (30).

5) Install pinion assembly (29).
a Install so that the part with the small
outside diameter is facing the outside.
2. Output shaft
Install output shaft (27).
3. Gear assembly
6) Assemble shim, then install cage (28).
1) Using tool J6, press fit bearing (26) to
gear (25).
a Select the shim thickness to be

assembled as follows.
1] Install pinion without fitting O-ring
to cage.
2] Hold cage down by hand, and
use a thickness gauge to mea-
sure clearance between gauge
and case at 2 places on the cir-
cumference.
3] Select shim from thickness of
measured clearance (a).
Shim thickness: (a) + 0 – 0.1 mm
a If clearance (a) is 0, ensure
that the rotation torque of
the pinion is 0.98 Nm {0.1
kgm} or less.
50-300 82 D65EX, PX, WX-16

300 Power train
2) Install thrust washer (35) to case. 4) Using eyebolts [7], install cover assembly
3) Using eyebolts [9], install gear assembly (21) to case, then tighten mounting bolts.
(24).
5. Sprocket, hub assembly

4. Cover assembly 1) Using tool J7, press fit outer race (18) to
1) Install spacer (20) to cover (36). hub (13).
2) Using tool J4, press fit bearing (19). 2) Using tool J3, install floating seal (16).
a A press can be used instead of the a Remove all oil and grease from the
puller. O-ring and O-ring contact surface,
3) Using tool J3, install floating seal. and dry before installing.
a Remove all oil and grease from the a After installing the floating seal, check
O-ring and O-ring contact surface, that the angle of the seal is less than
and dry before installing. 1 mm.
a After installing the floating seal, check
that the angle of the seal is less than
1 mm.
D65EX, PX, WX-16 50-300 83

300 Power train
3) Check that there is no dirt or dust on slid- 8) Set holder (10) in position.
ing surface of floating seal, then coat a The bearings are set parts, so there is
thinly with power train oil (refer to the sec- no need to adjust them, but in order to
tion “Fuel, coolant and lubricants” for check that there are no defective
detail). parts, measure the preload as fol-
4) Using eyebolts [13], set sprocket and hub lows.
assembly (15) in cover. 1] With no preload given to the
bearings, measure the rotating
torque of the sprocket hub, and
take this rotating torque as (b).
a Measure the sliding resis-
tance of the floating seal
first.
2] Rotate the sprocket and tighten
the plate holder bolt to 245.2 –
308.9 Nm {25.0 – 31.5 kgm}.
3] After tightening the bolt, check
that the rotating torque is (b) + 0
to 61.8 Nm {0 to 6.3 kgm}.
5) Using tool J4, rotate sprocket and hub

assembly, and press fit bearing (19).
a Press fit to a point which does not
give any preload.
6) Set hub (13) to ring gear (14), and install

snap ring (12).
7) Using eyebolts [5], install ring gear and
hub assembly (11).
50-300 84 D65EX, PX, WX-16

300 Power train
6. Shaft 4) Expand fit shaft (6).

Using eyebolts [4], install shaft (9). a Leave in dry ice for approx. 30 minutes.
5) Install lock plates (2).
7. Carrier assembly 3 Mounting bolt:
1) Using tool J8, press fit outer race (8) to 98 – 123 Nm {10.0 – 12.5 kgm}
planetary gear (5).
a The bearing is set parts, so be careful
not to change the combination.
6) Using eyebolts [1], install carrier assembly

(1).
3 Mounting bolt:
245.2 – 308.9 Nm {25.0 – 31.5 kgm}
7) Install cover.
2) Assemble 2 bearings (7) to gear (5), and

set to carrier (17).
a Center with the shaft hole.
3) Align with dowel pin and install plate (3).
3 Mounting bolt:
490.3 – 608.0 Nm {50 – 62 kgm}
D65EX, PX, WX-16 50-300 85

300 Power train
SEN05112-01 Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type)
Disassembly and assembly of final drive assembly (Planetary gear

installed inside of sprocket type) 1
Special tools Disassembly

1. Shaft
New/Redesign
1) Set the final drive assembly on the blocks
Necessity
Sketch
Symb
with the sprocket side up.
Q'ty
Part number Part name
ol
2) Remove mounting bolts (1).
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
10 790-101-2470 Adapter (M20) t 2
790-101-2450 Adapter (M12) t 2
790-201-2680 Plate t 1
790-101-2102 Puller t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 1
01643-22460 Washer t 1
3) Using eyebolts, remove shaft (2).
11 790-101-2420 Adapter (M16) t 1
790-201-2840 Spacer t 1
790-101-2102 Puller t 1
790-431-1031 Black t 1
791-520-4140 Screw t 1
791-112-1180 Nut t 2
J
01643-22460 Washer t 2
12
791T-527-1130 Plate t 1 N Q
791T-527-1120 Push tool t 1 N Q
790-101-2102 Puller t 1
13 791-580-8110 Installer t 1
790-101-5201 Push tool kit t 1 2. Sprocket hub assembly
790-101-5321 • Plate t 1 1) Remove mounting bolts (3) and plate (4).
14 790-101-5311 • Plate t 1
790-101-5221 • Grip t 1
01010-51225 • Bolt t 1
790-101-5441 • Plate t 1
15 790-101-5431 • Plate t 1
790-101-5421 • Grip t 1
01010-51240 • Bolt t 1
790-101-5630 Plate t 1 N
16 790-101-5421 Grip t 1
01010-51240 Bolt t 1
50-300 86 D65EX, PX, WX-16

300 Power train
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type) SEN05112-01
2) Remove shim (5). 3. Cover assembly

1) Remove spacer (11).
2) Remove mounting bolts (12).
3) Using tool 2, disconnect sprocket hub

assembly (6) and bearing (7).
4) Using eyebolts, remove sprocket hub 3) Sling and remove cover assembly (13).
assembly (6).

6) Remove bearing outer race (9).
7) Reverse sprocket hub assembly (6) and
remove bearing outer race (10).
D65EX, PX, WX-16 50-300 87

300 Power train
5) Set two bars [2] under bearing (15) and pull 4. Carrier assembly
out bearing (15) about 5 mm by using flange 1) Using three eyebolts, remove carrier
(P) of the cover as a fulcrum. assembly (19).
a Pull out the bearing evenly by a couple of
worker.
2) Remove bolts (20) to remove holder (21).

3) Pull out planetary gear shaft (22) and remove
6) Using puller [3], pull out bearing (15). planetary gear (23) and bearings (25a) and
(25b).
a Take care of spacer (25d) between the
bearings.
7) Reverse cover assembly (13) and remove

four lock plates (16).
8) Remove ring gear (18).
50-300 88 D65EX, PX, WX-16

300 Power train
4) Remove two bearing outer races (25c) from 3) Using eyebolts, remove gear (29).
the planetary gear.
4) Remove mounting bolts (30) and plate (31).

5. Hub and case assembly
1) Remove thrust washer (26) and sun gear
(27).
5) Using tool J10, separate hub assembly (32)

from the case.
2) Remove gear mounting bolts (28).
D65EX, PX, WX-16 50-300 89

300 Power train
6) Remove bearing (33). 10)Use puller [3], remove bearing (35).

7) Using the eyebolts, remove hub assembly
(32).
6. Cage assembly
1) Reverse the case and remove mounting
8) Remove bearing outer race (33a) from the bolts (38) of cage assembly (37).
hub assembly. 2) Using forcing screws [4], remove cage
assembly (37) from the case.
9) Remove spacer (34).

3) Remove shim (39).
50-300 90 D65EX, PX, WX-16

300 Power train
4) Remove outer race (41) and oil seal (42) from 8. Case
cage (40). 1) Remove outer race (47) and oil seal (48) from
the case.
7. Gear assembly
1) Remove gear assembly (43).
2) Using puller [5], remove bearings (44) and

(45) from gear (46).
D65EX, PX, WX-16 50-300 91

300 Power train
Assembly 3) Using push tool [6], press fit bearings (44)

a Clean the all parts and check them for dirt or and (45) to gear (46).
damage before installing. q Press fitting force of bearing: 6 to 19 kN
a Coat the sliding surfaces of the all parts with {0.6 to 2.0 ton}
engine oil before installing. 4) Install gear assembly (45).
a Lower and install the gear assembly grad-
1. Gear assembly ually so that the oil seal lip will not be dam-
1) Using J13, install oil seal (48) to case (49). aged.
a When installing the oil seal, take care of its
direction.
a Apply the liquid gasket thinly to the inside
of the housing hole and wipe off the pro-
jected part.
2 Oil seal lip:
Grease(G2-LI)
2 Between oil seal lips (part G):
rease (G2-LI) (Filling rate 40 to 60 %)
2 Oil seal press-fitting portion:
Liquid gasket (LG-5)
2. Cage assembly
1) Using tool J14, install oil seal (42) to cage
(40).
a When installing the oil seal, take care of its
direction.
2 Between oil seal lips (part G):
Grease (G2-LI) (Filling rate 40 to 60 %)
a Apply the liquid gasket thinly to the inside
of the housing hole and wipe off the pro-
jected part.
2 Oil seal lip:
2) Using tool J15, press fit bearing outer race Grease(G2-LI)
(47) to the case. 2 Oil seal press-fitting surface:
q Press fitting force of bearing: 0 to 8 kN {0 Liquid gasket (LG-5)
to 0.9 ton}
50-300 92 D65EX, PX, WX-16

300 Power train
2) Using tool J15, press fit bearing outer race

(41) to cage (40).
q Press fitting force of bearing: 0 to 8 kN {0
to 0.9 ton}
Table 1
a + b (mm) Combination of shims Total
14X-27- 14X-27- 14X-27- shim
Larger
Below 11260 11270 11280 thickness
3) Install the O-ring to cage assembly (37) and than
(t = 0.2) (t = 0.3) (t = 1.0) δ (mm)
adjust shim (39). 0.98 1.18 2 1 0.70
1.18 1.38 1 2 0.80
1.38 1.58 3 0.90
1.58 1.78 1 1.00
1.78 1.98 1 3 1.10
1.98 2.18 1 1 1.20
2.18 2.38 1 1 1.30
2.38 2.58 2 1 1.40
2.58 2.78 1 1 1 1.50
2.78 2.98 2 1 1.60
2.98 3.18 2 1 1 1.70
3.18 3.38 1 2 1 1.80
3.38 3.58 3 1 1.90
3.58 3.78 2 2.00
4) Adjustment of shim
3.78 3.98 1 3 1 2.10
q Adjust the clearance of the pinion bearing
3.98 4.18 1 2 2.20
according to the following procedure.
Tighten cage (40) mounting bolts B, C, E, 4.18 4.38 1 2 2.30
and F evenly. 4.38 4.58 2 2 2.40
3 Mounting bolt:
4.58 4.78 1 1 2 2.50
20 Nm {2 kgm} 4.78 4.98 2 2 2.60
1] Using feeler gauges under this condition, 4.98 5.18 2 1 2 2.70
measure clearance a and b between 5.18 5.38 1 2 2 2.80
cage (40) and case (49). 5.38 5.58 3 2 2.90
2] Referring to Table 1, set shim quantity c 5.58 5.78 3 3.00
from the total of clearances a and b.
3] Install set shim (39) to cage (40) and
tighten the six cage mounting bolts
evenly.
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
D65EX, PX, WX-16 50-300 93

300 Power train
3. Hub and case assembly 5) Set the bearing to the shaft.

1) Using tool J11, press fit bearing (35) to case
(49).
q Press fitting force of bearing: 12 to 34 kN
{1.3 to 3.4 ton}
2) Install spacer (34).
6) Using tool J11, press fit bearing (33) to case

(49).
{1.3 to 3.4 ton}
3) Using tool J14, press fit two bearing outer

races (33a) to hub (32).
{0.1 to 1.0 ton}
7) Install plate (31).

Adhesive (LT-2)
230 - 289 Nm {23.5 - 29.5 kgm}
4) Using eyebolts, set hub assembly (31) to the
shaft.
50-300 94 D65EX, PX, WX-16

300 Power train
8) Using eyebolts, install gear (29). 4. Carrier assembly

a Match the identification marks of the inner
race, outer race and spacer when assem-
bling because the bearings for the plane-
tary gears are kept in matched set.
1) Using tool J13, press fit bearing outer race
(25C) to planetary gear (24).
{0.4 to 1.6 ton}
9) Tighten gear mounting bolts (28).

2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 - 123 Nm {10.0 - 12.5 kgm}
2) Install bearings (25A) and (25B) and spacer

(25D) to planetary gear (24).
10)Install sun gear (27) and thrust washer (26).
3) Set the planetary gear assembly to the

carrier and press fit shaft (23).
a Aligning the holes of the bearing and
spacer, press-fit the shaft gradually.
D65EX, PX, WX-16 50-300 95

300 Power train
4) Install bolts (21) and holders (22). 2) Install spacer (15a).

2 Mounting bolt: 3) Using tool J12, press fit bearing (15). Press
Adhesive (LT-2) fitting force of bearing: 11 to 39 kN {1.2 to
3 Mounting bolt: 3.9 ton}
230 - 289 Nm {23.5 - 29.5 kgm}
4) Using eyebolts, install the O-ring to cover

5) Using 3 eyebolts, install carrier assembly
assembly (13), and then install them to the
(19).
case assembly.
a Check that there is no dent, rust, oil,
grease, or water on the mating surfaces of
the case and cover.
5. Cover assembly
1) Install ring gear (18) and tighten four lock
plates (16).
5) Tighten mounting bolts (12).
3 Mounting bolt:
230 - 289 Nm {23.5 - 29.5 kgm}
6) Install spacer (11).
50-300 96 D65EX, PX, WX-16

300 Power train
7) Using tool J13, press fit floating seal (14). 2) Install sprocket teeth (10) to the sprocket
a Remove oil and grease completely from hub.
the O-ring and O-ring contact surface, and 3 Mounting bolt:
dry before installing. 931 ± 98 Nm {95 ± 10 kgm}
a After installing the floating seal, check that
its leaning is less than 1 mm.
3) Using tool J13, press fit floating seal (7).

a Remove oil and grease completely from
the O-ring and O-ring contact surface, and
6. Sprocket hub assembly dry before installing.
1) Using tool J16, press fit bearing outer race (9). a After installing the floating seal, check that
q Press fitting force of bearing: 7 to 32 kN its leaning is less than 1 mm.
{0.7 to 3.2 ton}
D65EX, PX, WX-16 50-300 97

300 Power train
4) Using eyebolts, install sprocket hub

assembly (6) to the cover assembly.
a Check that the sliding surface of the float-
ing seal is free from dirt and apply engine
oil to it lightly.
5) Set bearing (7).
δA + δB (mm) Quantity of shims

Total shim
14X-27 14X-27 thickness
Larger
Below -51370 -51380 δ (mm)
than
(t = 0.5) (t = 0.2)
0.00 0.50 0 0 0.0
0.50 0.90 0 1 0.2
6) Using tool [3], press fit bearing (6). 0.90 1.10 0 2 0.4
a Rotate the sprocket hub assembly while 1.10 1.50 1 0 0.5
performing the press fitting. 1.50 1.90 1 1 0.7
q Press fitting force of bearing: 11 to 39 kN 1.90 2.10 1 2 0.9
{1.2 to 3.9 ton} 2.10 2.50 2 0 1.0
7) Install plate (4) and secure it with the

mounting bolts.
a Tighten the nine bolts evenly.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
230 - 289 Nm {23.5 - 29.5 kgm}
a Adjust the clearance between the end

face of cover (3) and bearing (6) accord-
ing to the following procedure.
1] Seat the bearing perfectly and
measure the level difference between
the bearing inner race and cover end
face at two diagonal places on the
circumference.
2] Determine quantity δ of the shim to be
inserted according to Table 2.
(If shrink fit is applied, measure after
cooling.)
50-300 98 D65EX, PX, WX-16

300 Power train
7. Shaft
Install the O-ring to the sprocket hub assembly
side. Using eyebolts, install shaft (2).
3 Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
q Refilling of oil
Tighten the drain plug and supply oil through
the oil filler port to the specified level.
a After installing the final drive assembly to the

chassis, check the oil level finally.
5 Final drive case
D65EX-16: 21 l
D65PX-16: 25 l
3 Oil filler and drain plug:
127 - 176 Nm {13 - 18 kgm}
3 Oil level detection port plug:
58.8 - 76.4 Nm {6 - 8 kgm}
D65EX, PX, WX-16 50-300 99

SEN05112-01
D65EX, PX, WX-16 Bulldozer

©2011 KOMATSU
All Rights Reserved
50-300 100
SEN04935-02
BULLDOZER
D65EX-16
D65PX-16
D65WX-16

D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
90 Diagrams and drawings 1
200 Electrical diagrams and drawings

Electrical circuit diagram ................................................................................................................................. 3
Electrical circuit diagram (Sand terrain specification) ................................................................................... 23
Electrical circuit diagram (FRP canopy specification) ................................................................................... 29
D65EX, PX, WX-16 90-200 1

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©2011 KOMATSU
All Rights Reserved
90-200 42
Electrical circuit diagram (1/10)
Electrical circuit diagram (1/10) D65EX-16, D65PX-16, D65WX-16
1
D65EX-16, D65PX-16, D65WX-16 (cab specification) (cab specification)

a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04935-02
D65EX, PX, WX-16
90-200 3
1

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1

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1

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1

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1

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Electrical circuit diagram (Sand ter-
Electrical circuit diagram (Sand terrain specification) (1/3) rain specification) (1/3)
1
D65EX-16 D65EX-16
SEN04935-02
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1
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1
D65EX-16 D65EX-16
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Electrical circuit diagram (FRP can-
Electrical circuit diagram (FRP canopy specification) (1/6) opy specification) (1/6)
1
D65EX-16 D65EX-16
SEN04935-02
D65EX, PX, WX-16
90-200 29
1
D65EX-16 D65EX-16
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1
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1
D65EX-16 D65EX-16
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1
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1
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SEN04935-02
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SEN04887-07

BULLDOZER D65EX -16

Machine model Serial number

00 Index and foreword 00

D65EX, PX, WX-16 00-100 1

Composition of shop manual 1

Section Title Form Number

00 Index and foreword .................................................................................................................... SEN04923-07

01 General ...................................................................................................................................... SEN04924-01

10 Structure, function and maintenance standard........................................................................... SEN04925-03

20 Standard value table................................................................................................................... SEN04926-01

30 Testing and adjusting ................................................................................................................. SEN04927-04

00-100 2 D65EX, PX, WX-16

305 Troubleshooting by failure code (Display of code), Part 5..................................................SEN05035-00

50 Disassembly and assembly ........................................................................................................SEN04929-03

90 Diagrams and drawings ..............................................................................................................SEN04930-02

D65EX, PX, WX-16 00-100 3

00 Index and foreword

10 Structure, function and maintenance standard

00-100 4 D65EX, PX, WX-16

20 Standard value table

30 Testing and adjusting

D65EX, PX, WX-16 00-100 5

Testing compression pressure ...................................................................................................................... 14

00-100 6 D65EX, PX, WX-16

200General information on troubleshootingSEN05030-01

D65EX, PX, WX-16 00-100 7

303Troubleshooting by failure code (Display of code), Part 3SEN05033-01

00-100 8 D65EX, PX, WX-16

Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................... 14

D65EX, PX, WX-16 00-100 9

Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 41

00-100 10 D65EX, PX, WX-16

H-17 Excessive hydraulic drift of blade tilt..................................................................................................... 16

50 Disassembly and assembly

D65EX, PX, WX-16 00-100 11

00-100 12 D65EX, PX, WX-16

Testing, adjusting and troubleshooting.............................................................................................................. 18

90 Diagrams and drawings

D65EX, PX, WX-16 00-100 13

D65EX-16, D65PX-16, D65WX-16 Bulldozer

Machine model Serial number

10 Structure, function and

202 Power train, Part 2

D65EX, PX, WX-16 10-202 1

Bevel gear shaft, HSS and brake 1

a HSS: Abbreviation for Hydrostatic Steering System

A: To transmission case (to power train and steering lubrication pump)

10-202 2 D65EX, PX, WX-16

D65EX, PX, WX-16 10-202 3

10-202 4 D65EX, PX, WX-16

D65EX, PX, WX-16 10-202 5

10-202 6 D65EX, PX, WX-16

Thickness 5.2 ± 0.1 4.7 Replace

D65EX, PX, WX-16 10-202 7

10-202 8 D65EX, PX, WX-16

D65EX, PX, WX-16 10-202 9

Bevel gear shaft Brake