2008– Komatsu D65EX-15, D65PX-15 & D65WX-15 Dozer Shop Manual (P/N SEBM029508)

This Komatsu shop manual, SEBM029508, covers the 2008 and newer D65EX-15, D65PX-15, and D65WX-15 dozers from serial number 67001 and up. The February 2008 printing includes semi-U, wide-gauge, long-track, and power-tilt configurations.

Text Search, Bookmarks, and Large Circuit Sheets

Navigation and diagram detail: Main text supports PDF searching, and embedded bookmarks link the main sections and individual procedures. Many drawing labels are not searchable. Small pin numbers and wire codes on the large circuit sheets require zooming.

Supplied as one printable 922-page PDF in English, including the title page, revision lists, and other front matter.

• Engine and fuel service: Valve-clearance adjustment, compression testing, fuel-circuit bleeding, and engine, cylinder-head, supply-pump, and injector removal and installation.

• TORQFLOW power train: Transmission, torque converter, and PTO disassembly and assembly, ECMV operation, and power-train pressure tests.

• Steering and brakes: HSS disassembly and assembly, bevel-gear setup, brake-performance checks, and steering/transmission controller adjustment.

• Undercarriage repair: Track-shoe expansion, field repair of individual links, idler and roller overhaul, recoil-spring service, and sprocket-wear inspection.

• Work-equipment hydraulics: Work-equipment/HSS pressure checks, PPC tests, cylinder leakage checks, and blade lift/tilt cylinder disassembly and assembly.

• Electrical diagnosis: CRI and PCCS troubleshooting, EMMS service functions, connector pin tables, wiring diagrams, and cab electrical circuits.

The workshop procedures are suited to experienced heavy-equipment technicians with hydraulic test equipment, lifting gear, and the specified service tools.

Engine Service and Fuel-System Coverage

Engine scope: This is the chassis shop manual. It includes selected engine service procedures and refers detailed engine-unit work to the separate 125-3 Series Engine Shop Manual, which is not included.

Cylinder-head instructions cover bolt-reuse limits, tightening sequences, and angle-tightening stages. Other procedures address nozzle-tip replacement, front and rear crankshaft seals, and radiator removal.

Fuel-circuit bleeding distinguishes routine service from a circuit emptied during extensive repairs. The section explains hard starting caused by air remaining on the low-pressure side; the high-pressure circuit bleeds automatically during cranking.

Transmission Builds, HSS, and Final Drives

Serial-specific clutch tables distinguish early and later transmission builds through disc counts and assembled-pack limits. Matching those tables to the machine’s serial number helps identify the applicable clutch arrangement before inspection or parts selection.

Gear-ratio tables and ECMV proportional-solenoid information accompany the transmission procedures. HSS assembly instructions cover bearing preload, bevel-gear backlash, and tooth-contact checks; step-by-step repair instructions extend to the torque converter, PTO, and final drives.

Factory test methods and matching reference values support fault isolation across the power train and hydraulics before a major teardown.

Hydraulic Tests and Electronic Fault Tracing

Hydraulic coverage explains the HPV95 hydraulic/HSS pump, HMF95 steering motor, PPC control, and load-sensing circuit. Tests address cylinder internal leakage and cooling-fan pump performance. Control-valve coverage combines removal and installation with assembly precautions and component standards.

EMMS service functions include real-time monitoring, electrical and mechanical error histories, and replacement-controller setup. Reduced-cylinder operation supports diagnosis of uneven engine output.

Engine-controller circuit drawings and connector arrangement drawings connect fault charts with test points and pin connections. Work-equipment hydraulic piping diagrams and cab electrical circuit diagrams support hose and harness tracing.

Review the manual’s safety and depressurization precautions before hydraulic component service.

Track Repairs and Workshop References

Track procedures cover complete link disassembly and field repair of one link. Oil or grease at the link counterbore can let the seal turn and reduce sealing performance. The manual also warns that excessive link-press force can break spacers and cause abnormal bushing wear.

Reference material includes metric-bolt, O-ring-boss-joint, and taper-seal torque tables, special-tool sketches, and a full-scale sprocket-tooth profile drawing for wear comparison. Tool lists identify the 799-301-1600 transmission oil leak tester and 791-432-1120 track-link seal installer.

Examples of Radiator Valve and Idler Clearance Data

The radiator specifications give a pressure-valve cracking pressure of 88.3 ± 14.7 kPa and a vacuum-valve cracking range of 0–4.9 kPa, alongside cooling-system component data.

For undercarriage adjustment, the specified clearance between the track frame and idler guide plate is 0.5–1.0 mm on each side. The related section covers clearance measurement and shim adjustment.