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SEBM029508

Machine model D65EX-15 D65PX-15 D65WX-15

Serial number 67001 and up 67001 and up 67001 and up

This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. D65-15 mount the SA6D125E-3 engine. For details of the engine, see the 125-3 Series Engine Shop Manual.

© 2008 All Rights Reserved Printed in Japan 02-08 (01)

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CONTENTS
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01 10 20 30 90

GENERAL ......................................................................................... 01-1 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1 TESTING AND ADJUSTING ............................................................ 20-1 DISASSEMBLY AND ASSEMBLY .................................................. 30-1 OTHERS ........................................................................................... 90-1

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D65EX,PX-15

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D65EX, PX-15

FOREWORD

SAFETY NOTICE

SAFETY NOTICE

(Rev. 2007/03)

Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. D65EX, PX-15 8) Before starting work, warm up your body thoroughly to start work under good condition. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Precautions against work which you are not used to or you are used to too much

6 Safety check before starting work 7 8

9 Good physical condition and preparation 10

2. Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

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FOREWORD

SAFETY NOTICE

3. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated.

11) When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

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D65EX, PX-15

FOREWORD

SAFETY NOTICE

4. Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. • Do not stand under the load. • Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. • Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. • Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. • After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. • If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. • Do not lift up the load slantingly.

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FOREWORD

SAFETY NOTICE

13) When lifting down a load, observe the following. • When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. • Check that the load is stable, and then remove the sling. • Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. 5. Precautions for using mobile crane ★ Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency. 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation.

15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

★ The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

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D65EX, PX-15

FOREWORD

SAFETY NOTICE

8. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. ★ Ask professional traders for collecting and filling operation of refrigerant (R134a). ★ Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles. 2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings. ★ Example of O-ring (Fitted to every joint of hoses and tubes)

★ For tightening torque, see the precautions for installation in each section of “Disassembly and assembly”.

D65EX, PX-15

00-7
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FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL
• • • Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.

1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. FOREWORD This section explains the safety and basic information. 01. GENERAL This section explains the specifications of the machine. 10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. TESTING AND ADJUSTING Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 30. DISASSEMBLY AND ASSEMBLY This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume) • Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. • Engine volume This section explains the method of reproducing, repairing, and replacing parts. 2. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most upto-date information before you start any work.

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D65EX, PX-15

FOREWORD

HOW TO READ THE SHOP MANUAL

3. Filing method • See the page number on the bottom of the page. File the pages in correct order. • Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function, Maintenance Standard) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. • Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5 Revised edition mark When a manual is revised, an edition mark ((1) (2) (3)....) is recorded on the bottom of the pages. Revisions Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

• •

4. Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol k a 4 3 2 5 6 Item Safety Caution Weight Tightening torque Coat Oil, coolant Drain Remarks Special safety precautions are necessary when performing work. Special technical precautions or other precautions for preserving standards are necessary when performing work. Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.

5. Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

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FOREWORD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance • To be accurate, the finishing size of parts is a little different from one to another. • To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. • The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. • The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size 120

Tolerance –0.022 –0.126

★ The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) • Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them Example: Standard size 60 Tolerance Shaft –0.030 –0.076 Hole +0.046 +0

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D65EX, PX-15

FOREWORD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

2. Standard clearance and standard value • The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. • When some parts are repaired, the clearance is generally adjusted to the standard clearance. • A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. • When some parts are repaired, the value of performance/function is set to the standard value. 3. Standard interference • When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. • The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. • After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. 4. Repair limit and allowable value • The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. • If a part is worn to the repair limit must be replaced or repaired. • The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the “allowable value”. • If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.

5. Clearance limit • Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. • If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. 6. Interference limit • The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. • The interference limit shows the repair limit of the part of smaller tolerance. • If the interference between the parts exceeds the interference limit, they must be replaced or repaired.

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FOREWORD

HOW TO READ ELECTRIC WIRE CODE

HOW TO READ ELECTRIC WIRE CODE
★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Symbol AV Conductor Insulator Conductor Insulator Conductor Insulator Material Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Using temperature range (°C) Example of use General wiring (Nominal No. 5 and above) –30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place

AVS

Heat-resistant low-voltAEX age wire for automobile

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D65EX, PX-15

FOREWORD

HOW TO READ ELECTRIC WIRE CODE

2.

Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard

8 50/0.45 7.95 3.7 – 5.5 5.3

15 84/0.45 13.36 4.8 – 7.0 7.0

20 41/0.80 20.61 6.0 – 8.2 8.2

30 70/0.80 35.19 8.0 – 10.8 10.8

40 85/0.80 42.73 8.6 – 11.4 11.4

50

60

85

100

108/0.80 127/0.80 169/0.80 217/0.80 54.29 9.8 – 13.0 13.0 63.84 10.4 – 13.6 13.6 84.96 12.0 – 16.0 16.0 109.1 13.6 – 17.6 17.6

“f” of nominal No. denotes flexible”.

D65EX, PX-15

00-13
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FOREWORD

HOW TO READ ELECTRIC WIRE CODE

3.

Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White. 4. Types of circuits and color codes

(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others

AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch WG
– – – – – – – – – – – – – – –

AEX R B R D Y G L
– – – – – – – – – – – –

RB YR GW LW BrW LgR
– – – – – –

RY YB GR LR BrR LgY
– – – – – –

RG YG GY LY BrY LgB
– – – – – –

RL YL GB LB BrB LgW
– – – – – –

YW GL
– – – – – – – – –

Gr Br
– – – – – – – – –

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D65EX, PX-15

5 18 16 13. tighten the forcing screws uniformly in turn. be sure to follow the general precautions given below when carrying out the operation. • • • • Precautions when carrying out removal work If the coolant contains antifreeze. PX-15 00-15 (8) . always hold the connectors when disconnecting the connectors.] 1. and keep in a safe place. and make match marks in the necessary places before removal to prevent any mistake when assembling. When draining oil. • When raising components. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Before removing any unit. • To prevent any excessive force from being applied to the wiring. the following corks can be used. Do not pull the wires. clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. be sure to use lifting equipment of ample strength. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2) Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234 Sleeve nut (elbow end) 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234 Split flange type hoses and tubes Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500 3) If the part is not under hydraulic pressure. dispose of it correctly. ★ Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. Confirm the match marks showing the installation position. prepare a container of adequate size to catch the oil. Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D d L 6 5 8 8 6.5 34 D65EX.5 20 18 15 22 20 17 25 22 18. • Check the number and thickness of the shims. cover them or fit plugs to prevent dirt or dust from entering.5 28 24 20 30 27 22. After disconnecting hoses or tubes. • When using forcing screws to remove any components.5 11 10 8.FOREWORD PRECAUTIONS WHEN CARRYING OUT OPERATION PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units.5 12 12 10 15 14 11.

pumps and other hydraulic equipment removed for repair. see Testing and adjusting. Coat rotating parts and sliding parts with engine oil. 3. • • • • • • • • • • • • • Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Clean all parts. stopping the cylinder 100 mm from the end of its stroke. After fitting snap rings. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage. check that there is no dirt or damage. retighten or repair it. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times. and add coolant to the specified level. operate the hydraulic cylinder 3 – 4 times to the end of its stroke. When connecting wiring connectors. When coating with adhesive. always bleed the air as follows: 1) Start the engine and run at low idle. If any part is loosened or damaged. Replace all gaskets. Run the engine to circulate the coolant through the system. coat the surface with anti-friction compound (LM-P). Run the engine to circulate the oil through the system. ★ When using the machine for the first time after repair or long storage. When using eyebolts. Install the hoses without twisting or interference and fix them with intermediate clamps. clean the part and remove all oil and grease. Then check the oil level again. retighten or repair it. oil and grease • If the coolant has been drained. clean the connector to remove all oil. If any part is loosened or damaged. and the joints for air suction and exhaust gas leakage. and align the direction of the hook. When coating with gasket sealant. follow the same procedure. When press fitting parts. always bleed the air from the system after reassembling the parts. When tightening split flanges. 00-16 (8) D65EX. If any part is loosened or damaged. add engine oil to the specified level. retighten or repair it. the mounting bolts and nuts for looseness. retighten it. • For the tightening torque. PX-15 . O-rings. check that there is no deformation or deterioration. If any part is loosened. run the engine at normal speed. and correct any damage. dirt. tighten the drain valve. Cooling system Check the piping for damage. Precautions when completing the operation 1) Refilling with coolant. and the joints for coolant leakage. dents. see “Disassembly and assembly”. ★ For details. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.FOREWORD PRECAUTIONS WHEN CARRYING OUT OPERATION 2. screw them in fully. 4) After doing this. and lock plates with new parts. the mounting bolts and nuts for looseness. clean the surface and remove all oil and grease. and the joints for fuel leakage. ★ When operating the hydraulic cylinders for the first time after reassembling cylinders. cotter pins. tighten uniformly in turn to prevent excessive tightening on one side. “Bleeding air”. Bend the cotter pins and lock plates securely. • If the hydraulic equipment has been removed and installed again. Fuel system Check the piping for damage. or rust. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. burrs. the mounting bolts and nuts for looseness. then coat the threaded portion with 2 – 3 drops of adhesive. check that the snap ring is fitted securely in the ring groove. • If the piping or hydraulic equipment have been removed. 3) Next. or water. then connect securely. Then check the coolant level again. then coat uniformly with gasket sealant. if there are any.

If any abnormal sound is heard. exhaust pipe and their mounting parts for a crack and damage.FOREWORD PRECAUTIONS WHEN CARRYING OUT OPERATION 4) Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler. If any part is damaged. 5) Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. exhaust pipe and their mounting parts for looseness. replace it. retighten it. 2] Check the mounting bolts and nuts of the muffler. repair the muffler. D65EX. PX-15 00-17 (8) . If any bolt or nut is loosened. referring to “Troubleshooting” and “Disassembly and assembly”.

2) After hose joint (2) is pushed into adapter (3). Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3). (Fig. 5) ★ When the hose is pulled back. (Fig. 4) ★ Do not hold rubber cap portion (4). (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. This does not indicate abnormality. k Even if the residual pressure is released from the hydraulic tank.5 mm. Type 1 1. aligning them with each other. 2.FOREWORD METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). Accordingly. prepare an oil receiving container. 1) ★ The adapter can be pushed in about 3. the rubber cap portion moves toward the hose about 3. prepare an oil receiving container. ★ Do not hold rubber cap portion (4). loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. however. PX-15 .5 mm. 00-18 (8) D65EX. some hydraulic oil flows out when the hose is disconnected. pull it back to check its connecting condition. press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) After inserting the hose in the mating adapter perfectly. 3) ★ Since some hydraulic oil flows out.

pull out whole body (7) to disconnect it. turn lever (8) to the right (clockwise). 8) 2. (Fig. (Fig. (Fig. PX-15 00-19 (8) . 7) 3) While holding the condition of Steps 1) and 2). Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end.FOREWORD METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER Type 2 1. (Fig. 9) D65EX. 6) 2) While holding the condition of Step 1). Connection • Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end.

(Fig. push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2). (Fig. (Fig. pull out whole body (9) to disconnect it. 13) 00-20 (8) D65EX. 10) 2) While holding the condition of Step 1). Connection • Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. PX-15 .FOREWORD METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER Type 3 1. 12) 2.

150 – 1.5 – 4.0 62.2 – 1.440 1.5 – 78.5 10.8 – 14.5 23.5 – 58. (When using torque wrench) ★ The following table corresponds to the bolts in Fig. Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Tightening torque Nm 11.3 – 46. Table of tightening torques for bolts and nuts ★ Unless there are special instructions.910 1.2 7.0 13.5 – 19.630 kgm 1. B D65EX.0 118 – 147 155 – 195 200 – 250 250 – 310 295 – 370 ★ The following table corresponds to the bolts in Fig.5 33.9 – 9.450 – 3.5 – 90.4 34.5 2.0 – 7.0 – 100.8 – 3.2 a Fig.040 2.0 – 12.5 1.450 2.890 – 3.1 3. Thread diameter of bolt mm 6 8 10 12 a Fig. tighten metric nuts and bolts to the torque below.4 – 2. A Width across flats mm 10 13 14 27 Tightening torque Nm kgm 5.7 – 23.FOREWORD STANDARD TIGHTENING TORQUE TABLE STANDARD TIGHTENING TORQUE TABLE 1.5 – 29.520 – 1.0 46. A.7 74.6 – 9.5 6.6 – 1. PX-15 00-21 (8) .8 0.7 27 – 34 59 – 74 98 – 123 153 – 190 235 – 285 320 – 400 455 – 565 610 – 765 785 – 980 1.960 – 2.0 80. B.5 15.0 – 41.

010 {76.5 – 3.9 {4.FOREWORD STANDARD TIGHTENING TORQUE TABLE 2. Table of tightening torques for O-ring boss plugs ★ Unless there are special instructions.5} 39.5 {2.4 – 367. tighten split flange bolts to the torque below.06 10.0 – 18.4 {3.0} on type of connec.3 {2.5} 49.0} 422 {43.0 – 2.8 – 78.5 – 34. 363 – 480 {37.0} tor.88 – 8.5} 84 – 132 { 8. Table of tightening torques for O-ring boss piping joints ★ Unless there are special instructions.04 05.0} 34.5} 274.0 – 12.5 – 2.0} Width across flats mm 4.1 {3.5} 22.75} 9.0} 127. Nominal No.1 {18.4 {33.5} 323.5 – 6.81 – 12.35 {0. tighten O-ring boss plugs to the torque below.5} 181.0} 151.0 {5.2 {4.5 10.5 – 4.3 – 44.6 {7.7 {21.0 – 37.5} 107.5 – 13.0} 17.5} 44 { 4.4 {6.6 – 24.27 {1.9 {15.3 – 240.0} 58.0} 93.0} 107.4 {13. Nominal No.0} 00-22 (8) D65EX.0 – 7.6 – 0. Thread diameter of bolt mm 10 12 16 Width across flats mm 14 17 22 Tightening torque Nm 59 – 74 98 – 123 235 – 285 kgm 6.5 { 9.15} 14.1 – 122.5} 210.3} 11.0} 746 – 1.5 23.1 – 53.8} 19.7 – 19.8 {11.12 14 Thread diameter mm 14 20 24 33 42 Tightening torque Nm {kgm} Range Target 35 – 63 { 3. Table of tightening torques for split flange bolts ★ Unless there are special instructions.74 {1.6 {1.0 – 8.5 – 29.4 – 176.5 – 5.0 {11. tighten O-ring boss piping joints to the torque below.0} 68.5 3. 02 03.128 – 186 {13.5} 103 {10.8 – 147.0 – 49.0} 44.0} 127. 08 10 12 14 16 18 20 24 30 33 36 42 52 Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52 Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – – Tightening torque Nm {kgm} Range Target 5.0 – 15.5 – 24.4 {13.9} 7.5 – 12.5} 29.0 – 103} 883 {90. PX-15 .0 – 1.64 {1.0 – 19.54 {2.5} Varies depending 157 {16.3} 24.5 {28.82 {0.

45 ± 0.41 3.5} 74 { 7. Table of tightening torques for 102.0} 246 – 343 {25.0} 245 {25. Table of tightening torques for hoses (taper seal type and face seal type) ★ Unless there are special instructions. Table of tightening torques for 102.0} 6.0} 216 {22.5} 78 { 8.02 ± 0.20 1.2 – – – – – – 44 { 4.5 – 13.4 1-3/16-12UN 30.5 – – 13/16-16UN 20.5 – 6. Tightening torque Nm {kgm} Nominal No.38 ± 0. 107 and 114 engine series to the torque below.61 7.5 – 5.0 – 10.5} 54 – 93 { 5. Thread size mm 6 8 10 12 14 Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 — Tightening torque Bolts and nuts kgm 1.5 – 9. 107 and 114 engine series (Bolts and nuts) ★ Unless there are special instructions.5} 157 {16. PX-15 00-23 (8) .5} 128 – 186 {13. tighten the hoses (taper seal type and face seal type) to the torque below.0} 84 – 132 { 8.0 – 30.22 — 7.0} 177 – 245 {18.0} 216 {22. tighten the metric eye joints of the 102.02 ± 0.0} Target Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42 Face seal Nominal No.22 ± 0.81 ± 0. 107 and 114 engine series (Eye joints) ★ Unless there are special instructions.0} 197 – 294 {20.20 2.6 1-14UNS 25.20 1. Thread diameNumber of ter (mm) (Refthreads. 107 and 114 engine series to the torque below.0 – 25.FOREWORD STANDARD TIGHTENING TORQUE TABLE 5.51 D65EX.0} 177 – 245 {18.0} 103 {10.41 4. of hose 02 03 04 05 06 (10) (12) (14) Width across flats 19 22 24 27 32 36 41 46 55 Range 34 – 54 { 3.5} 59 – 98 { 6.0 – 35.0 – 19. ★ Apply the following torque when the threads are coated (wet) with engine oil.85 ± 1.5} 34 – 63 { 3.20 2.0 – 25. tighten the metric bolts and nuts of the 102.3 – – 11/16-16UN 17. type of erence) thread 9/16-18UN 14.67 ± 0.0} 294 {30. Thread size mm 6 8 10 12 14 Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5 kgm 0.45 ± 0.

22 ± 0.10 0.81 ± 0. 107 and 114 engine series to the torque below. tighten the taper screws (unit: inch) of the 102.20 1.67 ± 0.31 ± 0.20 1.20 2.45 ± 0.12 ± 0.53 ± 0.92 00-24 (8) D65EX.41 3. Table of tightening torques for 102.51 6. PX-15 . 107 and 114 engine series (Taper screws) ★ Unless there are special instructions. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1 Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9 kgm 0.FOREWORD STANDARD TIGHTENING TORQUE TABLE 8.

3) The original value (550 mm) was divided by 10.362 2.575 1.126 2.858 2.756 3. so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. then draw a perpendicular line down from (B).654 2.378 1. Therefore.536 1.850 1.874 3.496 1.740 6 0.441 2.945 1.693 2.402 2.03937 in 7 8 9 0.732 2.244 2.598 2.063 1.929 2. This point (C) gives the value when converting from millimeters to inches.65 inches. see the example given below. Convert 550 mm into inches.512 0.079 0. take this as (B).283 2.047 2.189 3.260 1.165 inches.142 1.150 3. 1) The number 550 does not appear in the table.866 1.717 3.323 2.953 3. 3) Take the point where the 2 lines cross as (C).472 0.906 1.268 3.780 1 mm = 0.299 1.969 2.630 1.898 0 10 20 30 40 (A) 50 60 70 80 90 D65EX.165 2.890 1.520 2.307 3.748 1.425 3. and then draw a horizontal line from (A).354 0.480 2.386 3. 2) Carry out the same procedure as above to convert 55 mm to 2. For details of the method of using the conversion table.591 0.346 3. so multiply 2. 2) Locate the number 5 in the row across the top.827 1.228 3.102 1.008 2.984 1. Millimeters to inches 0 0 0.677 3.504 3.787 1. 55 mm = 2.559 2.638 3.583 2 0.157 0.913 3.772 (C) 2.039 0.315 0.543 1 0.819 2.795 3.622 3 0.110 3.614 2. PX-15 00-25 (8) . 1) Locate the number 50 in the vertical column at the left side. This gives 550 mm = 21. take this as (A).205 2.339 1.220 1.181 1.394 0.FOREWORD CONVERSION TABLE CONVERSION TABLE Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures.835 3.417 1.709 0.236 0. Convert 55 mm into inches.165 inches.276 0.087 2.024 1.197 0.701 (B) 5 0.669 0.118 0.661 4 0.465 3. 2.032 3.992 3.165 inches by 10 (move the decimal point one place to the right) to return to the original value.811 2.433 0.457 1.071 3. Example: Method of using the conversion table to convert from millimeters to inches 1.551 0.

157 0.465 3.964 20.276 0.83 3 6.969 2.39 209.504 3.133 7.926 24.341 22.982 11. PX-15 .378 3.299 1.80 116.850 2.638 3.12 174.913 3.737 16.748 1.586 18.040 13.339 1.874 3.492 21.795 17.05 130.64 19.152 12.480 2.625 15.150 3.598 2.775 13.73 180.80 213.812 7.811 2.10 163.07 152.496 1.583 2 0.2046 lb 6 7 8 9 13.472 0.047 2.75 94.115 18.86 51.85 127.44 1 kg = 2.402 2.718 11.244 2.907 19.118 0.126 2.71 72.85 138.719 25.559 2.057 3.361 15.925 8.91 171.68 41.614 2.21 121.170 5.14 88.346 3.889 15.102 1.94 182.087 2.322 17.53 178.441 2.819 1 mm = 0.001 16.795 3.669 1.41 26.953 3.25 143.529 17.585 1.51 167.340 8.96 97.89 57.520 2.03 4 8.205 2.FOREWORD CONVERSION TABLE Millimeters to inches 0 0 0.378 1.457 1.35 187.220 1.076 8.227 4.48 156.662 24.190 24.039 10.304 3 0.55 189.359 14.260 1.46 48.039 0.813 22.717 3.434 6.303 11.20 24.604 6.28 154.701 5 0.906 3.858 2.189 8.024 1.454 10.48 39.76 191.165 2.772 2.755 5.91 74.44 134.433 0.2642 U.473 16.62 105.095 13.189 3.624 14.849 2.510 9.774 10.30 68.394 0.512 0.27 37.264 0.71 169.379 19.417 1.983 25.315 0.236 0.929 2.82 30.416 12.37 198.709 0.661 4 0.209 15.756 21.228 20.643 19.21 218.64 125.832 1 l = 0.03937 in 8 9 0.511 26.944 14.82 108.283 5.78 85.07 55.42 1 2.268 3.03 123.19 207.110 3.362 2.98 101.888 12.00 119.14 185.869 7.197 0.693 2.57 83.247 25.549 22.079 0.181 1.66 147.61 28.307 3.05 141.732 2.491 4.058 17.020 21.59 114.265 16.153 0 10 20 30 40 50 60 70 80 90 00-26 (8) D65EX.455 25.793 3.677 3.831 11.622 3 0.850 18.605 23.680 12.228 3.Gal 5 6 7 8 9 1.756 3.134 23.41 103.78 202.898 0 10 20 30 40 50 60 70 80 90 Kilogram to pound 0 0 22.700 20.60 211.543 1 0.98 205.26 0 10 20 30 40 50 60 70 80 90 Liters to U.S.984 1.548 5.992 3.02 33.568 4 1.171 19.46 145.096 14.23 132.906 1.05 44.32 59. Gallons 0 1 2 0 0.18 110.780 7 0.55 92.567 10.827 1.96 194.23 15.963 4.142 1.S.283 2.321 1.698 6.866 1.397 7.354 0.87 149.93 79.34 90.063 1.835 3.435 20.945 1.01 216.32 176.536 1.425 3.69 158.032 3.870 23.84 35.53 61.077 22.890 1.43 17.62 2 4.071 3.630 1.246 9.66 50.50 70.008 2.12 77.39 112.09 66.551 0.30 165.740 6 0.591 0.528 2.25 46.285 21.642 2.113 2.323 2.17 196.57 200.386 3.73 63.89 160.64 136.37 81.787 1.398 24.575 1.661 9.24 5 11.654 2.16 99.019 6.

499 7.239 11.0 1113.139 8.6 123.0 752.9 1142.9 1374.6 462.640 4.839 7.8 1309.4 1265.658 13.7 1135.699 9.9 904.9 282.337 12.158 19.9 441.958 17.0 1251.8 1056.477 20.4 3 21.740 3.5 614.7 188.5 1048.7 217.1 1150.339 10.1 817.4 202.259 9.1 231.498 18.7 773.378 19.8 274.4 1171.7 622.8 839.6 1179.520 3.320 1.9 1280.1 940.797 1 0.878 14.200 4.0 1439.7 896.3 144.9 781.598 19.137 21.457 4 0.3 361.660 2.697 20.2 976.0 289.9 1027.5 86.4 1128.Gal 6 7 8 9 1.719 5.0 600.5 766.9 1157.3 1041.9 658.978 15.379 7.257 20.220 2.5 737.5 1077.298 16.0 1222.1 448.1 911.939 6.577 21.359 8.1 1316.7 311.4 889.3 484.0 1063.8 593.938 19.1 130.9 5 36.980 3.559 10.7 4 28.6 679.2 79.037 20.3 578.6 556.8 470.3 1129.899 12.618 17.3 701.6 831.0 694.998 13.357 21.0 383.5 708.1 477.279 7.017 2 0. PX-15 00-27 (8) .K.4 1388.2 2 14.638 15.4 1294.3 267.K.2 354.4 918.2 1258.0 506.5 1236.3 824.4 332.1 571.1 1410.3 947.5 303.198 15.420 4.1 6 43.1 1287.9 224.2 325.6 151.2 1164.2 137.179 5.6 1207.278 18.6 1019.860 5.528 14.7 1367.6 651.237 3 0.9 65.6 368.8 159.3 1200.418 15.8 1338.897 1 l = 0.9 101.119 10.2 1005.1 1034.5 983.818 20.2 1381.lb 0 0 72.178 17.0 1345.0 166.7 1273.838 18.438 13.557 12.3 1092.059 7.459 11.4 455.5 397.4 549.281 13.6 245.677 5 1.1 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 723.858 16.2 108.2 1070.2 1121.880 3.6 1 kgm = 7.3 173.5 954.599 8.lb 8 9 57.2 513.4 115.5 520.080 5.9 629.1 347.479 9.3 730.3 853.5 1330.117 12.7 716.760 1.0 412.8 745.718 18.7 1106. Gallons 0 0 2.738 16.758 14.7 1244.4 7 50.399 6.2 296.917 21.233 ft.518 16.5 860.777 0 10 20 30 40 50 60 70 80 90 kgm to ft.950 4.2 788.0 969.0 195.579 10.2 636.6 1301.679 11.0 1 7.7 990.5 585.FOREWORD CONVERSION TABLE Liters to U.8 376.019 11.1 260.3 1323.619 6.8 1432.159 6.7 94.9 1403.7 405.8 426.039 9.3 390.6 802.4 238.9 1186.5 180.0 846.1 665.6 340.7 1084.4 643.7 868.919 8.078 16.2 759.8 1215.5 209.6 1396.1 1352.2 542.098 14.7 528.3 672.9 810.2 882.100 3.9 318.540 1.9 535.058 18.4 1012.2 607.4 795.5 1099.3 1417.6 925.8 933.4 D65EX.21997 U.300 5.4 419.799 10.5 1359.7 434.9 998.1 1193.8 962.8 253.0 875.440 2.819 9.778 12.6 1424.398 17.318 14.8 499.8 564.8 687.5 491.

920 2.731 2.385 3.2 1.621 1.044 3.081 1.024 1.143 3.086 3.399 3.6 753.778 1.3 924.631 2.6 113.001 3.247 2.233 2.176 2.550 1.229 3.4 483.5 938.020 2.958 3.3 1.262 2.7 184.764 1.5 526.200 3.1 469.9 711.0 270.053 1.442 3 42.930 3.489 2.290 2.343 3.859 3.375 2.821 1.773 2.166 1.0 398.527 839.565 1.693 1.357 3.394 1.271 3.2233 lb/in2 7 8 9 99.067 1.9 583.347 2.048 2.7 953.038 1.280 1.9 810.674 2.830 2.005 2.456 4 56.508 1.1 910.266 1.190 2.532 2.015 3.451 1.493 1.8 128.4 867.314 3.304 2.323 1.2 284.465 1.124 1.2 384.446 2.660 2.FOREWORD CONVERSION TABLE kg/cm2 to lb/in2 0 0 142.3 540.437 1.4 611.0 241.513 825.2 981.802 2.721 1.9 455.759 2.892 2.987 3.944 3.475 2.6 1.664 1.333 2.129 3.309 1.8 768.0 654.030 3.2 853.276 2.119 2.432 2.404 2.806 1.916 3.257 3.7 1.0 1.7 312.6 881.351 1.8 256.209 1.214 3.101 3.717 2.105 2.148 2.418 2.745 2.318 2.010 1.749 1.091 2.934 2.4 1.607 1.963 2.636 1.678 1.873 3.5 1.205 2.7 568.1 1.300 3.2 156.337 1.134 2.0 967.863 2.294 1.3 796.5 682. PX-15 .195 1.5 426.7 440.877 2.072 3.6 625.152 1.4 170.845 2.077 2.707 1.574 2.389 2.5 554.835 1.9 199.3 227.887 3.286 3.650 1.522 1.380 1.991 2.503 2.1 597.109 1.1 213.252 1.7 696.6 1.058 3.365 1.158 3.371 3.1 341.788 2.8 640.4 995.9 327.560 2.237 1.6 369.589 2.3 412.7 668.1 782.460 2.499 1 kg/cm2 = 14.977 2.4 355.8 896.603 2.546 2.219 2.735 1.617 2.428 2 28.646 2.973 3.115 3.181 1.702 2.816 2.172 3.2 725.479 1.849 1.361 2.034 2.518 2.6 497.162 2.593 1.792 1.688 2.485 6 85.422 1.906 2.328 3.414 1 14.223 1.536 1.5 298.243 3.579 1.095 1.8 512.4 739.542 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 00-28 (8) D65EX.949 2.470 5 71.901 3.062 2.138 1.186 3.8 1.408 1.

0 35.1 6.0 15.9 –18. 1°C = 33.4 15.0 42.0 °C 7.4 210.7 –26.8 40.4 156.2 –6.0 293.8 206.8 23.4 10.7 54.7 –21.2 95.8 62.7 32.0 168.2 212.2 194.6 1.6 109.2 23.0 °C 27.4 –3.8 –22.6 208.0 –22.0 69.4 57.9 4.0 186.2 158.4 –23.4 25.0 6.6 –10.0 302.3 8.0 257.8 13.0 30.2 176.0 150. consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.6 68.1 48.0 –24.2 –40 –35 –30 –25 –20 –19 –18 –17 –16 –15 –14 –13 –12 –11 –10 –9 –8 –7 –6 –5 –4 –3 –2 –1 0 1 2 3 4 5 6 7 8 9 10 °F –40.3 28.9 34.2 122.4 183.2 –26.6 –20.2 50.0 62.2 59.6 154.3 –2.0 159.0 –14.1 –5.6 91.0 °C –11.2 140.7 79.2 203.2 86.8 –17.4 48.4 75.2 68.4 174.0 123.1 –15.0 266.0 132.6 73.2 –16.4 93.9 29.7 37.3 –17.0 –4.6 37.4 –13.0 311.4 39.2 185.1 –25.9 –13.4 111.0 °C –40.8 197.6 6.0 15.8 152.4 21.1 –10.8 53.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 °F 51.2 5.8 89.4 5.0 –2.8 –27.6 21.8 17.8 –12.7 17.8 –2.4 120.6 –15.4 D65EX.8 179.8 26.4 201.2 27.2 104.0 338.4 30.6 16.4 –18.2 37.8 18.0 87.7 2.8 –7.0 20.6 163.2 60.FOREWORD CONVERSION TABLE Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures.7 22.8 161.6 118.6 –5.6 199.3 3.3 13.8 3.4 1.8 143.4 165.0 329.9 19.0 347.3 46.0 195.6 64.3 23.7 7.7 –16.8 71.1 16.8 35.4 66.0 –31.2 77.6 100.7 12.9 –8.9 14.1 73.2 –0.6 136. When convert from Centigrade to Fahrenheit degrees.0 221.2 –1.0 10.3 –27.8 8. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.8 44.4 20.0 25.0 204.8 8.6 0 0.0 33.6 82.6 10.8 134.9 –23. When convert from Fahrenheit to Centigrade degrees.0 –4.6 11.3 –22.4 –8.3 –12.2 22.1 –0.2 12.2 –34.0 96.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 °F 114.0 24.2 2.4 30.6 55.6 46.4 84.3 33.0 230.4 –31.2 131.3 –7.9 51.7 –6.2 167.4 147.6 145.7 65.0 275.0 5.6 43.2 149.1 31.6 36.8 98.2 14.0 105.0 320.8°F °F 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 177.7 –11.9 –28.0 248.4 3.1 –20.4 102.2 17.8 80.4 129.1 21. and read the corresponding Fahrenheit temperature on the right.0 284.8 116.9 24.6 127.4 192.6 –25.6 19.1 36.2 113.1 1.7 –28.9 9.0 78.4 57.6 181.4 35.0 –9.0 –13.2 –21.6 26.6 31.8 28.3 71.9 76.6 190.2 32.4 –37.0 239.2 32.0 60.9 –3.1 11.8 170.7 –1.0 –19.6 28.8 188. PX-15 00-29 (8) .8 33.4 12.8 125. consider the center column to be a table of Centigrade values.8 107.0 141.2 41.6 172.4 138.1 26.3 18.

...................................GENERAL 01 GENERAL Specification dimensions ......2 01........................... 01....... coolant and lubricant ............................................................................................ Weight table .......................................................................................................................... Specifications ...... PX-15 01-1 ......3 01.......................................... Table of fuel......................................................................................................................8 01-10 D65EX............................................................

000 D65PX-15 20. cab.950 D65WX-15 20.6 5.GENERAL SPECIFICATION DIMENSIONS SPECIFICATION DIMENSIONS D65EX-15 semi-U dozer with ROPS guard.440 3.220 3. cab.9/6.255 3.770 142 {190}/1.970 3. and air conditioner Item Machine weight Engine name Rated engine output A Overall length B Overall height (excluding antenna) C Overall width Travel speed (1st/2nd/3rd gear speed) Forward Reverse Unit kg — kW {HP}/rpm mm mm mm km/h km/h D65EX-15 20.550 3.4 5.0/8.6/13. cab.440 3. PX-15 .640 01-2 (7) D65EX. and air conditioner D65WX-15 semi-U dozer with ROPS guard.8/10.455 5.220 3.860 Komatsu SA6D125E-3 diesel engine 5. and air conditioner D65PX-15 power tilt dozer with ROPS guard.

Machine mass • Tractor unit Mass • With work equipment • With work equipment and ROPS cab • With work equipment.640 2.285 510 405 30 35 3.62} (65.8 {0.025 2. and ROPS cab Min.115 2.46} 47.6 5.285 950 510 30 35 3.770 — — [Pivot turn] 17.050 20.675 510 405 30 35 3.550 3.79}) 4. right) Forward 1st Gear speed Forward 2nd Forward 3rd Reverse 1st Reverse 2nd Reverse 3rd Tractor unit Ground pressure With work equipment With work equipment and ROPS cab kg kg kg kg m deg.390 3.050 3.130 20.440 2.6 5.675 810 405 30 35 3.6 13.9 6.220 3.520 5.220 3.46} 47.60} 69. left.220 3.000 (21.740 (22.2 {0. km/h km/h km/h km/h km/h km/h kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} 16.220 3.270 20.0 8.080 2.040 20.28} 31.9 6.73} (77.8 10.335 5.000 3.440 2.860 (22.9 6.335 5.6 {0.4 38.255 3.880 3.890 3.0 8.640 2.0 8.GENERAL SPECIFICATIONS SPECIFICATIONS D65EX-15 Machine name and type Serial No.8 10.1 {0.420) — [Pivot turn] 17.680) — [Pivot turn] Semi-U dozer Semi-U dozer with wide gauge Semi-U dozer with long track D65PX-15 Power tilt dozer D65WX-15 Semi-U dozer 67001 and up 67001 and up 67001 and up 17.050 20.0) ({0.6 13.6 5.315 3.390 2.080 1.520 5.4 27.5 {0.4 {0.60} 60.455 2.1 {0.860 (22.0 {0.6 13.300 20.990 2.7) ({0.440 2.335 5.0 8.675 810 405 Performance With work equipment.0) ({0.270 19.5) ({0.315 3.990 2. ripper.1 {0.540) — [Pivot turn] 30 35 3.8 10. rear.6 {0.315 3.52}) 4.67}) 4.2 {0.220 3.9 6.050 2.540) — [Pivot turn] 17.39} 45.6 13.010 20.4 {0. swing radius Gradeability Stability (Front.6 13.050 2.39} 45.315 3. PX-15 01-3 (7) .350 3.71} 71. ripper.8 10.890 3.080 1.990 2.0 8.6 5.48} (51.220 3.52}) 4.4 38.845 2.880 2.970 3.4 58.255 3.1 {0.48} (51.220 3.130 20. deg.010 20.080 2.990 2.8 {0.990 2. kPa and ROPS cab {kg/cm2} Tractor unit With work equipment Tractor unit With work equipment Up to exhaust pipe Up to top of operator’s seat When ROPS cab is installed (excluding antenna) When ROPS canopy is installed When cab is installed (excluding antenna) mm mm mm mm mm mm mm mm mm mm mm mm mm Track gauge Length of track on ground Track width (Standard track shoe) Minimum ground clearance aValues in ( ) are shown for reference.32} 32.8 {0.51} 58.8 10.9 6.33} — 4.220 3.6 5. Overall height Dimensions Overall Overall width length D65EX.4 50.

manual electronic type Spiral bevel gear.400} 2.5 kW 24 V. water-cooled. 7.950 {190/1.04 {11. PX-15 . 50 A 12 V.2 mm Starting motor Alternator Battery (*1) Type of radiator core Torque converter Transmission Power train Bevel gear shaft HSS unit HSS Brake Final drive Type of suspension Carrier roller Track roller Undercarriage Track shoe • Assembly type single grouser shoe 8 pieces on each side Width: 510 mm 45 pieces on each side Pitch: 203. equalizing beam type 2 pieces on each side 7 pieces on each side Width: 510 mm Width: 810 mm 39 pieces on 39 pieces on each side each side Pitch: 203. splash lubrication type Semi-hard.2 mm • Assembly type special swamp shoe — — — Width: 950 mm 45 pieces on each side Pitch: 203. 01-4 (7) D65EX.2 mm 7 pieces on each side — Width: 810 mm 39 pieces on each side Pitch: 203.2 mm Pitch: 203. Name Type Number of cyl. 112 Ah. hydraulic type 1-stage spur gear/1-stage planetary gear reduction. in-line. multiple disc. manual electronic. spring-boosted. hydraulic. 2 units D-6 3-element. gear pump forced lubrication. hydraulic motor drive.GENERAL SPECIFICATIONS D65EX-15 Machine name and type Serial No. direct-injection diesel engine with turbocharger and aftercooler 6 – 125 x 150 11.040} 142/1. torque High idling speed under no load Low idling speed under no load Min.2 mm — *1 : The battery capacity (Ah) is on 5-hours rate. hydraulic type Wet multiple disc. foot-operated.950} Engine Max. gear pump forced lubrication type Differential planetary gear. – Bore x Stroke Total displacement Rated output Performance mm l {cc} kW/rpm {HP/ rpm} Nm/rpm {kgm/ rpm} rpm rpm g/kWh {g/HPh} Semi-U dozer Semi-U dozer with wide gauge Semi-U dozer with long track D65PX-15 Power tilt dozer D65WX-15 Semi-U dozer 67001 and up 67001 and up 67001 and up SA6D125E-3 4-cycle.100 ± 50 825 ± 25 222 {163} 24 V. 1-phase type Planetary gear. fuel consumption ratio 941/1. 1-stage.400 {96/1. 3 forward/reverse gear speeds.

variable-capacity piston. HSS pump • Type • Theoretical capacity Cooling fan pump Hydraulic pump • Type • Theoretical capacity Power train and lubricating oil pump • Type • Theoretical capacity Scavenging pump Hydraulic system • Type • Theoretical capacity HSS motor Hydraulic motor • Type • Motor capacity Cooling fan motor • Type • Motor capacity Control valve Type and quantity Control method cm3/rev cm3/rev cm3/rev Gear type 61. fixed-capacity piston type 28 3-spool type.GENERAL SPECIFICATIONS D65EX-15 Machine name and type Serial No. 1 piece 4-spool type.7 x 2 HMF95. gear type (Tandem) 43. variable-capacity piston type 30 SAL (2) 45 + 45.2 cm3/rev cm3/rev cm3/rev Semi-U dozer Semi-U dozer with wide gauge Semi-U dozer with long track D65PX-15 Power tilt dozer D65WX-15 Semi-U dozer 67001 and up 67001 and up 67001 and up HPV95. fixed-capacity piston type with brake valve 96 LMF28. PX-15 01-5 (7) . 1 piece (Machine with ripper: Optional) Hydraulic assist type Box type (External control valve type) Return side of tank Air-cooled type (3A-CS) Hydraulic tank Hydraulic oil filter Oil cooler D65EX. load sensing type 112 LPV30.

080 750 Power tilt dozer Left: Brace. mm mm deg.455 1.180 565 680 ±7 3.165 1.077 Semi-U dozer Semi-U dozer with wide gauge Semi-U dozer with long track D65PX-15 Power tilt dozer D65WX-15 Semi-U dozer 67001 and up 95 65 67001 and up 67001 and up 95 65 1.415 1.080 750 mm mm mm mm mm mm mm mm mm mm 95 65 1. PX-15 .410 55 Dimensions 3.105 1.480 55 440 820 ±7 Dimensions Semi-U dozer Left: Brace.415 1.685 520 140 70 145 1. 1. Right: Tilt cylinder 1. distance between pins Min.165 1.110 57 — — Work equipment Type Blade supporting method Performance Max.105 440 855 ±7 3.205 440 890 ±7 3.105 1. distance between pins Type Ripper cylinder Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins Type Blade supporting method Performance Max.685 520 Double-acting piston type 1. Right: Tilt cylinder 1. Type Lift cylinder Cylinder bore Piston rod diameter Stroke Max.170 470 870 ±7 3. tilting distance Blade angle range Blade width Blade height Blade angle mm mm mm deg.110 55 1. distance between pins Min. mm mm deg.460 1.105 440 870 ±7 3. distance between pins Tilt and pitch cylinder Type Cylinder bore Piston rod diameter Stroke Max. drop (below ground) Max.225 55 — — mm mm mm mm mm 140 70 330 1.GENERAL SPECIFICATIONS D65EX-15 Machine name and type Serial No. lift (above ground) Max.480 55 — — 1.105 440 820 ±7 3.222 1. lift (above ground) Max. 1.410 55 01-6 (7) D65EX. drop (below ground) Max.905 800 Double-acting piston type Work equipment hydraulic system Double-acting piston type — — — — — 140 70 330 1.970 1.640 1. tilting distance Blade angle range Blade width Blade height Blade angle mm mm mm deg.640 1.

mm mm deg. power pitch dozer Left: Tilt cylinder. PX-15 01-7 (7) . 1. Type Blade supporting method Performance Max.970 1.170 3 55/45 Changeable to 3 levels 595 640 950/950 — — Type Beam length Number of shanks Ripper Digging angle (A/B) Performance Digging depth Max. tilting distance Blade angle range Blade width Blade height Blade angle mm mm mm deg.110 57 Parallelogram mm piece deg. lift Shank position (Left/Right) Dimensions D65EX. angle Blade width Blade height Blade angle mm mm mm deg. Right: Pitch cylinder 1.120 55 — — — — Semi-U dozer Semi-U dozer with wide gauge Semi-U dozer with long track D65PX-15 Power tilt dozer D65WX-15 Semi-U dozer 67001 and up Angledozer Both sides: Brace 67001 and up 67001 and up — — Work equipment Dimensions — — Type Blade supporting method Performance Max. digging depth Max.180 460 400 25 3. drop (below ground) Max. mm mm deg. — — — — Power tilt. lift (above ground) Max. tilting distance Max.970 — 1. 2.GENERAL SPECIFICATIONS D65EX-15 Machine name and type Serial No.200 — 445 890 +9/–7 3. drop (below ground) Max. lift (above ground) Max.170 3 55/45 Changeable to 3 levels mm mm mm 595 640 950/950 — — Parallelogram 2.

200 25 2 22 145 125 12 28 13 200 1.200 25 2 22 145 125 12 28 13 200 1. PX-15 .GENERAL WEIGHT TABLE WEIGHT TABLE k This weight table is for reference in handling or transporting components.300 1.300 1. D65EX-15 Standard Wide gauge 67001 and up 1.3 x 9 2.300 1.435 290 340 13 6 710 6 45 65 20 5 75 Long track D65PX-15 Standard D65WX-15 Wide gauge 67001 and up 67001 and up 1.200 25 2 22 145 125 12 28 13 200 1. Unit: kg Machine name and type Serial No.140 105 30 84 95 765 8.140 105 30 01-8 (7) D65EX.300 1.3 x 9 2.435 290 340 13 6 710 6 45 65 20 5 75 1.435 290 340 13 6 710 6 45 65 20 5 75 1.140 105 30 84 95 790 8.140 105 30 84 95 790 8.140 105 30 84 95 790 8.300 1.3 x 9 2.200 25 2 22 145 125 12 28 13 200 1.3 x 9 2.435 290 340 13 6 710 6 45 65 20 5 75 1.3 x 9 2.435 290 340 13 6 710 6 45 65 20 5 75 Engine and damper assembly (Excluding coolant and oil) • Engine assembly • Damper assembly • Engine-related parts (Wiring) Universal joint Cooling assembly (Excluding coolant and oil) • Radiator assembly • Hydraulic oil cooler Cooling fan pump Cooling fan motor Fuel tank (Excluding fuel) Power train unit assembly (Excluding oil) • Torque converter and PTO assembly • Transmission assembly • Transmission ECMV assembly • Main relief valve assembly • HSS unit assembly • Brake valve assembly HSS motor HSS pump Power train and lubricating oil pump Scavenging pump Hydraulic tank (Excluding oil) Control valve • 3-spool valve • 4-spool valve (Machine with ripper: Optional) Final drive assembly (Each side) Sprocket (Each side) Frame assembly Engine underguard Transmission underguard 84 95 765 8.200 25 2 22 145 125 12 28 13 200 1.

495 590 200 250 54 x 5 61 x 2 30 x 2 D65EX.360 — 1. PX-15 01-9 (7) .735 — 100 145 300 59 410 220 410 2.530 75 — 1.355 285 75 95 x 2 1.580 — — 90 125 300 59 410 220 410 2. Track group assembly (Each side) • Track frame • Idler assembly (Each side) • Recoil spring assembly (Each side) • Single flange track roller assembly (Each side) • Double flange track roller assembly (Each side) • Carrier roller assembly (Each side) Track shoe assembly (Each side) • Single grouser shoe (510 mm) • Single grouser shoe (810 mm) • Swamp shoe (950 mm) Pivot shaft (Each side) Equalizer bar Floor frame assembly Operator’s seat Cab assembly ROPS guard assembly (for cab) ROPS canopy assembly Semi-U dozer Power tilt dozer assembly • Blade • Straight frame (Each side) • Tilt cylinder assembly Lift cylinder assembly Ripper assembly Ripper cylinder assembly 1.530 75 — — 2.495 590 200 250 54 x 5 61 x 2 30 x 2 D65EX-15 Standard Wide gauge 67001 and up 1.190 285 75 95 x 2 — — — 1.355 285 75 95 x 2 1.GENERAL WEIGHT TABLE Unit: kg Machine name and type Serial No.530 75 1.695 700 200 250 54 x 6 61 x 2 30 x 2 Long track D65PX-15 Standard D65WX-15 Wide gauge 67001 and up 67001 and up 1.310 — — 90 125 300 59 410 220 410 2.360 — 1.530 75 1.280 — 1.495 590 200 250 54 x 5 61 x 2 30 x 2 1.325 285 75 95 x 2 1.695 700 200 250 54 x 6 61 x 2 30 x 2 1.280 — 1.735 — 100 145 300 59 410 220 410 2.110 100 145 300 59 410 220 410 — 2.030 1.325 285 75 95 x 2 1.

01-10 (7) D65EX.15 0. PX-15 .GENERAL TABLE OF FUEL.2 415 — *1 Add antifreeze 59 — Cooling system (Incl.7 0. For this reason. If kerosene or other fuel with low lubricating ability is used.32 95 55 SAE 30 44 38 Specified Refilled oil amount oil amount 104ºF 122ºF (l) (l) 40ºC 50ºC SAE 30 Engine oil SAE 10W 68 48 EX: 24 EX: 24 PX.25 1.1 NOTICE Use only diesel fuel. there will be a big drop in durability.32 GO 140 0.2 — 0. The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel consumption and good exhaust gas characteristics. reservoir tank) Coolant *1. it requires high precision for the parts and good lubrication.25 Gear oil Grease Fuel tank Diesel fuel ASTM D975 No.7 0. transmission and bevel gear case Final drive case (each side) Damper case Idler (each) Pivot shaft case (each side) SAE 10W Hydraulic oil SAE 10W-30 SAE 15W-40 Track roller (each) Carrier roller (each) Grease fitting 0. ASTM D975 No.WX: 27 PX. COOLANT AND LUBRICANT Refilling position Kind of oil –22 –30 –4 –20 Ambient temperature 14 32 50 68 86 –10 0 10 20 30 SAE 30 SAE 10W Engine oil pan SAE 10W-30 SAE 15W-40 SAE 5W-30 Power train case including torque converter.15 0. COOLANT AND LUBRICANT TABLE OF FUEL.24 NLGI No.24 — 0.WX: 27 1.

GENERAL TABLE OF FUEL.5%. PX-15 01-11 .5 to 1. Change oil according to the following table if fuel sulphur content is above 0. Use API classification CD as engine oil and if API classification CC. SAE10W-30 and SAE15W-40. 15W-40). be sure to use engine oil of SAE10W.0% Change interval of oil in engine oil pan 1/2 of regular interval 1/4 of regular interval D65EX.5%. When staring the engine with an atmospheric temperature of lower than 0ºC (32ºF). but be sure to add single grade oil that matches the temperature range in the table. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Fuel sulphur content 0. • • • • Specified capacity: Total amount of oil including oil for components and oil in piping. reduce the engine oil change interval to half. There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30.0% Above 1. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. COOLANT AND LUBRICANT REMARK • When fuel sulphur content is less than 0. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. even though the atmospheric temperature goes up to 10ºC (50ºF) more or less during the day. change oil in the oil pan according to the periodic maintenance hours described in this manual.

.... Track roller ..... FUNCTION AND MAINTENANCE STANDARD 10 STRUCTURE..................................... PX-15 10-1 ........................39 10......... Cooling fan motor .................................................................................14 10.................. Brake valve .... Track frame.40 10.............. HSS pump ... end bit .................. Cooling system control system ............................................ Main relief valve ........................ Suspension .............61 10.................................... lubrication pump ...88 10..................................................... Overall drawing of power train unit ........................................................................................................ Carrier roller ..... Work equipment hydraulic piping diagram ........................ Hydraulic.......................................... Quick drop valve ........................................................... Hydraulic piping of power train .... 10-120 10-122 10-124 10-125 10-126 10-128 10-129 10-131 10-139 10-145 10-155 10-158 10-190 10-197 10-201 10-202 10-203 10-204 10-206 10-207 10-208 10-210 10-212 10-214 10-216 10-218 10-220 10-222 10-224 10-228 D65EX.... PPC valve ............................. Transmission and steering controller ............................................................................. Transmission .12 10............................................................. Cab ............................ Engine control .................. Palm command control system ......................................... Power train pump......................................... Piston valve ....................................................... recoil spring . Engine controller ......................... PTO .....9 10.. Idler .... Ripper .....2 10................ HSS...........................36 10.............................................................................. HSS motor ...........................................................................................7 10.................................................................................. Torque converter...............30 10................ Power train ................... Engine control system .... Frame assembly ...41 10........................ Hydraulic cylinder ............... Sprocket ................... Cutting edge.... System components ...................................................... Sensors ...............................STRUCTURE.............................................. Monitor panel ...5 10........ Bevel gear shaft.... Hydraulic tank ............................. Engine mount ....... CRI engine control system ........................................................................... Track shoe ....... Transmission.................... Transmission ECMV ....................................................................................................... Monitor system ..4 10............... Air conditioner piping ..................... PCCS lever ....... HSS system ...................... brake ........ FUNCTION AND MAINTENANCE STANDARD Engine-related parts Cooling system . Accumulator .83 10......................... Cooling fan pump .68 10........................ Cab mount ..95 10-101 10-105 10-107 10-108 10-109 10-113 10-118 Work equipment control ...... universal joint ................... PPC lock valve ..................................19 10...... steering...... Final drive ..........93 10..........43 10................................... brake control ...... Self pressure reducing valve .................. Damper...................... Lubrication relief valve ................. Work equipment .....................10 10............................. Control valve ........................38 10............ 10......................................................... Scavenging pump ..

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM COOLING SYSTEM Engine-related parts 10-2 D65EX. PX-15 .

05} Power train oil cooler PTO-OL — 1.5 1. 9. PX-15 10-3 .722 — — Hydraulic oil cooler 3A-CS 3. 4. Power train oil cooler inlet Power train oil cooler outlet Hydraulic oil cooler inlet Hydraulic oil cooler outlet Cooling fan motor Radiator Radiator inlet hose Hydraulic oil cooler Reservoir tank Radiator outlet hose Radiator cap Cooling fan Power train oil cooler (built in radiator lower tank) 10. 7.9 {0 – 0. 3. 5.627 88. 8.15} 0 – 4.9 ± 0.3 ± 14. 2.STRUCTURE.0 52. FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM A: B: C: D: 1. 6. Drain plug Specifications Radiator Core type Fin pitch (mm) Total heat dissipation surface (m2) Pressure valve cracking pressure (kPa {kg/cm2}) Vacuum valve cracking pressure (kPa {kg/cm2}) D-6 4.7 {0.860 — — D65EX.

Check item Standard size 60 2 Free height of mount rubber Criteria Tolerance Shaft –0.100 –0.346 Repair limit 88 Clearance limit 0. FUNCTION AND MAINTENANCE STANDARD ENGINE MOUNT ENGINE MOUNT Unit: mm No.STRUCTURE.300 Standard size 90 Hole +0.4 Replace Remedy Clearance between bracket and 1 cushion 10-4 D65EX. PX-15 .100 – 0.046 0 Standard clearance 0.

STRUCTURE. Cooling fan motor (19) is rotated with the oil discharged from cooling fan pump (6) driven by PTO (5). FUNCTION AND MAINTENANCE STANDARD POWER TRAIN POWER TRAIN Outline • The power generated by engine (1) has its torsional vibration dampened by damper (2). It connects 2 sets of clutches selected according to the change in load and transmits the power to bevel gear (9) from the bevel pinion at the rear end of the transmission. Transmission (8) uses a combination of a planetary gear system and hydraulic clutches to reduce the speed and shift the gears (3 forward gears and 3 reverse gears). PX-15 10-5 . Final drive (13) consists of a single-stage spur gear and a single-stage planetary gear system. It reduces the speed and rotates sprocket (14) to drive track shoe (15) and move the machine. The steering direction is controlled by generating a difference in speed on the right and left. Brake (12) is a wet. and then passes through universal joint (3) and is transmitted to torque converter (7). spring boosted type. The rotation of the pair of the HSS gears on the right and left is controlled by HSS motor (11). • • • • • D65EX. Brake (12) built in HSS unit (10) is used for braking the machine. • The power transmitted to HSS unit (10) is transmitted through the bevel gear shaft to the HSS. and output oil of the HSS pump drives HSS motor (11). The power sent from brake (12) is transmitted to final drive (13). HSS pump (4) is driven by PTO (5). It is also possible to use the HSS mechanism to rotate the right and left sides in opposite directions to carry out pivot turns. The power from the engine is transmitted through the oil by torque converter (7) to the transmission input shaft in accordance with the change in load. multiple disc clutch.

10. 12. HSS motor Brake Final drive Sprocket Track shoe Power train pump Lubricating oil pump Scavenging pump Cooling fan motor 10-6 D65EX. PX-15 . 9. 19. 4. 2. 15. Engine Damper Universal joint HSS pump PTO Cooling fan pump Torque converter Transmission Bevel gear HSS unit 11.STRUCTURE. 5. 18. 7. 16. FUNCTION AND MAINTENANCE STANDARD POWER TRAIN 1. 13. 6. 17. 3. 8. 14.

9. and HSS unit (11). HSS pump Cooling fan pump HSS motor Lubricating oil pump Power train pump Torque converter and PTO Main relief valve Transmission ECMV Transmission Brake valve HSS unit Scavenging pump Power train oil strainer Outline • The power train unit consists of the main components of torque converter and PTO (6). after the power train unit is removed. bevel gear shaft. 8. PX-15 10-7 .STRUCTURE. and HSS unit (11). it can be divided into torque converter and PTO (6). and brake. Accordingly. 11. 7. 5. 3. HSS motor (3). • D65EX. transmission (9). 2. FUNCTION AND MAINTENANCE STANDARD OVERALL DRAWING OF POWER TRAIN UNIT OVERALL DRAWING OF POWER TRAIN UNIT 1. planetary gear system. HSS unit (11) consists of the bevel pinion unit. transmission (9). 12. 10. 13. 6. 4.

0 Replace Remedy Clearance between bracket and 1 cushion 4 Free height of rear mount rubber 10-8 D65EX.096 +0. Check item Standard size 60 2 Clearance between steering case cover and bushing 204 Criteria Tolerance Shaft –0. FUNCTION AND MAINTENANCE STANDARD OVERALL DRAWING OF POWER TRAIN UNIT Unit: mm No. PX-15 .050 Standard size 3 Free height of front mount rubber 90 43 Hole +0.100 –0.STRUCTURE.4 Max.046 0 Standard clearance 0.346 –0.300 +0.096 – –0.004 Repair limit 88 41 Clearance limit 0.100 – 0.046 0 +0.

STRUCTURE. 6. 3. 5. PX-15 10-9 . 9. 7. 2. 4. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING OF POWER TRAIN HYDRAULIC PIPING OF POWER TRAIN A: B: C: D: E: F: Load sensing oil pressure pickup port Main pump discharge oil pressure pickup port Transmission oil pressure pickup port Torque converter outlet oil pressure pickup port Torque converter inlet oil pressure pickup port Brake oil pressure pickup port 1. Centralized pressure pickup ports Power train oil filter Transmission ECMV Brake valve Power train pump Lubricating oil pump Main relief valve Scavenging pump Power train oil cooler (Built in radiator lower tank) D65EX. 8.

FUNCTION AND MAINTENANCE STANDARD DAMPER. UNIVERSAL JOINT 10-10 D65EX. PX-15 . UNIVERSAL JOINT DAMPER.STRUCTURE.

13. 1. 4. 11. 16. Stopper angle: 4º Stopper torque: 2. 5. • D65EX. 14. Breather Oil filler plug Inspection plug Drain plug Damper case Coupling Spider Yoke Shaft Bearing Drive plate Torsion spring Stopper pin Friction plate Friction spring Hub Cover Outline • The damper is a wet friction spring type. 7.5 (when damper shaft and transmission input shaft are rotated simultaneously) Adjust 2. Radial runout: Max. PX-15 10-11 .087 Repair limit 84. Check item Inside diameter of contact surfaces of coupling and oil seal Facial and radial runout of coupling Standard size 85 Criteria Tolerance 0 –0. 12. 10. 3. transmission. 1. UNIVERSAL JOINT Unit: mm No.670 Nm {272 kgm} The damper damps the torsional vibration caused by fluctuation of the engine torque and the impact torque caused by sudden acceleration and heavy digging work to protect the torque converter.38). and other power train components.STRUCTURE. 9. 6. 18. 8. 17.0 (at 148.8 Plate with hard chromium or replace Remedy 1 — Facial runout: Max. 15. FUNCTION AND MAINTENANCE STANDARD DAMPER.

BRAKE CONTROL TRANSMISSION. BRAKE CONTROL a PCCS: Abbreviation for Palm Command Control System 10-12 D65EX. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION. STEERING.STRUCTURE. PX-15 . STEERING.

3. 5. BRAKE CONTROL 1. Steering/directional/gear shift lever (6) sends electric signals to transmission and steering controller (8). Brake pedal Decelerator pedal Brake valve Transmission ECMV Fuel control dial Steering/directional/gear shift lever (PCCS lever) Neutral safety limit switch Transmission and steering controller Rod Brake potentiometer Cable Packing brake lever Outline • • The transmission.STRUCTURE. Brake pedal (1) operates brake valve (3) through rod (9) to control the brake. If parking brake lever (12) is not set in the LOCK position. • • • D65EX. steering system. which is also used as the parking brake valve. and brake are controlled with steering/directional/gear shift lever (PCCS lever) (6). the transmission and steering controller sends signals to the EPC valve of the control valve to change the discharge of the HSS pump and control the HSS motor. PX-15 10-13 (7) . 9. 7. neutral safety limit switch (7) does not work. 12. Parking brake lever (12) operates brake valve (3). 6. 11. through cable (11). 10. 8. 2. STEERING. 4. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION. thus the engine does not start. Upon receiving these electric signals.

PTO a PTO: Abbreviation for Power Take Off 10-14 D65EX. PX-15 . PTO TORQUE CONVERTER.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER.

FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER.STRUCTURE. PTO D65EX. PX-15 10-15 .

Cooling fan pump mounting opening 6. Pump 16. Power train and lubricating oil pump drive gear (Number of teeth: 53) 20. input shaft (7).STRUCTURE. which is combined with the transmission into 1 unit. Power train strainer 23. PTO idler gear (Number of teeth: 63) 11. and (20). PTO drive gear shaft 10. Stator 15. Scavenging pump strainer 22. 1-stage. Transmission input shaft 18. PTO case 12. PTO A: From transmission case (To torque converter) B: To oil cooler C: From traffic accident (To scavenging pump) D: From transmission case (To power train and lubricating oil pump) E: To transmission case (Drain) Outline • The torque converter is a 3-element. PX-15 . HSS pump mounting opening 2. (19). FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER. PTO drive gear (8). HSS and work equipment pump and fan pump drive gear (Number of teeth: 53) 19. Stator shaft 17. Stator (14) is combined with stator shaft (16) into 1 unit and fixed to PTO case (11). and pump drive gears (18). PTO drive gear (Number of teeth: 62) 9. Drive case 13. Pump (15) is combined with coupling (6). and drive case (12) into 1 unit and rotated by the engine power. Power train and lubricating oil pump mounting opening 3. Scavenging pump drive gear (Number of teeth: 56) 21. Turbine (13) is combined with transmission input shaft (17) into 1 unit and rotated by the oil from pump (15). Scavenging pump mounting opening 4. Sleeve • • 10-16 D65EX. PTO idler gear (10). Each pump installed to the PTO case is driven with the power transmitted through PTO drive gear (8). PTO lubrication tube 5. and 1-phase type. • • 1. Input shaft 8. Turbine 14. Coupling 7.

PTO D65EX. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER.STRUCTURE. PX-15 10-17 .

16 – 0.021 +0. PX-15 .013 0 –0.015 +0.17 – 0.005 Hole –0.STRUCTURE.021 +0.022 –0.002 0 –0.5 Plate with hard chromium or replace Remedy 1 2 3 Backlash between PTO idler gear and 4 HSS pump and cooling fan pump drive gear Backlash between PTO idler gear and 5 power train and lubricating oil pump drive gear 6 Backlash between PTO drive gear and scavenging pump drive gear Standard size Fit tolerance of PTO 7 idler gear bearing Outside diameter Inside diameter Outside diameter (Cover side) 0.010 Replace 110 60 Fit tolerance of HSS pump and cooling fan 8 pump drive gear bearing 120 Outside diameter (Case side) Inside diameter Outside diameter (Cover side) 55 Fit tolerance of power train and lubricating oil 9 pump drive gear bearing 120 Outside diameter (Case side) Inside diameter Outside diameter Inside diameter 55 72 35 Fit tolerance of 10 scavenging pump drive gear bearing 10-18 D65EX.16 – 0.42 0.010 –0.015 +0.015 +0.011 –0.8 105. Check item Outside diameter of oil seal contact surface of input coupling Inside diameter of seal ring contact surface of retainer Backlash between PTO drive gear and PTO idler gear Standard size 110 105 Criteria Tolerance 0 –0.035 0 0.035 0 +0.015 +0.030 0 0 –0.035 0 +0.17 – 0.013 +0.015 0 –0. FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER.015 +0.46 Tolerance Shaft 0 –0. PTO Unit: mm No.013 0 –0.46 0.019 0 –0.002 0 –0.087 +0.022 –0.035 0 –0.42 Repair limit 109.

FUNCTION AND MAINTENANCE STANDARD TRANSMISSION TRANSMISSION D65EX.STRUCTURE. PX-15 10-19 .

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION A: B: C: D: E: F: G: H: J: K: L: M: N: P: R: S: T: 1st clutch oil pressure pickup port 3rd clutch oil pressure pickup port R clutch oil pressure pickup port 2nd clutch oil pressure pickup port F clutch oil pressure pickup port From power train pump (To brake valve) To PTO case (To torque converter) From oil cooler To PTO case (To scavenging pump) From PTO case (Drain) To PTO case (To power train and lubricating oil pump) From steering case From transmission ECMV (For R clutch) From transmission ECMV (For 3rd clutch) From transmission ECMV (For 1st clutch) From transmission ECMV (For 2nd clutch) From transmission ECMV (For F clutch) 10-20 D65EX. PX-15 .

16. F sun gear (Number of teeth: 29) 30. 5.STRUCTURE. 13. 17. 2nd ring gear (Number of internal teeth: 75) 26. 4. F clutch housing 29. 2nd planetary pinion (Number of teeth: 21) 25. Output shaft (3rd sun gear section. : 67136 and up D65WX-15 Serial No. F ring gear (Number of internal teeth: 75) 31. 1st ring gear (Number of internal teeth: 75) 23. 11. : 67001 and up 1. number of teeth: 17) 20. 2nd and 3rd carrier 28. Main relief valve Transmission ECMV cover Transmission case Transmission ECMV Lubricating oil relief valve Transmission input shaft R sun gear (Number of teeth: 26) R planetary pinion (Number of teeth: 22) R ring gear (Number of teeth: 70) Disc Plate Piston F planetary pinion (Number of teeth: 23) 3rd planetary pinion (Number of teeth: 30) 3rd ring gear (Number of internal teeth: 76) 2nd sun gear (Number of teeth: 33) 1st planetary pinion (Number of teeth: 18) 1st sun gear (Number of teeth: 39) 19. F carrier 32. 10. PX-15 10-21 (7) . 14. R carrier D65EX. 2nd clutch housing 24. 6. F clutch housing 33. D65EX-15 Serial No. 1st carrier 21. 9. 1st clutch housing 22. Return spring 34. 15. 3rd clutch housing 27. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION *1. 12. 8. : 67137 and up D65PX-15 Serial No. R ring gear (hub) (Number of internal teeth: 75) 35. 7. 3. 2. 18.

FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Outline • • The transmission consists of planetary gear systems and disc clutches and has “3 forward gear speeds and 3 reverse gear speeds”.823 0. 2nd.67135 Serial No. D65EX-15 D65PX-15 *2. or 3rd clutch is filled with low-pressure oil.948 1.656 — 1. PX-15 . The transmission changes the speed of the power of the transmission input shaft to the forward 1st – 3rd or reverse 1st – 3rd gear speed with the F and R clutches and 3 speed clutches. • Number of plates and discs Clutch No. : 67137 and up Serial No. : 67001. 10-22 (7) D65EX. Among the 5 sets of planetary gear system and disc clutches of the transmission.STRUCTURE.096 0.462 0. : 67001 and up Gear speeds and operated clutches Gear speed Forward 1st Forward 2nd Forward 3rd Neutral Reverse 1st Reverse 2nd Reverse 3rd Operated clutches F x 1st F x 2nd F x 3rd Reduction ratio 1.67136 Serial No. and then transmits the converted power to the output shaft. R clutch F clutch 3rd clutch 2nd clutch 1st clutch Number of plates 6 Number of discs 5 7 4 4 3 *1 *2 *1 *2 *1 *2 *1 *2 6 8 3 5 3 5 2 4 *1. : 67001. D65EX-15 D65PX-15 D65WX-15 Serial No. : 67136 and up Serial No.492 * R x 1st R x 2nd R x 3rd *: The 1st. 2 clutches are fixed hydraulically with the ECMV to select 1 rotating direction and rotating speed.

FUNCTION AND MAINTENANCE STANDARD TRANSMISSION *1. D65EX-15 Serial No.STRUCTURE. PX-15 10-23 (7) . : 67137 and up D65PX-15 Serial No. : 67001 and up D65EX. : 67136 and up D65WX-15 Serial No.

14 – 0.) 4 2nd clutch spring (5 pcs.14 – 0.0 2.2 8 Total thickness of assembled 4 3rd clutch discs and 3 plates thickness of assembled 9 Totalclutch discs and 3 plates4 2nd Replace 10 Total thickness of assembled 3 1st clutch discs and 2 plates 11 Thickness of clutch disc 12 Thickness of clutch plate 13 Wear of seal ring of transmission input shaft between R/F/2nd/1st 14 Backlash and planetary pinion sun gear Width Thickness 3.67135 Serial No.STRUCTURE.6 23.30 0.0 26.5 55.5 55.) 5 1st clutch spring (5 pcs. PX-15 . : 67001.0 59.26 ±0.6 44. : 67001.0 59.) of 6 Total thicknessandassembled 5 R clutch discs 6 plates 77.33 0.7 kg} 121 N {12.30 ±0.0 49.26 ±0.26 ±0.3 233.4 43.7 kg} 146.38 0.11 – 0.67136 Serial No.03 ±0.4 14.4 23.0 3.44 0.0 Standard size 36.9 2.11 – 0.01 –0.0 N {14.1 –0.8 20.0 59. Check item Standard size Criteria Repair limit Free length 65.3 kg} 123 N {12.4 55.7 63. : 67136 and up Serial No.39 198 N {20.33 ±0.5 Installed load Remedy 1 R clutch spring (5 pcs.6 2.10 0.2 37.2 Repair limit 32.2 kg} 81 N {8.36 ±0.15 of assembled 7 Total thicknessand 6 plates 7 F clutch discs *1 *2 *1 *2 *1 *2 *1 *2 43. : 67137 and up Serial No.6 16.1 44.7 kg} Tolerance ±0. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Unit: mm No.1 ±0.12 – 0.3 15 Backlash between 3rd sun gear and planetary pinion 16 Backlash between planetary pinion and internal teeth of ring gear carrier 17 Backlash between Rgear and internal teeth of ring carrier 18 Backlash between F gear and internal teeth of ring 19 Backlash between 1st carrier and internal teeth of ring gear *1.70 2.30 ±0.2 N {9.1 N {14. D65EX-15 D65PX-15 D65WX-15 Serial No.14 – 0.5 44.2 29.2 20.2 kg} 125 N {12.2 29.5 58.2 N {23.1 N {14.9 kg} 142.4 20.39 ±0.) Free length Installed length Installed load 69.4 3.22 ±0.) 3 3rd clutch spring (5 pcs.3 72.5 kg} 144.6 23.5 kg} 2 F clutch spring (5 pcs.0 26.29 0. D65EX-15 D65PX-15 *2.8 kg} 95.6 2. : 67001 and up 10-24 (7) D65EX.

to secure ring gear (1). Oil passage in speed clutch • When the steering/directional/gear shift lever is set in the NEUTRAL position. The piston chamber of the clutch corresponding to the selected gear speed is filled with oil by electronically controlling the hydraulic circuit of each clutch. the pump is required to supply oil of quantity to fill the piston chamber of the F clutch or R clutch. PX-15 10-25 . the pump is required to supply oil of only quantity to fit the plate and disc of the 2nd clutch together since the F clutch has been filled with the oil. piston (2) is returned to the right by return spring (6). Piston (2) presses plate (3) and disc (3) to fit them together. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Disc clutch Structure • The disc clutch consists of piston (2). • • • • • • D65EX. ring gear (1) is fixed. The time lag in the gear shifting operation is reduced by controlling the oil in the clutch circuit as explained above. etc.STRUCTURE. When the steering/directional/gear shift lever is shifted from the NEUTRAL position to the FORWARD or REVERSE position. return spring (6). Since the internal teeth of disc (4) are meshed with the external teeth of ring gear (1). the 1st. pin (5). 2nd. Clutch “OFF” (Released) • When the oil sent from the ECMV is shut off. • • • Operation Clutch “ON” (Fixed) • The oil sent from the ECMV flows through the oil passage in housing (7) to the back side of piston (2) to move piston (2) to the left. or 3rd speed is selected. Plate (3) is secured to clutch housing (7) with pin (5). The internal teeth of disc (4) are meshed with the external teeth of ring gear (1). When the gear speed is changed from FORWARD 1st to FORWARD 2nd. plate (3). disc (4). The friction force between plate (3) and disc (4) is released and ring gear (1) is released. and disc (4) is stopped by the friction force between it and plate (3).

and holds 1st ring gear (18). and holds F ring gear (4). Since 1st ring gear (18) is held by the 1st clutch.STRUCTURE. Accordingly. The F clutch is actuated by the hydraulic pressure applied to the F clutch piston. PX-15 . the rotation of F carrier (10) is transmitted through 2nd planetary pinion (13) to 2nd ring gear (15). Since 2nd ring gear (15) and 1st carrier (16) are meshed with each other. • • • F carrier (10) and 2nd and 3rd carriers (11) are connected by a spline. and then transmitted through F sun gear (2) to F planetary pinion (3). and rotate as one unit. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (21). The 1st clutch is actuated by the hydraulic pressure applied to the 1st clutch piston. the power transmitted to F planetary pinion (3) to rotate F carrier (10) on the inside of F ring gear (4). the power transmitted to 1st planetary pinion (17) is transmitted through 1st sun gear (20) to output shaft (21). 10-26 D65EX. the F clutch and 1st clutch are engaged. Since F ring gear (4) is held by the F clutch. the power transmitted to 2nd ring gear (15) is transmitted to 1st planetary pinion (17). The power from the torque converter is transmitted to input shaft (1). FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Power train route Forward 1st • • • • When the transmission is set to FORWARD 1st.

The 2nd clutch is actuated by the hydraulic pressure applied to the 2nd clutch piston. the F clutch and 2nd clutch are engaged. Since F ring gear (4) is held by the F clutch. • • F carrier (10) and 2nd and 3rd carriers (11) are connected by a spline.STRUCTURE. PX-15 10-27 . the rotation of F carrier (10) is transmitted to 2nd planetary pinion (13). The F clutch is actuated by the hydraulic pressure applied to the F clutch piston. D65EX. the power transmitted to 2nd planetary pinion (13) is transmitted through 2nd sun gear (19) to output shaft (21). Since 2nd ring gear (15) is held by the 2nd clutch. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Forward 2nd • • • • When the transmission is set to FORWARD 2nd. and holds 2nd ring gear (15). and holds F ring gear (4). the power transmitted to F planetary pinion (3) to rotate F carrier (10) on the inside of F ring gear (4). The power from the torque converter is transmitted to input shaft (1). and rotate as one unit. Accordingly. and then transmitted through F sun gear (2) to F planetary pinion (3). The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (21).

the power transmitted to 3rd planetary pinion (12) is transmitted to output shaft (21). the power transmitted to F planetary pinion (3) to rotate F carrier (10) on the inside of F ring gear (4). The F clutch is actuated by the hydraulic pressure applied to the F clutch piston. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (21). Since F ring gear (4) is held by the F clutch.STRUCTURE. and rotate as one unit. the F clutch and 3rd clutch are engaged. and holds F ring gear (4). Accordingly. and then transmitted through F sun gear (2) to F planetary pinion (3). Since 3rd ring gear (14) is held by the 3rd clutch. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Forward 3rd • • • • When the transmission is set to FORWARD 3rd. and holds 3rd ring gear (14). The power from the torque converter is transmitted to input shaft (1). the rotation of F carrier (10) is transmitted to 3rd planetary pinion (12). PX-15 . • • F carrier (10) and 2nd and 3rd carriers (11) are connected by a spline. The 3rd clutch is actuated by the hydraulic pressure applied to the 3rd clutch piston. 10-28 D65EX.

R ring gear (9) rotates F carrier (10) in the opposite direction to input shaft (1). Since 1st ring gear (18) is held by the 1st clutch. and holds ring gear (7). D65EX. and rotate as one unit. The R clutch is actuated by the hydraulic pressure applied to the R clutch piston. and then transmitted through R sun gear (5) to R planetary pinion (6). Since 2nd ring gear (15) and 1st carrier (16) are meshed with each other. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION Reverse 1st • • • • When the transmission is set to REVERSE 1st. and holds 1st ring gear (18). PX-15 10-29 .STRUCTURE. The 1st clutch is actuated by the hydraulic pressure applied to the 1st clutch piston. • • • F carrier (10) and 2nd and 3rd carriers (11) are connected by a spline. The power transmitted from the torque converter to input shaft (1) is then transmitted to output shaft (21). Accordingly. the R clutch and 1st clutch are engaged. Since ring gear (7) is meshed with carrier (8) and held by the R clutch. the rotation of F carrier (10) is transmitted through 2nd planetary pinion (13) to 2nd ring gear (15). the power transmitted to 1st planetary pinion (17) is transmitted through 1st sun gear (20) to output shaft (21). R planetary pinion (6) rotates R ring gear (9). The power from the torque converter is transmitted to input shaft (1). the power transmitted to 2nd ring gear (15) is transmitted to 1st planetary pinion (17).

PX-15 . FUNCTION AND MAINTENANCE STANDARD TRANSMISSION ECMV TRANSMISSION ECMV a ECMV: Abbreviation for Electronic Control Modulation Valve 10-30 D65EX.STRUCTURE.

Fill switch (For 1st clutch) Fill switch (For R clutch) Fill switch (For F clutch) Fill switch (For 3rd clutch) Fill switch (For 2nd clutch) Proportional solenoid (For 3rd clutch) Proportional solenoid (For 1st clutch) Proportional solenoid (For R clutch) Proportional solenoid (For F clutch) Proportional solenoid (For 2nd clutch) Fill switch connector (For 1st clutch) Fill switch connector (For R clutch) Fill switch connector (For F clutch) Fill switch connector (For 3rd clutch) Fill switch connector (For 2nd clutch) Proportional solenoid connector (For 1st clutch) Proportional solenoid connector (For 3rd clutch) Proportional solenoid connector (For R clutch) Proportional solenoid connector (For 2nd clutch) Proportional solenoid connector (For F clutch) Filter D65EX. 21.STRUCTURE. 5. 9. 18. 11. 15. 20. 8. 16. 6. 12. 2. PX-15 10-31 . 10. 4. 17. 3. 13. 7. 19. 14. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION ECMV P: PF: PR: P1: P2: P3: CF: CR: C1: C2: C3: SDF: SDR: SD1: SD2: SD3: Dr: From power train pump F clutch oil pressure pickup port R clutch oil pressure pickup port 1st clutch oil pressure pickup port 2nd clutch oil pressure pickup port 3rd clutch oil pressure pickup port To F clutch To R clutch To 1st clutch To 2nd clutch To 3rd clutch F fill switch drain R fill switch drain 1st fill switch drain 2nd fill switch drain 3rd fill switch drain Drain 1.

Fill switch Valve body (Upper) Pressure control valve Valve body (Lower) Proportional solenoid Oil pressure detection valve Plug 10-32 D65EX. 4. 6. 2. 3. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION ECMV 1. 5.STRUCTURE. PX-15 . 7.

STRUCTURE. a signal (the fill signal) is sent to the controller to notify that oil pressure is being applied. It has the functions below. By controlling the amount of command current. • Fill switch Detects that the clutch is filled with oil. D65EX. By this signal. 2) While oil pressure is being applied to the clutch. By making the proportional solenoid-produced thrust act on the pressure control valve spool. ECMV and fill switch • One fill switch is installed for one ECMV. After receiving the command current from the controller. If the clutch finishes filling. • Pressure control valve Converts a current sent from the transmission controller to the proportional solenoid valve. controlling the oil flow and oil pressure. PX-15 10-33 (7) . FUNCTION AND MAINTENANCE STANDARD TRANSMISSION ECMV Outline of ECMV • The ECMV consists of a pressure regulator valve and a fill switch. the fill switch is turned "ON" by the pressure of the clutch. to an oil pressure. a signal (the fill signal) is sent to the controller to notify that filling is finished. A range: Before shifting gear (when drained) B range: Filling C range: Pressure regulation D range: Filling (triggering) E point: Start of filling F point: Finish of filling ECMV and proportional solenoid • One proportional solenoid is installed for one ECMV. 1) When the clutch is filled with oil. it produces an oil pressure shown in the graph below. the thrust is changed to operate the pressure control valve. it produces thrust shown in the graph below. the oil pressure starts build-up. Current-Thrust characteristics of proportional solenoid Thrust-Oil pressure characteristics of proportional solenoid a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).

fill switch (4) is turned "OFF". and output signal of the fill switch is shown in the graph below. the pressure control valve (2) is draining the oil at the clutch port A through the drain port Dr. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION ECMV ECMV operation • The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. Before shifting gear (when drained) (A range in chart) When a current is not carried to the proportional solenoid (1).STRUCTURE. The relationship between the proportional command current for the ECMV. Arange: Before shifting gear (when drained) Brange: Filling Crange: Pressure regulation Drange: Filling (triggering) Epoint: Start of filling Fpoint: Finish of filling 1. clutch input pressure. PX-15 . Since oil pressure is not applied to oil pressure detector valve (3) at this time. 10-34 (7) D65EX. a The logic is such that the controller does not recognize finish of filling even if the fill switch is turned "ON" during the triggering operation (D range).

PX-15 10-35 (7) . the thrust of clutch port A. pump port P and clutch port A are opened and oil starts filling the clutch. Pressure is regulated by balancing the thrust of the solenoid.STRUCTURE. pushing the pressure control valve (2) rightward. D65EX. and reaction force of the pressure control spring (5). As a result. Filling (B range in chart) If you supply current to the proportional solenoid (1) with no oil in the clutch. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION ECMV 2. 3. an oil pressure proportional to the solenoid force acts on the chamber B. the solenoid produces thrust proportional to the current. If the clutch is filled with oil. fill switch (4) is turned "ON". Pressure regulation (C range in chart) If you supply current to the proportional solenoid (1).

5.078 0.1 N {14.3 75.035 – 0. torque converter relief valve PP: TC: drT: dr1: dr2: P1: P8: From pump To torque converter Drain port (for torque converter relief) Drain port Drain port Main relief oil pressure detection port Torque converter relief oil pressure detection port 1. 4.3 42 508.058 Free length 124.8 48.013 0 7 Repair limit Installed load 75.058 0.6 N {51.2 N {49.5 N {39.078 Replace Clearance between main relief 6 valve and valve body Clearance between torque converter relief valve and valve body Hole +0.035 –0. 3.3 kg} 382.2 104.045 –0.8 kg} 10-36 D65EX.035 – 0.0 N {15.045 Standard size 8 Main relief valve spring (outer) Free length 128 9 Main relief valve spring (inner) 10 Torque converter relief valve spring 108 50 Installed length Installed load Remedy Standard clearance 0.0 kg} 145.8 N {41. 2.013 0 +0.STRUCTURE. Check item Standard size 28 22 Criteria Tolerance Shaft –0. FUNCTION AND MAINTENANCE STANDARD MAIN RELIEF VALVE MAIN RELIEF VALVE Main relief.9 kg} 401.035 –0. Body Piston Torque converter relief valve Piston Main relief valve Unit: mm No.6 kg} 483. PX-15 .0 kg} 153.5 Clearance limit 0.

8 kg/cm2} (engine at rated speed) D65EX. passes through orifice b of spool (2) and enters chamber D. the oil entering chamber B pushes piston (4).31 MPa {33. When the circuit leading to the torque converter becomes filled with oil. the oil entering chamber D pushes piston (9). The reaction force compresses valve spring (3) and moves spool (2)to the right to open the circuit between port C and port E. The reaction force compresses valve spring (7) and moves spool (6) to the left to open the circuit between port A and port C. Set pressure: 0.STRUCTURE. the oil at port A is relieved to port C and flows from port C to the torque converter.5 kg/cm2} (cracking pressure) • As the oil pressure in the circuit rises. The oil pressure at port C at this point is 0.5 kg/cm2} (Cracking pressure) Main relief valve • The main relief valve holds the oil pressure in the transmission and brake at the set pressure. It then passes through orifice a of spool (6) and enters chamber B. • As the oil pressure going to the torque converter rises.8 kg/cm2} (Engine at rated speed) Operation of main relief valve • The oil from the hydraulic pump passes through the filter and enters port A of the relief valve. When this happens. When the oil from the pump fills the circuit. the oil pressure starts to rise. When this happens. the oil at port C is relieved to port E and drains to the oil tank.31 MPa {33. the oil pressure starts to rise.83 MPa {8. Set pressure: 3.83 MPa {8. FUNCTION AND MAINTENANCE STANDARD MAIN RELIEF VALVE Outline Torque converter relief valve • The torque converter relief valve protects the torque converter from abnormally high pressure by keeping the oil pressure in the torque converter inlet port circuit below the set pressure. The oil pressure at port A at this point is 3. PX-15 10-37 . Operation Operation of torque converter relief valve • The oil relieved by the main relief valve flows from port C into the torque converter and the same time.

0 N {1.7 12.5 – 1. PX-15 .15 {0.05 – 0.STRUCTURE. Piston 3.4 N {1. And prevents any abnormal pressure in the lubrication oil.0} Unit: mm No.16 kg} 10-38 D65EX. Specified value Normal pressure (MPa {kg/cm }) Cracking pressure (MPa {kg/cm2}) 2 • 0. It then goes through the lubrication relief valve and lubricates the transmission and PTO. Spring 4.29 {3. The lubrication relief valve is installed to the right side face of the forward clutch housing. Forward clutch housing A: From oil cooler B: Drain C: Drain Outline • The oil leaving the torque converter passes through the oil cooler built in the radiator lower tank.5} 0. Check item Standard size Criteria Repair limit Installed load Remedy 1 Lubrication relief valve spring Free length 26 Installed length Free length 25.2 Installed load Replace 23. FUNCTION AND MAINTENANCE STANDARD LUBRICATION RELIEF VALVE LUBRICATION RELIEF VALVE 2.22 kg} 11.

• Specifications Type Theoretical capacity (cc/rev) Max.STRUCTURE.29 {3. discharge pressure (MPa {kg/cm2}) Max. speed (rpm) Gear pump 61.0} 2.2 0. FUNCTION AND MAINTENANCE STANDARD SCAVENGING PUMP SCAVENGING PUMP Outline • The scavenging pump is installed to the lower part of the PTO case and driven with the power from the engine.500 D65EX. PX-15 10-39 . The scavenging pump draws oil collected in the transmission case bottom through a strainer and returns it to the steering case.

6 – 1.000 Discharge pressure (MPa {kg/cm2}) Standard discharge (l/min) Allowable discharge (l/min) — 2. Lubricating oil pump Unit: mm No.4 kgm} Speed (rpm) 3.94 {30} 126 115 10-40 D65EX.STRUCTURE.8 Nm {0. Power train pump 2. PX-15 . LUBRICATION PUMP SAL (2) 45 + 45 1.15 0.125 Standard size 12 Tolerance 0 –0.8 – 13. LUBRICATION PUMP POWER TRAIN PUMP.10 – 0.20 Repair limit — Replace Remedy 4 5.19 0.060 – 0. Check item Type 3 Side clearance Clearance between inside of plain bearing and outside of gear shaft SAL (2) 45 SAL (2) 45 Type 5 Driving depth of pin 6 Rotating torque of spline Discharge — Oil: SAE10W Oil temperature: 45 – 55ºC Type SAL (2) 45 SAL (2) 45 Criteria Standard clearance 0.5 Clearance limit 0. FUNCTION AND MAINTENANCE STANDARD POWER TRAIN PUMP.

FUNCTION AND MAINTENANCE STANDARD HSS SYSTEM HSS SYSTEM a HSS: Abbreviation for Hydrostatic Steering System D65EX. PX-15 10-41 .STRUCTURE.

c. b. e. 11. 7. 13. 9. • Input and output signals a. 10. Forward and reverse signals Steering signal Engine control information Work equipment oil pressure signal CAN communication network • • 10-42 D65EX. HSS pump (6). 2. Transmission-steering controller (2) senses the engine speed and oil pressure at each part and controls HSS pump (6) and control valve (4) so that engine (10) will not stall. Steering/directional/gear shift lever (PCCS lever) Transmission and steering controller Engine controller Control valve EPC valve HSS pump Servo valve HSS motor HSS circuit Engine Final drive Sprocket Hydraulic tank Outline • The HSS system consists of control valve (4). HSS motor (8) acts on the planetary gear mechanism of the bevel gear shaft to make a difference in speed between both sprockets (12). and HSS motor (8). 6.STRUCTURE. 8. PX-15 . d. FUNCTION AND MAINTENANCE STANDARD HSS SYSTEM 1. 4. 3. the machine turns. As a result. 5. It turns the machine continuously without lowering the travel speed by making a difference in speed between both tracks. 12. Transmission-steering controller (2) controls EPC valve (5) of control valve (4) to control the rotating direction and speed of HSS motor (8) according to the tilting direction and angle of steering/directional/gear shift lever (1). The engine speed signal and other engine control information items are sent and received through the CAN communication network which connects engine controller (3) and transmissionsteering controller (2).

Servo valve D65EX.STRUCTURE. HSS PUMP HPV95 Outline This pump consists of a variable displacement swash plate type piston pump and LS valve.280 rpm 41. cut off pressure: HPV95 (112 cm3/rev) 112 ± 1 cm3/rev 2.2 MPa {420 kg/cm2} 1. Piston pump 2. PX-15 10-43 . FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. PA: PS: PD1: PD2: PLS1: PEN12: Pump discharge port Pump suction port Pump drain plug Pump drain Load pressure inlet port Control pressure detection plug Specification Model: Theoretical displacement capacity: Rated speed: Max. HSS PUMP HYDRAULIC.

PX-15 . HSS PUMP PISTON PUMP PA: PS: PA1: PD2: PNC1: Pump discharge port Pump suction port Pump pressure signal port Pump drain Control pressure port 10-44 D65EX. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC.STRUCTURE.

5. PX-15 10-45 . 12. 4. HSS PUMP 1. 7. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. 11. 6. Piston Cylinder block Valve plate End cap Impeller Spline D65EX. Shaft Case Cradle Rocker cam Shoe Servo piston Rod 8. 10. 13. 3. 2.STRUCTURE. 9.

Rocker cam (4) forms a static beaing sending high pressure oil at cylindrical surface B of cradle (3). • • • • Piston (8) carries out motion relative to the axial direction inside each cylinder chamber of cylinder block (9). The cylinder block (9) carries out rotation relative to valve plate (10) while sealing the pressurized oil. The oil inside each cylinder chamber of clinder block (9) is sucked in and dischaged through valve plate (10). • 10-46 D65EX.STRUCTURE. and this surface ensures that the hydraulic balance is maintained correctly. The end of piston (8) has a concave ball shape and shoe (5) is calked to it to form one unit. and shoe (5) is always pressed against this surface as it slides in a circle. it makes it easier for the oil sucked in from the suction port to be sucked in and sends it into the cylinder chamber by centrifugal force. and shaft (1) is supported by the front and rear bearings. It is possible to change the discharge amount by changing the swash plate angle. and carries out a sliding movement. PX-15 . and rotates together with the shaft. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. Rocker cam (4) holds plane A. HSS PUMP Outline • The engine rotation and torque transmitted to the pump shaft is converted to hydraulic energy and pressurized oil is discharged according to the load. Impeller (12) is fixed to shaft (1). Piston (8) and shoe (5) from a spherical bearing. • • • • Structure • Cylinder block (9) is supported to shaft (1) by a spline (13). which is fixed to the case.

The amount of suction and discharge is equal to difference F – E. so pump does not suction and discharge. This angle is called the swash plate angle. • When center line X of rocker cam (4) is the same as the axial direction of cylinder block (9) (swash plate angle = 0). HSS PUMP Operation 1. piston (8) slides inside cylinder block (9). the difference between volumes E’ and F’ indside cylinder block (9) is 0. plane A acts as a cam for shoe (5). D65EX. so oil is discharged during this process. Operation of pump • Cylinder block (9) rotates toghther with shaft (1). and as a result.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. a difference is generated between volumes E and F inside the cylinder block. and shoe (5) slides on plane A. cylinder block (9) rotates. and no pumping’s carried out. PX-15 10-47 . At the same time. In other words. Actually swash plate angle does not become 0. In this way. rocker cam (4) moves along cylindrical surface B. The swash plate angle is proportional to pump discharge volume. the volume of chamber F becomes larger and oil is sucked in this process. When this happens. • • • • With swash plate angle formed by the angle between center line X of rocker cam (4) to the axial direction of cylinder block (9). so angle of center line X of arocker cam (4) to the axial direction of cylinder block (9) changes. and the volume of chamber E becomes smaller.

HSS PUMP 2. and the comparative size of the ratio of area receiving the pressure at the large diameter piston end and small diameter piston end.STRUCTURE. • Output pressure PNC of the servo valve is applied to the chamber receiving the pressure at the large diameter piston end (which receives pressure of the pump). FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. PX-15 . and oil discharge Q is incleased. • The movement of servo piston (6) is controlled by the relationship of the size of pump pressure PP and the pressure at the large diameter piston end. which is supported on the cylindrical surface by creadle (3) rotates on the cylindrical surface. and the receiving pressure at the small diameter piston end is always connected with main pump discharge pressure (self pressure) PP. the difference between volumes E and F becomes larger. • The area receiving the pressure is different at the left and right sides of servo piston (6). 10-48 D65EX. and rocker cam (4). • Servo piston (6) carrise out reciprocal movement in a straight line ( ) according to the command from the servo valve single pressure. Control of discharge amount • If swash plate angle becomes larger. Swash plate angle is changed by servo piston (6). This straight line movement is trasmitted to rocker cam (4) through rod (7).

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. HSS PUMP SERVO VALVE PT: PA1: PLS1: PEN11: PEN12: Drain port Pump self pressure port Load pressure input port Control pressure port Control pressure detection port D65EX. PX-15 10-49 .

5. 14. HSS PUMP LS VALVE 1. 6. 12. 9. 10. 13. 11. 20. 19. 7. 2. Screw Locknut Spring Seat Spool Block Plug 10-50 D65EX. 18. 21. 17. Plate Piston Sleeve Spring Spring Piston Lever Valve body VARIABLE THROTTLE VALVE 16. 4.STRUCTURE. 15. Locknut Plug Spring Spool Sleeve Piston Plug TCC VALVE 8. 3. 22. PX-15 . FUNCTION AND MAINTENANCE STANDARD HYDRAULIC.

FUNCTION AND MAINTENANCE STANDARD HYDRAULIC.STRUCTURE. 3. 2. (the difference between main pump pressure PP and LS pressure PLS) (= PP – PLS) changes as shown in the diagram. if the load during the operation becomes larger and the pump discharge pressure rises. and if the pump discharge pressure drops. it increases the discharge amount from the pump. Variable throttle valve • Because the main pump controls its own prssure. pressure PLS {called the LS pressure} coming from the control valve output enter this valve. LS valve • The LS valve detects the load and controls the discharge amount. the TCC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. • In other words. TCC valve • When the pump discharge pressure PP is high. • The characteristics of the variable throttle valve are as shown in the diagram. • Main pump pressure PP. to reduce the impact force on the rod and other parts of the main pump. and by preventing the above problems (1) and (2) at high pressure. it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. • The relationship between pump discharge pressure PP and pump discharge amount Q when this happens is shown in the diagram. D65EX. (2) To prevent cavitation at the suction port caused by the sudden increase in the suction volume when changing from MIN to MAX. and to prevent excessive response. HSS PUMP Function 1. • This valve controls main pump discharge amount Q according to differential pressure PLS (= PP – PLS) (the difference between main pump pressure PP and control valve outlet port pressure PLS) {called the LS differential pressure}. • The variable throttle valve has been installed for the following reasons. it reduces the discharge amount from the pump. there is a tendency for the response speed of the swash plate to be quick at high pressure and slow at low pressure. (1) To reduce the swash plate speed between MIN and MAX at high pressure. It has the function and property of maintaining the response during operations at low pressure by making the area of the opening smaller at high pressure and the area of the opening larger at low pressure. • In this way. • The relationship between discharge amount Q and differential pressure PLS. PX-15 10-51 .

10-52 D65EX. spool (4) is pushed to the left. • The same pump pressure PP also enters the small diameter end of the piston. (It is interconnected with the drain circuit through the control valve spool. LS pressure PLS is 0 MPa {0 kg/cm2}. Before the engine is started. so the swash plate is moved to the minimum angle by the difference in area of piston (1).STRUCTURE. HSS PUMP Operation 1. The size of the LS pressure PLS + force F of spring (3) and the main pump pressure (self pressure) PP determines the position of spool (4). Pump pressure PP enters the large diameter end of the piston from port h. servo piston (1) is pushed to the right by spring (7) installed to rod (2). PX-15 . with pressure PLS (LS pressure) from the outlet port of the control valve brought to spring chamber i. and port d and port c are connected.) At this point. and main pump discharge pressure PP brought to chamber j of plug (6). (See the diagram on the right) When the engine is started and the control lever is at the “NEUTRAL” position. LS valve (1) When control valve is at “neutral” position • • • The LS valve is a three-way selector valve. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC.

when the area of opening of the control valve becomes larger and pump pressure PP drops). so servo piston (1) is pushed to the right. spool (4) is pushed to the right by the combined force of LS pressure PLS and the force of spring (3). so circuit c – h becomes drain pressure PT. rod (2) moves to the right and moves the swash plate in the direction to make the discharge amount larger.STRUCTURE. When this happens. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. D65EX. Therefore. port b and port c are joined and connected to the TCC valve. an d p ump pressure PP enters the small diameter end. When spool (4) moves. HSS PUMP (2) Operation in maximum direction for pump discharge amount • • When the difference between main pump pressure PP and LS pressure PLS. (The operation of the TCC valve is explained later. the pressure at the large piston diameter end of servo piston (1) bec om es dra in pr es s ur e P T.) • • For this reason. PX-15 10-53 . in other words. LS differential pressure PLS becomes smaller (for example. the TCC valve is connected to the drain port.

servo piston (1) is pushed to the left. When LS pressure PLS becomes larger (for example. and from port h. it enters the large piston diameter end. • • Main pump pressure PP also enters the small piston diameter end. rod (2) moves in the direction to make the swash plate angle smaller.STRUCTURE. As a result. When spool (4) moves. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. when the area of opening of the control valve becomes smaller and pump pressure PP rises). HSS PUMP (3) Operation in minimum direction for pump discharge amount • • • The following explains the situation if servo piston (1) moves to the left (the discharge amount becomes smaller). PX-15 . pump pressure PP pushes spool (4) to the left. 10-54 D65EX. main pump pressure PP flows from port d to port c. but because of the difference in area between the large piston diameter end of servo piston (1) and the small piston diameter end.

96 MPa {20 kg/ cm2}. If the main pump pressure PP of the LS valve and the combined force of force F of spring (3) and LS pressure PLS are balanced. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. The position where spool (4) is balanced and stopped is the standard center. the relationship between the area receiving the pressure at both ends of piston (1) is A0:A1 = 1:2. and the pressure flowing into the large piston diameter end as Pen.STRUCTURE. and the force of spring (3) is adjusted so that it is determined when PP – PLS = 1. and the relationship is A0 x PP = A1 x Pen. The servo piston (1) will stop in that position. the area receiving the pressure at the small diameter end as A0.) • • At this point. and the swash plate will be kept at an intermediate position. PX-15 10-55 . HSS PUMP (4) When servo piston is balanced • • • Let us take the area receiving the pressure at the large piston diameter end as A1. (It will stop at a position where the opening from port b to port c and from port d to port c of spool (4) is approximately the same. D65EX. so the pressure applied to both ends of the piston when it is balanced becomes PP:Pen C Pen 2:1.

When pump pressure PP is small. the pressure entering the large piston diameter end from port f becomes drain pressure PT. If piston (5) moves to the right. the small piston diameter end of servo piston (9). At this point. When this happens. and the pressure entering the LS valve becomes drain pressure PT. In other words. and port a. which is connected to rod (8). the spring load is changed by piston (5) extending or contacting springs (3) and (4). LS valve). 10-56 D65EX. If port h and port e of the LS valve are connected (see 1. and if it moves further to the right. HSS PUMP 2.STRUCTURE. lever (6) is rotated by the angle of cam (7). • • • • Port c of the TCC valve is connected to port e of the LS valve (see 1. spring (3) is compressed. Self pressure PP enters port b. When servo piston (9) moves. and servo piston (9) moves to the right. cam (7). PX-15 . also moves. TCC valve (1) When the load on the actuator is small and pump pressure PP is low • • • • The spring load of springs (3) and (4) in the TCC valve is determined by the swash plate position. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. LS valve). and position (5) moves to the right and left. spring (4) contacts seat (10). piston (2) is on the right. port c and port d are connected. so both spring (3) and spring (4) function.

As a result. and the pressure at the large piston diameter end also rises. cam (7) and lever (6). In other words. As servo piston (9) moves further. the pump discharge amount moves in the direction of increase. Springs (3) and (4) expand and the spring force becomes weaker. so the movement of piston (9) to the right is stopped.STRUCTURE. D65EX. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. and the pump discharge pressure is connected to port b. piston (2) moves to the left. HSS PUMP • • • • • In this way. When the spring force becomes weaker. PX-15 10-57 . the stop position for piston (9) (= pump discharge amount) is decided at the point where for the force of springs (3) and (4) and the pushing force created by pressure PP acting on piston (2) are in balance. piston (5) is moved to the left by rod (8). so the connection between port c and port d is cut. the pressure at port c rises.

the pressure at port c (= f) drops. main pump pressure PP flows to port c and acts to make the discharge amount the minimum. Because of this force. As a result. springs (3) and (4) are compressed and push back piston (2). as shown in the diagram above. 10-58 D65EX. and servo piston (9) stops. HSS PUMP (2) When load on actuator is small and pump discharge pressure is high • • • When the load is large and pump discharge pressure PP is high. For this reason. and piston (9) stops moving to the left. and port c and port d are connected. piston (5) is moved to the right by cam (7) and lever (6). FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. When this happens. piston (2) cuts of the connection from port b to port c. When port h and port e of the LS valve are connected (see 1. LS valve). When piston (9) moves to the left. the force pushing piston (2) to the left becomes larger and piston (2) moves to the position shown in the diagram above. part of the pressurized oil from port b flows out to port d and the pressure oil flowing from port c to the LS valve becomes approximately half of main pump pressure PP. • • • • • If main pump pressure PP increases further and piston (2) moves further to the left. the pressure from port f enters the large piston diameter end of servo piston (9). The position in which piston (9) stops when this happens is further to the left than the position when pump pressure PP is low.STRUCTURE. PX-15 .

The relationship between pump pressure PP and pump discharge amount Q is shown in the figure.STRUCTURE. D65EX. HSS PUMP • The relation of pump pressure PP and the position of servo piston (9) forms a bent line because of the double-spring effect of springs (3) and (4). FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. PX-15 10-59 .

STRUCTURE. • At this point. • If spool (4) moves to the right. 10-60 D65EX. spool (4) moves to the right. the opening area of part A increases and the oil flowing from the large diameter end of servo piston (1) through port c to port b is not limited and the moving speed of servo piston (1) is heightened. (2) Operation to reduce pump discharge • The hydraulic oil flows from port b through port c to the large diameter side of servo piston (1). PX-15 . Accordingly. the opening area between ports c and b is reduced by the notch at part A. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC. 2) When main pump pressure PP is low • Even if main pump pressure PP enters chamber e through port a. • Spool (4) operates according to main pump pressure PP as explained in the above section. less oil flows from the large diameter end of servo piston (1) and the moving speed of servo piston (1) is lowered. 1) When main pump pressure PP is high • If the pressure becomes higher than the force of spring (3) because of the difference in sectional area of spool (4) in chamber e. spool (4) pushes spring (3) less strongly and moves to the right for shorter distance. Variable throttle valve (1) Operation in maximum direction for pump discharge amount • Main pump pressure PP enters the variable throttle valve through port a. HSS PUMP 3.

fixed swash plate type piston motor. 4.2 MPa {390 kg/cm2} 2. flashing shuttle valve.0 cc/rev 38. FUNCTION AND MAINTENANCE STANDARD HSS MOTOR HSS MOTOR HMF95 Outline • Motor is composed of fixed capacity. PX-15 10-61 . bypass valve and charge relief valve. 1. 2. 3.430 rpm PA: From control valve PB: From control valve T2: To hydraulic tank D65EX.STRUCTURE. HSS motor assembly Counterbalance valve Safety valve Check valve Specifications Model: Theoretical displacement: Rated output pressure: Rated speed: HMF95 96.

Counterbalance valve Safety valve Check valve Check valve spring Sub bearing Spline Shoe Main bearing Unit: mm No. 13. 11.27 N {0.13 kg} 154 N {15. 2. 5. Output shaft Motor case Swash plate Piston Cylinde Valve plate End cover Brake valve assembly Spool return spring 10. 4. PX-15 . 7.8 40. 17.6 kg} 1.98 N {0.0 19 Check valve spring 43 x 13. 16.STRUCTURE. 3. 9. 14. 15. Check item Standard size 18 Spool return spring Free length x OD Installed length Installed load Criteria Repair limit Free length — — Installed load Remedy 42.7 kg} 0.10 kg} Replace spring if damaged or deformed 10-62 D65EX.5 32.7 x 30. 12.9 192 N {19. 8. 6. FUNCTION AND MAINTENANCE STANDARD HSS MOTOR 1.

STRUCTURE. Cylinder block (5) carries out rotation relative to valve plate (6) while sealing the pressurized oil. FUNCTION AND MAINTENANCE STANDARD HSS MOTOR Outline • Pressurized oil sent from pump is converted to rotation torque and is transmitted to output shaft. Piston (4) carries out motion relative to the axial direction inside each cylinder chamber of cylinder block (5). and shoe (16) is caulked to it to form one unit. • • • • • D65EX. and shaft (1) is supported by main and sub bearings (17) and (14). Piston (4) and shoe (15) form a spherical bearing. and this surface ensures that the hydraulic balance is maintained correctly. The oil inside each cylinder chamber of cylinder block (5) is sucked in and discharged through valve plate (6). The end of piston (4) has a concave ball shape. Structure • Cylinder block (5) is supported to shaft (1) by a spline (15). PX-15 10-63 .

reaction force FR in a direction at right angles to plane A is generated. Q = qN Q: Total flow (q = E – F) q: Flow per 1 turn N: Rotation speed Pq P: Pressure T= 2 T: Rotating torque • • • • • • Shaft (1). which is meshed to cylinder block (5) by spline (15) transmits this rotation torque to the output side. when the condition goes beyond volume F and changes to volume E. With shoe (16). Cylinder block (5) rotates. Operation of motor • The pressurized oil sent from the pump enters cylinder block (5) and pushes piston (4) from the back face. 2. and piston axial force FO is generated. PX-15 . 19º. 10-64 D65EX. motor speed N is heightened. FUNCTION AND MAINTENANCE STANDARD HSS MOTOR Operation 1. if we take the example of one of pistons (4). Swash plate angle is approx. Rotation speed and torque control • • As flow Q from the HSS pump is increased. As a result.STRUCTURE. torque T is proportional to pressure P. the oil is pushed out and returned to the pump. On the other hand. The combined force of FO and FR is FP. and pressure P is generated according to the load. which is joined to piston (4) by the spherical surface. Since the swash plate angle of the HSS motor is fixed ( is constant). and while the condition changes from volume E to volume F. In the case of the motor. oil pressure is applied to the back face of the right. pressurized oil from the pump flows into the cylinder chamber. the center line of plate (3) is always at an angle (swash plate angle a to the axial direction of cylinder block (5). and this becomes the force to rotate cylinder block (5).

this valve is installed to carry out the steeting in accordance with the engine speed (pump discharge volume). and this will create an extremely dangerous condition. It pushes open check valve (12a). the outlet port side of the HSS motor is closed by check valve (12b) and spool (10). The function and operation of each component is as given below. and flows from HSS motor inet port MA to HSS motor outlet port MB. 1. To prevent this. Counterbalance valve. • D65EX. if the engine is run at low speed and the steering is operated. the HSS motor will overrun. the pressurized oil from the control valve is supplied to port PA. so the pressure at the side where the oil is being supplied rises. Because of this. counterbalance valve (10). • • Operation when oil is supplied • When the steering lever is operated. and safety valve and (11). check valve Function • When operation the steering on slopes. the weight on the machine produces a force in the downward direction which makes the machine try to turn faster than the speed of the HSS motor. PX-15 10-65 . and forms a circuit such as that shown below. FUNCTION AND MAINTENANCE STANDARD HSS MOTOR OPERATION OF BRAKE VALVE • The brake valve consists of check valve (12).STRUCTURE. However.

if the machine attempts to run away. In other words.STRUCTURE. the spool moves to a position where it balances the pressure at outlet port MB with the force resulting from the weight of the machine and the pressure at the inlet port. the HSS motor will rotate under no load. If the pressure in chamber S1 drops below the spool switching pressure. This drop in pressure will pass through orifice E1. • • • 10-66 D65EX. spool (10) is pushed to the right. spool (10) is pushed to the left by spring (9). and this creates a resistance to the rotation of the HSS motor which prevents the motor from overrunning. In this way. And when the pressure in chamber S1 bcomes greater than the spool switching pressure. and the oil pressure at the inlet port of the HSS motor will drop. PX-15 . port MB and port PB are connected. Action of brakes when oprating steering on downhill slopes • When the steering is operated on a down hill slopes. As a result. so the pressure in chamber S1 will also drop. FUNCTION AND MAINTENANCE STANDARD HSS MOTOR • • The pressurized oil at the side where the oil is being supplied flows from orifice E1 of spool (10) into chamber S1. so the outlet port side of the HSS motor is opened and the HSS motor starts to turn. the pressure at the outlet port rises. In this way. and outlet port MB is throttled. it throttles the outlet port circuit and controls the motor to a speed that matches the amount of oil discharged from the pump.

the pressure at the outlet port of the HSS motor becomes extremely high. counterbalance valve (10) closes the circuit at the inlet and outlet ports of the HSS motor. As a result. The safety valve acts to release this abnormal pressure to the inlet port of the HSS motor to protect the equipment from damage. but the pressure at the outlet port side continues to rise because of inertia. But the HSS motor continues to turn because of inertia.STRUCTURE. Safety valve Function • When the operation of the steering stops. D65EX. and this will damage the HSS motor and the piping. the force of /4 (D12 – D22) x pressure resulting from the difference in area of D1 and D2 (or the force of /4 (D32 – D12) x pressure resulting from the difference in area of D3 and D1) becomes greater than the force of the spring and moves the poppet to the right. The oil then flows to chamber F (or chamber E) in the circuit on the opposite side. • If the pressure in chamber E (or chamber F) goes above the set pressure. PX-15 10-67 . the check valve of the counterbalance valve closes chamber E (or chamber F) in the outlet port circuit. FUNCTION AND MAINTENANCE STANDARD HSS MOTOR 2. • • Operation • When the operation of the steering is stopped.

FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT.STRUCTURE. PX-15 . HSS. HSS. BRAKE a HSS: Abbreviation for Hydrostatic Steering System 10-68 D65EX. BRAKE BEVEL GEAR SHAFT.

STRUCTURE. PX-15 10-69 . BRAKE D65EX. HSS. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT.

PX-15 . BRAKE 10-70 D65EX. HSS.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT.

10. 32. 16. HSS. 23. 21. 7. 4. 9. 31. 30. 19. 3. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. 27. 14. 26. 2. 15. 29. PX-15 10-71 . 24. 5. 25. 22. BRAKE 1. 17. Brake valve HSS motor Output shaft Brake spring (Large) Brake spring (Small) Spacer Hub Cage Piston Cover Plate (4 pieces on 1 side) Disc (5 pieces on 1 side) Brake drum Brake hub Gear A (Number of teeth: 38/55 Cage Gear B (Number of teeth: 32) Bevel gear shaft Bevel gear (Number of teeth: 35) Bearing Shaft Gear C (Number of teeth: 32) Planetary pinion (Number of teeth: 26) Ring gear (Number of teeth: 91) Pinion shaft Hub Carrier Gear D shaft Gear D (Number of teeth: 48) HSS motor drive gear (Number of teeth: 25) Bevel pinion (Number of teeth: 23) Cage D65EX. 8. 18. 20. 28. 11. 13. 12.STRUCTURE. 6.

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. HSS. BRAKE 10-72 D65EX. PX-15 .

adjust preload. 0.35 0.7 0.0 — 5.7 Nm {1.3 4. Adjust D65EX.38 Replace If starting torque is below 9.3 Clearance limit — — — Remedy 5.05 – 1.25 ±0. starting torque must be 10. HSS.15 ±0.2 — 46.14 – 0.1 Max. PX-15 10-73 .3 Repair limit 4. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT.50 kgm}.3 – 14.15 – 0.8 Nm {1.06 – 0.STRUCTURE. 0. After adjustment.4 43.0 kgm}.0 Standard clearance Replace Distortion Repair or replace Replace Repair or replace Thickness 2 Brake disc Distortion 3 Total thickness of assembled 4 brake plates and 5 discs 4 Backlash between gear A and gear B Backlash between gear A and 5 planetary pinion 6 7 Backlash between planetary pinion and ring gear Preload on bevel gear shaft tapered roller bearing 0.1 Max.65 0.7 0. BRAKE Unit: mm No. Check item Standard size 1 Brake plate Thickness Criteria Tolerance ±0.

STRUCTURE. HSS. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. PX-15 . BRAKE 10-74 D65EX.

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT.10 – 0. Check item Backlash between gear A and gear D Backlash between gear C and gear D Backlash between gear D and HSS motor drive gear Backlash between bevel pinion and bevel gear Standard clearance 0. BRAKE Unit: mm No.20 – 0.28 Criteria Clearance limit — — — — Adjust Replace Remedy 1 2 3 4 D65EX.49 0.15 – 0. HSS. PX-15 10-75 .40 0.64 0.09 – 0.

Bevel pinion (31) and bevel gear (19) of the bevel gear shaft device are spiral bevel gears. Brake drum (13) and cover (10) are fixed to the steering case. Then. which area lubricated with oil splashed by the lubricating oil pump and scavenging pump. and bevel gear shaft cage (16). Output shaft (3) is connected to hub (7) by spline and fixed by spacer (6) in the axial direction. The planetary gear unit consists of gear A (15). hub (26) connected to the bevel gear shaft and ring gear (24) by spline. The brake consists of carrier (27). as the hydraulic pressure in the circuit rises. however. and carrier (27) connected to brake hub (14). brake hub (14) connected to hub (7). Accordingly. The turning direction of the machine is changed by stopping or changing the revolution direction of HSS motor (2). While the engine is stopped. gear A (15) supported by the bearing on the bevel gear shaft. The brake is a wet-type. planetary shaft (25). multiple disc clutchtype. the brake is “released”. After the engine is started again. plate (11). gear B (17) connected to shaft (21). and cage (8). planetary pinion (23). The brake is lubricated forcedly with oil supplied by the lubricating oil pump and scavenging pump. disc (12) meshed with the brake hub. disc (12). the periphery of which is connected to brake drum (13) by spline. the bevel gear shaft device engages bevel pinion (31) with bevel gear (19) to turn the engine power at right angles into the lateral direction and reduce the revolving speed. The lubricating oil flows through the paths in the steering case. • • • • • 10-76 D65EX. BRAKE Outline Bevel gear shaft • The engine power is transmitted through the torque converter to the transmission. The transfer unit consists of HSS motor drive gear (30) connected to HSS motor (2) by spline. bearing (20) to support the bevel gear shaft. The planetary gear unit is lubricated forcedly with oil supplied by the scavenging pump and lubricating oil pump. The bevel gear shaft device consists of bevel gear (19) meshed with bevel pinion (31). The transfer unit employs a spur gear speed reduction mechanism and is lubricated with oil splashed by the scavenging pump and lubricating oil pump. gear A (15) meshed with gear D (29). Brake • • The brake is installed to brake the machine and connected to brake hub (14). the back pressure of the brake piston lowers and the brake is “applied”. gear C (22) meshed with gear D. spring-boosted brake. the parking brake must be kept locked. HSS. cage (8). cover (10). FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. PX-15 . and cover to support these parts. cover (10). bevel gear shaft (18). even if the brake pedal is not pressed. piston (9) and springs (4) and (5) to press the disc and plate against each other. and plate (11). and output shaft (3) to support these parts.STRUCTURE. It is driven hydraulically by the brake valve operated with brake pedal. gear D (29) meshed with the HSS motor drive gear. • • • • HSS • The HSS consists of the transfer unit to reverse the revolution direction of HSS motor (2) and transmit it to gear A (15) and the planetary gear unit to increase or decrease the input for ring gear (24) and gear A (15) and output it to carrier (27).

FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT.STRUCTURE. The power transmitted to ring gear (5) is further transmitted through planetary pinion (6) and planetary pinion shaft (7) to carrier (8). PX-15 10-77 . Under this condition. The power transmitted to carrier (8) is further transmitted through brake hub (9) and hub (10) to output shaft (11). BRAKE Operation of HSS When steering lever is in neutral (Straight travel) • • • • While the PCCS lever is in neutral. • Accordingly. Rotation direction of HSS motor Steering operation of PCCS lever Direction changing operation of PCCS lever Turning direction of HSS motor seen from left of chassis Neutral Turning to right Turning to left Any Neutral Forward Reverse Neutral Forward Reverse Stopped Left Left Right Right Right Left : Pivot turn D65EX. HSS motor (1) is stopped and gears A (2) of the transfer unit and planetary gear unit do not rotate. HSS. the power from bevel gear shaft (3) is transmitted through hub (4) to ring gear (5). the output speeds on both sides are the same and the machine travels straight.

HSS motor (1) rotates counterclockwise as seen from the left side of the machine. the rotating speed of left carrier (8) is higher than when traveling straight forward by the amount of the power of HSS motor. At the same time. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. PX-15 . • • Bevel gear shaft (1) and ring gear (5) connected to rotate clockwise as seen from the left side of the machine. As a result. 10-78 D65EX. because of the difference in the rotating speed between both planetary gear units. the rotating speed of right carrier (8) is lower than when traveling straight forward. the machine travels forward and turns to the right. BRAKE When steering lever is operated to right (Forward) A: Transmission power B: HSS motor power C:Combined power 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) • If the steering lever is operated to the right while the machine is traveling forward. HSS. On the other hand. Accordingly.STRUCTURE. left gear A (2) rotates clockwise and right gear A (2) rotates counterclockwise. where the output speed is lower.

FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. • • Bevel gear shaft (1) and ring gear (5) connected to rotate counterclockwise as seen from the left side of the machine. On the other hand. At the same time. Accordingly. HSS. D65EX. HSS motor (1) rotates clockwise as seen from the left side of the machine. because of the difference in the rotating speed between both planetary gear units. BRAKE When steering lever is operated to right (Reverse) A: Transmission power B: HSS motor power C:Combined power 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) • If the steering lever is operated to the right while the machine is traveling in reverse. left gear A (2) rotates counterclockwise and right gear A (2) rotates clockwise. PX-15 10-79 . where the output speed is lower. the rotating speed of left carrier (8) is higher than when traveling straight in reverse by the amount of the power of HSS motor. As a result.STRUCTURE. the rotating speed of right carrier (8) is lower than when traveling straight in reverse. the machine travels in reverse and turns to the right.

left gear A (2) rotates counterclockwise and right gear A (2) rotates clockwise. On the other hand. the rotating speed of left carrier (8) is lower than when traveling straight forward. where the output speed is lower. • • Bevel gear shaft (1) and ring gear (5) connected to rotate clockwise as seen from the left side of the machine. As a result. At the same time. because of the difference in the rotating speed between both planetary gear units. HSS. BRAKE When steering lever is operated to left (Forward) A: Transmission power B: HSS motor power C:Combined power 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) • If the steering lever is operated to the left while the machine is traveling forward. PX-15 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. the machine travels forward and turns to the left. HSS motor (1) rotates clockwise as seen from the left side of the machine. the rotating speed of right carrier (8) is higher than when traveling straight forward by the amount of the power of HSS motor. Accordingly. 10-80 D65EX.

HSS motor (1) rotates counterclockwise as seen from the left side of the machine. HSS. At the same time. D65EX.STRUCTURE. On the other hand. left gear A (2) rotates clockwise and right gear A (2) rotates counterclockwise. BRAKE When steering lever is operated to left (Reverse) A: Transmission power B: HSS motor power C:Combined power 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) • If the steering lever is operated to the left while the machine is traveling in reverse. As a result. Accordingly. • • Bevel gear shaft (1) and ring gear (5) connected to rotate counterclockwise as seen from the left side of the machine. PX-15 10-81 . FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. where the output speed is lower. the rotating speed of right carrier (8) is higher than when traveling straight in reverse by the amount of the power of HSS motor. the rotating speed of left carrier (8) is lower than when traveling straight in reverse. the machine travels in reverse and turns to the left. because of the difference in the rotating speed between both planetary gear units.

STRUCTURE. As the oil pressure rises. FUNCTION AND MAINTENANCE STANDARD BEVEL GEAR SHAFT. HSS. The hydraulic force applied to piston (1). BRAKE Operation of brake When brake is released When brake is applied (When brake pedal is depressed) • • • While the brake pedal is released. piston (1) is moved to the right by the tension of springs (2) and (3) to press discs (4) and plates (5) against brake drum (6). The power transmitted from the bevel gear shaft through the HSS to brake hub (7) is further transmitted through hub (8) and output shaft (9) to the final drive. or the power to output shaft (9). is restricted since discs (4) and plates (5) are pressed together. the brake valve is in the neutral position and oil enters the back-pressure port of piston (1). Brake drum (6) is connected and fixed to the steering case. The power of brake hub (7). 10-82 D65EX. piston (1) compresses springs (2) and (3) to the left to release discs (4) and plates (5). As the pressure in the back-pressure port lowers. PX-15 . or the braking force. the brake valve switches and the oil in the back-pressure port of piston (1) is drained. • • • • If the brake pedal is depressed. can be controlled by controlling the depressing distance of the brake pedal.

From power train pump To steering case To steering case To right brake To left brake Outline • The brake valve is in the circuit between the power train pump and the brake piston in the HSS unit and installed to the top of the HSS unit. 5. since the brakes are used only for braking (the brakes have no connection with the steering control). the right and left brakes are applied simultaneously. PX-15 10-83 . If each valve operates. 2. 3. If the brake pedal is depressed. the parking brake valve operates. the oil flowing in the backpressure port of the brake piston is shut off and the brake is applied. main brake valve (3) operates. 4.STRUCTURE. If the parking brake lever is set in the LOCK position. 6. In the case of the HSS. • Parking brake valve Body Main brake valve Piston Shaft Guide • • D65EX. FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE BRAKE VALVE P: T1: T2: Br (R): Br (L): 1.

055 0. Check item Standard size 19 2 3 Clearance between brake valve and piston Clearance between parking brake valve and body 9 19 Criteria Tolerance Shaft –0.08 0.11 kg} 16.3 kg} 15.7 N {1.034 –0.6 N {7. PX-15 .034 – 0.015 0 +0.6 kg} 10-84 D65EX.08 Replace Clearance between brake valve 1 and body Hole +0.9 N {16.7 kg} 71.056 Free length 46.STRUCTURE.013 0 Repair limit Installed load 36 38 28. FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE Unit: mm No.043 0.4 Clearance limit 0.5 75.4 35.5 Installed length Installed load Remedy Standard clearance 0.040 –0.07 0.3 N {7.68 kg} 157.020 –0.7 N {1.030 –0.043 Standard size 4 Brake modulating spring Free length 48 5 Brake valve return spring 6 Parking brake valve return spring 52 36.3 kg} 150 N {15.030 –0.013 0 +0.020 – 0.6 50.030 – 0.

84 MPa {29. Main brake valve (3) opens chamber B and port Br with the tension of return spring (4). The brake piston moves to the left and compresses the brake spring to release the brake.0 kg/cm2} and can be measured at oil pressure pickup port Q. D65EX.STRUCTURE. PX-15 10-85 . the oil pressure is kept at 2. parking brake valve (1) opens port P and chamber A with the tension of return spring (2). At this time. chambers A and B. and then the oil flows through port P. The pressure of the oil from the power train pump is regulated by the main relief valve. and port Br to the back-pressure port of the brake piston. FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE Operation When brake is released (When brake pedal is released and parking brake lever in FREE position) • • • • • While the brake pedal is released (While it is not depressed).

A part of the oil which has flowed in the backpressure port of the brake piston is drained through port T2. The oil pressure after port Br is decided by the tension of return spring (6). If the oil after port Br is drained through port T2 and its pressure lowers. if the stroke of the brake pedal is short. Then. the oil pressure after port Br is high and the brake is “half applied”. 10-86 D65EX. ports Br and chamber B are disconnected and ports Br and T2 are connected. the force which has pushed main brake valve (3) to the right is reduced and main brake valve (3) is moved to the left by the tension of return spring (4). If main brake valve (3) is moved to the stroke end. As shaft (6) is pushed. Accordingly. The other part flows through orifice a to chamber D.STRUCTURE. • • • If the brake pedal is pressed further. it compresses modulating spring (7) and its reaction force moves main brake valve (3) to the right. PX-15 . the oil pressure is low and the brake is “applied”. If the stroke is long. As a result. the load on which changes according to the stroke of the brake pedal. ports Br and T2 are disconnected so that the oil pressure after port Br will not lower. The oil from the power train pump flows through port P to chamber A and stops at chamber B. the brake is turned applied perfectly. If main brake valve (3) is moved to the left. FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE When brake is applied (When brake pedal is depressed and parking brake lever in FREE position) • • • • • • If the brake pedal is depressed. guide (5) and shaft (6) are pushed to the right. the above operation is repeated. it enters chamber D and pushes piston (8).

PX-15 10-87 . FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE When parking brake is applied (When brake pedal is released and brake lock lever is at LOCK position) • • • • • If the parking brake lever is set in the LOCK position. A. As a result. parking brake valve (1) is pulled to the left. the oil pressure in the back-pressure port of the brake piston continues lowering. and C. Then. D65EX. ports P and A are disconnected and ports A and C are connected. The oil from the power train pump is stopped at port P.STRUCTURE. This condition is maintained even after the engine is started again. chambers B. the brake is kept “applied”. The oil which has flowed in the back-pressure port of the brake piston is drained through port Br. Since parking brake valve (1) is kept pulled to the left. and port T1.

10-88 D65EX.STRUCTURE. The lubrication is of splash type using the rotation of the gears. PX-15 . The final drive can be removed and installed as a single unit. FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE FINAL DRIVE Outline • • • • The final drive is a single stage spur gear. single stage planetary gear reduction type. Floating seal (1) is installed to the rotating sliding portion of the sprocket to prevent the entry of dirt or sand and to prevent leakage of lubricating oil.

STRUCTURE. Pinion (Number of teeth: 13) Carrier Ring gear (Number of teeth: 68) Floating seal Cover 1st pinion cover Final drive case Bearing cage 9. 2. 5. 4. 8. 1st pinion (Number of teeth: 21) 1st pinion (Number of teeth: 78) Sprocket hub Sprocket teeth Hub Planetary pinion (Number of teeth: 27) Pinion shaft D65EX. FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE a The following drawing shows D65EX-15. PX-15 10-89 . 3. 7. 6. 11. 13. 10. 1. 14. 15. 12.

PX-15 . 10-90 D65EX. FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE a The following drawing shows D65EX-15.STRUCTURE.

18 – 0.002 Adjust 1.030 0 0 – 0.9 Standard interference 0.23 – 0.074 0 –0. PX-15 10-91 .STRUCTURE.45 0.9 69.032 Hole +0.0 Tolerance 0 –0.2 317 317 Repair limit 1. FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE Unit: mm No.61 0.0 1.051 Interference limit Remedy 1 2 3 4 5 Replace Interference between pinion shaft 6 and carrier 0.002 – 0.5 299 301 Replace 9 Wear of sprocket 10 tooth surface Repair by buildup welding or replace D65EX.051 +0.67 Standard size 80 70 Standard size 56 7 8 Axial clearance of 1st pinion bearing Standard shim thickness of 1st pinion bearing cage Projection of ball from 1st pinion cover Standard bushing type Rotary bushing type Criteria Clearance limit 1.23 – 0.0 1.5 Standard size 5. Check item Backlash between 1st pinion and 1st gear Backlash between pinion and planetary pinion Backlash between planetary pinion and ring gear Outside diameter of oil seal contact surface of 1st pinion (Large) Outside diameter of oil seal contact surface of 1st pinion (Small) Standard clearance 0.1 Repair limit 79.074 Tolerance Shaft +0.

• • • The power from the HSS unit is transmitted to 1st pinion (1). Accordingly. 10-92 D65EX. Cover (6) and ring gear (5) are connected by hub (7). revolving pinion (3) along ring gear (5). Planetary pinion (4) is meshed with ring gear (5). • • The power transmitted to pinion (3) is transmitted to sprocket hub (9) as a force to rotate carrier (8) which supports planetary pinion (4). planetary pinion (4) rotates on its axis. The rotation force transmitted sprocket hub (9) is transmitted to sprocket teeth (10).STRUCTURE. FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE Power train route a The following drawing shows D65EX-15. The rotation direction of carrier (8) is the same as that of pinion (3). PX-15 . and then transmitted through 1st gear (2) and pinion (3) to planetary pinion (4).

FUNCTION AND MAINTENANCE STANDARD FRAME ASSEMBLY FRAME ASSEMBLY D65EX.STRUCTURE. PX-15 10-93 .

on which the radiator guard.100 Standard clearance 0.5 Replace bushing Remedy Clearance between cylinder yoke 1 and bushing (Large) 3.174 +0. main frame. PX-15 . 6.120 +0. FUNCTION AND MAINTENANCE STANDARD FRAME ASSEMBLY Unit: mm No.5 0.156 – 0. and transmission guard are assembled into 1 unit. 10-94 D65EX.STRUCTURE.207 +0. 4.130 – 0.090 –0. Frame assembly Undercover Engine mount Power train unit mount Outline • Frame assembly (3) has a hull frame structure.036 –0. Check item Standard size 85 2 Clearance between cylinder yoke and bushing (Small) 65 Criteria Tolerance Shaft –0. 5.250 Clearance limit 0.297 0. steering case.030 –0.076 Hole +0.

FUNCTION AND MAINTENANCE STANDARD SUSPENSION SUSPENSION D65EX-15 D65EX-15 (Long track specification) D65EX.STRUCTURE. PX-15 10-95 (7) .

6 72. Equalizer bar Center pin Side pin Pivot shaft Bushing Seal Seal Bushing Bushing (Large) Plug (Oil filler) Bushing (Small) Cover Seal Outline • • The track frame moves the front part of the track frame up and down around pivot shaft (4) in its rear. PX-15 . 8.6 10-96 (7) D65EX. 3. 2. 6. 13. 5. FUNCTION AND MAINTENANCE STANDARD SUSPENSION 1. 4. Equalizer bar (1) rocks around center pin (2) and is connected to both track frames by side pin (3). 10. 12. 9.STRUCTURE. 7. D65EX-15 D65EX-15 (Long track specification) Displacement at center of equalizer bar side pin (mm) Upward Downward 72. 11.

1 – 2.5 Replace bushing Remedy Clearance between pivot shaft 14 and bushing (Large) Clearance between pivot shaft and bushing (Small) Clearance between center pin and bushing Clearance between side pin and bushing Press fitting force of pivot shaft bushing (Large) Press fitting force of pivot shaft bushing (Small) Quantity of oil in pivot shaft section 15 16 17 18 19 — 0.200 – 0.98 – 22.146 Hole +0.054 0 +0.1 – 3.7 ton} 4.146 –0.174 +0. FUNCTION AND MAINTENANCE STANDARD SUSPENSION Unit: mm No.100 +0. Check item Standard size 148 105 70 60 Criteria Tolerance Shaft –0.271 0.063 0 +0.3 kN {0.120 –0.156 Clearance limit 1.045 –0.5 l (Engine oil: SAE30) — D65EX.080 – 0.3 ton} 0.STRUCTURE.228 0.100 –0.120 – 0.208 –0.010 –0.100 –0.145 – 0.020 Standard clearance 0.6 kN {0. PX-15 10-97 .174 –0.0 0.5 0.0 1.320 0.98 – 36.

STRUCTURE. PX-15 . FUNCTION AND MAINTENANCE STANDARD SUSPENSION D65PX-15 D65EX-15 (Wide gauge specification) D65WX-15 10-98 (7) D65EX.

9. 3. 12. Equalizer bar Center pin Side pin Pivot shaft Bushing Seal Seal Bushing Bushing (Large) Plug (Oil filler) Bushing (Small) Cover Seal Outline • • The track frame moves the front part of the track frame up and down around pivot shaft (4) in its rear. 2. 6.9 D65EX. Equalizer bar (1) rocks around center pin (2) and is connected to both track frames by side pin (3).STRUCTURE. PX-15 10-99 (7) . 13. 5. FUNCTION AND MAINTENANCE STANDARD SUSPENSION 1.9 81. 4. 8. 10. 11. D65PX-15 D65EX-15 (Wide gauge specification) D65WX-15 Displacement at center of equalizer bar side pin (mm) Upward Downward 81. 7.

146 –0.98 – 22.1 – 3.3 ton} 0.98 – 36.145 – 0.STRUCTURE.0 0.120 –0.3 kN {0.010 –0.020 Standard clearance 0.174 +0.063 0 +0.0 1.200 – 0.5 l (Engine oil: SAE30) — 10-100 D65EX.5 0.156 Clearance limit 1.100 –0.045 –0.080 – 0.146 Hole +0.5 Replace bushing Remedy Clearance between pivot shaft 14 and bushing (Large) Clearance between pivot shaft and bushing (Small) Clearance between center pin and bushing Clearance between side pin and bushing Press fitting force of pivot shaft bushing (Large) Press fitting force of pivot shaft bushing (Small) Quantity of oil in pivot shaft section 15 16 17 18 19 — 0.174 –0.6 kN {0.100 +0.7 ton} 4.1 – 2.208 –0.120 – 0. FUNCTION AND MAINTENANCE STANDARD SUSPENSION Unit: mm No.100 –0. Check item Standard size 148 105 70 60 Criteria Tolerance Shaft –0.228 0.054 0 +0.271 0. PX-15 .320 0.

2. 8. 16. 14. 11. 5. 18. RECOIL SPRING D65EX-15 D65EX-15 (Wide gauge specification) D65WX-15 1. RECOIL SPRING TRACK FRAME. 12. 9. FUNCTION AND MAINTENANCE STANDARD TRACK FRAME.STRUCTURE. 7. 4. 3. 6. Recoil spring Wear ring U-packing Cabin Nut Lubricator Cylinder Bushing Holder D65EX. 13. 17. PX-15 10-101 (7) . 15. Idler Carrier roller Track frame Sprocket teeth Track roller guard Track roller Yoke Seal Piston 10.

100 – 0. S.320 kg} Hole +0.360 Installed load Replace 791. Q’ty on each side D65EX-15 D65EX-15 (Wide gauge specification) D65WX-15 Flange type and arrangement 7 pcs.270 +0. S. FUNCTION AND MAINTENANCE STANDARD TRACK FRAME.0 Adjust — Clearance between piston and 21 bushing Standard size 90 Tolerance Shaft –0. S S: Single flange W: Double flange 10-102 (7) D65EX. S.039 –0.6 kN {17.061 168. D. Check item Item 19 Deformation of track frame Bend Twist Opening of idler Standard size 20 Recoil spring Free length x Outside diameter Criteria Repair limit 7 (in length of 3.090 Replace bushing 22 Press fitting force of idler yoke — Quantity of grease 392 kN {40 ton} 140 cc (Grease: G2-LI) Outline • Recoil spring (10) is used to adjust the track shoe tension by supplying grease through lubricator (15) or discharge existing grease and moving piston (9) forward or in reverse.STRUCTURE. D.195 kg} Clearance limit 1. PX-15 . RECOIL SPRING Unit: mm No.000) 3 (in length of 300) 5 Repair limit Installed load Remedy Repair Installed length Free length 772 Standard clearance 0. It also damps sudden shocks applied to idler (1).5 kN {19. S.5 x 239 634 189.

2. 8. 14. 18. 15. 16. 11. Recoil spring Wear ring U-packing Cabin Nut Lubricator Cylinder Bushing Holder D65EX. 3.STRUCTURE. 17. 12. Idler Carrier roller Track frame Sprocket teeth Track roller guard Track roller Yoke Seal Piston 10. FUNCTION AND MAINTENANCE STANDARD TRACK FRAME. 6. 7. 13. 4. 9. RECOIL SPRING D65PX-15 D65EX-15 (Long track specification) 1. PX-15 10-103 . 5.

D. S.5 kN {19. PX-15 .STRUCTURE.061 168.100 – 0. S: Single flange W: Double flange 10-104 D65EX.039 –0. S.090 Replace bushing 22 Press fitting force of idler yoke — Quantity of grease 392 kN {40 ton} 140 cc (Grease: G2-LI) Outline • Recoil spring (10) is used to adjust the track shoe tension by supplying grease through lubricator (15) or discharge existing grease and moving piston (9) forward or in reverse. RECOIL SPRING Unit: mm No.270 +0.5 x 239 634 189. Check item Item 19 Deformation of track frame Bend Twist Opening of idler Standard size 20 Recoil spring Free length x Outside diameter Criteria Repair limit 7 (in length of 3. FUNCTION AND MAINTENANCE STANDARD TRACK FRAME. S.360 Installed load Replace 791.195 kg} Clearance limit 1. It also damps sudden shocks applied to idler (1).000) 3 (in length of 300) 5 Repair limit Installed load Remedy Repair Installed length Free length 772 Standard clearance 0. S. D. S 8 pcs. Q’ty on each side D65PX-15 D65EX-15 (Long track specification) Flange type and arrangement S.6 kN {17.320 kg} Hole +0.0 Adjust — Clearance between piston and 21 bushing Standard size 90 Tolerance Shaft –0.

FUNCTION AND MAINTENANCE STANDARD IDLER IDLER D65EX. PX-15 10-105 .STRUCTURE.

5 — Clearance limit — — Replace Repair by buildup welding or replace Remedy 2 Outside diameter of tread 3 Depth of tread 4 Thickness of tread 5 Width of tread 6 Overall width Clearance between shaft and 7 bushing Standard clearance 9 Axial play of shaft Clearance between guide plate and support Clearance between guide plate and side plate 0. Check item Standard size 1 Outside diameter of projection 630 590 20 15 44.350 Hole +0.26 – 0.242 – 0.250 –0.492 0.350 –0.STRUCTURE.5 190 Standard size 65 8 Clearance between shaft and support 64.142 –0.7 Tolerance Shaft –0.0 4. PX-15 . FUNCTION AND MAINTENANCE STANDARD IDLER Unit: mm No.66 2.0 1.090 0 Standard clearance 0.0 Clearance limit — — — Repair by buildup welding or replace Adjust shim or replace plate 10 11 Standard shim thickness at side 12 plate fitting part 10-106 D65EX.250 –0.008 +0.440 Criteria Repair limit — 570 30 5 48.250 – 0.

250 Criteria Repair limit — — 174 51 13.7 235 Standard size 65 11 Clearance between shaft and collar 64.5 13. FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER TRACK ROLLER a The following drawing shows the double-flange type.350 –0.STRUCTURE. Unit: mm No.5 47 47.493 0.26 – 0.250 –0.7 Tolerance Shaft –0.5 — — — Clearance limit — — Replace Remedy 1 2 3 Outside diameter of tread 4 Thickness of tread 5 Width of flange (outside) 6 Width of flange (inside) 7 8 Width of tread (Single-flange type) Width of tread (Double-flange type) Repair by buildup welding or replace 9 Overall width Clearance between shaft and 10 bushing Standard clearance 12 Axial play of roller 0.250 –0.100 – 0.100 –0. Check item Outside diameter of flange (outside) Outside diameter of flange (inside) Standard size 240 236 210 69 19.350 Hole +0.150 Standard clearance 0.243 – 0.5 19. PX-15 10-107 .143 –0.66 Clearance limit — D65EX.007 –0.

030 0 Standard clearance 0.100 – 0. Check item Standard size 1 Outside diameter of flange 215 185 37. FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER CARRIER ROLLER Unit: mm No.100 – 0.200 Shaft +0.22 Clearance limit — 10-108 D65EX.5 21 Standard size 61 Standard size 61.100 –0.5 15 Clearance limit — Interference limit Remedy 2 Outside diameter of tread 3 Thickness of tread 4 Width of tread 5 Width of flange Rebuild or replace Clearance between shaft and 6 support Tolerance Interference between shaft and 7 seal guard Replace — Standard clearance 0 – 0. PX-15 .5 8 Play in axial direction of shaft Tolerance Shaft –0.5 49.150 +0.500 Standard interference 0.5 55.150 Criteria Repair limit — 163 26.STRUCTURE.300 0 Hole +0.130 Hole +0.

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD SPROCKET SPROCKET Unit: mm No. Check item Standard size 1 Wear of tooth root 2 Thickness of tooth root 87 26 Criteria Repair limit 77 17 Rebuild or replace Remedy D65EX. PX-15 10-109 (7) .

and then copy the whole drawing to an OHP sheet. FUNCTION AND MAINTENANCE STANDARD SPROCKET Full-scale drawing of sprocket tooth profile a Set the rule to the full-scale size.STRUCTURE. 10-110 D65EX. PX-15 .

Single shoe *2. PX-15 10-113 (7) .STRUCTURE. Swamp shoe a Part P is the link on the bushing fitting side. D65EX. FUNCTION AND MAINTENANCE STANDARD TRACK SHOE TRACK SHOE *1.

415 Interference between bushing 7 and link Interference between regular pin and link 8 Adjust or replace Tolerance Interference between regular pin 9 and bushing 10-114 D65EX. Regular link 6 Shoe bolt b.5 32.435 +0.230 – 0.411 Standard clearance 0.915 +0.) Criteria Repair limit 206.404 +0.199 – 0.235 +0.180 – 0.285 Shaft +0.45 Turning over Light load 62.3 Remedy Turn over or replace Repair or replace Replace Retighten 180 (0/–20) Tolerance Shaft +0.404 0.074 0 +0.3 Retightening angle (deg.304 +0.8 Tightening torque (Nm {kgm}) 539 ± 49 {55 ± 5} Tightening torque (Nm {kgm}) 343 ± 39 {35 ± 4} Standard size 66.) 120 ± 10 Lower limit of torque (Nm {kgm}) 784 {80} Standard interference 0.9 Standard size 132 44.085 Hole +0.45 Standard size 2 Outside diameter of bushing 73 3 Thickness of bushing 4 Height of link 5 Thickness of link (Bushing fitting part) a.086 +0.5 44.4 Standard size 44. Master link 13. 1 Link pitch Check item Standard size 203.6 Retightening angle (deg. FUNCTION AND MAINTENANCE STANDARD TRACK SHOE Unit: mm No.4 6.024 Hole +0.8 3. PX-15 .7 Repair limit 119.STRUCTURE.830 Heavy load 65.

5 5 Repair by buildup welding or replace Remedy D65EX. PX-15 10-117 (5) . Check item Standard size 1 Height of grouser 2 Thickness of grouser 65 77 Criteria Repair limit 25 37 Repair by buildup welding or replace Remedy Swamp shoe Unit: mm No.5 20 Criteria Repair limit 94. FUNCTION AND MAINTENANCE STANDARD TRACK SHOE Single shoe Unit: mm No.STRUCTURE. Check item Standard size 1 Height of grouser 2 Thickness of grouser 109.

FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 10-118 D65EX. PX-15 .STRUCTURE.

Blade PPC valve 17. Scavenging pump D65EX. SEMI-U dozer) Pitch cylinder (PTP dozer) 4. Cooling fan motor 2. Power train and lubricating oil pump 18. Tilt cylinder (PTP dozer) 20. Transmission ECMV 15. Quick drop valve 3. Cooling fan pump 9. Power train oil filter 11. FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 1. Accumulator 19. PPC lock valve 10. Tilt cylinder (PT. Radiator 6. HSS motor 14. Main relief valve 16. Self-reducing pressure valve 7. Control valve 12. Hydraulic tank 13. HSS pump 8.STRUCTURE. Lift cylinder 5. PX-15 10-119 .

PX-15 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL WORK EQUIPMENT CONTROL 10-120 D65EX.

it is connected to PPC lock valve (6) and the operator can move blade control lever (3) and ripper control lever (4) but cannot operate the work equipment. If work equipment lock lever (1) is set in the LOCK position. the hydraulic detent of blade PPC valve (2) works so that blade control lever (3) will hold itself. 5. the hydraulic detent does not work even. 2. which moves each spool of the control valves through blade control lever (3) and blade PPC valve (2) and through ripper control lever (4) and ripper PPC valve (5). FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL 1. 3. PX-15 10-121 (7) . if blade control lever (3) is in the FLOAT position. Work equipment lock lever Blade PPC valve Blade control lever Ripper control lever (D65EX-15: If equipped) Ripper PPC valve (D65EX-15: If equipped) PPC lock valve Outline • The work equipment control system is a PPC system. the hydraulic detent is reset and blade control lever (3) returns to the HOLD position automatically. 6. 4. • • • D65EX.STRUCTURE. While the engine is stopped. If work equipment lock lever (1) is set in the LOCK position. and blade control lever (3) returns to the HOLD position automatically. If blade control lever (3) is set in the FLOAT position.

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK HYDRAULIC TANK 10-122 D65EX. PX-15 .

5 ± 0. 3. Oil filler cap Hydraulic tank Element Bypass valve Strainer Drain plug Sight gauge Specifications Tank capacity (l) Quantity of oil in tank (l) Set pressure of bypass valve (MPa {kg/cm2}) Cracking pressure of pressure valve (kPa {kg/cm2}) Actuating pressure of vacuum valve (kPa {kg/cm2}) 80 55 0.39 ± 0.3} 38 ± 14 {0. 6.15 ± 0.STRUCTURE.046} D65EX. 2. 4.03 {1.5 {0 – 0. 5. 7.15} 0 – 4. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK 1. PX-15 10-123 .

FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR ACCUMULATOR For PPC valve 1. using pressure: Nitrogen gas 300 cc 1.STRUCTURE. 4. the operator can send the pilot oil pressure to the control valve to have the work equipment lower with its own weight by using the nitrogen gas pressure in the accumulator. 5.18 MPa {12 kg/cm2} (at 80ºC) 6.86 MPa {70 kg/cm2} 10-124 D65EX. Glass plug Shell Poppet Holder Bladder Oil port Outline • The accumulator is installed between the fan pump and blade PPC valve. 6. 2. 3. Even if the engine stopped with the work equipment raised. Specifications Gas used: Quantity of gas: Charged gas pressure: Max. PX-15 .

3. If the work equipment lock lever is set in the LOCK position. thus the operator cannot operate the work equipment.STRUCTURE. 4. 5. 2. PX-15 10-125 (7) . D65EX. the lock valve connected to it shuts off the oil in the PPC circuit. FUNCTION AND MAINTENANCE STANDARD PPC LOCK VALVE PPC LOCK VALVE a PPC: Abbreviation for Proportional Pressure Control 1. Lever End cap Ball Seat Body Outline • The PPC lock valve is installed between the fan pump and blade PPC valve.

: 67001. : 67001. D65EX-15 (Serial No. PX-15 .67401) 10-126 (7) D65EX.67431) D65PX-15 (Serial No. FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER HYDRAULIC CYLINDER BLADE LIFT CYLINDER D65EX-15 D65EX-15 (Wide gauge specification) D65WX-15 BLADE LIFT CYLINDER D65PX-15 D65EX-15 (Long track specification) BLADE TILT CYLINDER BLADE PITCH CYLINDER *1.STRUCTURE.

FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER RIPPER LIFT CYLINDER D65EX-15 D65WX-15 *1.030 –0.3 –0.025 –0.0 kgm} (Width across flats: 50 mm) 3.280 – 0.375 0.0 Nm {75.3 –0.2 –0.5 ± 1.116 0 +0.262 +0.7 Nm {16.542 0.666 0.130 – 0.40 kNm {405 ± 40.271 +0. : 67001.67322) Unit: mm No.030 –0.130 – 0.366 0.174 +0.100 –0.025 –0.STRUCTURE. D65EX-15 (Serial No.030 –0.105 – 0.5 kgm} 162 ± 14.080 +0.675 1.375 0. Check item Cylinder name Criteria Standard size 65 70 70 S 85 S 90 (Shaft) S 91 (Hole) Remedy Standard clearance 0.2 – 0.11 kNm {110 ± 11.0 1.142 +0.0 1.067 +0.0 1.087 –0.0 ± 7.200 –0.5 kgm} (Width across flats: 80 mm) 3.100 +0.5 kgm} 162 ± 14.5 0.5 ± 1.174 +0.5 kgm} (Width across flats: 80 mm) 5 Tightening torque of cylinder piston clamping nut Tilt Pitch Ripper D65EX.174 –0.1 –0.97 ± 0.076 Hole +0.400 –0.97 ± 0.064 –0.075 +0.100 – 0.271 +0.100 Clearance between piston rod 1 and bushing Lift Tilt Pitch Ripper Spherical clearance between piston rod and trunnion Spherical clearance between 2 piston rod and bracket Clearance between piston rod support shaft and bushing Clearance between cylinder boss and bushing 3 Clearance between cylinder bottom support shaft and bushing Tightening torque of cylinder head 4 Tightening torque of cylinder head mounting bolt Lift Tilt Pitch Ripper Lift Tilt Pitch Ripper Lift Tilt Pitch Ripper Lift 75 55 50 75 735 ± 74.3 0 +1.40 kNm {405 ± 40.5 0.2 – 0.250 Clearance limit 0.08 ± 0.076 –0.0 0 +0.675 0.5 kgm} Retighten 1.105 – 0. PX-15 10-127 (7) .0 Replace bushing Adjust shim or replace Replace bushing Tolerance Shaft –0.290 0.075 +0.7 Nm {16.250 0.097 – 0.0 2.0 1.104 –0.

the oil which has been stopped by piston valve (3) is sent through piston valve seats (4) and (5) to the bottom side. When the piston rod is at the stroke end. • The end of piston valve (3) touches cylinder bottom (a) before piston rod (1) reaches the stroke end. Then. and then only piston (2) continues moving. thus the oil pressure in the cylinder lowers. At this time. 10-128 D65EX.STRUCTURE. the oil from the pump is sent to the port on the opposite side to lower the oil pressure applied to the piston. The oil is also sent to the port on the opposite side before the piston rod reaches the stroke end to lower the surge pressure and reduce the shock made when the piston rod reaches the stroke end. PX-15 . Operation When piston valve is closed When piston valve is open • The oil from the pump acts on piston (2) and piston valve (3). the oil pressure in the cylinder rises to move piston (2) to the right. piston valve (3) is pushed to the right to seal the tapered part of piston valve seat (4). FUNCTION AND MAINTENANCE STANDARD PISTON VALVE PISTON VALVE (Blade lift cylinder) Outline • • The piston valve is installed to the piston of the blade lift cylinder. As a result.

blade LOWER From control valve.6 N {0.080 0.1 N {0.0 kg} 4.1 kg} 4. 8.075 Free length 97. 7.054 Standard size 3 Valve spring Free length 108.039 – 0.STRUCTURE.3 Installed length Installed load Remedy Standard clearance 0. Body Valve Piston Plug VH: VB: CH2: CB1: CB2: From control valve.080 Replace Clearance between valve and 1 body Hole +0.034 – 0.5 24.2 N {9.42 kg} 5.025 0 +0.075 0.47 kg} 79.6 Clearance limit 0.050 –0. Check item Standard size 33 2 Clearance between piston and plug 25 Criteria Tolerance Shaft –0. 6.4 N {8.3 4 Piston spring 27. PX-15 10-129 . blade RAISE To both blade lift cylinder heads To left blade lift cylinder bottom To right blade lift cylinder bottom D65EX. FUNCTION AND MAINTENANCE STANDARD QUICK DROP VALVE QUICK DROP VALVE (Blade lift cylinder) Unit: mm No.034 –0.021 0 Repair limit Installed load 26 26 88.039 –0.

It can be heightened. the oil flow rate is reduced by orifice a and a pressure difference is made between before and after the orifice. PX-15 . and then flows through port VH and control valve to the hydraulic tank. 10-130 D65EX. Accordingly. • Operation Start of lowering blade While lowering blade • • If the blade control lever is set in the LOWER position. The blade lowering speed is almost decided by the pump discharge. When the blade control lever is set in the LOWER position. valve (3) and piston (4) move to the right. At this time. the oil from the control valve flows in port VB and further flows through ports CB1 and CB2 to the cylinder bottom and pushes the cylinder piston. by installing the quick drop valve. Since ports VB and CH2 are connected. • • • • The oil pushed out of the cylinder head side flows through port CH2 to port VH. the quick drop valve prevents a vacuum on the cylinder bottom side and shortens the time lag in starting digging. the blade lowering speed is increased by the quantity of the oil flowing into the cylinder bottom side and a vacuum on the bottom side is prevented. If the oil pressure in port CH2 rises higher than the tension of springs (1) and (2). however. FUNCTION AND MAINTENANCE STANDARD QUICK DROP VALVE Outline • The quick drop valve is installed between the control valve and blade lift cylinder. The oil on the cylinder head side is pushed out by the cylinder piston into port CH2.STRUCTURE. a part of the oil which has been flowing from port CH2 to port VH merges with the oil from the control valve and flows into the cylinder bottom side.

FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP COOLING FAN PUMP LPV30 P1: Pump discharge pressure PS: Pump suction TO: Drain T1: Drain plug PEPC: EPC valve main pressure PCEPC: EPC valve output pressure detection plug D65EX.STRUCTURE. PX-15 10-131 .

10. PX-15 . 8. 5. 6. 3. 7. Shaft Oil seal Case Rocker cam Shoe Piston Cylinder block Valve plate Spring Servo piston 10-132 D65EX. 4. FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP 1.STRUCTURE. 2. 9.

PX-15 10-133 . • The end of piston (6) has a spherical hollow which is combined with shoe (5). • • • • • Structure • Cylinder block (7) is supported on shaft (1) through spline a. FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP Function • The rotation and torque of the engine are transmitted to the shaft of this pump and converted into hydraulic energy in this pump.STRUCTURE. Shoe (5) is kept pressed against plane A and slid circularly. The oil in each cylinder of cylinder block (7) can be sucked and discharged through valve plate (8). sealing the pressurized oil. Piston (6) and shoe (5) form a spherical bearing. Rocker cam (4) slides around ball (11). This pump discharges the pressurized oil according to the load. Cylinder block (7) rotates relatively against valve plate (8). D65EX. Shaft (1) is supported by the front and rear bearings. Piston (6) in each cylinder of cylinder block (7) moves relatively in the axial direction. The discharge of this pump can be changed by changing the swash plate angle in it. and the hydraulic balance is maintained properly. Rocker cam (4) has plane A.

chamber F is at the end of the suction stroke and chamber E is at the end of the discharge stroke. (The swash plate angle is not set to 0 actually. Accordingly. On the other hand. swash plate angle is in proportion to the pump discharge. the volume of chamber F is increased and the oil is sucked in chamber F. angle between center line X of rocker cam (4) and the axis of cylinder block (7) changes.) In short. plane A works as a cam for shoe (5). if cylinder block (7) rotates and the volume of chamber E is decreased. FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP Operation 1. (In the figure. there is not a difference between volumes E and F in cylinder block (7) and oil is not sucked or discharged. In other words.) • If center line X of rocker cam (4) is equal to the axial of cylinder block (7) (the swash plate angle is 0). As a result. rocker cam (4) tilts around ball (11). • • • • 10-134 D65EX. Angle is called the swash plate angle. PX-15 . piston (6) slides inside cylinder block (7) and a difference is made between volumes E and F in cylinder block (7). however. Operation of pump • Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane A.STRUCTURE. each piston (6) sucks and discharges oil by F – E. At this time. If angle is made between center line X of rocker cam (7) and the axis of cylinder block (7). the oil is discharged from chamber E. As a result.

STRUCTURE. the difference between volumes E and F is increased. FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP 2. or discharge Q is increased. rocker cam (4) supported on ball (11) slides around ball (11). This straight motion is transmitted to rocker cam (4). Swash plate angle is changed with servo piston (10). Servo piston (10) reciprocates straight according to the signal pressure of the servo valve. Control of discharge • If swash plate angle is increased. PX-15 10-135 . Then. • D65EX.

STRUCTURE. 7. 3. FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP SERBO VALVE P: T: PE: PH: 1. EPC valve main pressure Drain Control piston pressure Pump discharge pressure Plug Lever Retainer Seat Spool Piston Sleeve 10-136 D65EX. 2. 5. PX-15 . 6. 4.

PX-15 10-137 . FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP A: Drain side B: Pump discharge pressure input side C: EPC output pressure received D: EPC output pressure D65EX.STRUCTURE.

The position feedback is applied and the lever moves to compress the spring. These processes are repeated until the swash plate is fixed to a position where the EPC output is balanced with the spring force. FUNCTION AND MAINTENANCE STANDARD COOLING FAN PUMP Function • The servo valve controls the current input to the EPC valve and the swash plate angle of the pump so that they will be related as shown in the figure. Accordingly. • • • • • The relationship between the input current to the EPC valve and the output pressure of the EPC valve is as follows. the pump discharge circuit and the servo piston circuit are shut off. Then. as the EPC output pressure is heightened. PX-15 . Operation • The output pressure of the EPC valve is applied to the piston chamber to push the piston. Piston (6) pushes spool (5) until it is balanced with the spring. • 10-138 D65EX. the swash plate angle is decreased. The pressure in the servo piston chamber lowers and the rocker cam returns toward the maximum swash plate angle. the land of the servo piston pressure passage is connected to the pump discharge passages by the cut of spool (5) and the discharge pressure is led to the servo piston. If spool (5) is pushed back. The servo piston is raised by the rocker cam. the swash plate angle is increased.STRUCTURE. As the EPC output pressure is lowered.

STRUCTURE. FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR COOLING FAN MOTOR LMF28 P: From fan pump T: From oil cooler to hydraulic tank TC: To hydraulic tank Specifications Model: LMF28 Capacity: 28 cc/rev Rated speed: 1. PX-15 10-139 .8 l/min Cracking pressure of check valve: 44.1 kPa {0.45 kg/cm2} D65EX.850 rpm Rated flow rate: 51.

26 kg} Remedy 9 Check valve spring Free length x Outside diameter Installed length 7. 3.55 N {0.0 If damaged or deformed. 6. 10. replace spring 13. 9.0 x 6. FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR 1. 13. Output shaft Case Thrust plate Piston assembly Cylinder block Valve plate End cover 8. 11. Check item Standard size Criteria Repair limit Installed load 3.43 N {0. 14. PX-15 .STRUCTURE. 7. 4. Center spring Check valve spring Check valve Pilot valve Reversible valve spool Reversible valve spring Safety valve Unit: mm No.5 10-140 D65EX. 12. 5.35 kg} Free length — Installed load 2. 2.

This oil can flow on only 1 side of the Y – Y line connecting the top dead center and bottom dead center of the stroke of piston (4). FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR 1. Since thrust plate (2) is fixed to the angle of degrees to the output shaft (1). • • • • • D65EX. the force is divided into components F2 and F3. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. This force is applied to thrust plate (2). Principle of operation • The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5). The resultant of this torque [T = (F3 x ri)] rotates the cylinder block (5) through the piston. The radial component F3 generates torque against the Y – Y line connecting the top dead center and bottom dead center (T = F3 x ri). PX-15 10-141 (7) . Since the cylinder block (5) is coupled with the output shaft by means of spline. Hydraulic motor unit Function • This hydraulic motor is called a swash plate-type axial piston motor. The oil sent to 1 side of cylinder block (5) presses pistons (4) (2 or 3 pieces) and generates force F1 (F1 kg = P kg/cm2 x /4D2 cm2). the output shaft revolves to transmit the torque.STRUCTURE.

PX-15 . the suction valve sucks in the oil on the outlet side and supplies it to the port MA where there is not sufficient oil to prevent cavitation. the hydraulic oil does not flow into the motor. • Operation (1) When pump is started • If the hydraulic oil from the pump is supplied to port P and the pressure on the MA side rises and starting torque is generated in the motor. (2) When pump is stopped • If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm. As the hydraulic oil is not supplied to the MA side of the motor. Since the motor continues revolution because of the force of inertia. the oil in port T on the outlet side is sent by the suction valve (1) to the MA side to prevent cavitation. The oil on the outlet MB side of the motor returns through port T to the tank.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR 2. the hydraulic oil from the pump is not supplied to port P any more. Suction valve Function • If the fan pump stops. the pressure on the outlet side of the motor rises. When the oil stops flowing in from inlet port P. 10-142 D65EX. however. • If the motor shaft is revolved by the force of inertia while the oil flow in the port P is reducing. the motor speed lowers gradually to stop. the motor starts revolution.

• Accordingly. OPERATION OF REVERSIBLE VALVE (1) When ON-OFF solenoid for reversible valve is turned OFF • If ON-OFF solenoid (1) for reversible valve is turned “OFF”. the hydraulic oil from the pump is blocked by ON-OFF reversible valve (2) and port C is connected to the tank circuit. • The hydraulic oil in chamber D pushes reversible valve spool (3) against reversible valve spool spring (4).STRUCTURE. D65EX. As a result. motor port MB opens and the hydraulic oil flows in to revolve the motor in reverse (counterclockwise). ON-OFF reversible valve (2) changes to let the hydraulic oil from the pump flow through port C into spool chamber D. FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR 3. reversible valve spool (3) is pushed by reversible valve spool spring (4) to the right to open motor port MA and then the hydraulic oil flows in to revolve the motor forward (clockwise). (2) When ON-OFF solenoid for reversible valve is turned ON • If ON-OFF solenoid (1) for reversible valve is turned “ON”. PX-15 10-143 .

PX-15 . 10-144 D65EX. the pressure in port P of the fan motor is heightened in some cases.STRUCTURE. By this operation. Operation • If the pressure in port P rises above the cracking pressure of safety valve (1). Safety valve Function • • When the engine is started. Safety valve (1) is installed to protect the fan system circuit. generation of abnormal pressure in port P is prevented. valve (2) of safety valve (1) opens to release the hydraulic oil into port T. FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR 4.

STRUCTURE. PX-15 10-145 . FUNCTION AND MAINTENANCE STANDARD PPC VALVE PPC VALVE FOR BLADE LIFT. BLADE TILT a PPC: Abbreviation for Proportional Pressure Control P: From self pressure reducing valve T: To hydraulic tank P1: P2: P3: P4: To blade lift valve port PA3 To blade lift valve port PB3 To blade tilt valve port PA2 To blade tilt valve port PB2 D65EX.

Disc 2. PX-15 . FUNCTION AND MAINTENANCE STANDARD PPC VALVE 1. Body 10-146 D65EX. Plate 3.STRUCTURE.

FUNCTION AND MAINTENANCE STANDARD PPC VALVE OPERATION 1. At Neutral 1) For blade lift • Ports PA3 and PB3 of the blade lift control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f spool (1). PX-15 10-147 .STRUCTURE. D65EX. 2) For blade tilt • Ports PA2 and PB2 of the blade tilt control valve and ports P3 and P4 of the PPC valve are connected to drain chamber D through fine control hole f of spool (1).

at almost the same time. fine control hole f is connected to drain chamber D. During fine control (Neutral o fine control) • When piston (4) is pushed by disc (5). spool (1) moves up and down so that the force of metering spring (2) is balanced with the pressure at port P1. During fine control (when control lever is returned) • When disc (5) starts to be returned. It passes through port P2. the oil at drain chamber D flows in from fine control hole f’ in the valve on the side that is not moving.STRUCTURE. at almost the same time. and the oil fills the chamber. so the pressure at port P1 also rises in proportion to the movement of the control lever. When the control valve spool returns. and moves down. • • • • • • • • 10-148 D65EX. it is connected to pump pressure chamber PP. so the pressure oil at port P1 is relieved. if spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. and the pilot pressure oil passes through fine control hole f and flows from port P1 to port PA3. 3. spool (1) is pushed down by metering spring (2). retainer (9) is pushed. and spool (1) is also pushed through metering spring (2). it is connected with pump pressure chamber PP. Fine control hole f is shut off from drain chamber D. As a result. FUNCTION AND MAINTENANCE STANDARD PPC VALVE 2. if fine control hole f is shut off from drain chamber D. The control valve spool moves to a position where the pressure in chamber PA3 (same as pressure at port P1) is balanced with the force of the return spring. As a result. If the pressure at port P1 goes down to far. Pump pressure is supplied until the pressure at port P1 recovers to a pressure equivalent to the position of the lever. When the pressure at port P1 becomes high. is taken to chamber PB3. As a result. The relation between the positions of spool (1) and body (10) (fine control hole f is at the midpoint between drain chamber D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). it is connected with drain chamber D and released the pressure at port P1. metering spring (2) is compressed an amount proportional to the movement of the control lever. and at almost the same time. Therefore. spool (1) is pushed up by the pressure at port P1 and the force of centering spring (3). PX-15 .

Passage d is connected to port P1. The return oil from chamber PB3 passes from port P2 through fine control hole f’. FUNCTION AND MAINTENANCE STANDARD PPC VALVE 4. and piston (4’) follows disc (5). the oil inside chamber F passes through b and c. ball (11) contacts protrusion a of the piston during the stroke. is taken from port P1 to chamber PA3. the control valve also moves to the FLOAT position and the circuit is set to the FLOAT condition. Therefore. PX-15 10-149 . passage d and chamber E. Chamber E is normally connected to drain chamber D. the pilot pressure oil passes through fine control hole f. When this happens. 5. are connected and the pressure oil flows. which were shut off. • • • • • • • • D65EX. and then flows to drain chamber D. As a result. When lever is operated fully • When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1). it escapes to the outside and passes over protrusion a of the piston. but if ball (11) passes over protrusion a of the piston. At the same time.STRUCTURE. it is held at the FLOAT position.) When piston (4) pushed in further. so more or less the same pressure is applied as is applied to port P1. so even if the lever is released. and pushes the control valve spool. fine control hole f is shut off from drain chamber D and is connected to pump pressure chamber PP. (Detent starts to act. When blade is operated to FLOAT • When piston (4) at the port P1 LOWER side is pushed by disc (5) and moves down. and flows to chamber E. which is being held by detent spring (13). piston (4’) on the opposite side is pushed up by spring (14). While pushing up collar (12). Piston (4’) is being pushed up by the oil pressure inside chamber E. ball (11) pushes up collar (12).

chamber E is shut off from passage d and is connected to the drain chamber. the oil pressure inside chamber E is lost. FUNCTION AND MAINTENANCE STANDARD PPC VALVE 6. and the FLOATposition is canceled. • 10-150 D65EX. it is pushed down by a force greater than the hydraulic force in chamber E.STRUCTURE. Therefore. PX-15 . As a result. When blade is released from FLOAT • When disc (5) is returned from the FLOAT position.

STRUCTURE. 5. 2. 8. 6. 3. PX-15 10-151 . FUNCTION AND MAINTENANCE STANDARD PPC VALVE FOR RIPPER T: P: P1: P2: To hydraulic tank From self pressure reducing valve To ripper spool (To control valve port PB4) To ripper spool (To control valve port PA4) 1. 7. 4. Spool Metering spring Centering spring Piston Lever Plate Retainer Body D65EX.

STRUCTURE.9 x 15. PX-15 . FUNCTION AND MAINTENANCE STANDARD PPC VALVE Unit: mm No.3 10 Metering spring 22.7 N {1.2 kg} 13.36 kg} Remedy Installed length 28. replace spring 10-152 D65EX.3 N {1.70 kg} Free length — — Installed load 100 N {10.0 33.4 22.7 kg} 16. Check item Standard size 9 Centering spring Free length x Outside diameter Criteria Repair limit Installed load 125 N {12.7 x 8.10 If damaged or deformed.

the retainer (7) is pushed too. At neutral • P1 and P2 ports of the operation valves A. the P1 port pressure too. PX-15 10-153 . the spool (1) is pushed back. connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. 2. By this move. By this move. the operation valve spool moves to the position where the pressure of A room (the same as P1 port pressure) is balanced against force of the operation valve spool return spring. thereby relieving P1 port pressure. • • • • • • D65EX. At the same time. connection of the fine control hole f is switched from the pump pressure room PP to the drain room D.STRUCTURE. As P1 port pressure increases. Thus. compressed in proportion to strokes of the operation lever. increases in proportion to strokes of the operation lever. As the result. therefore. The metering spring (2) is. As the result. and pilot pressure oil is conducted from P1 port to A port. the spool (1) is also pushed down via the metering spring (2). the spool (1) moves up and down so that force of the metering spring (2) and P1 port pressure may be balanced. Positional relationship between the spool (1) and body (8) (fine control hole f is situated at mid point between the drain room D and pump pressure room PP) remains unchanged until the retainer (7) is contacted against the spool (1). B and PPC valve are connected to drain room D via the fine control hole f on the spool (1). FUNCTION AND MAINTENANCE STANDARD PPC VALVE Operation 1. During fine control (Neutral o fine control) • As the piston (4) is pushed by disk (5).

• • • • 10-154 D65EX. And. This supply continues until the P1 port pressure is recovered to the level equivalent to the lever position. PX-15 . connection of the fine control hole f is switched from the drain room D. When the operation valve spool returns. and passage between fine control hole f and drain room D is shut down. to the pump pressure room PP. 4. the spool (1) is pushed down by the metering spring (2). Oil is then conducted via P2 port to the room B to fill it up. By this move. oil in the drain room D flows in through the fine control hole f’ on the not moving side valve. FUNCTION AND MAINTENANCE STANDARD PPC VALVE 3. During fine control (when control lever is returned) • As the lever (5) starts returning. Return oil from B room is conducted from P2 port to the drain room D via the fine control hole f’. the spool (1) is pushed up by force of the centering spring (3) and P1 port pressure. At full stroke • When the disk (5) pushes down piston (4) and the retainer (7) pushes down the spool (1). Thus. pilot pressurized oil from the control pump passes through fine control hole f and conducted to A room via P1 port to push the operation valve spool. almost at the same time. the fine control hole f is connected to the drain room D and relieves pressurized oil of P1 port to it. the hole is connected to the pump pressure room PP and starts supplying pump the pressure.STRUCTURE. If P1 port pressure goes excessively low.

PX-15 10-155 .STRUCTURE. Connector D65EX. 2. FUNCTION AND MAINTENANCE STANDARD PCCS LEVER PCCS LEVER FOR STEERING 1. 4. Lever 7. 3. Boot Bracket Plate Bolt 5. Screw 6.

FUNCTION AND MAINTENANCE STANDARD PCCS LEVER FUNCTION 1. and Reverse (Operating effort characteristics chart A).STRUCTURE. PX-15 . Operating effort characteristics (1) Operation for forward and reverse travel • The control lever is held at 3 positions of Forward. Neutral. (2) Operation for steering • Free return (Operating effort characteristics chart B). 10-156 D65EX.

FUNCTION AND MAINTENANCE STANDARD PCCS LEVER 2.STRUCTURE. PX-15 10-157 . Output voltage characteristics • The control unit is installed to the left control stand and the control lever is installed directly onto it. Each potentiometer outputs 2 signal voltages which are opposite to each other as shown in the figure at right. steering controller. The operating angle (stroke) of the control lever is sensed with potentiometers and signal voltages are output to the transmission. A potentiometer is installed in each of longitudinal direction and lateral direction. • • D65EX.

EPC valve 10-158 D65EX.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE CONTROL VALVE Outline • This manual explains the 3-spool valve (Blade lift + Tilt + Steering) and 4-spool valve (Ripper + Blade lift + Tilt + Steering). 1. 3-spool valve P: T: A1: A2: A3: B1: B2: B3: LS: PC: PI: TS: PA1: PA2: PA3: PB1: PB2: PB3: PLSC: From pump To hydraulic tank To HSS motor To tilt cylinder bottom To lift cylinder head To HSS motor To tilt cylinder head To lift cylinder bottom To pump LS valve Pump pressure plug From self-pressure reducing valve To hydraulic tank Connector (From controller) From PPC valve From PPC valve Connector (From controller) From PPC valve From PPC valve LS pressure plug 1. PX-15 .

STRUCTURE. PX-15 10-159 . FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE D65EX.

10. 11. 14. 6. 4. Pressure compensation valve Main relief valve LS relief valve (for steering valve) Unload valve LS relief valve (for work equipment valve) LS check valve (for work equipment valve) LS check valve (for steering valve) 10-160 D65EX. 12. Cover Lift spool Tilt spool Steering spool Valve body Steering priority valve Load check valve 8. 7. 9. 3. 5.STRUCTURE. 2. 13. PX-15 . FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 1.

81 N {1. replace spring 22 Unload valve spring D65EX.5 50 33.8 x 30 18 Road check valve spring 19 20 21 Pressure compensation valve spring (steering valve) Pressure compensation valve spring (tilt valve) Pressure compensation valve spring (lift valve) If damaged or deformed.4 x 31 16 17 Spool return spring (tilt.1 kg} 12.6 kg} 9. PX-15 10-161 .7 x 36.5 61. Check item Basic dimension 15 Spool return spring (for lift) Free length x Outside diameter Criteria Allowable limit Installed load 224 N {22.6 kg} 188 N {19.2 kg} Remedy Installed length 68.STRUCTURE.6 kg} 173 N {17.7 x 31.5 70 x 26.3 54.3 kg} 216 N {22 kg} 216 N {22 kg} 216 N {22 kg} 235 N {24 kg} Free length — — — — — — — — Installed load 178 N {18.8 x 10. steering) Spool return spring (for lift FLOAT) 51.4 kg} 173 N {17.5 20.8 69.6 kg} 173 N {17.2 70 x 26.2 kg} 112 N {11.7 N {1.3 kg} 217 N {22.5 73.5 70 x 26.5 13.5 94.8 61.8 kg} 140 N {14.8 61. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Unit: mm No.0 kg} 173 N {17.

Preset check valve 3.4 N {0.1 N {0. Suction valve 2.9 x 12.STRUCTURE.5 10-162 D65EX. PX-15 . Check item Standard size 4 Suction valve spring Free length x Outside diameter Criteria Repair limit Installed load 6. replace spring 64.52 kg} Remedy Installed length 56 If damaged or deformed. LS bypass valve Unit: mm No. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 1.65 kg} Free length — Installed load 5.

PX-15 10-163 . EPC valve D65EX. 4-spool valve P: T: A1: A2: A3: A4: B1: B2: B3: B4: LS: PC: PI: TS: PA1: PA2: PA3: PA4: PB1: PB2: PB3: PB4: PLSC: From pump To hydraulic tank To HSS motor To tilt cylinder bottom To lift cylinder head To ripper cylinder bottom To HSS motor To tilt cylinder head To lift cylinder bottom To ripper cylinder head To pump LS valve Pump pressure plug From self-pressure reducing valve To hydraulic tank Connector (From controller) From PPC valve From PPC valve From PPC valve Connector (From controller) From PPC valve From PPC valve From PPC valve LS pressure plug 1.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 2.

STRUCTURE. PX-15 . FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 10-164 D65EX.

5. 6. 3. Pressure compensation valve Main relief valve LS relief valve (for steering valve) Unload valve LS relief valve (for work equipment valve) LS check valve (for work equipment valve) LS check valve (for steering valve) D65EX. 7. 13. 14. 2. Valve block Ripper spool Lift spool Tilt spool Steering spool Valve body Steering priority valve Load check valve 9. 4. 8.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 1. PX-15 10-165 . 12. 11. 15. 10.

5 61.8 kg} 140 N {14.1 kg} 12.4 x 31 17 18 Spool return spring 51.3 kg} 216 N {22 kg} 216 N {22 kg} 216 N {22 kg} 216 N {22 kg} 235 N {24 kg} Free length — — — — — — — — — Installed load 178 N {18. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Unit: mm No.5 20.5 70 x 26.8 x 30 19 Load check valve spring 20 21 22 23 Pressure compensation valve spring (Steering valve) Pressure compensation valve spring (Tilt valve) Pressure compensation valve spring (Lift valve) Pressure compensation valve spring (Ripper valve) If damaged or deformed. Check item Standard size 16 Spool return spring (For lift) Free length x Outside diameter Criteria Repair limit Installed load 224 N {22.6 kg} 173 N {17.5 70 x 26.2 70 x 26.8 x 10.81 N {1.5 94.5 73.3 (For tilt and steering) Spool return spring (For lift “FLOAT”) 54.2 kg} 112 N {11.4 kg} 173 N {17.5 70 x 26.3 kg} 217 N {22. replace spring 24 Unload spring 10-166 D65EX.7 N {1.6 kg} 9.6 kg} 173 N {17.0 kg} 173 N {17.8 69.8 61.6 kg} 188 N {19.5 13.8 61.5 50 33. PX-15 .2 kg} Remedy Installed length 68.STRUCTURE.8 61.7 x 36.7 x 31.6 kg} 173 N {17.

Preset check valve 3.9 x 12. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 1. Suction valve 2.STRUCTURE.4 N {0.65 kg} Free length — Installed load 5. Check item Standard size Criteria Repair limit Installed load 6. Safety-suction valve Unit: mm No.52 kg} Remedy 5 Suction valve spring Free length x Outside diameter Installed length 56 If damaged or deformed.1 N {0.5 D65EX. PX-15 10-167 . replace spring 64. LS bypass valve 4.

so the pressure in the circuit is almost the same as the set load of spring (2). Actually. PX-15 . When oil is supplied from the pump. Chambers C and C’ are connected to the drain circuit. spool (1) is balanced at a position that matches the supply of oil from the pump. • • Operation • When the main spool is at the HOLD position. the pump pressure passes from chamber A through throttle (4) to chamber D. it drains the excess oil discharged by the pump. • 10-168 D65EX. and prevents the pressure from being formed in the circuit from rising.STRUCTURE. the amount of oil supplied from the pump is small. When FO becomes larger than set load FS of spring (2). the pressure in chamber D rises. AT HOLD (OPERATION OF UNLOAD VALVE) Function • When the main spool is at the HOLD position. the spool moves to the right and connects the passage between chamber A and chamber B. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE OPERATION OF MAIN CONTROL VALVE 1. so the oil from the pump is drained. Therefore. and spool (1) is pushed to the right by pressure which is determined by the cross-sectional area of piston (3) receiving the pressure.

the pump pressure is sent from chamber A through the notch in spool (3) of the steering priority valve. Chamber G is drained through chamber H to chamber F.STRUCTURE. • • D65EX. the area of the opening to spool (1) of the steering valve is at its minimum. CONTROL OF OIL FLOW (1) Steering valve Function • Use of the CLSS circuit (Closed Center Load Sensing System) makes it possible to control the oil flow by adjusting the area of opening of the spool driven by the EPC valve regardless of the load. and passes through chamber B to chamber C. • When this happens. the pump pressure is acting on the left end of spool (3) of the steering priority valve. PX-15 10-169 . so it pushes against the load of spring (4) and moves to the right to the maximum stroke position. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 2. In this condition. 1) At HOLD Operation • When the spool is at the HOLD position.

FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 2) When turning to left • • • PLS = Differential pressure between ports K and J = 2. PX-15 .0 MPa (20 kg/cm2) PLS’ = Differential pressure between ports I and D PLS C PLS’ 10-170 D65EX.STRUCTURE.

the load pressure in chamber D passes through LS ofifice (5) and chamber H. It is also sent from the LS circuit O to pump servo valve (7). so a suitable amount of oil flows to ensure that the loss of pressure at the control valve ( PLS’) is equal to PLS. and chamber G pressure C chamber D pressure. The condition of the pressure of spool (3) is chamber B pressure C chamber C pressure. In other words. so spool (3) moves in the direction to throttle the oil flow. In addition. C and D to HSS motor (6). When the pressure becomes greater than the set load of spring (2). if the oil flow is too large. • • • • • • • • • D65EX. and is sent to chamber G. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Operation • When the steering lever is operated to turn the machine to the left. spool (3) moves in the direction to increase the oil flow. pilot pressure PI acts on the right end of spool (1) through the PPC valve. and balances with spring (4). the differential pressure of spool (1) becomes larger. and is drained. It becomes balanced at a position that matches PPC output pressure PI. On the other hand.STRUCTURE. and the oil from the pump flows through ports A. Chamber C and chamber D are connected. so spool (3) is controlled by the differential pressure of spool (1) (chamber C pressure – chamber D pressure). The return oil flow from the HSS motor (6) passes through chamber E and chamber F. so the oil flow matches the opening of the spool. B. pump servo valve (7) is controlled so that the differential pressure between pump pressure P and LS pressure LS (LS differential pressure: PLS) remains constant. the spool to move to the left. At the same time. The loss of pressure in the control valve is determined by the area of the opening of the main spool. PX-15 10-171 . if the oil flow is too small.

PX-15 . 10-172 D65EX. lift valve.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE (2) Work equipment valve (tilt valve. ripper valve) a The diagram shows the blade lift valve.

The pump pressure passes through chambers A and B of steering priority valve (4). PX-15 10-173 . • • • D65EX. In the same way as for Item (1) Steering valve. the pump pressure (unload pressure) is sent to chambers D and D’. and the oil flow is determined so that the pressure loss of the control valve becomes equal to the differential pressure LS of LS valve (7). FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Operation • When spool (1) of the hydraulic valve is at the HOLD position. and is sent to chamber C of the main control valve.STRUCTURE. The pressure is not formed in chambers H and H’. the position of pressure compensation valve spool (3) is determined to match the opening of spool (1) of the work equipment valve. so pressure compensation valve spool (3) and steering compensation valve spool (4) are pushed completely to the right. From here it goes through chamber D and chamber E to chamber F.

PX-15 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE (3) Meter-out control when blade moves down under its own weight 10-174 D65EX.

and is supplied to the cylinder bottom. • • • D65EX. PX-15 10-175 . the oil flow of return oil from cylinder is controlled by the area of the opening of main spool (1).STRUCTURE. C and D. the flow of return oil from the lift cylinder is throttled by the area of opening between ports A and B. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Function • If the blade moves down under its own weight. The oil discharged from the pump passes through ports A’. B. When this happens. The oil flowing from the cylinder head end passes from the drain circuit through suction valve (2) and is supplied to the bottom end of the cylinder. the oil at the cylinder head passes through ports A. C’. D’ and E’. because of the weight of the blade. Operation • When the spool port is opened by pilot pressure PI. and is drained to the tank. B’. so the downward speed is controlled.

FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE (4) Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT) 10-176 D65EX. PX-15 .STRUCTURE.

• Operation • When the work equipmentc control lever is at the FLOAT position. and pump pressure P is formed. lift spool (1) is moved to the maximum stroke position. PX-15 10-177 . the cylinder port and drain port are connected to put the circuit in a no-load condition. The pump circuit chamber E and ports A3 and B3 are separated. If the cylinder is driven by the weight of the blade. the oil entering from port A3 flows to ports A.4 MPa (35 kg/cm2) or more. and the cylinder speed is controlled. B. and is drained. When the lift valve is in the FLOAT condition. the pump passage and cylinder ports A3 and B3 are separated so that the other control valves can be operated. When this happens. so it is possible to carry out compound operations with other control valves. B’ and A’. the oil flows is throttled by the area of opening between ports A and B of spool (1).STRUCTURE. ports A3 and B3 and the LS passage O are all connected to the drain circuit. • • • • D65EX. so there is no load on the lift cylinder. if pressure PA3 becomes 3. while the rest of the oil flows through ports C and D. In this condition. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Function • When the lift valve is at FLOAT.

PX-15 .STRUCTURE. 10-178 D65EX. AT RELIEF (1) Steering valve a The diagram shows the condition at relief for steering LS relief valve (5). FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 3.

(Ports E. Operation • If the pressure of HSS motor (7) becomes higher. If this differential pressure goes above the set pressure for unload valve (4). G. the system circuit is balanced at a circuit pressure which makes the pressure loss generated by the flow at steering LS relief valve (5). if the pressure in chambers H and I drops. P1 + P2 equal to LS differential pressure ( LS). if the minimum oil flow is greater than the LS relief oil flow + leakage at any part. and P2 will become larger. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE • • • • • P1 = P3 + P4 = Differential pressure between ports M and E P2 = Differential pressure between ports E and N P3 = Differential pressure between ports M and B P4 = Differential pressure between ports B and E LS = P1 + P2 = Differential pressure between ports M and N = 2. the unload valve is actuated to releive the excess oil flow and balance the circuit.0 MPa (20 kg/cm2) Function • If specifies the maximum pressure when the HSS is operated. so the flow to chambers B and C will be throttled and P4 will become larger. The pump swash plate is balanced at a position where the LS differential pressure is 2. and moves the pump swash plate from the maximum to the minimum position. Because of the pump swash plate control. there will be a drop in pressure in LS passage O starting from LS sensing hole F. so the LS differential pressure rises. PX-15 10-179 . F. the poppet of steering LS relief valve (5) will start to open and oil will be drained from LS circuit O.0 MPa (20 kg/cm2. and will make the opening between chambers B and C smaller. spool (2) will push against spring (3) and move to the right.STRUCTURE. K and L) As a result. the pressure is confined in the pump circuit (between the pump and chambers A and B). For the same reason. pump LS valve (6) detects the differential pressure generated by LS relief valve (5). When this happens. • • • • • • D65EX.) When the pump is at the minimum swash plate angle (minimum oil flow). J.

10-180 D65EX. PX-15 . tilt and ripper valve a The diagram shows the relief condition of work equipment LS relief valve (5) with the blade tilt at the end of its stroke. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE (2) Blade lift.STRUCTURE.

and P2 will become larger. the system circuit is balanced at a circuit pressure which makes the pressure loss generated by the flow at hydraulic LS relief valve (5) P1 + P2 equal to LS differential pressure ( LS). The pump swash plate is balanced at a position where the LS differential pressure is 2.0 MPa (20 kg/cm2. so the LS differential pressure rises.0 MPa (20 kg/cm2) Operation • If blade tilt valve (1) is moved. so the flow between chambers B and C will be throttled and P4 will become larger. if the minimum oil flow is greater than the LS relief oil flow + leakage at any part. K and L) As a result. G. there will be a drop in pressure in LS passage O starting from LS sensing hole F. if the pressure in chambers H and I drops. and will make the opening between chambers B and C smaller. • • • • • • D65EX. When this happens.STRUCTURE. the unload valve is actuated to releive the excess oil flow and balance the circuit. and moves the pump swash plate from the maximum to the minimum position. pump LS valve (6) detects the differential pressure generated by LS relief valve (5). (Ports E.) When the pump is at the minimum swash plate angle (minimum oil flow). For the same reason. the pressure is confined in the pump circuit (between the pump and chambers A and B). PX-15 10-181 . spool (2) will push against spring (3) and move to the right. poppet of work equipment LS relief valve (5) will start to open and oil will be drained from LS circuit O. J. F. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE • • • • • P1 = P3 + P4 = Differential pressure between ports M and P P2 = Differential pressure between ports P and N P3 = Differential pressure between ports M and B P4 = Differential pressure between ports B and P LS = P1 + P2 = Differential pressure between ports M and N = 2. If this differential pressure goes above the set pressure for unload valve (4). Because of the pump swash plate control. and the pressure of tilt cylinder (8) becomes higher.

10-182 D65EX. PX-15 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE (3) Steering + work equipment valve (compound operations) a The diagram shows the relief condition of LS relief valves (4) and (5) at steering stall with the blade tilt at the end of its stroke.

When this happens. J and K. the load pressure increases and LS relief valve (4) for the steering valve is actuated. I. D. and the port pressure is maintained at a constant value. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE • • • = P – P2 PO = Differential pressure between ports H and K Pressure P2 = LSO + PO Function • When steering valve (1) and work equipment valve (2) are relieved at the same time. F. see Item (1) Steering valve. and it moves the full stroke to the right.2 MPa (390 kg/cm2). pressure P2 (the pressure in chamber H) becomes the total (LSO + PO) of the circuit pressure loss of ports H. and drain oil flow Q1 flows to LS circuit O. and this is sent to chamber G of the work equipment valve.STRUCTURE. • • • • • • • D65EX. Operation • If HSS motor (6) reaches the stall condition. J and K. so the system is cut off. the pump pressure is separated by pressure compensation valve (3) in the work equipment valve. When this happens. and the set pressure of work equipment LS relief valve (5). Furthermore. E. When work equipment valve (2) is ooperated and the load on the work equipment valve is greater. G. PX-15 10-183 . I. For details. the opening between chambers D and E is throttled to the minimum size (pump pressure separated). a differential pressure is generated on the left and right sides of pressure compensation valve (4) by LS throttle M of spool (2). Oil flow Q1 is determined by pump pressure P and the total pressure loss (P – LSO) of ports C. work equipment LS relief valve (5) is actuated. the pump pressure is maintained at 38. As a result.

COMPOUND OPERATIONS (1) Steering valve + work equipment valve a The diagram shows the condition when the steering and blade lift valve are operated at the same time. PX-15 . FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 4. 10-184 D65EX.STRUCTURE.

the pump swash plate angle is controlled at PLS = 2. but in this condition. priority is given to the flow of oil to the steering valve. the smaller the flow of oil to the steering system becomes.STRUCTURE. • • • • • 1. When pump swash plate is at maximum angle • When the maximum flow of oil from the pump is smaller than the sum of the oil flow demanded by the steering valve and work equipment valve. so the pump swash plate angle moves in the maximum direction to supply an oil flow to make up the amount that the pressures drops. At this point. an amount of oil that matches the opening of steering spool (1) flows to the steering valve. Operation • When steering spool (1) is operated by pilot pressure P1 and the oil flows. When pump swash plate does not reach maximum angle • When the maximum oil flow from the pump is greater than the sum of the flow demanded by the steering valve and work equipment valve. The bigger P1 – P2 is. 2. the pump pressure momentarily drops. • An amount of oil that matches the opening of steering spool (1) flows to the steering valve.0 MPa (20 kg/cm2). Steering priority valve (3) is controlled by this differential pressure. PLS becomes smaller. and the flow of oil to the steering valve is fixed. • In this condition. D65EX. if downstream blade lift valve (2) is operated. the differential pressure between chambers C and D becomes smaller. a differential pressure is created between chambers C and D. At the same time. PX-15 10-185 . (1) When steering valve load Z work equipment valve load. • An amount of oil decided by the pump pressure and load pressure and area of opening of the spool flows to the work equipment valve. In this condition. so the pump pressure will drop. and steering priority valve (3) is moved to the left by the pressure in chamber E in the direction to throttle the opening to the hydraulic valve. • When this happens. (2) When steering valve load work equipment valve load. and at the same time. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Function • The steering valve is equipped with a steering priority valve (3). the flow of oil is divided in proportion to the difference in pressure between differential pressure P – P1 and differential pressure P – P2. See Item 2 – (1) Steering valve. and the remaining oil flows to work equipment valve. and the rest of the oil discharged from the pump goes to the work equipment valve. while at the same time reducing the size of the opening to the work equipment in order to ensure the flow of oil to the steering system. steering priority valve (3) increases the size of the opening to the steering system. if the downstream work equipment valve where the load is smaller is operated the difference in pressure will cause the oil to try to flow to the work equipment valve. • Pump pressure P is determined by the steering valve load. so if the steering valve and the downstream work equipment valve are operated at the same time.

STRUCTURE. PX-15 . 10-186 D65EX. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE (2) Compound operation of work equipment valve a The diagram shows the condition when the blade lift and tilt valves are operated at the same time.

an oil flow that matches the opening of the spool flows to both the tilt valve and lift valve. so the condition is just as if priority was given to the oil flow for the tilt valve. the flow of oil to the tilt valve and lift valve is divided according to differential pressurse PO – P2 and differential pressure PO – P3. PX-15 10-187 . more oil flows to P2 where the load is small. so the flow of oil to the tilt valve is given priority. so when compound operations are carried out. (1) When pump swash plate does not reach maximum angle • When the maximum flow of oil from the pump is greater than the total of the oil flow demanded by the tilt valve and lift valve. the tilt valve load pressure is smaller than the lift valve load pressure. the oil flow demanded by the tilt valve is smaller. (2) When pump swash plate is at maximum angle • When the maximum flow of oil from the pump is smaller than the total of the oil flow demanded by the tilt valve and lift valve. so an oil flow proportional to the size of the spool opening is distributed to each spool. Operation • When tilt spool (1) and lift spool (2) are at the HOLD position or are operated. 2. the oil flow is divided according to the size of each spool opening. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Function • It consists of a parallel circuit. Tilt spool (1) and lift spool (2) are actuated by PPC valve output pressure PA2 and PB3. When pressure P2 = pressure P3 • P – P2 C P – P3. and the size of the opening to the downstream area is at its maximum. • In other words.STRUCTURE. In addition. When pressure P2 Z P3 • Lift valve load pressure P3 is sent to pump LS valve (4) through LS passage O. D65EX. a In cases where the blade is raised in the air and the tilt valve and lift valve (for raise) are operated at the same time. steering priority valve (3) is pushed completely to the right. and each is balanced at a position that matches its own pilot pressure. • 1.

PX-15 .STRUCTURE. 10-188 D65EX. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 5. UNLOAD VALVE PRESET SYSTEM a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is operated.

At the same time. unload valve (7) closes. This pressure is called preset pressure P2. D and E to lift cylinder (8). check valve (3) prevents cylinder port pressure P3 from entering the pilot pressure circuit. Check valve (5) is installed in the spool so that preset pressure P2 will not be applied to the cylinder port. At this time. and oil is sent further to pump LS valve (6) to improve the response of the pump swash plate angle. and the pressure in the LS circuit rises. • • • • • • • D65EX. Because of this. Operation • When lift spool (1) is at the HOLD position. At the same time. so the pressure at the port starts to rise and the time lag becomes smaller. pilot pressure P1 (basic pressure of PPC valve) is sent through preset check valve (3) to the chamber F of the pressure compensation valve. When spool (1) is switched. so pressure compensation spool (2) moves to the left and the size of the opening between A and B becomes the maximum. B. the oil pushes up check valve (5) and flows through chamber F of the pressure compensation valve to pump LS valve (6). and compensating the rise of the LS circuit pressure. FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE Function • This improves the response of the systsem including the pump swash plate and pressure compensation valve by sending the pilot presssure (basic pressure of PPC valve) to the LS circuit. This makes it possible to reduce the response time for giving the necessary oil flow. but P1 + FO P (FO: load of spring (4)). If cylinder port pressure P3 rises higher than preset pressure P2. Unload pressure P flows immediately through chambers A.STRUCTURE. preset pressure P2 is supplied to LS circuit O by the timing of the spool. unload pressure P is being sent to chamber B. and then the normal PLS control starts. PX-15 10-189 . C.

FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE SELF PRESSURE REDUCING VALVE T: P1: P2: PR: To hydraulic tank From pump To fan motor Supply to PPC valve and EPC valve 10-190 D65EX.STRUCTURE. PX-15 .

9. 4.STRUCTURE. 3. FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE 1. PX-15 10-191 . 10. Spring (pressure reducing valve main) Valve (pressure reducing valve) Spring (safety valve) Ball Filter D65EX. 2. 8. Valve (sequence valve) Spring Screw Poppet Spring (pressure reducing valve pilot) 6. 5. 7.

2 x 7.1 x 7. PX-15 .80 kg} 28.8 N {6.STRUCTURE.80 16.4 N {3.0 13. 10-192 D65EX.1 59.0 16. etc.8 x 7.0 kg} 31. Check item Standard size 11 Spring (pressure reduction main) Free length x O.20 kg} 200 N {20. Installed length Installed load Criteria Repair limit Free length — — — — Installed load Remedy 19.4 19.7 N {6.20 12 Spring 17.4 N {2. as the control pressure.6 N {2.4 kg} 61.0 kg} 58. FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE Unit: mm No.90 kg} 186 N {19.0 x 18.7 N {1.D. the EPC valve.20 (pressure reduction valve pilot) 71.0 kg} Replace spring if any damages or deformations are found 13 Spring 14 Spring (safety valve) Function The self pressure reducing valves reduces the discharge pressure of the fan pump and supplies it to the PPC valve.1 12.30 kg} 17.

and the circuit between the ports P1 and PR is open. PX-15 10-193 .STRUCTURE. and the circuit between the ports PR and T is closed. The spring (7) pushes the valve (8) to the left side. D65EX. The spring (3) pushes the valve (2) to the left side. At engine stop (total low pressure) • • • The spring (6) pushes the poppet (5) the seat. FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE Operation 1. and the circuit between the ports P1 and P2 is closed.

When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve. there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port P1 and the PR opening. the poppet (5) will open and the hydraulic oil flows through the route from the PR port.STRUCTURE. the P1 pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure. When the PR pressure rises above the set pressure. 10-194 D65EX. the expression (P1 pressure C Spring (7) force + ( d area x PR pressure)) holds. • Therefore. When the hydraulic oil enters the P1 port. the poppet (5) opening to the tank port T. the hole a in the spool (8). FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE 2. Then. and the self pressure reducing valve will adjust the openings of the ports P1 and P2 so that the P1 pressure can be maintained higher than the PR pressure. PX-15 . • • The spring (3) and the PR pressure (0 MPa {0 kg/cm2} at the time of engine stop) pushes the valve (2) in the direction to close the circuit between the ports P1 and P2.

PX-15 10-195 . the poppet (5) opening to the tank port T. the P1 pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure. the poppet (5) will open and the hydraulic oil will flow through the route from the PR port. As a result. and the valve (2) will move to the right side till the stroke end. D65EX. Therefore. the expression (P1 pressure Spring (7) force + ( d area x PR pressure)) will hold. Then. the opening between the ports P1 and P2 will increase. • • When the PR pressure rises above the set pressure. FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE 3. Then. the pump delivery will increase and the P1 pressure will rise.STRUCTURE. At raise of load pressure P2 • When the load pressure P2 rises due to digging or other operations. the passage resistance will become smaller to reduce engine loss horsepower. the hole a in the spool (8). there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port P1 and the PR opening.

etc. the ball (10) will separate from the seat against the spring (9) force to flow the hydraulic oil to the output ports PR o T so as to reduce the PR pressure. the equipment (PPC valve.STRUCTURE. 10-196 D65EX. PX-15 . to which the oil pressure is supplied. solenoid valve. FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE 4. is protected from the abnormal high pressure. Then. At occurrence of abnormal high pressure • When the PR pressure of the self pressure reducing valve rises abnormally high.).

3. power pitch dozer (PTP) 1. PX-15 10-197 . SEMI-U) Pitch cylinder (PTP) D65EX. SEMI-U) Tilt cylinder (PTP) Right side: Tilt cylinder (PT. 5.STRUCTURE. 6. 7. FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT WORK EQUIPMENT Power tilt dozer (PT) Semi-U dozer (SEMI-U) Power tilt. Cutting edge Center brace End bit Straight frame Trunnion Blade Left side: Brace (PT. 4. 2.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm No. Check item Standard size S 140 2 3 4 5 6 7 8 9 10 Clearance between brace mounting pin and bracket Clearance between brace mounting pin and brace Spherical clearance between bracket and brace Spherical clearance between bearing and bushing Clearance between frame mounting pin and bracket Clearance between frame mounting pin and bearing Clearance between center brace mounting pin and bracket Clearance between center brace mounting pin and brace Spherical clearance between bracket and center brace 50 50
S 90 (Shaft) S 91 (Hole)

Criteria Tolerance Shaft –0.1 –0.5 –0.2 –0.4 –0.2 –0.4 –0.1 –0.3 –0.1 –0.5 0 –0.3 0 –0.3 –0.2 –0.4 –0.2 –0.4 –0.1 –0.3 Hole +1.5 0 +0.2 0 +0.2 0 +1.0 0 +0.5 0 +0.6 +0.2 +0.5 +0.2 +0.2 0 +0.2 0 +1.0 0 Standard clearance 0.3 – 0.7 0.2 – 0.6 0.2 – 0.6 0.3 – 0.7 0.1 – 1.0 0.2 – 0.9 0.2 – 0.8 0.2 – 0.6 0.2 – 0.6 0.3 – 0.7 Clearance limit 5.0 2.0

Remedy

Spherical clearance between 1 trunnion and cap

Adjust shim or replace

Replace 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 Adjust shim or replace Replace Adjust shim or replace

S 90 55 55 50 50
S 90 (Shaft) S 91 (Hole)

10-198

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Angledozer (A)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Center shaft Cutting edge C-frame End bit Trunnion Joint Blade Arm Brace

D65EX, PX-15

10-199

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm No. Check item Standard size S 140 2 3 4 5 6 7 8 9 10 11 12 Clearance between arm mounting pin and bracket (Large) Clearance between arm mounting pin and bracket (Small) Clearance between brace mounting pin and arm bracket Clearance between brace mounting pin and brace Clearance between brace mounting pin and joint Clearance between brace mounting pin and bearing Clearance between joint mounting pin and bracket Clearance between joint mounting pin and joint Clearance between center shaft and frame Clearance between center shaft mounting pin and bracket Clearance between center shaft mounting pin and center shaft 100 80 50 50 50 50 50 50
79.5 (Shaft) 80 (Hole)

Criteria Tolerance Shaft –0.1 –0.5 –0.6 –1.0 –0.6 –1.0 –0.3 –0.6 –0.3 –0.6 0 –0.3 0 –0.3 –0.1 –0.3 –0.1 –0.3 –0.2 –0.5 –0.1 –0.3 –0.1 –0.3 Hole +1.5 0 +1.5 +1.0 +1.5 +1.0 +0.7 0 +0.2 0 +0.2 0 +0.5 0 +0.3 0 +0.2 0 +0.5 –0.5 +0.3 0 +0.5 +0.1 Standard clearance 0.1 – 2.0 1.6 – 2.5 1.6 – 2.5 0.3 – 1.3 0.3 – 0.8 0 – 0.5 0 – 0.8 0.1 – 0.6 0.1 – 0.5 0.2 – 1.5 0.1 – 0.6 5.2 – 5.8 Clearance limit 8.0 3.5 3.5 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 7.0

Remedy

Spherical clearance between 1 trunnion and cap

Replace

55
55 (Shaft) 60 (Hole)

10-200

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CUTTING EDGE, END BIT

CUTTING EDGE, END BIT

Unit: mm No. Check item Standard size PT (EX) 1 PT (PX) Height of end bit (outside) PTP (PX) SEMI-U (EX,WX) A (EX) PT (EX) 2 Width of end bit PT (PX) PTP (PX) SEMI-U (EX,WX) A (EX) PT (EX) PT (PX) PTP (PX) Height of end bit 3 (inside) SEMI-U (EX,WX) A (EX) PT (EX) Height of cutting edge PT (PX) PTP (PX) 4 (From center of bolt SEMI-U hole to end face) (EX,WX) A (EX) PT (EX) Tightening torque of 5 end bit and cutting edge PT (PX) PTP (PX) SEMI-U (EX,WX) A (EX) 242 204 315 242 330 325 540 330 204 204 254 204 102 102 102 102 Criteria Repair limit 187 187 237 187 300 300 515 300 187 187 237 187 85 85 85 85 Replace Remedy

392.2 – 529.2 Nm {40 – 54 kgm} 392.2 – 529.2 Nm {40 – 54 kgm} Cutting edge: 392.2 – 529.2 Nm {40 – 54 kgm} End bit: 637 – 852.6 Nm {65 – 87 kgm} 392.2 – 490.3 Nm {40 – 50 kgm} Retighten

PT: For power tilt dozer, PTP: For power tilt, power pitch dozer, SEMI-U: semi-U dozer, A: For angledozer

D65EX, PX-15

10-201
(7)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

RIPPER

RIPPER
D65EX-15 D65WX-15 (If equipped)

Unit: mm No. Check item Standard size 56 Criteria Tolerance Shaft –0.030 –0.076 Standard size 2 Wear of point 222 Hole +0.299 +0.169 Standard clearance 0.199 – 0.375 Repair limit 152 Clearance limit 1.0 Replace Remedy

Clearance between pin and 1 bushing

3. 4. 5. 6. 7. 8. 9.

Bracket Upper link Ripper cylinder Beam Shank Point Lower link

A: Pin hole A (Point digging angle: 55 deg.) B: Pin hole B (Point digging angle: 45 deg.)

10-202
(7)

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CAB MOUNT

CAB MOUNT

1. Support 2. Damper mount (front) 3. Damper mount (rear)

Outline • Viscous damper mounts (2) and (3) are installed at two places at the front and two places at the rear to secure the floor frame and cab. An oil-filled damper mount is used to absorb the vibration.

D65EX, PX-15

10-203

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CAB

CAB

1. 2. 3. 4.

Front wiper Front glass Rear wiper Door

10-204

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CAB

ROPS GUARD
a ROPS: Abbreviation for ROllover Protective Structure

1. ROPS guard

D65EX, PX-15

10-205

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

AIR CONDITIONER PIPING

AIR CONDITIONER PIPING

1. 2. 3. 4. 5. 6. 7. 8.

Condenser Valve (hot water outlet) Hot water pick-up piping Refrigerant piping Receiver tank Hot water return piping Air conditioner compressor Valve (hot water inlet)

9. 10. 11. 12. 13.

Front window defroster Air conditioner unit Vent Blower motor Side window defroster

A. Fresh air B. Recirculated air C. Hot air/cold air

10-206

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL

ENGINE CONTROL

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Battery Starting switch Engine Starting motor Engine controller Transmission and steering controller Neutral safety relay Limit switch Parking brake lever Electric lever Steering/directional/gear shift lever (PCCS lever)

Function • A limit switch is installed to the linkage of the parking brake. The transmission and steering controller permits the engine to start only when the parking brake is in the LOCK position and the steering/directional/gear shift lever is in the N (Neutral) position.

Input and output signals a. b. c. d. e. Battery power source Engine start signal Starting switch ACC signal Parking brake signal Neutral signal

D65EX, PX-15

10-207
(7)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Battery Starting switch Neutral safety relay Fuel supply pump power relay Engine controller Transmission and steering controller Monitor panel Fuel control dial Decelerator pedal Engine Engine speed sensor Coolant temperature sensor Engine oil pressure sensor Injector Fuel supply pump valve

Input and output signals a. b. c. d. e. f. g. h. i. j. 1st throttle signal (Fuel control dial signal) 2nd throttle signal (Decelerator pedal signal) 3rd throttle signal (Controller control signal) Starting switch ACC signal Controller power source Engine speed signal Coolant temperature signal Engine oil pressure signal Sensor signal Monitor display signal

10-208

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

ENGINE CONTROL SYSTEM

Engine speed control mechanism • The engine controller receives the 1st throttle signal (fuel control dial signal) and 2nd throttle signal (decelerator pedal signal). It also receives the 3rd throttle signal (controller control signal) from the transmission and steering controller, and then selects the lowest command signal and controls the fuel supply pump and injector. The 3rd throttle signal has 1) Automatic deceleration (F3, R3). The transmission and steering controller calculates proper engine speed from the information of 1) and sends it as the 3rd throttle signal to the engine controller. 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. The automatic deceleration is a function of lowering the engine speed temporarily when the travel direction is changed from F3 or R3 (for protection of the transmission clutch).

Engine stop mechanism • If the starting switch is set in the OFF position, the starting switch ACC signal to the engine controller is turned OFF. At this time, any current does not flow in the coil of the fuel supply pump power relay. As a result, the relay is turned OFF to cut out the operating current of the engine controller to prevent a malfunction. The engine controller stops supplying fuel to the engine to stop the engine.

D65EX, PX-15

10-209
(7)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CRI ENGINE CONTROL SYSTEM

CRI ENGINE CONTROL SYSTEM
a CRI: Abbreviation for Common Rail Injection

SYSTEM DIAGRAM

1. Fuel tank 2. Fuel supply pump assembly 2a. PCV (Discharge control valve) 2b. High pressure pump 2c. Priming pump 2d. Feed pump 2e. Bypass valve 2f. G speed sensor 3. Fuel filter 4. Overflow valve 5. Common rail

6. Pressure limiter 7. Flow damper 8. Injector assembly 8a. Orifice 8b. Control chamber 8c. Hydraulic piston 8d. Injector 8e. Nozzle 9. Engine controller 10. NE speed sensor

10-210

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

CRI ENGINE CONTROL SYSTEM

Outline • • The signals detected by various sensors are input to the engine controller. The input signals are processed by the controller and output to each actuator to control the fuel injection rate and fuel injection timing.

System configuration • The CRI system consists of fuel supply pump assembly (2), common rail (5), injector assembly (8), engine controller (9) to control them, and sensors. The fuel supply pump assembly (2) generates fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply pump assembly (2). The discharge rate is controlled by turning on and off PCV (discharge control valve) (2a) of the fuel supply pump assembly (2) according to the electric signals from the engine controller. The common rail (5) receives the pressurized fuel from the fuel supply pump assembly (2) and distributes it to the cylinders. The fuel pressure is sensed by the common rail (5) fuel pressure sensor installed to the common rail and controlled by the feedback method so that the actual fuel pressure will match to the command pressure set according to the engine speed and the load on the engine. The fuel pressure in the common rail is applied to the nozzle (8e) side of the injector assembly (8) and control chamber (8b) through the fuel injection pipe of each cylinder. The injector assembly (8) controls the fuel injection rate and fuel injection timing by turning on and off the TWV (2-way solenoid valve). If the TWV is turned on, the fuel circuit is so changed that the high-pressure fuel in the control chamber (8b) will flow through orifice (8a). The needle valve is raised to start fuel injection by the nozzle (8e) cracking pressure applied as the high-pressure fuel on the nozzle side. If the TWV is turned OFF, high-pressure fuel is supplied through orifice (8a) to control chamber (8b). As a result, the needle valve of nozzle (8e) lowers to stop fuel injection. Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the timing to turn on the TWV and the length of the turn-on time of the TWV.

• •

• •

D65EX, PX-15

10-211

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

COOLING SYSTEM CONTROL SYSTEM

COOLING SYSTEM CONTROL SYSTEM

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Battery Battery relay Transmission and steering controller Engine controller Monitor panel Cooling fan motor Cooling fan pump Fan rotation selector switch Power train oil temperature sensor Hydraulic oil temperature sensor Engine Engine speed sensor Coolant temperature sensor

Input and output signals a. b. c. d. e. f. g. h. i. Controller power source Fan rotation selector signal Power train oil temperature signal Hydraulic oil temperature signal Engine speed signal Coolant temperature signal CAN signal Pump control signal Fan reverse signal

10-212
(7)

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

COOLING SYSTEM CONTROL SYSTEM

Outline • The transmission and steering controller monitors the coolant, power train oil, and hydraulic oil temperatures and controls the fan speed according to those temperatures.

Selection of fan rotation mode • While the starting switch is in the ON position and the engine is stopped, one of the following fan rotation modes can be selected with the fan rotation selector switch. 1) Forward rotation mode 2) Reverse rotation mode 3) Cleaning mode The transmission and steering controller operates the reverse solenoid valve of the cooling fan motor to change the rotation direction of the fan according to the selected mode. 1) Forward rotation mode In this mode, the reverse solenoid valve does not operate and the fan rotates forward. The fan speed varies with the temperature sensor signal. This mode is selected normally. 2) Reverse rotation mode In this mode, the reverse solenoid valve operates and the fan rotates in reverse. The fan can warm the operator’s cab as a substitute for a reversible fan. Since the cooling efficiency is low in this mode, the engine overheats easily. Accordingly, this mode shall be used only in cold weather. 3) Cleaning mode In this mode, the fan rotates in reverse at high speed to blow off dirt from the radiator fins, regardless of the temperature sensor signals. If this mode is used periodically, the cleaning interval of the radiator fins can be expanded. Interlock for changing rotation mode • If the rotation direction of the fan is changed while the fan is rotating, the fan drive circuit is broken. To prevent this, the fan rotation selector switch signal is ignored while the engine is running. In this case, the fan operation pilot lamp on the monitor panel flashes.

Function Fan speed control • The transmission and steering controller controls the discharge of the cooling fan to set the fan speed properly according to the information from the coolant, power train oil, and hydraulic oil temperature sensors. The transmission and steering controller selects the maximum target fan speed obtained from the coolant, power train oil, and hydraulic oil temperatures and outputs it as the pump control signal to the cooling fan pump. The cooling fan pump changes its swash plate angle to controls its oil discharge for the cooling fan motor.

D65EX, PX-15

10-213
(7)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PALM COMMAND CONTROL SYSTEM

PALM COMMAND CONTROL SYSTEM

1. 2. 3. 4. 5. 6. 7. 8.

Monitor panel Automatic shift-down switch Preset mode switch Steering/directional/gear shift lever (PCCS lever) Engine controller Transmission and steering controller Engine speed sensor Engine

9. 10. 11. 12. 13. 14.

Torque converter Transmission Transmission control valve Transmission output shaft speed sensor HSS unit Control valve 14a. Steering control valve 15. HSS motor

10-214

D65EX, PX-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

PALM COMMAND CONTROL SYSTEM

Preset mode function • The gear speed applied for forward travel and reverse travel can be set in advance. Preset mode 1: F1-R1 Preset mode 2: F1-R2 Preset mode 3: F2-R2 Preset mode 4: F2-R3

Automatic shift-down function • If the travel speed lowers because of the loading condition, the transmission gear is shifted down automatically. 1) The traction force (load on the chassis) is calculated from the engine speed, transmission output shaft speed, and the throttle information sent from the transmission and steering controller, and then the transmission gear is shifted down automatically according to the load and travel speed. 2) Once the transmission gear is shifted automatically, it is not shifted up again automatically. (It can be shifted up with the UP switch of the PCCS lever, however.) 3) This function is applicable to both forward and reverse travels.

1. How to use 1) Set the PCCS lever in the N (Neutral) position. 2) Set the preset mode switch (1) to the ON position. 3) Press the UP/DOWN switch of the PCCS lever to select a mode.

1. How to use 1) Set the automatic shift-down switch (2) to the ON position.

2. Display • The selected mode is displayed on display panel B of the monitor panel.

D65EX, PX-15

10-215

4. Knob Dial Spring Ball Potentiometer Connector Function • • The fuel control dial is installed to the left side of the operator’s seat. 6. • 10-216 (7) D65EX. If knob (1) is turned. 3. PX-15 . 2. The hatched areas in the following graph is the abnormality detection areas. the shaft of potentiometer (5) is turned to change the resistance of the variable resistor and send a throttle signal to the engine controller. the engine speed is reduced to a half. 5. In those areas. FUNCTION AND MAINTENANCE STANDARD SYSTEM COMPONENTS SYSTEM COMPONENTS Fuel control dial 1.STRUCTURE.

PX-15 10-217 . 6. Lever Shaft Coupling Body Potentiometer Stopper Connector Function • The decelerator pedal potentiometer is installed under the front part of the floor and connected to the decelerator pedal by the linkage. 5. 7. 4. FUNCTION AND MAINTENANCE STANDARD SYSTEM COMPONENTS Decelerator pedal potentiometer 1. • D65EX. If the decelerator pedal is operated. 2. 3. the shaft of potentiometer (5) is turned through the linkage to change the resistance of the variable resistor and send a deceleration signal to the engine controller.STRUCTURE.

STRUCTURE. PX-15 . FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROLLER ENGINE CONTROLLER 10-218 D65EX.

PX-15 10-219 . 13 14 15 16 17 18 19 20 21 22 23 24 Signal name Starting switch (ACC) NC Engine oil pressure (H) NC NC NC Starting switch (ACC) Starting switch (C) Engine oil pressure (L) NC NC NC Input/Output signal Input — Input — — — Input Input Input — — — DEUTSCH-40P (1) [CN-EN2] Pin No. supply pump) NC NC Injector 3 (+) Injector 2 (+) Transmission neutral signal 1 NC NC NC GND (Battery ground) Fuel supply pump 1 (+) Fuel supply pump 2 (+) Injector 1 (+) Injector 3 (–) Injector 2 (–) Transmission neutral signal 2 NC NC NC Input/Output signal — — — — Output Output Input — — — — Output Output Output Output Output Input — — — Pin No.STRUCTURE. supply pump) Power source (Injector. FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROLLER Input and output signals DEUTSCH-24P [CN-EN1] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name Power source (Injector. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name NC CAN0 (L) NC Flash ROM write permission signal G sensor (–) Ne sensor (–) Engine coolant temperature sensor (H) NC GND (Sensor) NC NC CAN0 (H) NC GND (RS232C) G sensor (+) Ne sensor (+) Engine coolant temperature sensor (L) Decelerator pedal signal GND (Sensor) Common rail pressure sensor Input/Output signal — Input/Output — Input Input Input Input — — — — Input/Output — — Input Input Input Input — Input DEUTSCH-40P (2) [CN-EN3] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name NC NC NC RS232C RX1 NC NC NC NC Sensor power source (+5 V) Fuel control dial NC CAN shield NC RS232C TX1 G shield Ne shield Fuel temperature sensor NC Sensor power source (+5 V) Boost pressure sensor Input/Output signal — — — Input — — — — Output Input — — — Output — — Input — Output Input Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name Service power source (+24 V) Service power source (+24 V) Model selection 1 NC NC NC GND (Battery ground) GND (Battery ground) NC NC NC Preheating Input/Output signal — — Input — — — — — — — — Output Pin No. supply pump) Fuel supply pump 1 (–) Fuel supply pump 2 (–) Injector 1 (–) Injector 6 (+) Injector 4 (+) NC NC NC NC GND (Battery ground) GND (Battery ground) Injector 5 (–) Injector 5 (+) Injector 6 (–) Injector 4 (–) NC NC NC NC Input/Output signal — Output Output Output Output Output — — — — — — Output Output Output Output — — — — D65EX. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name Power source (Injector.

PX-15 .STRUCTURE. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION AND STEERING CONTROLLER TRANSMISSION AND STEERING CONTROLLER 10-220 D65EX.

STRUCTURE. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name NC Swing control lever potentiometer 1 Brake pedal potentiometer GND (Signal) NC Service switch Travel lever potentiometer 4 Pitch angle sensor Hydraulic oil temperature sensor NC NC Shift-up switch (NC) Input/Output signal — Input Input — — Input Input Input Input — — Input Pin No. FUNCTION AND MAINTENANCE STANDARD TRANSMISSION AND STEERING CONTROLLER Input and output signals DEUTSCH-24P [CN-ST1] Pin No. PX-15 10-221 . 13 14 15 16 17 18 19 20 21 22 23 24 Signal name Travel lever potentiometer 3 NC Alternator (R) Sensor power source (+24 V) NC Shift-down switch (NO) Travel lever potentiometer 2 NC GND (Analog) Sensor power source (+5 V) NC Shift-down switch (NC) Input/Output signal Input — Input Output — Input Input — — Output — Input DEUTSCH-40P (1) [CN-ST2] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name NC NC NC Flash ROM write (Rx) Parking switch (NC) Cursor switch 2 Fan reverse switch Neutral safety relay NC Manual mode switch NC CAN shield NC Flash ROM write (Tx) Parking switch (NO) Cursor switch 1 Fan forward switch Backup alarm relay Transmission (N) Immobilize signal Input/Output signal — — — Input Input Input Input Input — Input — — — Output Input Input Input Output Output Input Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name GND (Power source) Power source (Solenoid) GND (Solenoid. common) Starting switch (ACC) HSS spool (Left) 3rd gear speed ECMV Forward ECMV NC Transmission 2nd gear fill switch HSS specification selection GND (Power source) GND (Power source) GND (Power source) NC HSS spool (Right) Fan control solenoid Reverse ECMV NC Transmission 3rd gear fill switch C/B specification selection Input/Output signal Input Input Input Input Output Output Output — Input Input — — — — Output Output Output — Input Input D65EX. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name NC CAN0 (L) NC Flash ROM write permission signal Transmission reverse fill switch Selector switch NC NC GND (Pulse) Transmission output shaft speed NC CAN0 (H) NC GND (Flash ROM write) Transmission forward fill switch Alarm buzzer cancel switch Automatic shift-down switch NC NC NC Input/Output signal — Input/Output — Input Input Input — — — Input — Input/Output — — Input Input Input — — — DEUTSCH-40P (2) [CN-ST3] Pin No. common) Starting switch (ACC) NC 2-spool ECMV Pitch selector solenoid Fan reverse solenoid Transmission 1st gear fill switch Pitch selector switch (NO) Input/Output signal Input Input Input Output — Output — — Input — Input Input Input Input — Output Output Output Input — Pin No. common) For driving battery relay NC 1st gear speed ECMV NC NC Shift-up switch (NO) Pitch selector switch (NC) Power source (Controller) Power source (Solenoid) GND (Solenoid. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name Power source (Controller) Power source (Solenoid) GND (Solenoid.

If the machine has any trouble (and a sensor detects it). 1. h. j. Machine trouble alarm (Monitor section) 4. and fuel level (Gauge section) 3. g. d. and power supply. voltage. of each sensor and solenoid (Display panel B) f.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM MONITOR SYSTEM a. alarm buzzer. • • 10-222 D65EX. It monitors the machine condition with the sensors installed to the machine and processes and displays the obtained information on the monitor panel immediately. PX-15 . Engine speed. i. The alarm buzzer can be turned OFF temporarily with the buzzer cancel switch. gear speed (Display panel A) 2. sensors. c. hydraulic oil temperature. coolant temperature. e. • Each sensor Sensor signal Engine controller Transmission and steering controller CAN signal The monitor system notifies the operator of the machine condition. The component parts are connected by wiring harnesses and the monitor panel is powered by the battery. power train oil temperature. Controller signal Battery Power source Buzzer Buzzer signal • The monitor system consists of the monitor panel. Current. error code. the monitor and alarm lamp flash and the alarm buzzer sounds to protect the machine. The contents displayed on the panel are roughly classified as shown bellow. b. controller. Travel direction.

CAN signal 2) In failure history display mode A failure code (6-characteristics code) and the following are displayed. according to the contents of the trouble. Pm clinic auxiliary mode 3.) are sent to the monitor panel according to the informa. coolant temperature. see TESTING AND ADJUSTING. Mechanical system failure code display mode 8. and fuel level by gauge CAN signal • The controller processes the sensor signals and converts them into gauge levels and sends the result to the monitor panel. Special functions of monitor panel (EMMS). turn the service switch ON. Special functions of monitor panel (EMMS). • The signals of the item No. and up/ down (gear-shift) switch of the steering/directional/gear shift lever. Dual display monitoring mode Method Flow of signals a For details of the operating method. Display of travel direction and gear speed • Signals (F1. Selection of each item with information switch. see TESTING AND ADJUSTING. Filter and oil maintenance mode 2. Display of engine speed. Real-time monitoring mode 11. hydraulic oil temperature. Electric system failure code display mode 7.) CAN signal a For details of the operating method. buzzer cancel switch. 2. D65EX. • Elapsed time after first occurrence • Elapsed time after latest occurrence • Number of occurrences Each sensor/solenoid O Controller O Monitor panel Display of monitor panel Contents and conditions of processing Method Flow of signals Each sensor O Controller O Monitor panel 1. Other items Contents and conditions of processing 1. etc. FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM Processing in monitor panel (Common to all specifications) Display of monitor panel Contents and conditions of processing Method Flow of signals 1. PX-15 10-223 . each solenoid. Adjustment mode (Service) 9. and condition of each device are sent to the mon. R3. its failure code signal is sent to the monitor panel. 1) In normal state An action code is displayed. • Information about sounding the buzzer and flashing the caution lamp is sent. 2. Failure code display mode 4. etc. Display of each sensor. Display of trouble • If there is any trouble.CAN signal itor panel. 3. Adjustment mode (User) 5. Load saving display mode 10. (When using a mode for service. Maintenance interval change mode 6.STRUCTURE. power train oil temperature.CAN signal tion of the transmission and steering controller. communicating state of CAN signal.

Operation When power is turned ON (When starting switch is turned to ON position) • All the LC segments and lamps of the monitor panel light up for 2 seconds and the alarm buzzer sounds for 2 seconds. The monitor panel has a microcomputer. PX-15 . The alarm buzzer may sound at this time. if there is any abnormal one in the check-before-starting items. Caution items • The caution items are checked constantly while the engine is running. 10-224 D65EX. If any item is abnormal.STRUCTURE. it and alarm lamp flash synchronously. The items displayed on the monitor section and gauge section are shown in DISPLAY OF MONITOR PANEL. and controllers. FUNCTION AND MAINTENANCE STANDARD MONITOR PANEL MONITOR PANEL Outline • The monitor panel consists of the monitor section which outputs an alarm when the machine has any trouble and the gauge section and display panel which display the machine condition constantly. Check before starting • After the operation performed when the power is turned ON. solenoids. which processes and displays the signals from the sensors. the lamp of that item flashes or the contents of the abnormality are displayed on display panel B.

PX-15 10-225 .8 seconds. This does not indicate a trouble. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name CAN0-H CAN0-H CAN0-L CAN0-L CAN shield NC NC NC Alternator R terminal Fuel level NC Power train oil level Input/Output signal Input/Output Input/Output Input/Output Input/Output — — — — Input Input — Input D65EX. a The lamp lights up and goes off at the intervals of about 0. the buzzer is turned OFF temporarily. the buzzer sounds again. Input and output signals AMP070-20P [CN-S03] Pin No.STRUCTURE. While the buzzer is turned OFF. if a new trouble which turns on the buzzer is detected. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name Power source (24 V) Power source (24 V) GND GND Service power (24 V) Service power (24 V) Starting switch C terminal Night lighting Preheating NC NC NC NC NC NC Service switch NC Alarm buzzer NC NC Input/Output signal Input Input — — Input Input Input Input Input — — — — — — Input — Output — — AMP070-12P [CN-S04] Pin No. FUNCTION AND MAINTENANCE STANDARD MONITOR PANEL Buzzer cancel switch • If this switch is operated while the alarm buzzer is sounding. a The flashing intervals of the lamp may change a little when the temperature is low (below about –10ºC).

FUNCTION AND MAINTENANCE STANDARD MONITOR PANEL Monitor panel display 10-226 (7) D65EX.STRUCTURE. PX-15 .

STRUCTURE.9h engine is running display (service meter) (alternator is generating) Lamp is OFF OFF OFF (while engine is stopped) When charge is abnormal 7 Charge level (12V or lower) Lamp is flashing Flashing OFF (while engine is running) Red Caution Lamp is OFF OFF OFF Specified value or lower (while engine is stopped) 8 Engine oil pressure Lamp is flashing (49kPa {0.5kg/cm2}) Flashing ON (while engine is running) 9 Pilot Preheating In preheating mode Lamp is ON OFF OFF Green Before 30h or more OFF After starting switch is 10 Maintenance OFF OFF Orange turned "ON" Before 30h .N.99999.3) 3: PCCS lever gear speed switch in "3rd" At corresponding segment Gauge See diagram at left or lower all light up [*1] Time is counted while Character 6 Display panel B 0 . 5 LED D65EX.Replacement time Lamp lights up for 30 seconds 11 Warning lamp See the "Caution lamp output" column of this table Red Before 30h or more OFF Replacement time Before 30h .110°C 110°C or higher See diagram at left OFF Flashing Flashing OFF Flashing Flashing Fuel level - Travel direction (P.F. see Testing and adjusting.Replacement time After starting switch Lamp OFF OFF Yellow 12 is ON of filter and oil is turned "ON" FlashAfter replacement time Caution for 30 seconds ing • From when the starting switch is turned "ON" in the fan reverse and Lamp is ON cleaning mode when the engine is stopped Check of operaOFF OFF Orange 13 • Fan and selector switch are operated tion of fan while the engine is running • Time to keep the power ON after the Flashing starting switch is turned "OFF" in the fan reverse and cleaning mode *1: For details of the operation in the service mode. Special functions of monitor panel (EMMS).R) [*1] Display panel A Indicator (travel direction.2. engine tachometer) OFF OFF LCD 1: PCCS lever gear speed Black switch in "1st" 2: PCCS lever gear speed Gear speed switch in "2nd" (1. PX-15 10-227 (7) . gear speed.130°C 130°C or higher See diagram at left 100°C or lower 100°C .108°C 108°C or higher See diagram at left 120°C or lower 120°C . FUNCTION AND MAINTENANCE STANDARD MONITOR PANEL No. Display section Gauge Display item Display range See diagram at left Display method Corresponding segment (1 place) All light up OFF Flashing Flashing Corresponding segment (1 place) All light up OFF Flashing Flashing Corresponding segment (1 place) All light up OFF Flashing Flashing At corresponding segment or lower all light up P: Parking brake lever in "Lock" and PCCS lever in Neutral: lamp is ON N: PCCS lever in "Neutral": lamp is ON F: PCCS lever in "Forward": lamp is ON R: PCCS lever in "Reverse": lamp is ON Caution lamp Output Alarm buzzer Output Display color Remarks 1a 1b 2a 2b 3a 3b 4 OFF Flashing Flashing OFF OFF ON OFF OFF ON OFF OFF ON - Black Red Black Red Black Red LCD LED LCD LED LCD LED Coolant temperature Caution Gauge Caution Gauge Caution Gauge Hydraulic oil temperature Power train oil level 102°C or lower 102°C .

The sensors are classified into 4 types of contact. FUNCTION AND MAINTENANCE STANDARD SENSORS SENSORS • • • The signals from the sensors are input through the controller to the monitor panel.STRUCTURE. the switch is turned ON. Its diaphragm senses the oil pressure. If the oil pressure lowers below the specified level. Name of sensor Engine oil pressure Coolant temperature Power train oil temperature Hydraulic oil temperature Fuel level Engine speed Transmission output shaft speed Pitch angle Type of sensor Contact Resistance Resistance Resistance Resistance Electromagnetic Electromagnetic Capacitor When normal OFF — — — — — — — When abnormal ON — — — — — — — ENGINE OIL PRESSURE SENSOR 1. Contact 4. Contact ring Function • 3. and capacitor. Plug 2. electromagnetic. Either side of each sensor of contact type is always connected to the chassis ground. Diaphragm 5. Terminal The engine oil pressure sensor is installed to the engine cylinder block. 10-228 D65EX. resistance. PX-15 . Spring 6.

The temperature signals are sent through the network to the transmission and steering controller and used to control the cooling fan. Connector Function • 2. The hydraulic oil temperature sensor is installed to the hydraulic piping. These sensors sense the change of the temperature by the change of resistance of the thermistors in them. The power train oil temperature sensor is installed to the transmission outlet piping. COOLANT TEMPERATURE SENSOR (FOR PREHEATING) Fuel temperature sensor 1. FUNCTION AND MAINTENANCE STANDARD SENSORS COOLANT TEMPERATURE SENSOR (FOR MONITOR) Power train oil temperature sensor Hydraulic oil temperature sensor 1.STRUCTURE. These sensors sense the change of the temperature by the change of resistance of the thermistors in them. Connector Function • 2. Thermistor The coolant temperature sensor (for monitor) is installed to the engine cylinder block. D65EX. PX-15 10-229 (7) . Thermistor The coolant temperature sensor (for preheating) is installed to the engine coolant piping and the fuel temperature sensor is installed to the engine fuel piping. Plug 3. Plug 3.

Contact 7. As a result. Its float moves up and down according to the fuel level. 4. signals of change in resistance are generated. Spacer Function • The fuel level sensor is installed to the side of the fuel tank. 2.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD SENSORS FUEL LEVEL SENSOR 1. Spring 6. 10-230 D65EX. 3. PX-15 . The movement of the float operates the variable resistor through the arm. Connector Float Arm Body 5.

Sensor The engine speed sensor is installed to the ring gear of the flywheel housing. Wire Function • 3. Connector Function • 2. Terminal 5. It generates pulse voltages as the gear rotates. Boots 6. O-ring 3.STRUCTURE. D65EX. It generates pulse voltages as the gear rotates. Magnet 2. TRANSMISSION OUTPUT SHAFT SPEED SENSOR 1. FUNCTION AND MAINTENANCE STANDARD SENSORS ENGINE SPEED SENSOR 1. Connector The transmission output shaft speed sensor is installed to the bevel gear of steering case. Housing 4. PX-15 10-231 (7) .

Wire 4. 10-232 D65EX. There are multiple electrodes and oil in this sensor. and then those differences are converted into voltage signals. Tube Function • • 3. Body 2.STRUCTURE. FUNCTION AND MAINTENANCE STANDARD SENSORS PITCH ANGLE SENSOR 1. Connector The pitch angle sensor is installed to the base of the ROPS in the filter cover on the right side of the chassis. The changes of the oil level made by inclination of the machine are sensed by the differences in electrostatic capacity between the electrodes. PX-15 .

............................................................ The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests.......................................4 20-101 20-301 a Note the following when making judgements using the standard value tables for testing...... adjusting................................. TROUBLESHOOTING ...........................................TESTING AND ADJUSTING 20 TESTING AND ADJUSTING STANDARD VALUE TABLE Standard value table for engine ......... 2. It is used as a guideline for judging the progress of wear after the machine has been operated................ These standard values are not the standards used in dealing with claims...... D65EX........................... 20.. or troubleshooting................. Standard value table for chassis ............... 1............ It is used for reference together with the state of repair and the history of operation to judge if there is a failure................... and as a reference value when carrying out repairs........................2 20............... PX-15 20-1 (1) .............................. 3.............................................. TESTING AND ADJUSTING ........................ The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference..........................

WX-15 SA6D125E-3 Standard value for Service limit value new machine 2.5} Min. 58.0 Max. 600} Max.98 {Max. 1. 6 kg} Deflection when pressed with a finger force of approx.0} 90 – 120 206 {2. 10 kg} ºC kPa {kg/cm2} 392 – 690 {4.5 2. PX. 2. 1.5} Min. 650 0. 147 {Min.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE STANDARD VALUE TABLE FOR ENGINE Machine model Engine Item Measurement conditions High idling Engine speed Low idling Rated speed Air supply Exhaust gas color Exhaust temperature (Torbocharger inlet temperature) Valve clearance Compression pressure (SAE30 or SAE15W-40) Blow-by pressure (SAE30 or SAE15W-40) At rated output At sudden acceleration At high idling Whole speed range (Ambient temperature 20ºC) Intake valve Exhaust valve Oil temperature: 40 – 60ºC (Engine speed) (Water temperature: Operating range) At rated output (Water temperature: Operating range) At high idling (SAE30 or SAE15W-40) Oil pressure At high idling (SAE10W) At low idling (SAE30 or SAE15W-40) At low idling (SAE10W) Oil temperature Whole speed range (Inside oil pan) Deflection when pressed with a finger force of approx.5 Max. PX-15 . 1.7} 69 {0.9 {Min.8 {Min.1} 176 {1.100 ± 50 825 ± 50 — 60 {450} 6.71 Min.8} 69 {0. 0.96 {200} Alternatorcrankshaft pulley mm Air conditionercrankshaft pulley 13 — Belt tension 15 – 18 — 20-2 (7) D65EX.0} 343 – 640 {3. 98 {Min. 120 kPa {mmHg} Bosch index ºC mm MPa {kg/cm2} (rpm) kPa {mmH2O} rpm Unit D65EX.0 – 7. 98 N {approx. 4. 100} 2. 79.0 700 — — — 1.33 0.7} Min.100 ± 50 825 ± 50 1.5 – 6.8 N {approx.950 Min. 30} (150 – 200) Max.

770 ± 100 1.4 ± 9.000 ± 25 rpm 1.6 ± 2.0} N {kg} 20-4 (7) D65EX.5 ± 19.8 {2.6 ± 1.2 ± 2.6 {5.5 ± 9.8 {2. Neutral o Forward Neutral o Reverse Forward and reverse Forward o Neutral • Stop engine.0} 25.4 ± 9. Neutral Neutral o Left Steering Neutral o Right • Engine: Low idling Decelerator pedal • Set pedal to center.5 ± 9. 3) 52 ± 9 mm 79 ± 12 72 ± 11 52 ± 9 54 ± 8 30 ± 10 30 ± 10 40 ± 15 (Play: Max.6 ± 1.6 ± 1.6 {5.650 Service limit value 1. • Set lever knob to center. PX-15 .8 {2.5 ± 1.000 ± 25 • Engine water temperature: Decelerator pedal Within operating range speed • Power train oil temperature: Within operating range • Hydraulic oil temperature: Within operating range Torque converter • Decelerator pedal speed: Press pedal.0} 25. Reverse o • Set lever knob to center.0} 73.5 ± 9.0 ± 1.6 ± 1. 3) 40 ± 15 (Play: Max.8 {2.8 ± 2.0 ± 1.0} 25.5 ± 24.0} 24. WX-15 Standard value for new machine 1.5 ± 9.8 ± 1.6 ± 2.0} 27.5 ± 9.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS STANDARD VALUE TABLE FOR CHASSIS Machine model Category Item Measurement conditions Unit D65EX.8 {2.0} 25.0} Operating effort of control lever/pedal 51 ± 19. Neutral o Left/Right tilt • Engine: Low idling Neutral o Ripper lever • Hydraulic oil temperature: (If equipped) 45 – 55ºC Raise/Lower • Set lever knob to center.0} 74.5 ± 2.6 {7.6 {5. Lower PCCS lever PCCS lever Engine speed 30 ± 10 30 ± 10 40 ± 15 (Play: Max.0} 51 ± 19.5 ± 19.0} 27.8 {2.0} 25.8 {2. Decelerator pedal • Set pedal to center. Neutral o Raise/Float • Engine: Low idling • Hydraulic oil temperature: Neutral o Blade lever 45 – 55ºC Lower • Set lever knob to center.0} 25.5 {7.0} 73.4 ± 9.5 ± 24.8 {3.8 {2. • Engine: Low idling Brake pedal All stroke • Set pedal to center. stall speed • Torque converter stall speed: F3 Neutral o Forward Forward and reverse Neutral o Reverse • Stop engine.5 ± 9.0} 29.2 ± 2.8 {3.6 ± 1.9 ± 19.8 {2.8 {2.5 ± 9.5 ± 1.4 ± 9.0} 74.6 ± 1. • Engine: Low idling Brake pedal • Set pedal to center.8 ± 2. Neutral o Left Steering Neutral o Right • Stop engine. Neutral o Left/Right tilt Neutral o • Engine: Low idling Raise Ripper lever • Hydraulic oil temperature: (If equipped) 45 – 55ºC Neutral o • Set lever knob to center. 3) 40 ± 15 (Play: Max. Neutral o Raise/Lower • Engine: Low idling • Hydraulic oil temperature: Neutral o Blade lever 45 – 55ºC Float • Set lever knob to center.0} 56.5 {7.5 ± 9. 3) 52 ± 9 79 ± 12 72 ± 11 52 ± 9 54 ± 8 Stroke of control lever/pedal 54 ± 8 54 ± 8 56.9 ± 19.0} 24.6 {5.5 ± 2.5} 510 ± 88 {52 ± 9.8 ± 1.6 {7.5} 666 {68} 29.

5 ± 9.0} 51 ± 19.0 ± 1.0} 27.6 {5.0} 25.650 30 ± 10 30 ± 10 40 ± 15 (Play: Max.770 ± 100 1.8 {2.5 ± 24.5 {7.5 ± 24.5 ± 1.000 ± 25 Service limit value 1.5 ± 1.6 {5.6 {7.4 ± 9.0} 27.8 ± 2.0} 24.6 ± 1.0} 73.8 {3.4 ± 9.5 ± 9.5 ± 2.8 {2.4 ± 9.8 ± 1.0} 25.6 ± 2.0} — — 51 ± 19. 3) 52 ± 9 79 ± 12 72 ± 11 52 ± 9 54 ± 8 30 ± 10 30 ± 10 40 ± 15 (Play: Max.6 {5.5} 666 {68} 29.6 ± 2.8 ± 1.0 ± 1.0} 73.9 ± 19.2 ± 2.2 ± 2. 3) 40 ± 15 (Play: Max.8 ± 2.5 ± 9.6 ± 1.8 {3. PX-15 20-5 (1) .TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS D65PX-15 Standard value for new machine 1.5 ± 2.4 ± 9.8 {2. 3) 40 ± 15 (Play: Max.8 {2.0} — — D65EX.0} 24.5 {7.8 {2.0} 74.000 ± 25 1.5} 510 ± 88 {52 ± 9.0} 29.5 ± 19.5 ± 9.8 {2.0} 56.5 ± 19.0} 74. 3) 52 ± 9 79 ± 12 72 ± 11 52 ± 9 54 ± 8 — — 56.6 {7.9 ± 19.6 {5.

0} 3.33 ± 0.1 {32 ± 1.1 – 0.05 – 0.0 {375 ± 20} 34.9 ± 0.1 {34.8 ± 2. 31} Min. 31} Min. 2. 2.04 {Min.5 Engine: Low idling Engine: High idling Engine: Low idling Torque converter outlet pressure Engine: High idling Engine: Transmission Low idling main relief Engine: pressure High idling Engine: Low idling Transmission F clutch pressure Engine: High idling Engine: Low idling Transmission R clutch pressure Engine: • Power train oil temperature: High idling 70 – 80ºC Engine: Low idling Transmission 1st clutch pressure Engine: High idling Engine: Low idling Transmission 2nd clutch pressure Engine: High idling Engine: Low idling Transmission 3rd clutch pressure Engine: High idling Transmission lubricating oil Engine: pressure High idling (For reference) Engine: Low idling Brake pressure Engine: High idling Relief pressure LS pressure (Load sensing pressure) HSS pressure Power train oil pressure • Hydraulic oil temperature: 45 – 55ºC • Engine: High idling F1 • Flat road • Engine water temperature: Within operating range • Power train oil temperature: 70 – 80ºC • Engine: High idling • Run up distance: 10 – 30 m • Measuring distance: 20 m F2 F3 Performance of power train Travel speed 20-6 (7) D65EX.55 {Min.33 ± 0.1 {32 ± 1.0 ± 1.0} 3.5 ± 0.8 {Min. 9} 0.25 {1. 0.94 {28 – 30} 2.0} 3.75 – 2.1 – 0.6 4.9 ± 0.29 {0. 3.5 km/h R1 R2 R3 4.33 ± 0.29 {0.0 ± 1.0} 3. PX-15 .1 {34.33 ± 0.0} 3.4 ± 0. WX-15 Standard value for new machine 0.13 ± 0.04 {Min.1 {34.3 9.88 {Max.2 ± 0.84 {Min.8 ± 2.04 {Min.5 – 3} 0.9 {Min. 29} Min.1 – 0.7 ± 0.1 {32 ± 1.0 ± 0.0 ± 1. 3.04 {Min.5} Min.84 {Min.75 – 2.5 {1 – 5} Max.0} 3. 29} Min.13 ± 0.0} 3. 2.0 ± 1.04 {Min.39 – 0.4 12.84 {Min.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Machine model Category Item Torque converter inlet pressure Measurement conditions Unit D65EX. 2. PX.33 ± 0.5 {1 – 5} Max.39 – 0. 3.0} 3. 2.33 ± 0.0 – 2.2 6. 30. 26} Min. 335} Min. 31} Min.0 ± 1. 2.3 9.13 ± 0.0 ± 1.1 {34.3 8.7 ± 0.0} 3.2 ± 0. 26} Min.0 – 2. 3. 29} Min.1 {32 ± 1.0 {355 ± 20} 3. 31} 0.4 12.5 ± 0. 2. 3.0} 0.55 {Min.5 – 3} 0.84 {Min. 9} 0.4 ± 0.84 {Min.69 {4 – 7} Min.0 ± 0.13 ± 0.1 {32 ± 1. 2. 29} Min.94 {28 – 30} 36.0} 3.13 ± 0.88 {Max.1 – 0. 315} 3.84 {Min. 29} Min.1 {34.25 {1.13 ± 0.04 {Min.2 6.5} 2.6 Service limit value 0.0} {kg/cm2} 3. 3. 29} Min. 31} Min.1 MPa {32 ± 1. 0.3 8.1 {34. 31} Min. 32.05 – 0.69 {4 – 7} 3.

9 1. Engine: Relief pressure: High idling Set cylinder to stroke Engine: end.6 {200} 17.0 {220 ± 20} 4.37 0 +14 0 } Service limit value 3. High idling Engine: Low idling Engine: High idling Unit D65EX-15 Standard value for new machine 3.6 {Min.6 {180} 4.2 1. 19. MPa Low idling {kg/cm2} LS pressure: Set cylinder to stroke Engine: end.6 {Min.6 ± 2. 19. 200} 23.0 3.9 ± 0. 19.6 {Min. 19.3 ± 0.4 ± 0.0 — 2.2 1.43 {35 Min.6 {Min. PX-15 .53 – 4.6 ± 2.6 {180} 17.0 {220 ± 20} 21.7 ± 0.5 ± 0.5} 3.53 – 4.4 1.6 {Min.6 {200} Min. • Between ground level and rising end of blade • Engine: High idling aSee the figure B • Hydraulic oil temperature: 45 – 55ºC • Apply no load to blade.5 ± 0.1 +1.41 {36 – 45} 2. 19.5 +1. 19.98 {240 ± 10} Min.5 ± 0.25 {43. fan) PPC valve output pressure • • Hydraulic oil temperature: 45 – 55ºC • Engine: High idling aSee the figure A • Hydraulic oil temperature: 45 – 55ºC • Apply no load to blade.25 {43. • Pitch in – pitch back • Engine: High idling Left tilt Raise Blade lift Lower Straight tilt Power tilt Straight tilt Power tilt Low idling High idling Low idling High idling Pitch in sec 1.9 2.37 0 +14 0 } Blade lift relief pressure Work equipment oil pressure • Ripper lift relief pressure LS pressure (Load sensing pressure) Control circuit main pressure (HSS.6 {Min.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Machine model Category Item Unload pressure Measurement conditions Engine: High idling • • Blade tilt relief pressure Engine: Low idling Hydraulic oil temperature: Engine: 45 – 55ºC High idling Unload pressure: Engine: Set all equipment in Low idling neutral.41 {36 – 45} 3.6 — Work equipment speed Blade tilt Work equipment Ripper lift (If equipped) Pitch speed (If equipped) Lower Raise Right tilt Pitch back — — 20-8 (1) D65EX.8 — 2. 200} 23.1 ± 0.6 +0.5 ± 2.27 ± 0.3 — 2.27 ± 0.43 {35 Min. 200} 19. • Between ground level and rising end of blade aSee the figure D • Hydraulic oil temperature: 45 – 55ºC • Apply no load to blade.3 — 2.5 ± 2.2 1.2 — 2.4 ± 0. 200} 23.2 2.5 ± 0.2 – 0.6 {200} Min. 200} 19. • Between left tilt end and right tilt end • Engine: High idling aSee the figure C • Hydraulic oil temperature: 45 – 55ºC • Apply no load to ripper. 200} 19.98 {240 ± 10} Min.98 {240 ± 10} 21.5} 3. PPC.

5 4. 19.37 0 +14 0 } Service limit value 3. 19.53 – 4.5} 3.25 {43.0 3.25 {43.6 {200} Min.0 2.6 {180} 17.5 ± 0.8 2.3 ± 0.53 – 4.3 — — — — 3. 200} 19.41 {36 – 45} 2.5 ± 0.3 ± 0.41 {36 – 45} 2.3 2.6 {Min. 19.4 ± 0.3 2.7 3.9 +1.98 {240 ± 10} — — — — 21.27 ± 0.5 ± 0.6 {200} — — — — 17. 19.6 {Min.6 {Min. 200} 19.27 ± 0.6 ± 2. PX-15 20-9 (7) .2 D65EX.5 ± 2.43 {35 Min.5 1.3 2.0 {220 ± 20} 21.43 {35 Min.0 {220 ± 20} 4.5 ± 0.6 {180} 4.6 {Min. 200} 23.2 2.5 ± 2.4 +0.2 3.5 ± 0.5 ± 0.8 — — — — 4.5 +1.98 {240 ± 10} Min. 200} 23.37 0 +14 0 } 1.6 ± 2.2 – 0.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS D65PX. WX-15 Standard value for new machine 3.5} 3.

200 Max.6 Hydraulic drift of lifted blade Work equipment Hydraulic drift Hydraulic drift of tilted blade Hydraulic drift of lifted ripper Leakage from cylinder Blade tilt cylinder Ripper lift cylinder Max.750 1.6 Fan 100% speed mode For EU spec. Left aSee the figure F tilt • Hydraulic oil temperature: 45 – 55ºC • Engine: Stopped Right • Reduction of blade tip height tilt aSee the figure G • Hydraulic oil temperature: 45 – 55ºC • Engine: Stopped • Measure reduction of shank bottom height h (for 15 minutes).TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Machine model Category Item Measurement conditions • Hydraulic oil temperature: 45 – 55ºC • Move lever to stroke end.500 18. PX-15 . 100 Max. 200 Max. 1. 80ºC 45 – 55ºC • Engine: High Standard 1. • Engine: High idling • Hydraulic oil temperature: 45 – 55ºC • Relieve cylinder and measure leakage for 1 minute. 1. • Lower blade from max.600 +100 0 speed mode spec. {160 – 190} Engine: High idling Min. • Engine: High idling aSee the figure E • Hydraulic oil temperature: 45 – 55ºC • Engine: Stopped • Measure reduction of blade bottom height h (for 15 minutes).7 {140} 20-10 (7) D65EX.6 {190} 13.6 – 22.7 – 18. speed HSS motor 30 700 1. 200 Max. rising position and measure time after blade comes in contact with ground until idler is lifted.5 Standard 45 – 55ºC {200 – 230} MPa Fan forward 2 {kg/cm } 15.3 Max. 15 Brake pedal: Pressed Engine: High idling • Engine: Low idling • Coolant temperature: rpm 800 ± 50 Power train oil Hydraulic oil temperature: temperature: Max. 200 Max. 50 — 4 cc/min 4 16 16 Leakage • Fan speed Cooling fan • • Fan pump pressure • • • Hydraulic oil temperature: 45 – 55ºC Steering lever: Full Transmission lever: Neutral l/min Max. 100 mm/ 15 min Max. speed Max. • • • • • Unit D65EX-15 Standard value for new machine Service limit value Time lag Blade sec Max.850 +100 Fan forward 0 idling • Fan 100% For EU 1. Hydraulic oil temperature: 19.

100 Max. 1.7 {140} 19. 200 — — 4 16 4 16 Max. 1. 200 Max.600 +100 0 +100 0 1.6 {160 – 190} D65EX.750 1.3 Max.500 18.6 Max. WX-15 Standard value for new machine Service limit value Max.6 {190} 13. 200 Max.7 – 18.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS D65PX.850 1. PX-15 20-11 (7) . 15 30 800 ± 50 700 1. 200 Max. 100 Max.5 {200 – 230} 15.6 – 22.

B Fig. D 20-12 (1) D65EX. F Fig. PX-15 . A Fig. E Fig.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS Illustration related standard value table Fig. G Fig. C Fig.

................................ Undercarriage troubleshooting report .................................................. Special functions of monitor panel (EMMS) .................. Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed) ......................... Measuring fan pump circuit pressure ............................................................................................................................................ Pm clinic service ................................................................................. D65EX................................................................................. Adjusting straight tiltdozer ............ adjusting....................................................................... Adjusting play of work equipment PPC valve ................................................................................... Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed) ..................................................................................................................................................................................................... Testing and adjusting track shoe tension .............. Measuring fan motor speed .................................................................... Measuring internal leakage of work equipment cylinder ................................................................................................................ Measuring intake air pressure (boost pressure) .................................................................................................................................................................................................................................................................................................................................................................................................................................. Testing and adjusting alternator belt tension ............................................................................................................................................... Inspecting wear of sprocket ................................. Handling of fuel system devices ..............................................................................................117 20..................................................... Measuring engine speed ......................... Testing and adjusting operator’s cab ........................ Testing and adjusting air conditioner compressor belt tension .............................................................. Testing control circuit main pressure ....................................... Bleeding air from work equipment cylinder ................................. Preparation work for troubleshooting for electric system ............118 20................... Adjusting brake pedal .................... Adjusting valve clearance ................................................................................................................... Adjusting clearance of idler ............................................................................................................................. Emergency escape method when power train has trouble ................................ and troubleshooting .................................................................................. Measuring exhaust gas color ..116 20.................................................................................. Adjusting transmission speed sensor (replacement procedure) ..........................................................................TESTING AND ADJUSTING TESTING AND ADJUSTING Tools for testing............................................... Testing and adjusting work equipment and HSS oil pressure ........................ Bleeding air from fuel circuit ............................................ Measuring PPC valve output pressure .... Releasing residual pressure from fuel system ................................................. Adjusting fuel control dial and decelerator pedal .119 20-120 20-123 20-124 20-125 20-125 20-126 20-128 20-133 20-134 20-135 20-138 20-141 20-141 20-142 20-143 20-146 20-147 20-149 20-150 20-150 20-151 20-151 20-152 20-153 20-154 20-155 20-156 20-158 20-162 20-199 20-199 20-201 20-203 20-210 20-101 (8) ................................................................................. Measuring compression pressure ...................................................................................112 20................................................................ Measuring blow-by pressure ......................................................114 20................................................................................................................... Measuring fuel pressure ...................................................................................................................................................................................... Handling of high-voltage circuit of engine controller ................................................................................. Reduced cylinder mode operation for engine ..................................................................................................................................................... Inspection of fuel circuit for leakage .. Bleeding air from fan pump ......................................................................................118 20................................................................................................... PX-15 20-103 20-105 20-107 20-109 20......................................................................................................................................................................... Adjusting work equipment lock lever ............................................. Adjustment method of replaced controller ........................................................................................................................................................................................................................110 20........ Simple method of testing brake performance ...................... Measuring engine oil pressure .......................................................................................................................... Measuring exhaust temperature ................................................................................................................................................................ Measuring power train oil pressure ..............................................................

If the radiator cap is removed when the water is still hot. When carrying out work together with other workers. fan belt. or troubleshooting. D65EX. always wait for the water to cool down. park the machine on level ground and use the safety pins and blocks to prevent the machine from moving. When checking the water level. the water will spurt out and cause burns. or other rotating parts.TESTING AND ADJUSTING k k k k When carrying out testing. adjusting. always use signals and do not let unauthorized people near the machine. Be careful not to get caught in the fan. PX-15 20-102 (1) .

Work equipment pressure E F C D Symbol A B Part No.5. 40. 60 MPa {25. 400.: 795-502-1205 –99. Oil temperature.9 rpm Pressure gauge: 2. Exhaust temperature Exhaust color Valve clearance Compression pressure Blow-by pressure Engine oil pressure.5. 400. 400. 6. 60 MPa {25.71 mm 0 – 7 MPa {0 – 70 kg/cm2} Kit part No.33 mm. 6. ADJUSTING.5. Fuel pressure. 40.299ºC Bosch index: Level 0 – 9 Remarks –101 – 200 kPa {–760 – 1. 6. AND TROUBLESHOOTING Check or measurement item Boost pressure Water temperature. 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Face seal type (#03) Emergency escape when power train has trouble H 2 790-190-1600 3 144-865-6260 799-101-5002 1 Control circuit main pressure J 2 790-261-1204 799-401-3200 02896-11009 799-101-5002 1 PPC valve outlet pressure K 2 790-261-1204 799-401-3100 02896-11008 Commercially available 799-205-1100 Oil leakage of work equipment cylinder Fan motor speed L M D65EX. PX-15 20-103 (8) . 60. ADJUSTING. 60 MPa {25.500 mmHg} 1 799-201-2202 2 790-301-1530 799-101-1502 1 799-201-9001 2 Commercially available Commercially available 1 795-502-1590 2 795-471-1410 799-201-1504 799-101-5002 1 G 790-261-1204 2 799-401-2320 1 19M-06-32820 Switch assembly 17M-06-41530 Wiring harness Pump assembly Elbow (R 3/8 x M18) Hydraulic tester Digital hydraulic tester Adapter O-ring Hydraulic tester Digital hydraulic tester Adapter O-ring Measuring cylinder Tachometer kit 100 cc Digital display : 6 – 99999. 60.9 – 1.TESTING AND ADJUSTING TOOLS FOR TESTING. 40. Exhaust valve: 0. Power train pressure. 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Pressure gauge: 1 MPa {10 kg/cm2} Intake valve: 0. 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Face seal type (#02) Pressure gauge: 2. HST pressure. 60. AND TROUBLESHOOTING TOOLS FOR TESTING. Part name Boost gauge kit Elbow Digital temperature gauge Handy smoke checker Smoke meter Filler gauge Compression gauge Adapter Blow-by checker Hydraulic tester Digital hydraulic tester Hydraulic gauge 0 – 5 kPa {0 – 500 mmH2O} Pressure gauge: 2.

resistance value Q R S T 1 790-261-1204 799-401-3400 02896-11015 79A-264-0021 79A-264-0091 Commercially available Commercially available Commercially available 799-601-7400 799-601-7360 For relay (5-pin) For DT connector For DT connector (24-pin. 799-101-5002 Part name Hydraulic tester Digital hydraulic tester Adapter O-ring Push-pull scale Push-pull scale Scale Stopwatch Tester T-adapter kits Adapter T-adapter kits T-adapter kits Socket Adapter Socket Remarks Pressure gauge: 2. 60 MPa {25.TESTING AND ADJUSTING TOOLS FOR TESTING. Fuel pressure sensor For PCV solenoid 2 799-601-9000 Troubleshooting of wiring harness. 60. 40-pin) For NE sensor. PX-15 . hydraulic drift Work equipment speed Measuring voltage.5. 40. sensor U 3 799-601-9300 799-601-9410 4 799-601-9420 799-601-9430 20-104 (8) D65EX. 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Face seal type (#05) 0 – 294 N {0 – 30 kg} 0 – 490 N {0 – 50 kg} 1 Fan pump circuit oil pressure P 2 Operating effort Stroke. 400. ADJUSTING. AND TROUBLESHOOTING Check or measurement item Symbol Part No. G sensor For boost pressure sensor. 6.

2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed. Measuring high idling speed 1) Start the engine and set the fuel control dial in the high idling position. Measuring low idling speed 1) Start the engine and set the fuel control dial in the low idling position. Measuring decelerator pedal speed 1) Start the engine and set the fuel control dial in the high idling position. use the “Adjustment mode”. see “SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)”. 4. a The high idling speed measured in the “Monitoring mode” or in the “Pm Clinic auxiliary mode” is the auto-deceleration speed. PX-15 20-105 (1) . Adjustment code: 0007 (Engine decelerator cut mode) 2.TESTING AND ADJUSTING MEASURING ENGINE SPEED MEASURING ENGINE SPEED a Measure the engine speed under the following condition. a When measuring the high idling speed of the engine. 2) Set the PCCS lever and work equipment control lever in neutral and measure the engine speed. Preparation work Turn the starting switch ON and set the monitor panel in the “Monitoring mode” to prepare for measurement of the engine speed. • Engine water temperature: Within operating range • Hydraulic oil temperature: Within operating range • Power train oil temperature: Within operating range 1. D65EX. a For the operating method. 2) Set the PCCS lever and work equipment control lever in neutral and press the decelerator pedal and measure the engine speed. • Monitoring code: 01000 (Engine speed) 3.

7) Perform steps 2) – 4) again and measure the engine speed about 5 seconds after the power train oil temperature gauge reads the top line of the green range.TESTING AND ADJUSTING MEASURING ENGINE SPEED 5. PX-15 . 6) Repeat above steps 2) – 5) 3 times. a After finishing measurement. return the direction of the PCCS lever into neutral and lower the power train oil temperature with the engine at high idling. return the direction of the PCCS lever into neutral. however). a Before going to the next step. 4) Return the decelerator pedal slowly to stall the torque converter with the engine at high idling. check that the upper display unit of the monitor panel is set in the normal display state and it displays [F3]. a Keep the steering unit in neutral. 5) Just after the power train oil temperature gauge reads the top line of the green range. 3) Press the decelerator pedal and set the fuel control dial in the high idling position. k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. 2) Press the brake pedal securely and set the parking brake lever in the FREE position and set the PCCS lever in the FORWARD and 3rd gear speed position. a The engine speed can be measured in the “Pm Clinic auxiliary mode” of the monitor panel (Measure the high idling speed of the engine in the “Adjustment mode”. Measuring torque converter stall speed 1) Start the engine and set the fuel control dial in the low idling position. 20-106 (1) D65EX.

see MEASURING ENGINE SPEED. an approximate value can be obtained by stalling the torque converter. 3. 6.TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) a Measuring instruments for intake air pressure (boost pressure) Symbol A k Part No. 5. After finishing measurement. Open the left side cover of the engine. Remove air intake connector boost pressure pick-up plug (1). the intake air pressure (boost pressure) should be measured while the engine is operated at the rated output. a Normally. the air bleeding coupling (790-261-1130) in it may be used. Run the engine at medium or higher speed and drain the oil from the hose. When installing and removing the measuring instrument. 799-201-2202 790-301-1530 Name Boost gauge kit Elbow 1 2 4. In the field. Install elbow A2 and connect gauge [2] of boost gauge kit A1. a Insert the joint of the gauge and hose halfway and open the self-seal on the hose side repeatedly. Accordingly. remove the measuring instrument and return the removed parts. a If any oil is left in the hose. be sure to drain the oil. a Measure the intake air pressure (boost pressure) under the following condition. D65EX. a If Pm kit (A) is available. a For the procedure for stalling the torque converter. the gauge does not move. Run the engine at high idling and stall the torque converter and measure the intake air pressure (boost pressure) at this time. take care not to touch a hot part. 2. • Engine water temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: Within operating range 1. and the oil is drained. PX-15 20-107 (1) . however.

PX-15 .TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) a The boost pressure can be measured in the “Pm Clinic auxiliary mode” of the monitor panel. 20-108 (1) D65EX.

a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part during measurement. the torque converter oil temperature is overheated before the exhaust temperature is stabilized. a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). • Engine water temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: Within operating range 1. a Measure the exhaust temperature under the following condition. ii) Press the brake pedal securely and set the PCCS lever in the FORWARD 3rd gear speed position. Open the right side cover of the engine and remove turbocharger heat insulation cover (1). D65EX. if any abnormal value is obtained. 5. Accordingly. 3. 799-101-1502 Name Digital thermometer Install and remove the measuring instrument after the exhaust manifold is cooled. a Use the PEAK mode of the digital thermometer. and then extract the blade tilt cylinder to the stroke end with the blade control lever. Then stall the torque converter and relieve the blade tilt circuit simultaneously. PX-15 20-109 (1) .TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE MEASURING EXHAUST TEMPERATURE a Measuring instrument for exhaust temperature Symbol B k Part No. Accordingly. measure according to the following procedure. iv) Return the decelerator pedal slowly and run the engine at high idling. • Corrected value [ºC] = Measured value + 2 x (20 – Outside air temperature) 2. i) Start the engine and set the fuel control dial to the idling position. Install sensor [1] and connect them to digital thermometer B. Procedure for measuring exhaust temperature periodically for preventive maintenance a If the torque converter is stalled simply. Procedure for measuring maximum exhaust temperature for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. 4. Remove exhaust temperature pick-up plug (2). 1) Stall the torque converter fully to raise the exhaust temperature to about 650ºC according to the following procedure (Condition a in the figure). iii) Press the decelerator pedal and set the fuel control dial to the high idling position. k Press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. correct it by the following calculation.

Measuring with handy smoke checker C1 1) Stock a sheet of filter paper to C1. 4) Accelerate the engine suddenly or run it at high idling and operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas. a If an air source and a electric power source are not available in the field. 6.TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR 2) Stop only relieving the ripper and lower the exhaust temperature by only stalling the torque converter (Condition b in the figure). remove the measuring instrument and return the removed parts. MEASURING EXHAUST GAS COLOR a Measuring instrument for exhaust gas color Symbol C k Part No. When recording official data. k Just after the power train oil temperature gauge reads the red range. a If the temperature does not lower but rises. 799-201-9001 Purchased Name Handy smoke checker Smoke meter 1 2 When installing and removing the measuring instrument. 3) After the temperature lowers and is stabilized. use handy smoke checker C1. 6) After finishing measurement. measure it (Condition c in the figure). 2) Insert the exhaust gas intake pipe in the exhaust pipe. 5) Remove the filter paper and compare it with the attached scale. PX-15 . 3) Start the engine. • Engine water temperature: Within operating range 1. take care not to touch a hot part. 20-110 (8) D65EX. remove the measuring instrument and return the removed parts. return the direction of the PCCS lever into neutral and lower the power train oil temperature. a Measure the exhaust gas color under the following condition. use smoke meter C2. set the temperature in step 1). After finishing measurement.

check that the power switch of the smoke meter is turned off. Measuring with smoke meter C2 1) Insert probe [1] of smoke meter C2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip. receptacle of the accelerator switch. remove the measuring instrument and return the removed parts. and air hose to smoke meter C2.TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR 2. 6) Start the engine.5 MPa {15 kg/cm2}. a Before connecting the cable. 7) Accelerate the engine suddenly or run it at high idling and press the accelerator pedal of smoke meter C2 and collect the exhaust gas into the filter paper. 4) Loosen the cap nut of the suction pump and fit the filter paper. a Limit the supplied air pressure to 1. 3) Connect the power cable to a receptacle of AC power supply. 9) After finishing measurement. 2) Connect the probe hose. PX-15 20-111 (1) . 5) Turn on the power switch of smoke meter C2. 8) Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. D65EX. a Fit the filter paper securely so that the exhaust gas will not leak.

the rocker arms on both intake side and exhaust side can be moved by the valve clearance with the hand. PX-15 . Rotate the crankshaft forward to bring the stamped 1.TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE ADJUSTING VALVE CLEARANCE a Adjusting instrument for valve clearance Symbol D Part No. 4) Remove air cleaner assembly (10). 2) Disconnect air intake hose (8) from the air cleaner. 1.6TOP line a to pointer (15) and set the No. Open both engine side covers. a Use the damper mounting bolt to rotate the crankshaft. a When the No. Air cleaner 1) Remove cap assembly (1) and cover (2). a Move the cylinder head covers and seals toward the air intake manifold without removing them from the high-pressure tube. 5) Remove bracket (11). Purchased Filler gauge Name 3. 3) Remove band (9). a Turn the air cleaner assembly in the circumferential direction to let the end tube out of the cut hole of the hood. 2. Remove all cylinder head covers (13) and seals (14). rotate the crankshaft one more turn. If the rocker arms cannot be moved. 20-112 (8) D65EX. 4. 1 cylinder is at the compression top dead center. 6) Remove air intake connector (12). 1 cylinder to the top dead center.

9 ± 0. a With the filler gauge inserted.4 – 6.0 – 64.TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE 5.05 kgm} 9. Turn the crankshaft forward by 120 degrees each time and adjust the clearances of the air intake valve and exhaust valve of each cylinder according to the firing order by repeating steps 4 and 5.2 kgm} D65EX. 6. 3 Locknut: 7.8 ± 1.0 Nm {1. Insert filler gauge D in clearance b between rocker arm (4) and crosshead (5) and adjust the valve clearance with adjustment screw (6).5 Nm {0. return the removed parts.8 ± 0.1 kgm} 6.6 kgm} a After tightening the locknut.0 – 1.0 ± 0. turn the adjustment screw so that you can move the filler gauge lightly.8 ± 0.8 – 11. PX-15 20-113 (1) . tighten locknut (7). After finishing adjustment. a Firing order: 1 – 5 – 3 – 6 – 2 – 4 8.76 Nm {1.7 Nm {5. check the valve clearance again. 53. Fixing adjustment screw (6).49 Nm {69 ± 5 kgcm} 3 Air cleaner air intake hose clamp bolt: 3 Air cleaner band bolt: 8. 3 Cylinder head cover mounting bolt: 3 Air intake connector hose clamp bolt: 9.

a Turn the air cleaner assembly in the circumferential direction to let the end tube out of the cut hole of the hood. a Measure the compression pressure after the engine is warmed up.TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE MEASURING COMPRESSION PRESSURE a Measuring instruments for compression pressure Symbol E k 6) Remove air intake connector (12). Remove all of 6 cylinder head covers (4). Part No. etc. take care not to burn yourself on the exhaust manifold. 4. PX-15 . Air cleaner 1) Remove cap assembly (1) and cover (2). 3) Remove band (9). and then remove the all clamps so that the tubes can be moved. 4) Remove air cleaner assembly (10). 2. 2) Disconnect air intake hose (8) from the air cleaner. (Engine oil temperature: 40 – 60ºC) 1. 795-502-1590 795-471-1410 Name Compression gauge Adapter 1 2 When measuring the compression pressure. Remove all of 6 fuel high-pressure tubes (3). 5) Remove bracket (11). 20-114 (1) D65EX. muffler. or get caught in a rotating part. 3. Open both engine side covers.

a Secure the adapter with the injector holder. Remove wiring harness (5) and injector assembly (6).49 Nm {69 ± 5 kgcm} 3 Air intake connector hose clamp bolt: 3 Air cleaner air intake hose clamp bolt: 3 Air cleaner band bolt: 8.0 kgm} 9. although the fuel high-pressure tube is disconnected. 7.2 – 49. 8.8 ± 0.76 Nm {1.TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE 5. 3 Injector assembly mounting bolt: 3 Fuel high-pressure tube sleeve nut: 3 Cylinder head cover mounting bolt: 58.5 Nm {0.0 – 5. Disconnect concentrated connector (7) (E21) for the engine.0 – 7. 6.8 – 11.5 kgm} 39.0 Nm {4. After finishing measurement.8 ± 1. Install adapter E2 and connect it to compression gauge E1.0 Nm {1.1 kgm} 6. return the removed parts. 9.8 ± 0.0 ± 0. a Leakage can be prevented by applying a little amount of engine oil to the fitting faces of the adapter and gauge. Crank the engine with the starting motor and measure the compression pressure. to prevent electric leakage and grounding fault.9 ± 0. a Measure the pressure when the pointer of the gauge is stabilized. k Disconnect the concentrated connector for safety.05 kgm} 9.5 Nm {6. PX-15 20-115 (1) . k Cover the connector on the controller side with a vinyl sheet.8 – 73. etc.2 kgm} D65EX.0 – 1.

check for increase of oil consumption. 3. the blow-by pressure should be measured while the engine is operated at the rated output. however. an approximate value can be obtained by stalling the torque converter. a For the procedure for stalling the torque converter. PX-15 . a Normally. see MEASURING ENGINE SPEED. measure while the engine is running at high idling.TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE MEASURING BLOW-BY PRESSURE a Measuring instrument for blow-by pressure Symbol F Part No. 20-116 (8) D65EX. After finishing measurement. a If it is impossible to run the engine at the rated output or stall the torque converter. which are related to the abnormal blowby pressure. bad exhaust gas color. etc. and measure the blow-by pressure. stall the torque converter. If the measured value is judged abnormal. In the field. The value obtained in this case is about 80% of the blow-by pressure at the rated output. 2. a Measure the blow-by pressure under the following condition. • Engine water temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: Within operating range 1. remove the measuring instrument and return the removed parts. Install nozzle [1] of blow-by checker F to blow-by hose (1) and connect them to gauge [2]. 4. 799-201-1504 Name Blow-by checker a The blow-by pressure may vary largely with the engine condition. Run the engine at high idling. Remove the radiator bottom cover. high deterioration speed of oil. deterioration of oil.

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE
a Measuring instruments for engine oil pressure
Symbol 1 G 2 Part No. 799-101-5002 790-261-1204 799-401-2320 Name Hydraulic tester Digital hydraulic tester Hydraulic tester (1 MPa {10 kg/cm2})

3. Run the engine at low idling and high idling and measure the engine oil pressure in each speed.

a Measure the engine oil pressure under the following condition. • Engine water temperature: Within operating range 1. Open the left side cover of the engine and remove plug (1) RC 1/8.

4. After finishing measurement, remove the measuring instruments and return the removed parts.

2. Install nipple [1] of hydraulic tester G1 and connect them to hydraulic tester G2.

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HANDLING OF FUEL SYSTEM DEVICES RELEASING RESIDUAL PRESSURE FROM FUELDEVICES HANDLING OF FUEL SYSTEM SYSTEM

HANDLING OF FUEL SYSTEM DEVICES
a Precautions for testing and adjusting fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and adjusting the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. a Precautions for replacing fuel filter cartrige Be sure to use Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.

RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
a Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel filter – Fuel supply pump High-pressure circuit: Fuel supply pump – Common rail – Fuel injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. k Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)

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TESTING AND ADJUSTING

MEASURING FUEL PRESSURE

MEASURING FUEL PRESSURE
a Measuring instrument for fuel pressure
Symbol 1 G 2 Part No. 799-101-5002 790-261-1204 799-401-2320 Name Hydraulic tester Digital hydraulic tester Hydraulic tester (1 MPa {10 kg/cm2})

3. Run the engine at high idling and measure the fuel pressure. a For the standard value, see Troubleshooting when error code is displayed (Error code AD10L3).

a Measure only the fuel pressure in the low-pressure circuit from the feed pump to the fuel filter and fuel supply pump. k Since the pressure in the high-pressure circuit from the fuel supply pump to the common rail and fuel injector is very high, it cannot be measured. 1. Open the left side cover of the engine and remove fuel pressure pick-up plug (1).

4. After finishing measurement, remove the measuring instruments and return the removed parts.

2. Install nipple [1] of hydraulic tester G1 and connect them to hydraulic tester G2.

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BLEEDING AIR FROM FUEL CIRCUIT

BLEEDING AIR FROM FUEL CIRCUIT

a Bleeding the air as follows if the engine has run out of fuel or the fuel circut equipment has been removed and installed. 1. Remove fuel filter (1), fill with fuel, then install again. a When filling, use clean fuel and be careful not to let dirt get in. a Add fuel through inlet port portion a (8 places) of the filter. Portion b is the outlet port (clean side) after the fuel has been filtered, so never add fuel from here. a If clean fuel is not available, do not remove the filter. Operate the priming pump to fill the filter with fuel.

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BLEEDING AIR FROM FUEL CIRCUIT

2. Remove air bleed plug (2) of the fuel filter and operate priming pump (4). a Continue operating the priming pump until flow out from the plug hole. When fuel comes out, install the plug.

3 Air bleed plug:

Air bleeding steps i) Remove air bleeding plug (2) of fuel filter (1) and operate priming pump (4). • Continue to operate the priming pump until fuel is confirmed to flow out of the air bleeding plug hole and then tighten it.

7.8 – 9.8 Nm {0.8 – 1.0 Nm} 3. There are the following two cases that the engine does not start up easily after bleeding air from CRI, (Common Rail Injection System), i.e. even after carrying out the Items 1 and 2 above. a If air has not been removed completely, leaving some in the system, cranking up the engine with the engine starting motor cannot get rid of the remaining air in a short span of time. Thus the engine start-up becomes difficult. 1) In the cases that the fuel has run out, that the fuel filter has been replaced or that some fuel device has been removed and installed. • Most of the fuel is left in the fuel circuit, so the engine may be started after bleeding air with the air bleeding methods introduced in the Item 1 and 2 above. 2) In the case that a number of fuel devices have been removed and installed in course of engine overhauling. • Little fuel is left in the fuel circuit, so air cannot be get rid of completely with the air bleeding methods introduced in the Item 1 and 2 above (i.e. ordinary method). In that case, bleed air in the following manner.

3 Air bleeding plug:

7.8 – 9.8 Nm {0.8 – 1.0 kgm} ii) Remove fuel pressure measuring plug (3) for the fuel filter and operate priming pump (4). • Continue to operate the priming pump until fuel is confirmed to flow out of the air bleeding plug hole and then tighten it.

3 Fuel pressure measuring plug:

3.9 – 6.9 Nm {0.4 – 0.7 kgm} iii) Loosen air bleeder (5) of the fuel supply pump (only after loosening the lock nut) and operate priming (4) 90 to 100 times. • Continue to operate the priming pump until fuel is confirmed to flow out of air bleeder (5) and then tighten it.

3 Air bleeder:

4.9 – 6.9 Nm {0.5 – 0.7 kgm} Still continue to operate the priming pump until it becomes harder to operate and a relief sound of overflow valve (6) in the fuel supply pump is heard. (A high pitch sound) it requires approx. 50 times of operation to reach that stage.

iv) Push in the knob of priming pump (4) to tighten it. v) Crank up the engine with the engine starting motor for start-up. a Do not keep the engine starting motor running idly for more than 20 seconds. Moreover try to start up the engine only after two minute pause. a If the engine does not start up even after repeating to crank for 20 seconds 4 times, insufficient air bleeding is suspected of. In that case, start the air bleeding steps once again from the beginning.

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BLEEDING AIR FROM FUEL CIRCUIT

4. Loosen air bleeder (5) of the fuel supply pump and operate priming pump (4) 90 to 100 times. a Continue operating the priming pump until fuel flow out from the bleeder. When fuel comes out, tighten the bleeder, then operate several times until the priming pump becomes stiff.

3 Air bleeder:

4.9 – 6.9 Nm {0.5 – 0.7 kgm} 5. Crank the engine with the starting motor and start the engine. a When the engine is cranked, the air in the high-pressure circuit is automatically bled. a If the engine does not start, the air has probably been not properly bled from the lowpressure circuit, so repeat the procedure from Step 2.

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INSPECTION OF FUEL CIRCUIT FOR LEAKAGE

INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, inspect it for fuel leakage according to the following procedure. a Clean and degrease the engine and the parts around it in advance so that you can inspect it easily for fuel leakage. 1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. 2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. 3. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 4. Run the engine at low idling. 5. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 6. Run the engine at high idling. 7. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2.
k

8. Run the engine at high idling and apply a load to it. a Relieve the oil by tilting the blade or raising the ripper. 9. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. a If any fuel leakage is not detected, inspection is completed.

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TESTING AND ADJUSTING

REDUCED CYLINDER MODE OPERATION FOR ENGINE

REDUCED CYLINDER MODE OPERATION FOR ENGINE
a Reduced cylinder mode operation for the engine means setting the fuel injectors of a single cylinder or multiple cylinders electronically to the NO injection condition to run the engine on a reduced number of cylinders. The reduced cylinder mode operation is used when it is though that one of the engine cylinders is not giving normal output (combustion). It is a method to determine which cylinder is not operating normally. a The reduced cylinder mode operation is carried out by using the reduced cylinder mode operation setting function on the monitor panel. a For details of the method of operation, see the TESTING AND ADJUSTING of chassis volume, Special functions of monitor panel.

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TESTING AND ADJUSTING ALTERNATOR BELT TENSION TESTING AND ADJUSTING TESTING AND ADJUSTINGANDCONDITIONER COMPRESSORBELT TENSION TESTING AIR ADJUSTING ALTERNATOR BELT TENSION

TESTING AND ADJUSTING ALTERNATOR BELT TENSION
Testing • Press the intermediate point between alternator pulley and drive pulley with a finger and measure deflection a of the belt. a Pressing force: Approx. 58.8 N {Approx. 6 kg}

TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
Testing • Press the intermediate point between air conditioner compressor pulley and drive pulley with a finger and measure deflection a of the belt. a Pressing force: Approx. 98 N {Approx. 10 kg}

Adjusting a If the deflection is abnormal, adjust it according to the following procedure. 1. Loosen the 2 alternator mounting bolts and the 1 adjustment rod set bolt. 2. Loosen locknut (1) and turn adjustment nut (2) to move alternator (3) and adjust the belt tension. 3. Tighten the 2 alternator mounting bolts and the 1 adjustment rod set bolt.

Adjusting a If the deflection is abnormal, adjust it according to the following procedure. 1. Loosen the 2 compressor bracket mounting bolts (1). 2. Loosen locknut (2) and turn adjustment nut (3) and adjust the belt tension. 3. Tighten the 2 compressor bracket mounting bolts (1).

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ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL

ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system • The following signals are input as rotation command signals to the engine controller. • Fuel control dial potentiometer signal • Decelerator pedal potentiometer signal • 3rd throttle signal The engine controller controls the fuel control system of the engine (CRI system) according to the one of the above input signals having the lowest engine speed. • Adjust the deceleration slow rotation by adjusting the decelerator pedal linkage.

2. Preparation work 1) Start the engine, set the monitor panel in the “Adjustment mode”, and prepare for measuring the engine speed. a For the method of operation, see “Special functions of monitor panel (EMMS)”. • Adjustment code: 0007 (Engine deceleration cut mode) a The engine speed is displayed in 1 rpm.

[1] [2] [3] [4] [5] [6] [7] [8]

Fuel control dial Engine controller Steering and transmission controller Decelerator pedal Decelerator pedal potentiometer Engine (CRI system) 3rd throttle signal Rod

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TESTING AND ADJUSTING

ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL

3. Adjusting decelerator pedal engine speed With the fuel control dial in the high idling position, press decelerator pedal (1) to stopper bolt (2) and check that the decelerator pedal engine speed is normal. • Decelerator pedal engine speed: 975 – 1,025 rpm • Potentiometer output: 3.8 ± 0.1 V a If the decelerator pedal engine speed is abnormal, adjust installed dimension a of stopper bolt (2). • Standard installed dimension a of stopper bolt: 23 mm 4. High idling engine speed Set the fuel control dial in the high idling position and check that the high idling engine speed is normal. • High idling engine speed: 2,050 – 2,150 rpm • Potentiometer output: 0.8 ± 0.1 V • Standard installed dimension b of stopper bolt: 24 mm a If the engine speed is abnormal, perform the following. • When the engine speed is above 2,150 rpm: Lower the engine speed below 2,050 rpm temporarily with stopper bolt (3) to eliminate the play of the decelerator pedal, and then adjust the engine speed to the high idling speed. • When the engine speed is below 2,050 rpm: Adjust the engine speed to the high idling speed with stopper bolt (3).

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TESTING AND ADJUSTING

MEASURING POWER TRAIN OIL PRESSURE

MEASURING POWER TRAIN OIL PRESSURE
a Measuring instruments for power train pressure
Symbol 1 G 2
k

Part No. 799-101-5002 790-261-1204 799-401-2320

Name Hydraulic tester Digital hydraulic tester Hydraulic tester (1 MPa {10 kg/cm2})

Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and safety lock lever in the LOCK position. a Measure the power train oil pressure under the following condition. • Power train oil temperature: 70 – 80ºC a The centralized power train pressure pickup ports are installed inside the inspection cover (1) on the right outside of the operator’s cab.

1. Measuring brake pressure 1) Remove oil pressure pickup plug (1) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/ cm2}.

a List of oil pressure measuring points and gauges to be used
No. 1 2 3 4 Measured oil pressure Steering brake pressure Torque converter inlet pressure Torque converter outlet pressure Transmission main relief pressure Gauge (MPa {kg/cm2}) 6 {60} 2.5 {25} 1 {10} 6 {60}

2) Run the engine and set the parking brake lever in the FREE position. 3) Measure the oil pressure while the engine is running at low idling and high idling. a Check that the oil pressure lowers to 0 when the brake pedal is pressed or the parking brake lever is set in the LOCK position.

4) After finishing measurement, remove the measuring instrument and return the removed parts.

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MEASURING POWER TRAIN OIL PRESSURE

2. Measuring torque converter inlet pressure 1) Remove oil pressure pickup plug (2) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.

3. Measuring torque converter outlet pressure 1) Remove oil pressure pickup plug (3) and connect hydraulic tester G2. a Use an oil pressure gauge of 1 MPa {10 kg/ cm2}.

2) Start the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling. 4) After finishing measurement, remove the measuring instrument and return the removed parts. a For the oil pressure gauge, see BPD11546.

2) Start the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling.

4) After finishing measurement, remove the measuring instrument and return the removed parts.

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MEASURING POWER TRAIN OIL PRESSURE

4. Measuring transmission main relief pressure 1) Remove oil pressure pickup plug (4) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/ cm2}.

5. Measuring clutch pressure • Remove the operator’s seat assembly and measure the clutch pressure from the top of the floor frame. a List of oil pressure measuring points and necessary gauges
No. 5 6 7 8 9 Measuring point Transmission forward clutch pressure Transmission reverse clutch pressure Transmission 1st clutch pressure Transmission 2nd clutch pressure Transmission 3rd clutch pressure Gauge (MPa {kg/cm2}) 6 {60} 6 {60} 6 {60} 6 {60} 6 {60}

2) Start the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling. 4) After finishing measurement, remove the measuring instrument and return the removed parts. a For the oil pressure gauge, see BPD11546.

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TESTING AND ADJUSTING

MEASURING POWER TRAIN OIL PRESSURE

1) Measuring transmission forward clutch pressure i) Remove oil pressure pickup plug (5) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the FORWARD and 3rd gear speed position. iv) Measure the oil pressure while the engine is running at high idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. v) After finishing measurement, remove the measuring instrument and return the removed parts. 2) Measuring transmission reverse clutch pressure i) Remove oil pressure pickup plug (6) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the REVERSE and 3rd gear speed position. iv) Measure the oil pressure while the engine is running at high idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. v) After finishing measurement, remove the measuring instrument and return the removed parts.

3) Measuring transmission 1st clutch pressure i) Remove oil pressure pickup plug (7) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the FORWARD and 1st gear speed position. iv) Measure the oil pressure while the engine is running at low idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. k Do not run the engine at high idling while measuring. v) After finishing measurement, remove the measuring instrument and return the removed parts. 4) Measuring transmission 2nd clutch pressure i) Remove oil pressure pickup plug (8) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the FORWARD and 2nd gear speed position. iv) Measure the oil pressure while the engine is running at low idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. k Do not run the engine at high idling while measuring. v) After finishing measurement, remove the measuring instrument and return the removed parts.

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TESTING AND ADJUSTING

MEASURING POWER TRAIN OIL PRESSURE

5) Measuring transmission 3rd clutch pressure i) Remove oil pressure pickup plug (9) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the FORWARD and 3rd gear speed position. iv) Measure the oil pressure while the engine is running at low idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. k Do not run the engine at high idling while measuring. v) After finishing measurement, remove the measuring instrument and return the removed parts.

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TESTING AND ADJUSTING

ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)

ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)
1. Remove the undercover of the fuel tank, and then remove transmission speed sensor assembly (1) from steering case (2).

2) Pull the connector of sensor (3) out of the flange hole of tube (6) and insert it in connector assembly (7) (securely until it clicks).

3) Install connector assembly (7) to tube (6). 4.9 – 6.9 Nm {0.5 – 0.7 kgm} 4) Insert sensor (3) in the boss of tube (6) and secure it with nuts (4) and (5). a Installed dimension of sensor: Dimension L measured when removed ± 0.2 mm

3 Mounting bolt:

2. Measure dimension L of removed sensor (3). a When replacing the sensor, be sure to measure dimension L.

3 Locknut: 49 – 68.7 Nm {5 – 7 kgm} 2 Threads of sensor: Adhesive (LT-2)

4. Install sensor assembly (1) to steering case (2). • Standard clearance between bevel gear and sensor tip: 0.65 – 1.65 mm 5. After finishing adjustment, set the monitor panel in the “Monitoring display mode” and check that it displays the transmission speed normally. a For the operating method, see “Special functions of monitor panel (EMMS)”. a Monitoring code: 31400 (Transmission speed)

3. Assembly procedure for sensor assembly 1) Remove only nut (4) from sensor (3) and insert sensor (3) in the opening at the end of tube (6) from the connector side.

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SIMPLE METHOD OF TESTING BRAKE PERFORMANCE

SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
a Carry out the simple test of brake performance under the following condition. • Power train oil temperature: Within operating range 1. Set the blade and ripper (if equipped) in the travel position on a level place.

2. Run the engine and set the parking brake lever in the FREE position. 3. Run the engine at low idling and press the brake pedal and set the PCCS lever in the FORWARD and 2nd gear speed position. k If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd gear speed. a Set the steering unit in neutral. 4. Press the decelerator pedal and set the fuel control dial in the high idling position. 5. Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idling level. k Since the torque converter will be stalled, press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.

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D65EX, PX-15

Lightly push rod (3) on the valve side toward the rear of the machine. 3.5 mm • Fitting dimension b of damper: 25 mm 2. and turn only joint (7) to connect rods (3) and (6). Adjust fitting dimension b of damper (2) so that the soroke of brake pedal (1) will be dimension a. and bend the cotter pins securely. • Pedal stroke a: 77. then connect to brake valve lever (4).3 – 58. PX-15 20-135 (1) . 3 Joint: 34. • Fitting dimension c of rod: 773 mm a Fully screw joint (5) into the valve side.8 Nm {3.0 kgm} D65EX.5 – 6.8 – 19.6 N {1 – 2 kg}. then connect to brake pedal (1). a Push rod (3) with a force of about 9. Adjust fitting dimension d of rod (6) on the pedal side.TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL ADJUSTING BRAKE PEDAL 1 Tighten the locknuts of the rods and cables securely. • Fitting dimension d of rod: 175 mm 4. 1. Adjust fitting dimension c of rod (3) on the valve side.

After adjusting the pedal. adijust its play with dimension e between the poins of rod assembly (8). 26} 0 Remarks Engine at full throttle 8. 20-136 (1) D65EX. adjust the zero point of the brake potentiometer (Adjustment mode: 0005). Checking brake oil pressure Oil pressure MPa {kg/cm2} Brake OFF Brake ON Min.55 {Min. • Play of pedal: 3 – 8 mm (Center of pedal) • Dimension e between pins of rod assembly: 978 mm a Adjust by turning joints (5) and (7) in the same direction. When brake pedal (1) released. 7. With brake pedal (1) released. check that brake pedal (1) is in contact with damper (2). 2. a For the method of operation.TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL 5. 6. PX-15 . see “Special functions of monitor panel (EMMS)”.

• Spool stroke h: 13. a For the method of measuring the brake oil pressure. lowered: ON • Operation stroke of limit switch: 3 mm 2) Install lever assembly (1). see MEASURING POWER TRAIN OIL PRESSURE. see “SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)”. Checking brake oil pressure Check that the brake oil pressure is as follows when the parking brake lever is set in the FREE and ROCK positions. • Monitoring code: 40910 (Steering controller related switch input 1) D65EX. Assembling and installing lever assembly 1) Assemble lever assembly (1) and adjust the operation of limit switch (2). Adjusting length of parking brake cable 1) Connect parking brake cable (3) to the lever and valve and adjust dimensions a and b. Checking limit switch Change the monitor panel to the monitoring display mode and set the parking brake lever in the FREE and ROCK positions. 2. Check that the limit switch signal is normal at this time. a For the operating method of the monitoring display mode.3 mm 3.5 mm • Dimension b of cable: 166 mm 2) Operate parking brake lever (4) between the FREE and LOCK positions and adjust rod end (6) so that spool stroke h of brake valve (5) will be normal. • Dimension a of cable: 148. a When assembling the lever assembly.TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL Adjusting at parking brake lever 1. • LOCK position: 0 FREE position: Specified pressure 4. PX-15 20-137 (1) . • When lever is raised: OFF. disconnect the parking brake cable from the lever.

1. steering). 20-138 (1) D65EX.TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE a Devices used for emergency escape Symbol 1 H 2 3 Part No. k Set the all gear speed switches of switch assembly [1] in the OFF position and the direction switch in the P position to prevent the machine from starting suddenly. a Since the male side of connector PL2 is kept disconnected. etc. PX-15 . gear speed. If the engine cannot be started. • Connector PL2 (2): Connect to female side. • Connector PL1 (1): Connect to male side and female side. 1) Connect switch assembly [1] to wiring harness [2] of emergency escape device H1. escape according to the following procedure. mask it with a vinyl sheet. a The engine must be startable for the following procedure. 3) Open the battery cover on the left of the cab and remove the cover of relay box (3). Name 19M-06-32820 Switch assembly 17M-06-41530 Wiring harness 790-190-1600 144-865-6260 Pump assembly Elbow (R 3/8 x M18) 2) Remove the cover on the left of the toe board and connect wiring harness [2] to connectors PL1 (1) and PL2 (2). Escape with switch box (Use H1) a If the machine cannot be moved because of a trouble in the electric system of the power train control unit (travel direction. see EMERGENCY ESCAPE WITH BRAKE RELEASING DEVICE.

Accordingly. a The gear speed switch is so made that the switch on the lower gear speed will be operated first. 2) Install volume pump [6] of pump assembly H2 to the outside of the operator’s cab. PX-15 20-139 (1) . a model selection error is made and the neutral safety relay does not work. 6) Operate switch assembly [1] and move the machine to a safe place. be sure to carry out troubleshooting and repair the trouble. escape according to the following procedure. before starting the engine. The above work must be performed to avoid this phenomenon. 2. D65EX. If the engine does not start in another case. set the parking brake lever in the LOCK position and set the PCCS lever in the full neutral position. k Start the engine by this method only in an emergency.TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 4) Disconnect the neutral safety relay (NSF) and connect pins [3] and [5] of the connector on the wiring harness side. 1) Assemble pump assembly H2. the neutral safety function does not work. 5) Start the engine and set the parking brake lever in the FREE position. 3) Remove the fuel tank undercover and plug (5) (R 3/8) of the brake release pressure supply port of brake valve (4). Escape with brake releasing device (Use H2) a If the engine cannot be started and the parking brake cannot be released. a If the connector (PL2) is disconnected. k If the engine is started by this method.

5) Turn the starting switch ON and set the parking brake lever in the FREE position.TESTING AND ADJUSTING EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 4) Install elbow H3 and connect end hose [7] of pump assembly H2. 20-140 (1) D65EX.74 MPa {28 kg/cm2} a Since an accumulator is installed in the circuit. operate the volume pump again to raise the brake releasing pressure to the intial pressure. In this case. the relief valve may be set to low pressure. the handle must be operated 30 – 50 times to raise the oil pressure.5 MPa {16 kg/cm2}. a If the oil pressure does not rise above a certain level. adjust the set pressure of the relief valve. In this case. loosen the screw slowly and do not stand in the spouting direction of the oil. 6) Operate the vacuum pump to raise the brake releasing oil pressure to the initial pressure. 7) Tow the machine to a safe place. • Initial pressure: Approx. 2. a The brake releasing oil pressure lowers gradually because of internal leakage and the brake is applied again about 1 minutes after. the brake is applied. Accordingly. 8) When disconnecting the hose after finishing the work. a If the brake releasing pressure lowers to about 1. work quickly. PX-15 .

and outside).0 mm INSPECTING WEAR OF SPROCKET a Use the “Full-scale dimensions drawing of sprocket profile” in “Sprocket” in STRUCTURE. OPERATION. a Make a copy of the “Full-scale dimensions drawing of sprocket profile” on a transparent paper or sheet and apply it directly to the sprocket to see if the sprocket can be used. 1. D65EX.5 – 1. • Standard clearance a on each side: 0. inside. Adjustment procedure 1) Drive the machine 1 – 2 m on flat ground. 2) If clearance a is larger than 4 mm. and then measure clearance a between the track frame and guide plate (at 4 places on both sides. AND MAINTENANCE STANDARD as a gauge for measuring wear of the sprocket. PX-15 20-141 (1) . loosen bolt (1) and reduce shim (2).0 mm • Shim thickness: 1.TESTING AND ADJUSTING ADJUSTING CLEARANCE OF IDLER ADJUSTING CLEARANCE OF IDLER INSPECTING WEAR OF SPROCKET ADJUSTING CLEARANCE OF IDLER a If the lateral guide of the idler are so worn that the idler runs out or slants. adjust the clearance of the idler according to the following procedure.

3 Plug: 59 – 88 Nm {6 – 9 kgm} 3. a Do not apply the brake when stopping. • Standard clearance a: 20 – 30 mm Adjusting a If the track shoe tension is abnormal. a If the track shoe is not tensed well. 20-142 (1) D65EX. do not loosen the plug more than 1 turn. 1. 2. then stop it. PX-15 . When tension is low Add grease through grease fitting (3). When the tension is too high Loosen plug (2) to discharge the grease. Place straight steel bar between the idler and front carrier roller and measure clearance a between the bottom of the steel bar and shoe grouser. drive the machine forward and in reverse slowly.TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION TESTING AND ADJUSTING TRACK SHOE TENSION Testing 1. Remove cover (1). k Since the high-pressure grease may spout out. Drive the machine slowly on a level place. adjust it according to the following procedure. 2.

and set the parking brake lever and work equipment lock lever in the LOCK position. Part No. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}. 2) Running the engine at high idling. D65EX. a Oil pressure measuring points (2): Main pump pressure (3): Load sensing pressure (LS pressure) 3) After finishing measurement. set the blade lever and ripper lever in neutral and measure the oil pressure.TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE a Testing and adjusting instruments for work equipment and HSS oil pressure Symbol G1 k 1. PX-15 20-143 (8) . a Measure the work equipment and HSS oil pressure under the following condition. remove the measuring instrument and return the removed parts. lower the work equipment to the ground. Measuring unload pressure 1) Remove oil pressure pickup plug (2) and connect oil pressure gauge [1] of hydraulic tester G1. • Hydraulic oil temperature: Within operating range a The centralized work equipment and HSS oil pressure pickup ports are installed inside the inspection cover (1) on the right outside of the operator’s cab. 795-101-5002 790-261-1204 Name Hydraulic tester Digital hydraulic tester Stop the machine on a level place.

ii) Run the engine at high idling and operate the blade lever and ripper lever. PX-15 . a Block the return hose of the blade lift cylinder. When each cylinder is relieved at the stroke end. k Since the steering circuit will be stalled. iii) After finishing measurement. Work equipment oil pressure i) Run the engine and set the work equipment lock lever in the FREE position. remove the measuring instrument and return the removed parts. and press the brake pedal. keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. When the steering circuit is relieved. Measuring work equipment and HSS oil pressure 1) Connect oil pressure gauges [1] of hydraulic tester G1 to pump oil pressure pickup port (2) and load sensing pressure pickup port (3). ii) Run the engine at high idling and steer to the right or left with the PCCS lever. measure the oil pressure. remove the measuring instrument and return the removed parts. a Use the following oil pressure gauges Work equipment oil pressure: 40 MPa {400 kg/cm2} HSS oil pressure: 60 MPa {600 kg/cm2} HSS oil pressure i) Run the engine. 20-144 (8) D65EX. set the parking brake lever in the FREE position. measure the oil pressure.TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE 2. iii) After finishing measurement.

the oil pressure is heightened. 2) LS pressure (Load sensing pressure) of HSS Loosen locknut (7) of HSS LS valve (6) and rotate adjustment screw (8) to adjust the LS pressure.1 MPa {154 kg/cm2}. the pressure is heightened or lowered by 17. check the relief pressure and LS pressure of work equipment again. a If the adjustment screw is rotated 1 turn. PX-15 20-145 (1) . D65EX.TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE 3. a If the adjustment screw is • rotated to the right. 68.6 MPa {179 kg/cm2}. • rotated to the left. • rotated to the left. the oil pressure is heightened.5 Nm {7 – 8 kgm} After adjusting.6 – 78. the pressure is heightened or lowered by 15. 3 Locknut: • 3 Locknut: • 29.4 – 39. a If the adjustment screw is • rotated to the right. a If the adjustment screw is rotated 1 turn. the oil pressure is lowered. check the relief pressure and LS pressure of work equipment again. the oil pressure is lowered. Adjusting 1) LS pressure (Load sensing pressure) of work equipment Loosen locknut (4) of work equipment LS valve (3) and rotate adjustment screw (5) to adjust the LS pressure.2 Nm {3 – 4 kgm} After adjusting.

6. It is used commonly for blade PPC. • Hydraulic oil temperature: Within operating range 1. Measuring k Stop the machine on a level place. 799-101-5002 790-261-1204 799-401-3200 02896-11009 Name Hydraulic tester Digital hydraulic tester Oil pressure pickup adapter (Size 03) O-ring 4. a Use an oil pressure gauge of 6 MPa {60 kg/ cm2}. fan pump control. 3. After finishing measurement. remove the measuring instrument and return the removed parts. and set the parking brake lever and work equipment lock lever in the LOCK position. a Measure the control circuit main pressure under the following condition. PX-15 . steering EPC and ripper PPC (if equipped). 2. 20-146 (8) D65EX. Install nipple [1] of hydraulic tester J1 and connect oil pressure gauge [2]. Run the engine at high idling and set the blade lever and ripper lever in neutral and measure the oil pressure. Adjusting a The self-pressure reducing valve cannot be adjusted. Open the main control valve cover on the right of the operator’s cab. lower the work equipment to the ground. Install oil pressure pickup adapter J2 and connect the disconnected hose again.TESTING AND ADJUSTING TESTING CONTROL CIRCUIT MAIN PRESSURE TESTING CONTROL CIRCUIT MAIN PRESSURE a Testing and adjusting instruments for control circuit main pressure Symbol 1 J 2 Part No. 5. a The control circuit main pressure is the pressure lowered by the self-pressure reducing valve. Disconnect hose (1).

operate the lever until the blade floats. see the drawing on the next page. lower the work equipment to the ground. • Hydraulic oil temperature: Within operating range 5.TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE MEASURING PPC VALVE OUTPUT PRESSURE a Measuring instruments for PPC valve output pressure Symbol 1 K 2 k 4. 3. 799-101-5002 790-261-1204 799-401-3100 02896-11008 Name Hydraulic tester Digital hydraulic tester Oil pressure pickup adapter (Size 02) O-ring Stop the machine on a level place. D65EX. Part No. a Before measuring the PPC valve output pressure. Run the engine at high idling and operate the control lever of the circuit to be measured and measure the oil pressure. a For the circuits to be measured. a When measuring the blade circuit. 6. 2. a Measure the PPC valve output pressure under the following condition. 7. Disconnect PPC valve output pressure hose (1). Open the main control valve cover on the right of the operator’s cab. After finishing measurement. and set the parking brake lever and work equipment lock lever in the LOCK position. Install oil pressure pickup adapter K2 and connect the disconnected hose again. Install oil pressure pickup adapters K2. Start the engine and set the work equipment lock lever in the FREE position. remove the measuring instrument and return the removed parts. a Measure the oil pressure with the lever at a stroke end. Install nipple [1] of hydraulic tester K1 and connect oil pressure gauge [2]. 1. check that the control circuit main pressure is normal. PX-15 20-147 (8) .

2.TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE 1. Main valve Self-pressure reducing valve PPC lock valve Blade PPC valve Ripper PPC valve (If equipped) A. Blade LEFT TILT Blade LOWER Ripper RAISE Ripper LOWER Blade RAISE Blade RIGHT TILT 20-148 (1) D65EX. 4. F. D. E. B. PX-15 . C. 5. 3.

a If the end play of the blade lever is excessive. Remove boot (1). PX-15 20-149 (1) . D65EX. Install boot (1).0 mm at 200 mm from revolution center of lever (in both longitudinal and lateral directions) 1. • Standard play a: 0. 3. adjust it with their PPC valves according to the following procedure. Fix disc (3) and tighten locknut (2). Loosen locknut (2) and turn disc (3) to adjust the play. a Do not move the piston at this time. 2.5 – 3.TESTING AND ADJUSTING ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE a The ripper valve is not adjustable. 3 Locknut: 98 – 127 Nm {10 – 13 kgm} 4.

Run the engine at high idling and apply the relief pressure to the cylinder bottom side. • Ripper tilt cylinder: Operate to tilt ripper forward. • Hydraulic oil temperature: 45 – 55ºC a Since the blade lift cylinder is equipped with a piston valve. PX-15 . 1. a Measure the internal leakage of work equipment cylinder under the following condition. 1) Blade tilt cylinder Lower the blade tip to the ground. 3. 4. its internal leakage cannot be measured. Run the engine at low idling for about 5 minutes. measure leakage in 1 minute. Disconnect hose on the cylinder head side and block the hose side with a plug. • Ripper lift cylinder: Operate to lower ripper. extend and retract the cylinder to be bled 4 – 5 times. BLEEDING AIR FROM WORK EQUIPMENT CYLINDER a If the work equipment cylinder is removed and installed or its piping is disconnected and connected. After 30 second. 3) Ripper tilt cylinder Tilt the ripper forward to the end. return the removed parts. 20-150 (5) D65EX. 1. a Remove the hose cover of the blade tilt cylinder. After finishing measurement. move the cylinder to the stroke end to relieve the oil. Extend the cylinder to be measured to the stroke end and set the machine in the measuring position. bleed air from its circuit according to the following procedure. k Take care not to disconnect the hose on the bottom side. Running the engine at high idling and carry out the operation in 2. 4. 2) Ripper lift cylinder Pull out the shank pin and lower the ripper to the end.TESTING AND ADJUSTING MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER BLEEDING AIR FROM MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER a Measuring instruments for internal leakage of work equipment cylinder Symbol L Part No. 5. a Move the piston rod to about 100 mm before the stroke end and never relieve the oil. Purchased Name Measuring cylinder 3. 2. • Blade tilt cylinder: Operate to tilt blade to left. 2. Running the engine at low idling. Running the engine at low idling.

4. backward. 1. to the right.> • Start the engine again and perform steps 1 and 2 (This operation is recommended). 2. perform either of the following operations. Run the engine at low idling and lower the blade and ripper to the ground without relieving each hydraulic cylinder. 1. the residual pressure in the accumulator is fully released. 3. release the residual pressure in the circuit according to the following procedure. a After turning the starting switch OFF. D65EX. RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (If PPC accumulator is not installed) a When disconnecting the piping between the control valve and work equipment cylinder.TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (If PPC accumulator is installed) RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (If PPC accumulator is not installed) RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (If PPC accumulator is installed) a When disconnecting the piping between the control valve and work equipment cylinder. a After the levers are operated 2 .3 times. Apply cloths to the joint of the cylinder piping and loosen the sleeve nut gradually to release the residual pressure. a Lower the blade gradually to the ground. Loosen the hydraulic tank cap gradually to release the residual pressure in the tank.10 minutes after stopping the engine. • Wait for 5 . while shaking the hose slowly. 3. Loosen the hydraulic tank cap gradually to release the residual pressure in the tank. <If the engine was stopped while a hydraulic cylinder was relieved at the stroke end. Just after the blade reaches the ground. a Check that the residual pressure is released and oil does not spout out any more. Turn the starting switch OFF and quickly operate the blade lever and ripper lever forward. 4. a Lower the ripper gradually to the ground. Repeat above steps 2 and 3 by 2 . release the residual pressure in the circuit according to the following procedure. Set the work equipment lock lever in the FREE position and operate the blade lever and ripper lever forward. set the blade lever in the FLOAT position. to the right. operate the levers quickly until the engine stops completely. and then perform following steps 3 and 4. and to the left. PX-15 20-151 (8) .3 times. and then disconnect the piping. Run the engine at low idling for about 5 seconds. 2. and then stop it. backward. and to the left.

a Install connecting pin (4) on the work equipment lock lever side with the cotter pin on the outside of the machine. PX-15 . • Dimension a between pins: 330 mm 2. Adjust dimension a between pins of rod (1).TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT LOCK LEVER ADJUSTING WORK EQUIPMENT LOCK LEVER 1. 20-152 (8) D65EX. Connect rod (1) to work equipment lock lever (2) and PPC lock valve (3).

Remove fan guard (1). and set the monitor panel in the adjustment mode. Run the engine at high idling and low idling and measure the fan motor speed. 1. k Take care that the probe will not interfere with the fan. Close the radiator mask. k Be sure to close the radiator mask before starting the engine. Stick 1 sheet of reflecting tape [1] to fan (2). After finishing measurement. PX-15 20-153 (8) . a For the method of operation in the adjustment mode.TESTING AND ADJUSTING MEASURING FAN MOTOR SPEED MEASURING FAN MOTOR SPEED a Measuring instruments for fan motor speed Symbol M Part No. 799-205-1100 Name Tachometer kit 6. matching it to reflecting tape [1]. 2. 5. 7. run the engine. Set probe [2] of multitachometer [4] to stand [3]. see “Special functions of monitor panel (EMMS)”. a Adjustment code: 1005 (Fan 100% speed mode) D65EX. 3. remove the measuring instrument and return the removed parts. Open the radiator mask. Do not start the engine with the radiator mask open. 4. then connect it to multitachometer [4].

Open the radiator mask. Run the engine and set the monitor panel in the adjustment mode. After finishing measurement. Install nipple [1] of hydraulic tester P1 and connect oil pressure gauge [2]. 799-101-5002 790-261-1204 799-401-3400 02896-11015 Name Hydraulic tester Digital hydraulic tester Oil pressure pickup adapter (Size 05) O-ring 4. Remove fan guard (1). a Adjustment code: 1005 (Fan 100% speed mode) 6. remove the measuring instruments and return the removed parts. 5. a For the method of operation in the adjustment mode. Remove cover (2) and disconnect fan motor drive circuit hose (3). 3. see “Special functions of monitor panel (EMMS)”. a Use an oil pressure gauge which can measure 40 MPa {400 kg/cm2}. 2. 1. PX-15 . Install oil pressure pickup adapter P2 and connect hose (3) again. Run the engine at high idling and measure the fan circuit pressure. 7.TESTING AND ADJUSTING MEASURING FAN PUMP CIRCUIT PRESSURE MEASURING FAN PUMP CIRCUIT PRESSURE a Measuring instruments for fun pump circuit pressure Symbol 1 P 2 Part No. 20-154 (8) D65EX.

2. run the engine at low idling. 4.TESTING AND ADJUSTING BLEEDING AIR FROM FAN PUMP BLEEDING AIR FROM FAN PUMP a If the fan pump was removed and installed or its piping was disconnected and connected. After 15 minutes. PX-15 20-155 (1) . Loosen air bleeder (1) and leave it for 15 minutes. Remove the inspection cover on the right of the floor. D65EX. 3. tighten air bleeder (1). check that the hydraulic oil is at the specified level. 1. bleed air from the pump case according to the following procedure. a Before performing the following procedure. When oil flows out of the air bleeder (1). a Remove the operator’s seat.

Adjustment of shims Adjustment section Item Tilt section (3) Center section (4) Lift section (5) Unit: mm Trunnion section (6) 2) Measure right and left tilting distances B1 and B2. PX Right tilting distance B1 (mm) Left tilting distance B2 (mm) Approx. 1. PX-15 . • B1 B2: Increase installed dimension A finely. and trunnion section (6).2 – 1. 2.2 – 0. adjust the shims of tilt section (3). • Installed dimension A of brace PX A (mm) 1147 EX 1151 3) If the tilting distances are different remarkably. adjust it according to the following procedure. lift section (5).TESTING AND ADJUSTING ADJUSTING STRAIGHT TILTDOZER ADJUSTING STRAIGHT TILTDOZER a If the blade was removed and installed or disassembled and assembled. (5): Grease (G1-T) 20-156 (1) D65EX. center section (4). (4).7 0. 440 Clearance Standard clearance (Note) Standard thickness of shim a b c d 0. adjust installed dimension A of brace (1) according to the following procedure. adjust installed dimension A of brace (1) with handle (2).2 – 0. Adjusting shims for blade assembly 1) After assembling the blade.2 – 0. 440 2 Adjustment sections (3). Adjusting blade tilting distance 1) After installing the blade.2 5 5 4 10 Note: Play of spherical part in axial direction 2) Supply grease each adjustment section and check that each part rotates smoothly. 450 EX Approx.7 0. • B1 B2: Decrease installed dimension A finely. Approx.7 0. 450 Approx.

5 mm 2) Loosen bolt (9). Adjusting center brace a Adjust the center brace tension according to the following procedure. 3) Operate the blade control lever to float the blade. 4) Insert a bar in the hole of center brace (10) and turn it in the tensing direction.5 EX 995 a Adjust center brace (10) so that clearances e between the track and frame on both sides will be the same.TESTING AND ADJUSTING ADJUSTING STRAIGHT TILTDOZER 3. PX-15 20-157 (1) . a Tension adjustment torque of center brace (10) 3 Center brace: 24.2 – 0. 1) Adjust clearance b of ball joint (7) with shim (8). D65EX. lock it with the safety lever securely.5 – 49 Nm {2. • Clearance b: 0.5 – 5 kgm} 5) Installed dimension of center brace (10) Standard dimension C: PX C (mm) 991. k After operating the blade control lever.

a [a] side: Inside of cab (Pressurized) [b] side: Out of cab (Atmospheric pressure) 2. caulk the leaking part and check again.000 mm ii) Secure the inside end of the hose to the top of the back seat with a tape. Pass the other end of the hose through the bolt hole and take it out of inspection cover (2) on the left side of the cab.TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR’S CAB TESTING AND ADJUSTING OPERATOR’S CAB Check after installing cab assembly 1. 4) Check around the dashboard carefully. iii) Remove bolt (1) under the left console box. v) Fill the hose with water up to about the half level and bend the hose in the shape of letter U. a If water leaks. Length: 3. Measuring pressure in cab • Criterion: Measured value X 58. PX-15 . iv) Seal the hole of bolt (1) with tape (3). it is not necessary to splash pressurized water.9 Pa {6 mmH2O} • Engine speed: High idling • Fan speed: 100% mode (See the User adjustment mode of the monitor panel) • Fan switch of air conditioner: High • EXTERNAL/INTERNAL air changeover switch of air conditioner: Fresh air position a If the measured value is lower than the standard value. • Inside diameter: 6 mm. 3) Splash water horizontally from a hose over sealing surface (4). (Value c: Pa {mmH2O}) 20-158 (5) D65EX. check the seals of the holes for wiring harnesses and optional parts in the cab. Check of searing performance 1) Close the all openings of the cab. 1) A simple method of measuring the internal pressure is as follows. vii) Run the engine at high idling and measure water level difference c. i) Prepare a transparent vinyl hose. • At this time. vi) Set the water level in the vinyl hose out of the cab to that in the cab. 2) Splash water around the hatched part of the cab at the rate of about 19 l/min for 10 minutes.

PX-15 20-159 (5) . 2) Adjusting i) Adjusting height of damper rubber • Loosen the mounting bolts of damper rubber (1). etc. the damper rubber comes in contact lightly. repair it. • Increase or decrease of shims (5) under damper rubber (1) to adjust the height of damper rubber (1) properly.) • Stick adhesive tape 1 . 2 pieces on each. (Check both sides. check the contact face of adhesive tape 1 against the operator’s cab. the damper rubber does not come in contact or comes in contact so strongly that adhesive tape is removed. Normal: When the door is closed. • Close door (2) and check the engaging condition of latch (3) and striker (4). D65EX. • Normal: Error of “a” must be 0. If there is any fault. a You can remove and install the shims without removing the mounting bolts.5 mm or less. Then. a Check deviation a of latch center y and striker center x from each other from the direction of A. 1) Check of condition i) Check the installed height to damper rubber (1).TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR’S CAB 3. Testing door lock • Close the door and check the relationship between the operator’s cab and door. ii) Check the relationship between the door notch and striker (on both sides). Abnormal: When the door is closed. to the contact face of damper rubber (1) and open and close the door 2 – 3 times.

Accordingly. • Normal: Error of “e” must be 0. 4. If the door is not locked and unlocked smoothly (If the knob is heavy). 2 pieces on each. (4) Open and close the door and check that it is locked and unlocked smoothly.TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR’S CAB ii) Adjusting height of latch and striker (1) Tighten the mounting bolt of striker (4) temporarily bolt and close the door 2 – 3 times to align latch (3) and striker (4) with each other. (2) Check that the operating effort of unlock lever is not heavy. Testing open lock • Lock the door open and check the relationship between the operator’s cab and door.5 mm or less. repair it. a Operating effort of knob: 49 ± 19. If there is any fault. apply grease sufficiently. ii) Check the installed height of stopper rubber. (4) Check that the latch is not shifted from center (e) of the striker. perform the adjustment procedure from the first. a Move the door in the opening direction to check the engagement of the latch and striker. and tighten mounting bolt (7). (3) Tighten the mounting bolt of striker (4) securely. the knob becomes heavy. (3) Check that striker (4) does not slant from center (d) of the latch. a If latch (3) is not greased.) (1) Lock the door open and shake it in the forward and reverse directions to see if it has any play. PX-15 . 20-160 (5) D65EX. adjust striker (4) upright. 1) Check of condition i) Check the relationship between open lock latch (3) and striker (4) from the direction of B. 2) Adjusting i) Adjusting latch and striker • Loosen mounting bolt (7) of striker (4). (2) Check the engaging condition of latch (3) and striker (4).6 N {5 ± 2 kg} iii) Apply grease (G2-LI) to latch (3). (Check both sides.

(3) Tighten the locknut. lower side (9). a If the door is not locked easily or the unlock lever is heavy. (2) If there is any play. (11) of the stopper rubber upper side (8). D65EX. project (heighten) the stopper rubber until the play is eliminated. PX-15 20-161 (1) . return (lower) the stopper rubber in the range that the door does not hevy any play.TESTING AND ADJUSTING TESTING AND ADJUSTING OPERATOR’S CAB ii) Adjusting installed height of stopper rubber (1) Loosen the locknut (10).

Buzzer cancel switch 5. Upper display section (Gear speed display section) 2. Information switch 6. Lower display section (Multi-information section) Operation section 1 of special functions (Basic operation) 3. Service switch Operation section 2 of special functions (Changeover operation) 4. PX-15 .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) Display section of special functions 1. Shift-down switch a EMMS: Equipment Management Monitoring System 20-162 (1) D65EX. Shift-up switch 7.

and troubleshooting. filter maintenance mode Maintenance item: 12 items [ON] & [U]( ) Service mode Maintenance interval change mode [>] 6 [<] Electric system error code display mode [>] 7 [<] Mechanical system error code display mode [>] 8 9 [>] [>] [>] [>] 5 [<] Adjustment menu: 16 items Display menu: 3 items [<] [<] [<] [<] [ON]: [U]: [ T ]: [ > ]: [ < ]: ( ): Service switch Buzzer cancel switch (Left) Buzzer cancel switch (Right) Information switch (Right) Information switch (Left) Min. Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed according to the operation of the switches. 1. Flow of modes and functions Operator mode Normal display (Default) 1 2 Travel direction/Gear speed + Shift mode/Service meter [U] ( ) [T] (Automatic) Action code display function [T] 3 4 1 Oil. PX-15 20-163 (1) . Special function 1: Service mode With this function. 2. the operator can display and change the items displayed normally. Normal function: Operation mode With this function. filter maintenance mode [>] [>] [>] [>] [<] Auxiliary menu: 4 items [<] [<] Adjustment menu: 4 items [<] Pm clinic auxiliary mode Error code display mode Adjustment mode Oil. a serviceman can display and change the displayed items with special switches for testing.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) Normal function and special functions of monitor panel (EMMS) The monitor panel (EMMS) has the normal function and special functions and displays information of various types at the gear speed display section at its center and the multi-information section. 2. adjusting.5 sec Adjustment mode Load memory display mode 5 Maintenance item: 12 items 10 Real-time monitoring mode 11 Dual display monitoring mode Maintenance interval change mode D65EX.

PX-15 . No. • Front side: Gear shift mode (F1-R1·F1-R2·F2-R3) (Displayed when preset mode is set) • Rear side: Service meter (Unit: 0. Maintenance mode (1-OIL. the service meter and engine speed are displayed alternately. 1. a Gear speed display section (1) keeps displaying normally.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) Operation and display in operator mode (Outline) a In this section. 01 02 03 04 05 06 07 08 09 10 11 12 Engine oil Engine oil filter Fuel filter Hydraulic oil filter Corrosion resistor Bypass filter a Damper oil Final drive oil Hydraulic oil Power train oil Power train oil filter HSS charge filter (HSS specification) a Maintenance item The items marked with a are displayed but not used for this machine. FILTER MAINTENANCE MODE) In this mode. the time up to the next replacement of oils and filters is displayed on the multi-information section (2) and reset after the replacement. 20-164 (1) D65EX. Gear speed display section (1): • Front side: Travel direction (P·N·F·R) • Rear side: Gear speed (1·2·3) • Graphics: Engine speed Multi-information section (2): a Information is displayed in 2 lines of 16 characters each. For the details of the contents and operation method of each function and mode.1h) • Each time the information switch is set to the right or left. only the outline of the operation mode is described. Normal display mode (Default) The monitor panel displays the following information normally. see Operation Manual.

the contents of each fault in the machine are displayed by a 6-character error code on the multi-information section (2). When the user or the operator needs to be notified of the error code of each fault. even if any measuring instrument is not connected. this mode is applied. Error code display mode (3-ERROR CODE DISPLAY MODE) In this mode. the Electric system error code display mode and the Mechanical system error code display mode should be used for more detailed information. 3.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 2. D65EX.) a For the error codes list. and the all error codes detected currently are displayed at the interval of about 2 seconds. a Gear speed display section (1) keeps displaying normally. Pm clinic auxiliary mode (2-PM CLINIC MODE) In this mode. PX-15 20-165 (1) . a When a serviceman needs to check the error codes for troubleshooting. a Gear speed display section (1) keeps displaying normally. (To finish displaying. No. turn the buzzer cancel switch to the [ T ] position. a Method of checking error code: Turn buzzer cancel switch (4) to the [U] position on the screen shown at right. they are not used for this machine. 01 02 03 04 Pm clinic auxiliary item Engine speed Boost pressure Work equipment pressure a Battery voltage Although the items marked with a are displayed. the condition of the machine is displayed on multi-information section (2) as an auxiliary function of the periodic diagnoses such as the Pm clinic. see TROUBLESHOOTING.

a Gear speed display section (1) keeps displaying normally. 01 02 03 Adjustment item Brightness of LCD Brightness of display Contrast of display 20-166 (1) D65EX. PX-15 .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 4. the display condition of the monitor panel can be adjusted on the multi-information section (2). No. Adjustment mode (4-USER ADJUST MODE) In this mode.

depends on the form of the input No. • Call your Komatsu distributor for repair. • Machine stops. a Gear speed display section (1) keeps displaying normally. • Caution lamp flashes. (The form of the displayed phone No. are displayed on the multi-information section (2). • Fan speed is kept at maximum. • Stop machine immediately. • Gear is not shifted up or down. • Caution lamp flashes. • Steering performance lowers. and you can operate machine without limiting function. • Engine speed does not rise fully. • Machine cannot travel. Even if an action code is not displayed. be sure to check for a error code in the “Electric system error code display mode” and “Mechanical system error code display mode” of the service mode. however. • Engine cannot be controlled. an action code and a phone No. You must take care. • Backup alarm does not sound. • Caution buzzer sounds. E02 • Action code is displayed. • Call your Komatsu distributor for repair. is displayed for only important action codes. • Engine boost pressure is abnormal. • Stop engine and start it again. • Engine water temperature is defective. D65EX. PX-15 20-167 (1) . • Usable gear speeds are limited. • Move machine to safe place. • Exhaust gas color is bad when temperature is low. the caution lamp flashes and the caution buzzer sounds. The display shown at right is an example. CALL E03 • Action code is displayed. • Caution buzzer sounds. If you feel any abnormality.) a If an important action code is displayed. • Caution buzzer sounds. • Call your Komatsu distributor for repair.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) Action code display function If a fault to be notified to the operator occurs during work. • Gear shifting shocks become large. a fault may have occurred. • Caution lamp flashes. <Reference> An action code is displayed only when a serious fault occurs. E01 • Only action code is displayed. Action codes table Action code Indication method of fault Contents of fault Remedy • Automatic function stops or normal function stops partially but machine can work. • Call your Komatsu distributor for repair. CALL E04 • Action code is displayed. a The phone No.

a If the monitor panel is set in the service mode. 5 6 7 8 9 10 11 Gear speed display section Service mode item Maintenance interval change mode Electric system error code display mode Mechanical system error code display mode Adjustment mode Load memory display mode Real-time monitoring mode Dual display monitoring mode 1C EE bE Cb Ld 5R dR 20-168 (1) D65EX. • [ > ]: Next mode No. (2) When finishing the all operation: Turn off the starting switch. (1) When continuing the operation in another mode or function or in the operator mode: Return to the mode screen or function screen to be used next by operating buzzer cancel switch (4). 1) Special operation of switches Set the monitor panel in the service mode by operating service switch (3) and buzzer cancel switch (4). • [ < ]: Previous mode No. • [ T ]: Screen returns. a Each time the monitor panel is set in the service mode. see the following pages.5 seconds. [1C] is displayed on the gear speed display section (1). hold the buzzer cancel switch in the [U] position for 2. regardless of the current mode and hierarchy. PX-15 . 2) Selecting and executing mode to be used Select the mode to be used with information switch (5) and execute it with buzzer cancel switch (4). a Keeping the service switch in the ON position. 3) Finishing mode and function The current mode and function can be finished by either of the following method. • [U]: Execute mode. change the screen by the following special operation. the “Maintenance inter val change mode” is displayed first. a For the details of operation in each mode. No.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) Operation and display in service mode Method of changing to service mode a When using the service mode.

finish the operation on this screen. Maintenance interval change mode (5-EXCHG. a If the mode is selected. • [U]: Execute mode. INTVAL. SET MODE) In this mode. a If the replacement interval needs to be changed. code (1C) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). you can check and set the maintenance interval times of various filters and oils which are the bases of the maintenance display function in the operator mode. D65EX. • [U]: Execute item. 3) Contents of information section The following items are displayed on the information section. • [ > ]: Next code • [ < ]: Previous code ii) Display the maintenance item selection screen by operating buzzer cancel switch (4). 1 : Code 2 : Maintenance item 3 : Replacement interval time (Set time) a The items shown at right are examples. a If the replacement interval does not need to be changed. PX-15 20-169 (1) . ii) Display the maintenance item selection screen by operating buzzer cancel switch (4). 1) Selecting and executing mode i) Select “Maintenance interval change mode” on the mode selection screen. go to step 4).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 5. 2) Selecting and displaying maintenance item i) Operate information switch (5) on the maintenance item selection screen to select a maintenance item.

the information display screen appears after the screen shown at right. • [UP]: Increase number. ii) If the input time is correct. execute the above operation again. a If you do not use the maintenance function. and shift-down switch (7). enter the change of setting by operating buzzer cancel switch (4). In this case. • [ < ]: Move cursor to left. 20-170 (1) D65EX. shift-up switch (6).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 4) Changing replacement interval time i) Change the set time by operating information switch (5). • [U]: Enter change. a If the change is finished normally. set the all times to 0. a If the change is not finished normally. PX-15 . the information display screen before the change appears after the screen shown at right. • [DOWN]: Decrease number. • [ > ]: Move cursor to right.

and the former cannot be changed.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) Maintenance items table Replacement interval time Code 01 02 03 04 05 06 07 08 09 10 11 12 ENG OIL ENG FILT FUEL FILT HYD FILT CORR RES BYPS FILT DAMP OIL FNL OIL HYD OIL POWL OIL POWL FILT HSS FILT Maintenance item Engine oil Engine oil filter Fuel filter Hydraulic oil filter Corrosion resistor Bypass filter Damper oil Final drive oil Hydraulic oil Power train oil Power train oil filter HSS charge filter (HSS specification) 1st time (Cannot be changed) 0500h 0500h 0500h 2000h 1000h — 2000h 1000h 2000h 1000h 0500h — 2nd time and after (Can be changed) 0500h 0500h 0500h 2000h 1000h — 2000h 1000h 2000h 1000h 0500h — a The first replacement interval is the same as the second and after replacement intervals. PX-15 20-171 (1) . D65EX.

20-172 (1) D65EX. 3) Display in the case where 1 or more codes are recorded If any error code has been output up to now. • [U]: Execute mode. you can check the electric system error codes. 1) Selecting and executing mode i) Select “Electric system error code display mode” on the mode selection screen. ii) Display the error code display screen by operating buzzer cancel switch (4). the information section displays as shown at right. ERROR CODE MODE) In this mode.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 6. the information section displays as shown at right. see TROUBLESHOOTING. PX-15 . 1 : Record No. (Up to 20) 2 : Error code (Code being output currently is flashing) 3 : Number of past occurrences 4 : Time measured by service meter after first occurrence 5 : Time measured by service meter after last occurrence a The items shown at right are examples. code (EE) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). Electric system error code display mode (6-ELEC. a For the error codes list. 2) Display in the case where no codes are recorded If no error codes have been output up to now. a If the mode is selected.

5) Method of deleting error code While a error code to be deleted. After the starting switch is turn on or the engine is started again. When multiple codes are recorded. • [UP] or [DOWN]: Delete error code. 4) Operation to take when multiple codes are recorded. a A error code which is being output currently (which is flashing) cannot be deleted. A error code of communication starts lighting when the fault is solved. even if the starting switch is turned off.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) a Flashing and lighting of error code Flashing: Code is being output currently. Lighting: Code is not being output currently. it keeps flashing until the starting switch is turned off. PX-15 20-173 (1) . the error code keeps lighting until the same fault is detected. a Condition for detecting and keeping error code If a error code of any item other than communication is output. D65EX. they can be displayed one by one by operating information switch (5). • [ > ]: Next code • [ < ]: Previous code a The error codes are displayed from the oldest one in order of length of time after they were output. operate shift-up switch (6) or shift-down switch (7).

2 : Error code (Code being output currently is flashing) 3 : Number of past occurrences 4 : Time measured by service meter after first occurrence 5 : Time measured by service meter after last occurrence a The items shown at right are examples. a For the error codes list. a If the mode is selected. ii) Display the error code display screen by operating buzzer cancel switch (4). 3) Display in the case where 1 or more codes are recorded If any error code has been output up to now. PX-15 . 1) Selecting and executing mode i) Select “Mechanical system error code display mode” on the mode selection screen. 20-174 (1) D65EX. see TROUBLESHOOTING. Mechanical system error code display mode (7-MACHINE ERROR CODE MODE) In this mode. 1 : No. 2) Display in the case where no codes are recorded If no error codes have been output up to now. • [U]: Execute mode. the information section displays as shown at right. you can check the mechanical system error codes. code (bE) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2).TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 7. the information section displays as shown at right.

4) Operation to take when multiple codes are recorded When multiple codes are recorded. Lighting: Code is not being output currently. they can be displayed one by one by operating information switch (5). it keeps flashing until the starting switch is turned off. PX-15 20-175 (8) . the error code keeps lighting until the same fault is detected. After the starting switch is turned on or the engine is started again. • [ > ]: Next code • [ < ]: Previous code a The error codes are displayed all of them including no-failed modes in numerical order. even if the starting switch is turned off. A error code of communication starts lighting when the fault is solved. 5) Method of deleting error code The mechanical system error codes cannot be deleted. a Condition for detecting and keeping error code If a error code of any item other than communication is output. D65EX.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) a Flashing and lighting of error code Flashing: Code is being output currently.

a If the mode is selected. input the 4-digit code of the item to be adjusted by operating information switch (5). • [DOWN]: Decrease number. Adjustment mode (8-SERVICE ADJUST MODE) In this mode. 2) Selecting adjustment items i) On the adjustment code input screen. ii) After inputting the code. operate buzzer cancel switch (4) to display the monitoring screen. code (Cb) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). • [ < ]: Move cursor to left. • [ > ]: Move cursor to right.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 8. PX-15 . shift-up switch (6). • [UP]: Increase number. • [U]: Enter input code. 1) Selecting and executing mode i) Select “Adjustment mode” on the mode selection screen. ii) Display the adjustment code input screen by operating buzzer cancel switch (4). • [U]: Execute mode. and shift-down switch (7). you can adjust the control system and various devices of the machine. 20-176 (1) D65EX.

gear speed display section (1) displays normally and the machine can be operated normally.) To change the shift. 3) Contents of display on adjustment screen 1 : Code 2 : Adjustment item 3 : Related information a For the detailed information and adjustment procedure.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) a If an incorrect code is input. see “ADJUSTMENT MODE TABLE AND ADJUSTMENT PROCEDURE”. a At this time. the adjustment code input screen appears again after the screen shown at right. a To select another screen. even if the shift-up or shiftdown switch is pressed with the PCCS lever in the neutral position. execute the above operation again. D65EX. return the parking brake lever to the LOCK position and perform the necessary procedure. set the PCCS lever in the FORWARD or REVERSE position and press the shift-up or shift-down switch while the machine is traveling. PX-15 20-177 (1) . the shift cannot be changed. 4) When operating machine in adjustment mode If the parking brake lever is set in the FREE position. In this case. (The displayed number is the code of adjustment mode selection.

R-SET 2222 HSS ADJUST 9997 HI IDLE SET 9998 SFT INHIBIT Steering lever neutral set Steering lever left set Steering lever right set HSS lever initial current set High idling limit mode Gear speed limit mode Items marked with q in the Disassembly/Assembly column of the above table must be adjusted after the machine is assembled or any controller is replaced.FULL CH 0008 INJ->123456 0009 PITCH SENS. Adjustment mode table and adjustment procedure No. 20-178 (6) D65EX. input mode Steering and transmission controller specification set Machine specification set Brake potentiometer zero point adjustment Engine deceleration-cut mode Common rail reduced cylinder mode Pitch angle sensor initial set Related information Figure/Symbol Code Code Voltage Speed Speed Voltage Adjustment data Adjustment data Voltage Voltage Voltage Current Speed Symbol Disassembly/ Assembly q q q q 0010 FAN 70%MODE Fan 70% speed mode 1005 FAN100%MODE Fan 100% speed mode 1012 S/T N-SET 1013 S/T M. [1] a[2] a[3] a[4] a[5] [6] a[7] a[8] a[9] [10] [11] [12] [13] [14] [15] k Code 0001 INP TEL NO. Take care. (For the adjustment procedure.) a The numbers marked with a can be displayed in order by setting the information switch in the “ > ” or “ < ” position. see “ADJUSTMENT AFTER REPLACEMENT OF CONTROLLER”. PX-15 .L-SET 1014 S/T M. 0002 S/T S.CODE 0004 BODY TYPE 0005 BRAKE BASE 0007 ENG. a This operation is not accepted while the parking brake lever is in the FREE position.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 5) Changing adjustment item (Limited function) Once the adjustment items are selected. a An adjustment item can be selected by returning to the input screen and inputting the code for that item. Adjustment item Phone No. they can be selected with the information switch without inputting the codes again. • [ > ]: Next code • [ < ]: Previous code a This function is limited to the numbers marked with a in the “ADJUSTMENT ITEMS TABLE”.

• Adjustment method: 1) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. [ 2 ] 0002: Steering and transmission controller specification set • This code is used to initialize the specification codes recognized by the steering controller and the set values of the memory in the controller. a Sixteen digits of numeric characters are provided. and shift down switch (7). a If specification code [444] is not displayed.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) [ 1 ] 0001: Phone number input mode • This code inputs or changes a phone number to be displayed simultaneously with when the user code is displayed. • [ > ]: Moves the cursor rightward. input a phone number and symbols. input symbols other than numeric characters at digits you will not use. • The specification code is displayed on the lower line. • The lower part displays a phone number and symbols.) a The setting is enabled even after ending this code. • [ < ]: Moves the cursor leftward. 2) Check that the displayed specification code has changed from [4 4] to [444]. To avoid confusion. the setting is effective. the controller wiring harness or the controller unit may be defective. shift up switch (6). (No phone number is displayed under this condition. 2) Set buzzer cancel switch (4) in the [U] position and check that the alarm buzzer sounds. a 0 (zero) is input at all places of the lower part before shipment from our factory. PX-15 20-179 (1) . • Available characters: 0 1 2 3 4 5 6 7 8 9 : . < > ? • Instructions for use: 1) By operating the information switch (5). a Even if this code is turned off. • [DOWN]: Reverse the numeric character or character (in the reverse order of available characters). D65EX. • [UP]: Advance the numeric character or character (in the order of available characters).

a This code is not for adjustment of the braking performance. set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. • Adjustment method: a Since this code is reset when “Steering and transmission controller specification set” is executed. • The machine specification code is displayed on the lower line. k If the machine specification is different from the setting in the controller. Code 000 008 080 088 010 018 090 098 Standard For EU district For cold Specification For EU district + For cold district Pitch specification For EU district + Pitch specification For cold district + Pitch specification For EU district + For cold district + Pitch specification [ 4 ] 0005: Brake potentiometer zero point adjustment • This code is used to adjust the zero point of the potentiometer of the brake pedal. PX-15 .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) [ 3 ] 0004: Machine specification set • This code is used to have the machine specification recognized by the controllers which compose the system. a Even if the neutral position of the brake pedal is adjusted. the display of the lower line does not change. a Even if this code is turned off. the setting is effective. 20-180 (1) D65EX. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. adjust it after that. etc. 1) Select the code of the machine specification by setting shift up switch (6). the setting is effective. • The deviation from the standard is displayed by voltage on the lower line (Display range: –2500 – 2500). a Even if this code is turned off. Accordingly. be sure to match the setting to the machine specification. the machine may move abnormally or an error may be made. • Adjustment method: With the brake pedal released.

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) [ 5 ] 0007: Engine deceleration-cut mode • This code is used to stop the auto-deceleration function of the engine and check the high idling speed of the engine singly. • The engine speed is displayed on the lower line (Display range: 0 – 3000). • Using method: While this code is displayed. use this function while the engine is running. a Only one or more cylinders can be turned off for the reduced cylinder mode operation. • Using method: Select the cylinders to be turned off for the reduced cylinder mode operation by operating information switch (5) and buzzer cancel switch (4). this code is used to stop injecting fuel into 1 or more cylinders (reduce the number of effective cylinders) while the engine is running and find out a faulty cylinder from the change of the engine speed. 2 cylinder is turned off for reduced cylinder mode operation and turned on again (The cylinder No. its function is turned off. Use this method to turn on the selected cylinders again. • [ > ]: Move cursor to right. a The figure at right is an example that No. [ 6 ] 0008: Common rail reduced cylinder mode a When the engine common rail system seems to be faulty. too. a If this code is turned off. PX-15 20-181 (1) . lamp is turned off in the reduced cylinder mode operation and on in the normal mode operation). its function is turned on and the auto-deceleration function is turned off. • [U]: Execute or stop reduced cylinder mode operation. a If this code is turned off. D65EX. • The engine speed is displayed on the lower line (Display range: 0 – 3000). • [ < ]: Move cursor to left. its function is turned off. a Since a fault is detected by the difference of the engine speed in the reduced cylinder mode operation from that in the normal mode operation.

• Instructions for use: The function is enabled with this code displayed to control the rpm of cooling fan to approximately 70% of the maximum speed. then set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. the display of the lower line does not change. 20-182 (1) D65EX. PX-15 . the setting is effective. a Even if this code is turned off.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) [ 7 ] 0009: Pitch angle sensor initial set • This code is used to adjust the zero point and installation error of the pitch angle sensor. • The lower part displays data for adjustment. a Even after adjustment. • Adjustment method: Stop the machine on level ground. [ 8 ] 0010: Fan 70% speed mode • This code forcedly sets the rpm of cooling fan at approximately 70% of the maximum speed. a Ending this code disables the function. • The deviation from the standard neutral position is displayed by voltage on the lower line (Display range: –2500 – 2500).

• Instructions for use: The function is enabled with this code displayed to control the rpm of cooling fan to approximately 100% of the maximum speed. etc.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) [9] 1005: Fan 100% speed mode • This code forcedly sets the rpm of cooling fan at approximately 100% of the maximum speed. [10] 1012: Steering lever neutral set • This code is used to adjust the steering potentiometer neutral position of the PCCS lever. • The output signal of steering potentiometer from displayed by voltage on the lower line (Display range: 0 – 5000). the setting is effective. a Even if this code is turned off. D65EX. a Even after adjustment. a This code is not for adjustment of the steering performance. • The lower part displays data for adjustment. a Ending this code disables the function. • Adjustment method: 1) Shift the PCCS lever in the steering neutral position. the display of the lower line does not change. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. PX-15 20-183 (6) .

a Even if this code is turned off. a Even after adjustment. [12] 1014: Steering lever right set • This code is used to adjust the maximum right steering potentiometer position of the PCCS lever. • The output signal of the steering potentiometer from displayed by voltage on the lower line (Display range: 0 – 5000). PX-15 . 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. a Even if this code is turned off. a Even after adjustment. • Adjustment method: 1) Set the PCCS lever to the left steering stroke end. a This code is not for adjustment of the steering performance. etc. etc. • The output signal of steering potentiometer from displayed by voltage on the lower line (Display range: 0 – 5000). the display of the lower line does not change. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. the setting is effective. the setting is effective. • Adjustment method: 1) Set the PCCS lever to the right steering stroke end. a This code is not for adjustment of the steering performance. the display of the lower line does not change.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) [11] 1013: Steering lever left set • This code is used to adjust the maximum left steering potentiometer position of the PCCS lever. 20-184 (6) D65EX.

[14] 9997: High idling limit mode • This code is used to limit the use high idling speed.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) [13] 2222: HSS lever initial current set • When the steering start feeling is different by the steering direction. this code is used to adjust the turning radius at the start of steering. the setting is effective. the setting is effective. • Limit range: High idling speed – approx. the engine speed is not raised to the normal high idling level even if the fuel control dial is controlled so. the current becomes negative. a If the high idling speed is limited. a The figure at right is an example that the set current for steering to the left is reduced to increase the turning radius. display and keep the current to be set. • Adjustment method: 1) Gradually turning the PPC lever to the left or right. • If the lever is turned to the right. • If the lever is turned to the left. • The current to drive the HSS EPC solenoid is displayed on the lower line [Display range: –350 (Left end) – 0 – 350 (Right end)]. the current becomes positive. D65EX. the turning radius at the start of steering is decreased (the machine turns more quickly). a Even if this code is turned off. PX-15 20-185 (8) . 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds. –200 rpm • Using method: 1) Select a limit speed by setting information switch (5) in the [ > ] position or [ < ] position. a As the set current is increased in the positive or negative direction. a Even if this code is turned off. 2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer sounds.

and 1st from the left). • [ > ]: Do not prohibit shifting to 3rd gear speed. • Using method: Limit or allow the use of the maximum gear speed by operating information switch (5) and buzzer cancel switch (4). 20-186 (6) D65EX. the setting is effective. • Display on lower line [ ]: Gear speed is not effective. a Even if this code is turned off. the transmission is not shifted to that gear speed even if the gear shift-up switch is operated. • The usable gear speeds are displayed by bits on the lower line (in the order of the 3rd.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) [15] 9998: Gear speed limit mode • This code is used to limit the use of the 3 gear speeds. • [U]: Enter the selection. a If the use of a gear speed is limited. PX-15 . 2nd. • Display on lower line [o]: Gear speed is effective. • [ < ]: Prohibit shifting to 3rd gear speed.

you can check the load on the machine. forward odometer. D65EX. and reverse odometer. No. ii) Display the adjustment code input screen by operating buzzer cancel switch (4). 1) Selecting and executing mode i) Select “Load memory display mode” on the mode selection screen. code (Ld) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). a The data cannot be reset. 2) Changing information screen Change the information screen by operating information switch (5). PX-15 20-187 (1) . Load memory display mode (9-LOAD MEMORY DISPLAY MODE) In this mode.000 rpm service meter Forward odometer Reverse odometer 3) Display of 1. • [ < ]: Previous screen. • [U]: Execute mode.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 9. a If the mode is selected. 01 02 03 Displayed information 1.000 rpm service meter (01) This code is used to display the service meter which integrates the operation hours only while the engine speed is higher than 1.000 rpm. • [ > ]: Next screen.

return the parking brake lever to the LOCK position and perform the necessary procedure. even if the shift-up or shiftdown switch is pressed with the PCCS lever in the neutral position. 5) Display of reverse odometer (02) On this screen.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 4) Display of forward odometer (02) On this screen. (The displayed number is the code of load saving display mode. a At this time. the shift cannot be changed. set the PCCS lever in the FORWARD or REVERSE position and press the shift-up or shift-down switch while the machine is traveling. PX-15 . a The data cannot be reset. 20-188 (1) D65EX. gear speed display section (1) displays normally and the machine can be operated normally. the integrated reverse travel distance is displayed. a The data cannot be reset. the integrated forward travel distance is displayed. 6) When operating machine in load memory display mode If the parking brake lever is set in the FREE position. a To select another screen.) To change the shift.

D65EX. • [ > ]: Move cursor to right. • [ < ]: Move cursor to left. and shift-down switch (7). • [DOWN]: Decrease number. oil temperatures. • [U]: Decide selection. PX-15 20-189 (1) .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 10. 2) Selecting and entering monitored items i) On the code input screen. shift-up switch (6). ii) After inputting the code. voltages. a If the input code is correct. switches. a This mode is used to monitor the items one by one. display the monitoring screen by operating buzzer cancel switch (4). When monitoring two items simultaneously. a If the mode is selected. • [UP]: Increase number. input the 5digit code of the item to be monitored by operating information switch (5). Real-time monitoring mode (10-REAL TIME MONITORING MODE) In this mode. 1) Selecting and executing mode i) Select “Real-time monitoring mode” on the mode selection screen. oil pressures. • [U]: Enter input code. use the “Dual display monitoring mode”. and solenoids installed various parts of the machine. can be monitored by using the signals from sensors. the monitoring screen shown at right appears. ii) Display the monitoring code input screen by operating buzzer cancel switch (4). currents. the speeds. code (5R) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). etc.

a To select another screen. a While the monitored item is held. • [U]: Hold and release. (The displayed number is the code of monitoring mode. a At this time.) To change the shift. see the “MONITORING MODE TABLE”. 4) Function of holding monitoring information If an information item such as the engine speed is not stabilized and cannot be read easily in the monitoring mode. 5) When operating machine in monitoring mode If the parking brake lever is set in the FREE position. gear speed display section displays normally and the machine can be operated normally. the code input screen appears again after the screen shown at right. the shift cannot be changed. PX-15 . 3) Contents of display on monitoring screen (Right figure shows examples) 1 : Code 2 : Monitoring item 3 : Information 4 : Unit (Not displayed for some items) a For the details. 20-190 (1) D65EX.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) a If the input code is not correct. it can be held and released by operating buzzer cancel switch (4). set the PCCS lever in the FORWARD or REVERSE position and press the shift-up or shift-down switch while the machine is traveling. even if the shift-up or shiftdown switch is pressed with the PCCS lever in the neutral position. return the parking brake lever to the FREE position and perform the necessary procedure. the letter “H” is displayed at the left end of the lower line.

• [ > ]: Next code • [ < ]: Previous code a This function is applicable to only the numbers marked with .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 6) Changing monitored items (Limited function) Once the monitoring screen is selected in step 2). Take care. the monitored item can be changed by operating only information switch (5) without inputting the code again. PX-15 20-191 (1) . a This operation is not accepted while the parking brake lever is in the FREE position. D65EX.

TEMP. — ºC rpm Bit mA mA mA mA mA mA mA mA mA mA mA mA º MPa CA MPa KPa Character 0 – 150 0 – 5000 (See detailed information) 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 –30 – 30 0 – 150 –30. PROGRM 18 20300 KOMTRAX 19 30100 T/C TEMP.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) Monitoring mode table No. PX-15 . KOMTRAX LED display Torque converter oil temperature Transmission speed Input state of transmission-related fill switch Output command current of 1st clutch ECMV Output command current of 2nd clutch ECMV Output command current of 3rd clutch ECMV Output command current of reverse clutch ECMV Output command current of forward clutch ECMV Output FB current of 1st clutch ECMV Output FB current of 2nd clutch ECMV Output FB current of 3rd clutch ECMV Output FB current of reverse clutch ECMV Output FB current of forward clutch ECMV Output command current of cooling fan pump solenoid Output FB current of cooling fan pump solenoid Machine pitch angle Command value of fuel injection rate Command pressure of common rail Fuel injection timing Common rail pressure Boost pressure Engine control mode Converted torque of engine Fuel injection amount adjustment command value 1 Fuel injection amount adjustment command value 2 Travel speed (Theoretical value) Engine controller input signal 1 Engine controller input signal 2 Unit rpm mV % mV ºC ºC mV ºC ºC mV rpm Character Character Character Character Display range 0 – 3000 0 – 5000 0 – 100 0 – 30000 0 – 150 –30 – 100 0 – 5000 0 – 150 0 – 150 0 – 5000 0 – 2000 15 20200 MON. 13 10000 FAN REVO. PRESS 39 36500 BOOST. 20 31400 T/M OUT 21 31520 T/M-FILL 22 31602 1st CLUTCH 23 31603 2nd CLUTCH 24 31604 3rd CLUTCH 25 31606 Rev CLUTCH 26 31608 Frd CLUTCH 27 31612 1 CLUTCH F 28 31613 2 CLUTCH F 29 31614 3 CLUTCH F 30 31616 R CLUTCH F 31 31622 F CLUTCH F 32 31623 FAN PUMP. Steering controller program No. 12 04402 HYD.0 0 – 200 0 – 300 0 – 100 mm3/st –30 – 600 % Character 0123456789abcdef Character 0123456789abcdef km/h Bit Bit 0 – 100 (See detailed information) (See detailed information) 20-192 (1) D65EX.0 – 30. 14 20000 ENG-MACHIN 16 20202 S/T. TEMP. PRESS 37 36300 CRI-TIMING 38 36400 CRI. 17 20203 ENG-PROGRM Engine controller program No. CONTRL 41 36700 CRI-TORQUE 42 36800 CRI-Q-MOD1 43 36801 CRI-Q-MOD2 44 40001 VEHICLE SP 45 40900 ENG-SW 1 46 40901 ENG-SW 2 Monitored item Engine speed Voltage of fuel control dial Acceleration ratio Battery voltage Engine water temperature (High temperature side) Engine water temperature (Low temperature side) Fuel level sensor voltage Fuel temperature Hydraulic oil temperature Hydraulic oil temperature voltage Command speed of cooling fan Engine controller program No. SPEED 4 03000 FUEL DIAL 5 03001 FUEL DIAL 6 03200 BATTERY 7 04102 WATER HIGH 8 04104 WATER LOW 9 04200 FUEL SENS 10 04204 FUEL TEMP. PRES 40 36600 CRI.O 33 31624 FAN PUMP. PROGRM Monitor panel (Tachometer module) program No. Code 1 01000 ENG. 11 04401 HYD.F 34 32900 BODY ANGLE 35 36100 Q-INJECTOR 36 36200 CRI.

O 66 50900 N-SAFETY 67 51000 SSC ORDER 68 60000 TRACTION 69 60100 BODY ANGLE 70 60600 BR HOLD 71 60700 S/T MODE 72 60800 FILL MODE 73 60909 MOD.F 64 50602 HSS L.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) No. MODE 74 70000 CHG.H.F 63 50601 HSS R.H.1 55 50100 SSC 56 50101 SSC ORDER 57 50200 T/M LEVER 1 58 50201 T/M LEVER 2 59 50300 S/T LEVER 1 60 50301 S/T LEVER 2 61 50400 BRAKE PEDL 62 50600 HSS L. PX-15 20-193 (8) .1 77 70400 BACK ALARM 78 70500 Regulation Monitored item Transmission-related controller input signal 1 Transmission-related controller input signal 2 Transmission-related controller output signal Steering-related controller input signal 1 Steering-related controller input signal 2 Steering-related controller input signal 5 Output signal of steering controller 3rd throttle 3rd throttle command voltage Voltage of forward-reverse potentiometer 1 Voltage of forward-reverse potentiometer 2 Voltage of steering potentiometer 1 Voltage of steering potentiometer 2 Voltage of brake potentiometer Output FB current of left HSS solenoid Output FB current of right HSS solenoid Output command current of left HSS solenoid Output command current of right HSS solenoid Drive current of neutral safety relay 3rd throttle command speed Traction force (Theoretical value) Machine pitch angle sensor voltage Drive voltage of battery relay Steering state code Variable for setting fill condition Setting of modulation condition Variable for setting condition of gear shift point Input signal of work equipment-related controller Output signal of work equipment-related controller Drive voltage of back-up alarm relay Reguration speed Unit Bit Bit Bit Bit Bit Bit Bit % % mV mV mV mV mV mV mA mA mA mA mV rpm W mV mV Character Character Character Character Display range (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) 54 50000 DESEL PEDAL Deceleration ratio 0 – 100 0 – 100 0 – 5000 0 – 5000 0 – 5000 0 – 5000 0 – 5000 0 – 5000 0 – 1000 0 – 1000 0 – 1000 0 – 1000 0 – 30000 0 – 3000 0–0 0 – 5000 0 – 30000 Bit Bit mV rpm (See detailed information) (See detailed information) 0 – 30000 0 – 2200 The numbers marked with tion. Code 47 40905 T/M-SW1 48 40906 T/M-SW2 49 40909 T/M SOL. MODE 75 70300 B.H.KNOB SW 76 70304 T/M SOL.H. P.O 65 50603 HSS R. can be displayed in order by setting the information switch in the “ > ” or “ < ” posi- D65EX.2 50 40910 S/T-SW1 51 40911 S/T-SW2 52 40913 S/T-SW5 53 40914 S/T SOL.

PX-15 . a The bit information is displayed by [ _ ] for OFF and [o] for ON in the places 1 – 8 .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) Detailed information on bit display codes Examples of display of bit information a The display position of the bit information in the “Real-time monitoring mode (Display of only 1 item)” is different from that in the “Dual display monitoring mode (Simultaneous display of 2 items)”. 31520: Input state of transmission related fill switch 1 : Forward clutch fill switch: ON 2 : Reverse clutch fill switch: ON 3 : 1st clutch fill switch: ON 4 : 2nd clutch fill switch: ON 5 : 3rd clutch fill switch: ON 6 : (Unused) 7 : (Unused) 8 : (Unused) 40900: Engine controller input signal 1 1 : Starting switch signal C: Input 2 : (Unused) 3 : (Unused) 4 : Low engine oil pressure switch: ON 5 : High engine oil pressure switch: ON 6 : (Unused) 7 : (Unused) 8 : Model selection signal 1: ON 40901: Engine controller input signal 2 1 : Model selection signal 2: ON 2 : Model selection signal 3: ON 3 : (Unused) 4 : (Unused) 5 : N-signal 1: ON 6 : N-signal 2: ON 7 : (Unused) 8 : (Unused) 20-194 (8) D65EX. a The state of each item shown below is the condition for turning on the bit.

PX-15 20-195 (1) .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 40905: Transmission related controller input signal 1 1 : Gear shift-up switch: OFF 2 : Gear shift-up switch: ON 3 : Gear shift-down switch: OFF 4 : Gear shift-down switch: ON 5 : (Unused) 6 : (Unused) 7 : (Unused) 8 : (Unused) 40906: Transmission-related controller input signal 2 1 : Automatic gear shift-down switch: ON 2 : Fan reverse mode: ON 3 : Fan reverse 100% mode: ON 4 : (Unused) 5 : (Unused) 6 : (Unused) 7 : (Unused) 8 : (Unused) 40909: Transmission related controller output signal 1 : Transmission N-signal: ON 2 : N-signal 2: ON 3 : (Unused) 4 : Back-up alarm relay: ON 5 : Neutral safety relay: ON 6 : (Unused) 7 : (Unused) 8 : (Unused) 40910: Steering related controller input signal 1 1 : (Unused) 2 : (Unused) 3 : (Unused) 4 : (Unused) 5 : Parking brake lever switch: FREE 6 : Parking brake lever switch: LOCK 7 : (Unused) 8 : (Unused) D65EX.

PX-15 .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 40911: Steering related controller input signal 2 1 : Buzzer cancel switch: At U 2 : Buzzer cancel switch: At T 3 : Information switch: At < 4 : Information switch: At > 5 : Service switch: ON 6 : (Unused) 7 : (Unused) 8 : (Unused) 40913: Steering related controller input signal 5 1 : ACC signal: ON 2 : (Unused) 3 : (Unused) 4 : Motoring signal: ON 5 : (Unused) 6 : (Unused) 7 : (Unused) 8 : (Unused) 40914: Output signal of steering related controller 1 : (Unused) 2 : (Unused) 3 : Fan reverse solenoid: ON 4 : (Unused) 5 : Battery relay drive: ON 6 : (Unused) 7 : (Unused) 8 : (Unused) 70300: Input signal of work equipment related controller 1 : (Unused) 2 : (Unused) 3 : Pitch switch: OFF 4 : Pitch switch: ON 5 : (Unused) 6 : (Unused) 7 : (Unused) 8 : (Unused) 20-196 (8) D65EX.

PX-15 20-196-1 (8) .TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 70304: Output signal of work equipment related controller 1 : (Unused) 2 : Pitch solenoid: ON 3 : (Unused) 4 : (Unused) 5 : (Unused) 6 : (Unused) 7 : (Unused) 8 : (Unused) D65EX.

• [U]: Enter input code. and shift-down switch (7). a Note that only codes and monitoring information are displayed in this mode since the usable display columns are limited.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 11. 2 monitored items can be displayed simultaneously. D65EX. • [ < ]: Move cursor to left. • [U]: Execute mode. (Item names and units cannot be displayed. a If the mode is selected. Dual display monitoring mode (11-DUAL DISPLAY MONITORING MODE) In this mode. display the monitoring screen by operating buzzer cancel switch (4). input the 5digit codes of the items to be monitored to the upper and lower lines by operating information switch (5). • [DOWN]: Decrease number. ii) Display the monitoring code input screen by operating buzzer cancel switch (4). ii) After inputting the codes. code (dR) is displayed on gear speed display section (1) and the title is displayed on multi-information section (2). • [ > ]: Move cursor to right. 2) Selecting and entering monitored items i) On the code input screen. the monitoring screen shown at right appears. shift-up switch (6). • [UP]: Increase number. a If the input codes are normal.) 1) Selecting and executing mode i) Select “Dual display monitoring mode” on the mode selection screen. PX-15 20-197 (1) .

(The displayed number is the code of monitoring mode. gear speed display section (1) displays normally and the machine can be operated normally. even if the shift-up or shiftdown switch is pressed with the PCCS lever in the neutral position. 4) When operating machine in monitoring mode If the parking brake lever is set in the FREE position. set the PCCS lever in the FORWARD or REVERSE position and press the shift-up or shift-down switch while the machine is traveling. 20-198 (1) D65EX. see the “MONITORING MODE TABLE”. a To select another screen. PX-15 .) To change the shift. the code input screen appears again after the screen shown at right. return the parking brake lever to the FREE position and perform the necessary procedure.TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) a If the input codes are abnormal. 3) Contents of display on monitoring screen (Right figure shows examples) 1 : Code 1 2 : Information 1 3 : Code 2 4 : Information 2 a For the details. a At this time. the shift cannot be changed.

The following connectors are used in the highvoltage circuit.TESTING AND ADJUSTING HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER HANDLING OF HIGH-VOLTAGE CIRCUIT REPLACED CONTROLLER ADJUSTMENT METHOD OF OF ENGINE HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER ADJUSTMENT METHOD OF REPLACED CONTROLLER a After the machine is assembled or steering and transmission controller is replaced. k If the system is not adjusted. k If you touch the high-voltage circuit directly. CN-5. CN-6 • Injector head terminal (in head cover) 2. CN-2. 1. observe the following precautions. The engine controller has a high-voltage circuit (110 – 130 V) to drive the fuel injector. 2. Accordingly. • Engine controller connector: EN3 • Junction connector: E21 • Injector connectors: CN-1. a Precautions for replacing a controller: When replacing a controller. PX-15 20-199 (1) . be sure to adjust it. 1. 3. CN-4. adjust the system according to the following procedure. a Normally. To avoid this. k D65EX. the engine controller outputs the high voltage to the fuel injector only while the engine is running and stops outputting if the engine stops. be sure to turn off the starting switch. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting. When disconnecting or connecting a connector related to the high-voltage circuit. the memory of the oil and filter maintenance mode is reset. CN-3. take a record of the next replacement periods of the oils and filters. stop the machine in a safe place and turn the starting switch off. do not start the engine. you may get an electric shock. This circuit is connected to the wiring harness and connectors between the engine controller and fuel injector. Adjusting steering and transmission controller Select steering and transmission controller specification set (0002) and adjust the steering and transmission controller. Accordingly. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position. Setting system in service mode Turn the starting switch on and set the monitor panel in the “Adjustment mode” of the service mode. the machine may not operate normally and may move suddenly. a Precautions for replacing a controller: If a controller is replaced.

Turning power on again Turn the starting switch off and on. 2) See if any error code is being output currently. then set the monitor panel in the “Adjustment mode” of the service mode again. As a result. PX-15 . If any error code is not being output. 20-200 (1) D65EX. Adjusting pitch angle sensor Select and adjust the initial setting (0009) of the pitch angle sensor.TESTING AND ADJUSTING ADJUSTMENT METHOD OF REPLACED CONTROLLER 3. determine the first replacement periods of the oils and filters after the replacement of the controller according to the replacement periods recorded before the replacement of the controller. 6. remove its cause by troubleshooting and execute steps 6 and 7 again. 5. Adjusting brake potentiometer Select Brake potentiometer initial set (0005) and adjust the brake potentiometer. 8. To solve this problem. delete the all error codes. the replacement period displayed on the monitor panel may be different from the actual operating hours. 4. Adjusting machine specification Select Machine specification set (0004) and adjust the machine specification. a Precautions after replacing controller: If any controller is replaced. a If any error code is being output. Checking error codes 1) Set the monitor panel in the “Electric system error code display mode” of the service mode. Turning power on again Turn the starting switch off and on. 7. the service meter in the oil and filter maintenance mode is reset to 0.

tighten their screws to the specified torque. 2) Insert or connect T-adapters in or to connectors S03 and S04 on the back side of monitor panel (2). Engine controller 1) Remove left console box inspection cover (3). PX-15 20-201 (1) . and EN3 of engine controller (4). 3 Screw: 2. loosen those screws before disconnecting.288 kgm} D65EX.82 Nm {0. a Since the connectors are secured with screws. engine controller or steering and transmission controller. 2) Insert or connect T-adapters in or to connectors EN1. Monitor panel 1) Remove cover (1) above the dashboard. expose the related connectors according to the following procedure. a If the connectors cannot be disconnected and connected easily. EN2. 1. a When connecting the connectors again.TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM a When carrying out troubleshooting for an electric circuit related to the monitor panel. remove the controller from the floor frame. 2.

Steering and transmission controller 1) Insert or connect T-adapters in or to connectors ST1.TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM 3. a If the connectors cannot be disconnected and connected easily. loosen those screws before disconnecting. 3 Screw: 2. PX-15 . remove the controller from the floor frame. tighten their screws to the specified torque. a When connecting the connectors again. and ST3 of steering and transmission controller (5). ST2.82 Nm {0.288 kgm} 20-202 (1) D65EX. a Since the connectors are secured with screws.

PX. Min. digging Side cutting Grading Travel % % % % Existence of abnormalities Oil. Service meter h Date of clinic Serviceman D65EX. PX-15 20-203 (7) . Height above sea level m Operator's opinion Visual check results Service code history E Content: E Content: h h E Content: E Content: h h D65EX. range When necessary Power train Final drive Power train oil temperature Max. residential development Tunnels Type of soil (specific gravity ) Rock Gravel Sand Clay Type of work Dozing. water level check Engine coolant level Engine oil level Hydraulic oil level Engine coolant temperature Max. range Damper case ( ) Ambient temperature Max.TESTING AND ADJUSTING PM CLINIC SERVICE Pm CLINIC SERVICE Model Serial No. WX-15 User name Blade Semi-U blade Angle blade Straight tilt blade Specifications Attachment Multi-shank ripper Towing winch CAB ROPS 510 mm 560 mm 610 mm 660 mm Shoe width 810 mm 915 mm 950 mm Operating conditions Quarry. civil engineering Roads. mine Coal Gold Limestone Construction Construction.

WX-15 (1/2) “Reference Page for Measurement Procedure” designated. Blow-by pressure: 20-116 page 3. Boost pressure: 20-107 – 108 page 5. 1. Exhaust temprature: 20-109 – 110 page 20-204 (7) D65EX. PX. PX-15 . Engine oil pressure: 20-117 page 4.TESTING AND ADJUSTING PM CLINIC SERVICE Pm-clinic measuring points for D65EX. Engine speed: 20-105 page 2.

Phenomenon related to transmission: 20-130 page 8. 6. PX. WX-15 (2/2) “Reference Page for Measurement Procedure” designated. Phenomenon related to work equipment: 20-143 – 145 page D65EX.TESTING AND ADJUSTING PM CLINIC SERVICE Pm-clinic measuring points for D65EX. Phenomenon related to steering brake: 20-128 page 9. PX-15 20-205 (7) . Phenomenon related to torque converter: 20-129 page 7.

1.07 <0.39 – 0. 79. 650 Torque converter stall Blow-by pressure Torque converter stall Engine at low idling Engine at high idling Engine at low idling Engine at high idling Engine kPa <mmAq> SAE10W MPa <kg/cm2> SAE15W-40 SAE30 kPa <mmHg> ºC Engine oil pressure Boost pressure Torque converter stall Exhaust temperature Torque converter stall Item Torque converter Inlet oil pressure Outlet oil pressure Inlet oil pressure Outlet oil pressure Measurement conditions Unit Standard value for Service limit value Measurement results Pass new machine Fail Transmission: Neutral Oil temperature: 70 – 90ºC Engine at low idling MPa <kg/cm2> Engine at high idling 0.5 <1 – 5> 0. / Date / D65EX.6 {160 – 190} 20-206 (7) D65EX.69 <4.34 – 0.6 {190} 13. 1.7 {140} For EU spec.7> 0. PX. 9> 0. 3.04 <Min. MPa {kg/cm2} 19. 0.15 <Min.05 – 0.8 <Min. 29> Min.84 <Min.29 <0. 0.850 0 1. 1. +100 Fan pump pressure • Hydraulic oil temperature: 45 – 55ºC • Fan forward • Fan 100% speed mode • Engine: High idling Standard For EU spec.69 <4 – 7> 0.21 <2.07 <0. 2.5 {200 – 230} 15.8> 0.7 – 18. 9> 0.96 <Max.5 <1 – 5> 0.23 <31 – 33> 3.7> 0. PX-15 .0 – 7.0> Min. Serviceman Item Measurement conditions Low idling Unit Standard value for Service limit value Measurement results Pass new machine Fail 800 – 850 Deceleration pedal depressed 800 – 850 975 – 1025 2050 – 2150 1650 Max.6 – 22. 0. 200> 0.39 – 0.600 0 +100 1.1 – 0.64 <3.98 <Max. 100> Min.10 <Min.TESTING AND ADJUSTING PM CLINIC SERVICE Pm CLINIC CHECK SHEET Work order No.1 – 0. 80ºC Standard Unit Standard value for Service limit value Measurement results Pass new machine Fail Main relief pressure Transmission: Neutral MPa <kg/cm2> 3. 0. 600> Max. 31> Min.5> 0.1> 60 <450> 700 Engine speed High idling High idling rpm 975 – 1025 2050 – 2150 1670 – 1870 Max.23 – 3.5 – 3> Max.750 1.0> 0. WX-15 Service meter h Serial No. 0.18 <1.88 <Max.5 – 3> Max.500 18.88 <Max.43 <33 – 35> Min. speed rpm 800 ± 50 700 Cooling fan Fan speed idling • Fan 100% speed mode Max.5> Min.05 – 0.39 – 0.29 <0.03 – 3.69 <4 – 7> Item Transmission Measurement conditions Engine at low idling Engine at high idling • Engine: Low idling • Coolant temperature: Power train oil temperature: Max. speed • Hydraulic oil temperature: 45 – 55ºC • Fan forward • Engine: High 1.5 – 6.

9 Item Hydraulic drift Hydraulic oil temperature Blade lift cylinder Ripper tilt cylinder Measurement conditions Unit Standard value for Service limit value Measurement results Pass new machine Fail ºC Engine stopped mm/15 min.9 – 2.TESTING AND ADJUSTING PM CLINIC SERVICE Pm CLINIC CHECK SHEET Work order No.5 <230 – 250> 3. Date Service meter Repair record Date Service meter Repair record D65EX.75 – 2. Engine at high idling Engine at high idling Unit Standard value for Service limit value Measurement results Pass new machine EX: 2. 19.6 <Min.6 1.8 – 36.0 – 2.6 <Min.6 2.8 Max.8 <Min. 30.1 – 2. 2.55 <Min. 45 – 55 Max.9 Max. 200> Min. 200> 3.2 – 1. Measurement conditions Engine at high idling Ripper lift relief Engine at low idling Unit Machine must not move Standard value for Service limit value Measurement results Pass new machine Item Work equipment load sensing pressure Fail 19. 200 Item Measurement conditions Unit Standard value for Service limit value Measurement results Pass new machine Fail Visual inspection of final drive drain plug Engine stopped — There must be no excessive metal particles Always fill in the record when repairing. 32. 100 Max.1 Max.6 <Min.8 PX: 1.53 – 4. 315> Min. 200> Min. 335> Min.8 <335 – 375> 34.41 <36 – 45> Fail Hydraulic components HSS and work equipment pump Blade tilt relief Ripper lift relief Blade tilt relief Engine at high idling MPa <kg/cm2> PPC valve output Blade tilt relief pressure Item Work equipment speed Blade RAISE Single tilt (left o right) Ripper RAISE Measurement conditions Engine at high idling Sec. 19. WX-15 Service meter h Serial No.5 <230 – 250> 22. or replacing main parts.6 <Min.53 – 4. / Date / D65EX. 200> Min.6 <Min. 19.8 – 38. 2. 19.41 <36 – 45> Min.6 <Min. PX. 26. 19. 19. 17.6 Max.8 <355 – 395> 2.6 <Min.9 <Min.94 <28 – 30> Min. 1.0> Apply brake and run engine at full throttle with transmission gear in F2.6 <200 – 240> Min. 180> Min. 200> 22. 100 Max. 200 — Max. Serviceman Item Steering Steering load sensing pressure Measurement conditions Unit Standard value for Service limit value Measurement results Pass new machine Fail Engine at high idling Steering relief pressure Brake actuating pressure Brake performance Engine at high idling MPa <kg/cm2> Brake 32.5 – 24.6 – 23.5 – 24. 200> Min. 3. adjusting. PX-15 20-207 (7) . 2.

/ Date / D65EX .TESTING AND ADJUSTING PM CLINIC SERVICE Pm CLINIC UNDERCARRIAGE CHECK SHEET Work order No.4 Right track A: Clearance between links Pin No. 1. PX-15 . Serviceman • Measure the bushing temperature immediately after operations Left side of machine Measurement results Pas Fail s Right side of machine Measurement results Pas Fail s • Opening of track link Left track A: Clearance between links Pin No.4 20-208 (7) D65EX. WX-15 Service meter h Serial No. 1.

PX-15 20-209 (1) .4 Right track A: Clearance between links Pin No. Serviceman • Measure the bushing temperature immediately after operations Left side of machine Measurement results Pas Fail s Right side of machine Measurement results Pas Fail s • Opening of track link Left track A: Clearance between links Pin No.TESTING AND ADJUSTING PM CLINIC SERVICE Pm CLINIC UNDERCARRIAGE CHECK SHEET Work order No.4 D65EX. 1. 1. / Date / D65PX-15 Service meter h Serial No.

0 174.0 210.8 25.45 206.0 210.0 210.0 174.0 185.0 30.d2 and.3 IDLER IDLER H 1.45 Wear % New SMR Hours on Rebuilt Parts: Wear type NORMAL Comments/Observation L=l/4 l RH LH M master pin master i 1.0 185.0 210.45 LH 132.0 65.0 163.0 210.8 New 62.0 30.8 203.0 30.0 174.0 174.0 210.0 210.d3 d1 RH LH RH d 1 LH GROUSER HIGHT H 0 CARRIER CARRIER Front RH LH RH D Rear LH RH LH Front RH LH Rear 1.0 0.0 9.0 H LINK HEIGHT 1.0 174.0 174. PX.45 206.0 174.0 210.0 174.3 SPROCKET H is the smallest of h3 h1.0 185.0 210..0 174.5 New Turned Turned 62.5 119.0 210. WX-15 Serial No SMR Dealer Inspector Equip No Work Order No Wet.0 20.3 RH 203.0 210.0 210.3 BUSHIN G d D is the smallest ofd1.0 132.0 0.0 163.0 20.TESTING AND ADJUSTING UNDERCARRIAGE TROUBLESHOOTING REPORT UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) (Program form No.h3 h1 h2 10 1.0 20.h2.0 174.8 825.0 174.0 30.0 25.0 163.0 9.0 210.8 825.0 174.0 174.0 185.0 174.Date(yy/mm/dd) New 100% Measured Wear mm 813.0 174.: SELA195001) Y Komatsu Undercarriage Inspection Customer name: Address: Model Location D65EX.0 174.0 210.8 813.0 73.0 210.0 174.HD or Dry Shoe width (mm) Shoe type (yyyy/m/d) Wet SINGLE Soil condition Working condition LINK PITCH M L LH R Insp.0 163.0 210.0 20.0 210.0 174.AR.0 73.0 174.0 210.0 210.0 65. PX-15 .0 119.3 RH Remarks: 20-210 (7) D65EX.0 174.0 210.3 1 2 3 4 5 6 7 RH LH LH LH LH LH LH LH LH LH LH RH RH RH RH RH RH RH RH RH RH LH TRACK ROLLER 8 9 10 D h2 h1 1 2 3 4 5 6 7 8 9 D=2(h1-h2) 1.

0 30.0 174.0 174.8 825.0 185.0 20.0 132.0 174.0 210.0 185.5 New Turned Turned 65.0 174.0 174.0 9.d3 d1 RH LH RH d 1 LH GROUSER HIGHT H 0 CARRIER CARRIER Front RH LH RH D Rear LH RH LH Front RH LH Rear 1.8 825.0 210.0 185.0 174.3 RH 203.0 30.0 30.0 9.0 210.0 20.0 174.0 30.0 174.0 210.5 119. WX-15 Serial No SMR Dealer Inspector Equip No Work Order No Wet.4 25.45 LH 132.4 New 65.HD or Dry Shoe width (mm) Shoe type (yyyy/m/d) Wet SINGLE Soil condition Working condition LINK PITCH M L LH R Insp.0 174..0 210.0 73.0 210.0 174.0 163.0 H LINK HEIGHT 1.0 174.h2.0 163.3 IDLER IDLER H 1.0 210.8 813.0 163.0 210.45 206.0 119.0 0. PX.8 203.0 210.0 0.0 210.45 206.3 1 2 3 4 5 6 7 RH LH LH LH LH LH LH LH LH LH LH RH RH RH RH RH RH RH RH RH RH LH TRACK ROLLER 8 9 10 D h2 h1 1 2 3 4 5 6 7 8 9 D=2(h1-h2) 1.0 163.0 174.0 65.45 Wear % New SMR Hours on Rebuilt Parts: Wear type IMPACT Comments/Observation L=l/4 l RH LH M master pin master i 1.3 RH Remarks: D65EX.TESTING AND ADJUSTING UNDERCARRIAGE TROUBLESHOOTING REPORT UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) (Program form No.0 210.0 210.0 174.0 210.3 SPROCKET H is the smallest of h3 h1.0 174.0 210.AR.0 174.0 210. PX-15 20-211 (7) .0 25.0 210.3 BUSHIN G d D is the smallest ofd1.0 20.Date(yy/mm/dd) New 100% Measured Wear mm 813.0 174.0 210.0 210.0 20.: SELA195001) Y Komatsu Undercarriage Inspection Customer name: Address: Model Location D65EX.0 210.d2 and.0 174.0 73.0 174.h3 h1 h2 10 1.0 174.0 65.0 210.0 185.0 174.

.......................................................................................................................................................................................................................................... 20-302 20-303 20-304 20-312 20-313 20-316 20-322 20-328 20-330 20-332 20-334 20-370 20-401 20-601 20-701 20-801 D65EX................................................ T-branch box and T-branch adapter table ........................................................................................ Connector arrangement drawing ........ Troubleshooting of engine system (S-mode) .................................................................................................................................................................................................................................................................................................................................. Sequence of events in troubleshooting ..... Types and locations of connectors (D65EX.......................................... Troubleshooting of electrical system (E-mode) ............ Circuit drawing for monitor panel system (M circuit) ................................................. Troubleshooting of hydraulic and mechanical system (H-mode) ....................... PX-15 20-301 (8) ................................................................................ Circuit drawing for engine controller system (E circuit) ......................................................................................................................... Classification and procedures of troubleshooting ..................................................... Connection table for connector pin numbers ................................................................................ Troubleshooting when error code is displayed (Error code) ................................................................................... PX-15) .................. Checks before troubleshooting ......... Handling of electric equipment and hydraulic component ......................TROUBLESHOOTING TROUBLESHOOTING Points to remember when troubleshooting .................. Circuit drawing for steering and transmission controller system (ST · TM circuit) ...................

6. PX-15 . 4) Check the stroke of the control valve spool. a The basic procedure for troubleshooting is as follows. or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. and at the same time. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly. 3) Investigate other related parts or information. and do not allow any unauthorized person to come near. a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. do not carry out any investigation or measurement that may make the problem worse. always disconnect the negative (–) terminal of the battery first. Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. Then. and to prevent reoccurrence of the failure. so wait for the engine to cool down before starting troubleshooting. To prevent this. remove the root cause. water. or air. parts. 2) Start from the most likely points. However. an important point is of course to understand the structure and function. a When operating the machine to reenact the troubleshooting symptoms. etc. or oil or grease. if the root cause of the failure is not repaired. 4. The aim of troubleshooting is to pinpoint the basic cause of the failure. do not hurry to disassemble the components. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours. 20-302 (8) D65EX. When disconnecting wiring. 5. If the radiator cap is removed when the engine is hot. When carrying out troubleshooting. Confirming failure • Confirm the extent of the failure yourself. When installing measuring equipment. be sure to connect it properly.TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING k k k k k k Stop the machine in a level place. hot water may spurt out and cause burns. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. When carrying out the operation with two or more workers. to carry out repairs swiftly. 2. always release the internal pressure first. so check any item that is considered to be necessary. keep strictly to the agreed signals. and parking brake are securely fitted. 3) Check the travel of the control levers. Troubleshooting • Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure. For this reason. When removing the plug or cap from a location which is under pressure from oil. 1) Start from the simple points. when carrying out troubleshooting. it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. always investigate why the problem occurred. and check that the safety pin. blocks. When carrying out troubleshooting. 5) Other maintenance items can be checked externally. 1. and judge whether to handle it as a real failure or as a problem with the method of operation. the same failure will occur again. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. then use the troubleshooting flowchart to locate the position of the failure exactly. will also lose the confidence of the user or operator. Measures to remove root cause of failure • Even if the failure is repaired.

PX-15 20-303 (1) .TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING D65EX.

Points to remember when handling electric equipment 1. they are frequently removed and installed again. water. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector. it is necessary to be extremely careful when handling wiring harnesses. 20-304 (8) D65EX. “maintenance and inspection“. or because one or both of the connectors is deformed or the position is not correctly aligned. or because there is corrosion or oxidization of the contact surfaces. but if there is excessive force brought to bear on the wiring. 2.TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT To maintain the performance of the machine over a long period. connectors used for connecting and disconnecting one wire from another wire. wiring harnesses are more likely to be affected by the direct effects of rain. correct “operation“. Compared with other electrical components fitted in boxes or cases. For this purpose. Furthermore. PX-15 . and protectors or tubes used for protecting the wiring. during inspection and repair operations. or vibration. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion. so they are likely to suffer deformation or damage. heat. the plating at the joint will peel and cause improper connection or breakage. it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). “troubleshooting“. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this reason. and “repairs” must be carried out. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component. and to prevent failures or other troubles before they occur.

depending on the direction of the water jet. if water does enter.TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 3) Disconnections in wiring If the wiring is held and the connectors are pulled apart. it is difficult for it to be drained. Therefore. or components are lifted with a crane with the wiring still connected. 5) D65EX. take care not to splash water over the connector. the pins will be short-circuited by the water. or the soldering may be damaged. PX-15 20-305 (8) . so there will be defective contact. if water should get into the connector. but at the same time. the oil will not let the electricity pass. a When wiping the mating portion of the connector. water may enter the connector. immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins. or a heavy object hits the wiring. so if any water gets in. wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. the crimping of the connector may separate. the contacts will become even dirtier. or the wiring may be broken. a If there is oil or water in the compressed air. If there is oil or grease stuck to the connector. 4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure). be careful not to use excessive force or deform the pins. so remove the oil and water from the compressed air completely before cleaning with compressed air. The connector is designed to prevent water from entering. but if high-pressure water is sprayed directly on the connector. Accordingly.

loosen the screw fully. Removing. which are engaged with each other when the connector is installed. a If the connector is twisted up and down or to the left or right. then hold the male and female connectors in each hand and pull apart. installing. so always cover the connector. For connectors which have a lock stopper. 20-306 (8) D65EX. For connectors held by a screw. oil. When disconnecting the connectors. pull the connector in a parallel direction to the clip for removing stoppers. PX-15 . a If the machine is left disassembled for a long time. and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. dirt.TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 3. press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. it is particularly easy for improper contact to occur. cover it with a vinyl bag to prevent any dust. the housing may break. 3] Action to take after removing connectors After removing any connector. • When removing a connector from a clip. 2] • When removing from clips Both of the connector and clip have stoppers. hold the connectors. or water from getting in the connector portion.

or dirt stuck to the connector. D65EX. wipe it off with a dry cloth. a If there is any damage or breakage. Check also that there are no loose clamps.TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 2) Connecting connectors 1] Check the connector visually. replace the connector. and then insert it securely. if the wiring harness is misaligned. correct any protrusion of the boot. or water stuck to the connector pins (mating portion). Align the position of the connector correctly. 2] Fix the connector securely. or the clamp is out of position. push in the connector until the stopper clicks into position. defective contact. For connectors fitted with boots. water. a If there is any oil. adjust it to its correct position. corrosion. but be careful not to make it too hot as this will cause short circuits. If any water has got inside the connector. a If the connector cannot be corrected easily. Check that there is no damage or breakage to the outside of the connector. PX-15 20-307 (8) . Check that there is no deformation. Check that there is no oil. or damage to the connector pins. warm the inside of the wiring with a dryer. For connectors with the lock stopper. dirt. • If the connector clamp has been removed. In addition. be sure to return it to its original position. remove the clamp and adjust the position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness.

3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. Arrow: 1). (1): Male connector (2): Female connector (a). 2). (b): Locks • Disconnection • Connection (Example of incomplete setting of (a)) 20-308 (8) D65EX. pull out female connector (2).TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 3) Heavy duty wire connector (DT 8-pole. push in female connector (2) while moving it up and down until the locks are set normally. PX-15 . 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b). Arrow: 1) 2] Since locks (a) and (b) may not be set completely. Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks.

1] Disconnect the connector and wipe off the water with a dry cloth. Avoid washing it in water or using steam. do as follows. PX-15 20-309 (8) . If water gets directly on the connector. a After completely drying the conn e c t o r.TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 4) Drying wiring harness If there is any oil or dirt on the wiring harness. If the connector must be washed in water. D65EX. 2] Dry the inside of the connector with a dryer. 3] Carry out a continuity test on the connector. If water gets inside the connector. After drying. there is the risk that oil in the air may cause defective contact. leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a Hot air from the dryer can be used. a If the connector is blown dry with compressed air. but regulate the time that the hot air is used in order not to make the connector or related parts too hot. as this will cause deformation or damage to the connector. b l o w i t w i t h c o n t a c t restorer and reassemble. so remove all oil and water from the compressed air before blowing with air. do not use high-pressure water or steam directly on the wiring harness. use a dryer to dry the connector. wipe it off with a dry cloth.

resistance. or in any hot place. water. Fit an arc welding ground close to the welding point. unnecessary abnormality displays will be generated. (Place it on a suitable dry stand). Never touch the connector contacts with your hand. disconnect all wiring harness connectors connected to the controller. a If there is any change. These control all of the electronic circuits on the machine. PX-15 . 4) During rainy weather. 5) Do not place the controller on oil. continuity. do not leave the controller in a place where it is exposed to rain. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. check that all the related connectors are properly inserted. 6) Precautions when carrying out arc welding When carrying out arc welding on the body. move the related wiring and connectors several times and check that there is no change in the reading of the tester. even for a short time. a If the power is turned ON with the connectors still disconnected. 3) Always connect any disconnected connectors before going on to the next step. 4) When carrying out troubleshooting of circuits (measuring the voltage. 2) Before carrying out troubleshooting. 3) Cover the control connectors with tape or a vinyl bag. 5. Handling controller 1) The controller contains a microcomputer and electronic control circuits. there is probably defective contact in that circuit. or soil. 20-310 (8) D65EX. 2) Do not place objects on top of the controller. so be extremely careful when handling the controller. or current).TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 4. a Disconnect and connect the related connectors several times to check.

D65EX. tapes. there is danger of dust entering the equipment. replacing filters. so this is an even more effective method. It is also difficult to check the performance after repairs.TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment. so it is desirable to use unit exchange. or vinyl bags to prevent any dirt or dust from entering. 4. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field. the most common cause of failure is dirt (foreign material) in the hydraulic circuit. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. and also use clean pumps and oil containers. 1. If the opening is left open or is blocked with a rag. or repairing the machine in rain or high winds. 3. or places where there is a lot of dust. it is possible to filter out the dirt that has collected during storage. If an oil cleaning device is used. or when disassembling or assembling hydraulic equipment. Do not simply drain oil out onto the ground. 2. the openings should be sealed with caps. there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Sealing openings After any piping or equipment is removed. and the performance should be checked with special test equipment. When adding hydraulic oil. Avoid adding hydraulic oil. Be careful of the operating environment. but collect it and ask the customer to dispose of it. PX-15 20-311 (8) . it is necessary to be particularly careful. or take it back with you for disposal. Always keep the oil filler and the area around it clean. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop.

) If any old oil is left. Flushing operations After disassembling and assembling the equipment.) or when running the machine. so it is best to change the oil when it is still warm. flushing is carried out twice: primary flushing is carried out with flushing oil. etc. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove. PX-15 . the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. (Drain the oil from the hydraulic tank. as much as possible of the old hydraulic oil must be drained out. also drain the oil from the filter and from the drain plug in the circuit. the sludge can also be drained out easily from the circuit together with the oil. it flows easily. or changing the oil. Cleaning operations After repairing the hydraulic equipment (pump. 6. use flushing oil to remove the contaminants. 20-311-1 (8) D65EX. sludge. Normally. Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm. In addition. and old oil from the hydraulic circuit. carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. 7. When changing the oil. and secondary flushing is carried out with the specified hydraulic oil. control valve.TROUBLESHOOTING HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT 5. so it is an extremely effective device.

exposed wiring 19. Check for abnormal noise. Check for water on wiring 22.TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING Item 1. Check alternator voltage (engine running at 1/2 throttle or above) 23. Carry out air bleeding 16. Check for looseness. 8. OFF) — 20-312 (1) D65EX. Check for discolored. smell 14. Check battery electrolyte level 18. Check for looseness. corrosion of alternator terminal. 2. 4.5 V Action Add fuel Clean. Check for looseness. drain Add oil Add oil Add oil Add oil Add water Clean or replace Adjust Tighten or replace Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace Replace 10. 3. corrosion of starting motor terminal. wiring 11. Check operating sound of battery relay (starting switch ON. Check for water leaking on wiring (pay particularly careful attention to water leaking on connectors or terminals) 21. 7. 6. Check fuel level Check for impurities in fuel Check hydraulic oil level Check oil level in damper case Check power train oil level Check engine oil level (engine oil pan level) Check coolant level Check dust indicator for clogging Check travel of brake pedal Judgement Value — — — — — — — — — — — — — — — 20 – 30 V — — — — — After running for several minutes: 27. corrosion of battery terminal. hanging wire 20. Check for oil leakage 15. 9. Check battery voltage (engine stopped) 17. Check for missing wiring clamps. burnt. PX-15 . wiring 13. 5.5 – 29. wiring 12.

(For some codes. the failure has not always been corrected even if it lights when the starting switch is set to ON.) 2.) a When a error code has been recorded. execute the troubleshooting in the [E Mode]. be sure to reproduce the code and check if the problem of the code has still remained or has already been corrected. refer to the troubleshooting of the error code. When error codes have been recorded. check a error code in the error code display mode (electrical system. (For some codes.) a When a error code has been recorded. (For the reproducing method. In this case.) 3. according to the procedures below and proceed to the text of the relevant troubleshooting: 1. problems can be detected only when the starting switch is set to ON. a Since a error code flashes when a problem was detected. Execute a troubleshooting of the relevant [Error Code] in accordance with the displayed error code. mechanical system) on the monitor panel (EMMS). refer to the troubleshooting of the error code. PX-15 20-313 (1) . the failure has not always been corrected even if it lights when the starting switch is set to ON. Then. a failure that the machine cannot diagnose by itself is supposed to have occurred in the electrical system or the hydraulic/mechanical system. Troubleshooting Procedures when error codes have been recorded: When no action code is displayed on the monitor panel. be sure to reproduce the code and check if the problem of the code has still remained or has already been corrected. [H Mode] or [S Mode] related to the phenomenon. problems can be detected only when the starting switch is set to ON. select a Troubleshooting No. execute a troubleshooting of the relevant [Error Code] in accordance with the error code. display a error code in the error code display mode (electrical system. D65EX.TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING Classification of Troubleshooting Mode Error code E Mode H Mode S Mode Explanation Troubleshooting when a service code is displayed Troubleshooting of the electrical system Troubleshooting of the hydraulic and mechanical systems Troubleshooting of the engine body Troubleshooting Procedures When any phenomenon supposed to be a failure appeared on the machine. Troubleshooting Procedures when any action code is displayed on the monitor panel: When an action code is displayed on the monitor panel. check again a phenomenon supposed to be a failure and select the relevant phenomenon out of the table of “Phenomena supposed to be Failures and Troubleshooting No”. mechanical system) on the monitor display (EMMS). (For the reproducing method. Troubleshooting Procedures when no action code is displayed and error codes have not been recorded: When error codes have not been recorded in the monitor panel (EMMS). a Since a error code flashes when a problem was detected.

16 Engine oil pressure drops. The engine exhausts gas but does not rotate. (Overheat) 19 An abnormal noise occurs. The engine does not pick-up smoothly. Phenomenon related to engine The engine does not start smoothly. 31 Abnormal noise around the HSS and work equipment pump or the HSS motor Phenomenon related to work equipment 32 All the work equipment operates slowly. PX-15 . Phenomenon suppose to be Failure Phenomenon related to action code/error code 1 2 3 4 5 6 7 8 9 An action code is displayed on the monitor panel. (Poor follow-up performance) The engine stops during operation. 17 Oil increases. A error code is displayed in the error code display mode. (Left turn or right turn is impossible. (Hunting) E-1 S-1 S-2 a) S-2 b) S-2 c) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 E-2 Phenomenon related to power train 22 The power train has no power (no drawbar pull). 18 Water temperature rises too high. The engine rotates abnormally. 24 The power train does not start at all gear speeds. The engine does not start. Troubleshooting No.) 28 The steering speed is slow or the steering system has no power. 23 The power train does not travel (in case of 2-spool or 3-spool). 34 The blade lift moves slowly or has no power. 14 Large fuel consumption 15 Oil mixes in coolant. 36 The ripper lift moves slowly or has no power.TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING Phenomena supposed to be Failures and Troubleshooting No. 20-314 (1) D65EX. 37 Large hydraulic drift of the blade lift 38 Large hydraulic drift of the blade tilt 39 Large hydraulic drift of the ripper lift H-11 H-12 H-13 H-14 H-15 H-16 H-17 H-18 H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 S-6 q Check the error code. 35 The blade tilt moves slowly or has no power. 29 The brake does not work. 25 The power train travel forward or in reverse only 26 Large time lag at any gear speed or at forward-reverse shifting 27 Steering is not possible. 30 The power train oil is overheated.) The engine does not rotate. The engine rotates but does not exhaust gas. (Engine starting takes a time all the time. 33 All the work equipment does not operate. Error E Mode H Mode S Mode Code 10 Insufficient output or no power 11 Black exhaust (Imperfect combustion) 12 Large oil consumption or blue exhaust 13 Oil is contaminated fast. spurts or water reduces. 20 Large vibration 21 The preheater does not work.

55 The information switch does not work. rear lamp. 62 The air conditioner does not operate. 48 Indication of the fuel gauge is abnormal. no light on the monitor panel comes on. all the lights on the monitor panel do not go out. 51 The warning lamp does not flash or does not go out. E-20 Others 58 The back-up alarm does not sound. the battery charge caution items flash. the emergency warning items flash. 44 While the preheater is operating. 49 Indications of gear speed and engine speed are abnormal. the preheating pilot lamp does not come on. 61 Washing water does not come out. 52 The alarm buzzer does not sound or does not stop. 41 When the starting switch is set to ON. 60 The wiper malfunctions. Phenomenon related to monitor panel (Service mode: Special function screen) The monitor panel cannot be set in the service mode or cannot be set out of the 57 service mode. 56 The preset mode does not be operated or cancelled. E-21 E-22 E-23 E-24 E-25 D65EX. 47 Indication of the hydraulic oil temperature gauge is abnormal. Phenomenon suppose to be Failure Error E Mode H Mode S Mode Code E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 Phenomenon related to monitor panel (Operator mode: Normal screen) 40 When the starting switch is set to ON. 43 While the engine is operating. 59 The head lamp.TROUBLESHOOTING CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING Troubleshooting No. 46 Indication of the power train oil temperature gauge is abnormal. PX-15 20-315 (1) . 50 Indication of the preset mode service meter is abnormal. 53 Auto shift down is not possible or is not released. and ripper point lamp on the panel do not come on. 45 Indication of the engine water temperature gauge is abnormal. 42 While the engine is operating. 54 The buzzer cancel switch does not work.

W2 C6. V2 E8 C5 C8 C8 C7 C8 C7 C8 C7 C8 D8 PA DT YAZAKI M M M M M KES1 M KES1 SWP KES1 KES1 KES1 DT DT DT DTHD#12 DTHD#8 DT DT Relay (YAZAKI) Relay (YAZAKI) Relay Relay (YAZAKI) Relay Relay (YAZAKI) Relay Relay (YAZAKI) Relay 20-316 (1) D65EX.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS (D65EX. PX-15) TYPES AND LOCATIONS OF CONNECTORS (D65EX. PX-15) a The addresses in the following table are the addresses used in the connector arrangement drawing (3-dimensional drawing) and electric circuit diagram. PX-15 . Address Connector No. W2 C5. Type Number of pins Location Arrange.Engine ST MON ment system system system drawing diagram diagram diagram 1 2 4 6 7 8 9 9 10 10 11 11 12 12 13 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 DT KES1 KES1 One-pin connector 4 2 2 1 9 2 3 2 2 2 2 2 6 2 6 6 6 6 2 4 4 4 1 1 6 4 4 6 5 6 5 6 5 6 5 Intermediate connector [Cab specification] Rear speaker (Left) [Cab specification] Rear speaker (Right) [Cab specification] Heater wire glass [Cab specification] Radio [Cab specification] Accessory (12 V) [Cab specification] Heater wire glass switch [Cab specification] Washer motor (Left) Additional light switch [Cab specification] Washer motor (Right) Wiper intermittent switch [Cab specification] Washer motor (Front) Rear wiper switch [Cab specification] Washer motor (Rear) Right door wiper switch [Cab specification] Intermediate connector (Washer motor) Front wiper switch [Cab specification] Left door wiper switch [Cab specification] Room lamp [Cab specification] Right door wiper [Cab specification] Intermediate connector [Cab specification] Intermediate connector (Windshield washer motor) [Cab specification] Cab power supply [Cab specification] Cab power supply (Battery direct) [Cab specification] Front wiper [Cab specification] Left door wiper [Cab specification] For light [Cab specification] Left wiper intermittent relay [Cab specification] Left wiper intermittent selector relay [Cab specification] Front wiper intermittent relay [Cab specification] Front wiper intermittent selector relay [Cab specification] Right wiper intermittent relay [Cab specification] Right wiper intermittent selector relay [Cab specification] Rear wiper intermittent relay [Cab specification] Rear wiper intermittent selector relay [Cab specification] I9 I8 H9 H9 B9 B9 B8 D7 B8 D7 B9 D7 A9 E7 A9 E8 A9 A9 B7 B7 F8 C5.

Engine ST MON ment system system system drawing diagram diagram diagram 34 35 36 37 53 101 203 204 205 214 215 217 218 224 228 244 247 250 255 260 262 270 280 423 453 800 1SOL 2SOL 3SOL 1SW 2SW 3SW A/C AL/B AL/E 4 4 1 4 2 8 2 2 1 12 12 2 12 2 2 2 2 1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 2 1 1 Heater wire glass relay [Cab specification] Converter [Cab specification] Heater wire glass [Cab specification] Rear wiper [Cab specification] Intermediate connector (Pitch selector solenoid) (If equipped) Intermediate connector Right head lamp Left head lamp Horn Intermediate connector [Dashboard] Intermediate connector [Dashboard] Caution buzzer Intermediate connector [Air conditioner] Intermediate connector Rear lamp (If equipped) Backup alarm Rear lamp (Rear left) Starting switch (Terminal B) Starting switch (Terminal R1) Starting switch (Terminal BR) Horn switch Starting switch (Terminal ACC) Starting switch (Terminal C) Fuel level sensor Torque converter oil temperature sensor Service power supply 1st clutch ECMV solenoid 2nd clutch ECMV solenoid 3rd clutch ECMV solenoid 1st clutch ECMV fill switch 2nd clutch ECMV fill switch 3rd clutch ECMV fill switch Air conditioner compressor Alternator terminal B Alternator terminal E C8 C8 J8 I9 O5 B5 B4 B3 B3 O2 O2 O4 O2 J8 K7 K7 J8 N5 N4 M4 S9 M5 N5 K8 AI2 U1 AF6 AI3 AG6 AH7 AI3 AG6 Y2 Y6 Y6 K3 K3 K2 K3 K3 K2 J6 J9 J9 D9 D9 D1 D1 H8 H8 I9 J9 J9 C9 C9 A1 G8 D1 D1 D1 G8 G8 B7 D7 C8 B6 E6 B2 J7 J8 J8 M One-pin connector KES1 DT DT (Gr) DT DT Terminal DT (B) DT (G) DT DT (Br) DT DT DT DT Terminal Terminal Terminal DT Terminal Terminal DT DT DTHD#12 DT DT DT DT DT DT DT Terminal Terminal D65EX. PX-15) Address Connector No.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS (D65EX. PX-15 20-317 (1) . Type Relay (YAZAKI) Number of pins Location Arrange.

1 injector Engine No. PX-15 . For KOMTRAX use. 2 injector Engine No.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS (D65EX. 6 injector Information switch Decelerator pedal potentiometer Fuel control dial potentiometer Intermediate connector (Engine) Intermediate connector (Engine) Engine oil pressure sensor (High pressure) Engine controller Engine controller Engine controller Fan pump TVC solenoid Fan reverse mode switch Fan reverse solenoid Intermediate connector Front additional light (Left) Fusible link Software writing connector (Engine controller) Front additional light (Right) Y6 O6 P1 P1 D6 N7 V1 R1 P8 W4 X1 I1 L2 I9 Q9 M7 D6 AB2 AC2 AC3 AD5 AD6 AD6 O7 Q1 V8 C1. AD9 Z1 V1 W1 W1 AF6 O7 B2 K5 G9 W2 W1 F8 B3 K2 K1 J8 J8 C3 C7 E9 A7 A6 A4 J7 D8 A2 B1 G7 H1 H1 I2 K6 L8 K1 K1 A3 A2 A2 A1 A2 A2 E8 E8 J8 E8 F8 A2 F8 E1 A8 A8 C1 C9 D8 B2 C9 E8 YAZAKI DT DT DT DT DT DT KES1 DT M HD-24 HD-24 Terminal DRC-26 DRC-26 DRC-26 DT KES1 DT DT (Gr) DT L X DT 1. PX-15) Address Connector No. 3 injector Engine No. AC9 D1. 5 injector Engine No. Type Number of pins Location Arrange.Engine ST MON ment system system system drawing diagram diagram diagram AL/R AC1 AC2 AC3 ACC ASD BKA BRK BUZ C CA2 CA2 ( 1) CAN CB1 CIG CN-1 CN-2 CN-3 CN-4 CN-5 CN-6 CUR DCL DIAL E21 E22 E29 EN1 EN2 EN3 FAC FAM FAR FFC FL FL1 FLS FR Terminal MIC AMP AMP YAZAKI KES1 Relay DT KES1 Terminal DT DT DT (Gr) One-pin connector 1 17 16 12 2 4 5 3 3 1 3 3 12 2 2 2 2 2 2 2 2 3 3 3 31 31 1 24 40 40 2 4 2 6 2 2 4 2 Alternator terminal R Air conditioner unit Auto air conditioner controller Auto air conditioner controller Accessory socket [Cab specification] Auto shift-down switch Backup alarm relay Brake pedal potentiometer Buzzer cancel switch Battery relay power supply outlet CAN terminating resistor CAN terminating resistor Intermediate connector [KOMTRAX] Circuit breaker (20 A) (Starting switch) Cigarette lighter Engine No. 4 injector Engine No. 20-318 (1) D65EX.

PX-15 20-319 (1) .Engine ST MON ment system system system drawing diagram diagram diagram FS1 FS2 FSOL FSW FUSE1 FUSE2 FWL G ( 1) G01 ( 1) G02 ( 1) G03 ( 1) G04 ( 1) G05 GND GND1 GND1 GND2 GND2 GND3 GND3 GND4 GND01 GND03 GND04 H HSA HSB HT/A HT/B HT/S KEY ( 1) KOM2 ( 1) KOM3 ( 1) KOM4 M26 MAM NE NSF — — DT DT Terminal Terminal KES1 090 DRC-26 x x x x Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT DT Terminal Terminal Terminal DT GT5 BNC ML M KES1 090 Relay 2 2 1 1 4 2 40 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 6 1 1 1 6 4 2 5 Fuse box Fuse box Forward clutch ECMV solenoid Forward clutch ECMV (Fill switch) Fusible link (Battery side) Fusible link (Alternator side) Head lamp switch Engine speed G sensor KOMTRAX control Check connector (KOMTRAX) Check connector (KOMTRAX) Check connector (KOMTRAX) Check connector (KOMTRAX) Intermediate connector (Intermediate connector to ground) Ground [Cab specification] Ground (In cab) Ground (In cab) Ground [Engine] Ground [Cab specification] Ground [Engine] Ground Ground [Floor] Ground [Fender] Ground [Flame] Battery relay power supply inlet HSS-EPC (Left swing) HSS-EPC (Right swing) Intake air heater relay (Terminal A) Intake air heater relay (Terminal B) Intake air heater relay (Terminal coil) Intermediate connector (Starting switch) [Canopy specification] KOMTRAX controller KOMTRAX controller KOMTRAX controller (Antenna) Air conditioner unit Manual mode switch Engine speed NE sensor Neutral safety relay W4 W3 AJ3 AI7 AA9 AA9 O7 AB2 R9 P8 P8 P9 P9 AA9 B9 B9 B9 A5 D7 Y2 H9 T1 K5 B5 W4 AG8 AE6 AC9 AB9 AB9 O9 Q9 Q9 H9 O6 O7 AD3 U1 G2 G1 D2 D2 K4 K4 A1 A1 D8 E8 L8 B7 I1 K1 B7 I1 K1 F1 F1 F1 I1 E1 K7 K6 B8 B8 B8 F1 J5 I1 I1 I1 E8 E9 L7 F8 L8 F6 1.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS (D65EX. PX-15) Address Connector No. Type Number of pins Location Arrange. For KOMTRAX use. D65EX.

PX-15) Address Connector No.Engine ST MON ment system system system drawing diagram diagram diagram NSW P03 P04 PCV1 PCV2 PFUEL PIM PL1 PL2 PPR PSL PT1 R1 R2 R3 R4 RHR RL RR RSOL RSW RWL S03 S04 S13 S24 SDS SFTD SFTU ST ST/B ST1 ST2 ST3 STA STB STF SW DT DT DT 090 090 AMP 090 HD-24 HD-24 Relay Terminal DT Relay (YAZAKI) Relay (YAZAKI) Relay (YAZAKI) Relay (YAZAKI) 2 6 6 2 2 3 3 23 31 5 1 3 4 4 4 4 5 2 2 2 2 4 20 12 12 4 2 3 3 2 1 24 40 40 6 6 4 1 Safety lock switch Intermediate connector (Pitch selector switch) (If equipped) Intermediate connector (Pitch selector switch) (If equipped) Fuel supply pump Fuel supply pump Common rail fuel pressure switch Boost pressure sensor Intermediate connector [Power train] Intermediate connector [Power train] Supply pump power relay Engine oil pressure sensor (Low pressure) Pitch angle sensor Air conditioner relay Air conditioner relay Air conditioner relay Air conditioner relay Pre-heater relay Rear additional light (Left) [Cab specification] Rear additional light (Right) [Cab specification] Reverse clutch ECMV solenoid Reverse clutch ECMV fill switch Rear lamp switch Monitor panel Monitor panel Intermediate connector Service switch Hydraulic oil temperature sensor Shift-down switch Shift-up switch Starting motor Starting motor (Terminal B) Steering and transmission controller Steering and transmission controller Steering and transmission controller Intermediate connector (HSS-EPC) Intermediate connector (HSS-EPC) Software writing connector (Steering and transmission controller) Battery relay terminal BR W7 S9 S9 AB2 AB2 AD3 AO7 S1. PX-15 . AH2 V2 Z1 Q9 O5 O4 O4 O4 U1 I8 G9 AG7 AI7 O7 N9 N9 O3 M7 AE2 U9 U9 Y7 Y8 W3 X3 X3 AG1 AF9 X1 W5 J1 K2 H8 I7 K7 K7 E9 A8 A9 A2 A2 I4 I7 K8 D1 Relay DT DT DT DT KES1 AMP070 AMP070 DT (Gr) Terminal DT C C DT Terminal DRC-26 DRC-26 DRC-26 DT DT X Terminal E6 K4 K4 E8 A8 B8 C7 D9 J6 K8 K8 H2 D6 D9 A7 A6 A4 J7 J7 B8 E1 A4 A3 A3 20-320 (1) D65EX.TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS (D65EX. Type Number of pins Location Arrange. AH2 S1.

TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS (D65EX. (Br) = Brown Type of connector AMP AMP070 BNC C DRC-26 DT DTHD GT5 HD30 KES1 L M MIC ML PA SUMITOMO SWP X YAZAKI One-pin connector Terminal Relay Relay (YAZAKI) Detail Connector manufactured by NIPPON AMP Connector of type 070 manufactured by NIPPON AMP Connector of type BNC for coaxial cable Connector of type C manufactured by CALSONIC KANSEI DRC type connector DT type connector (08192-XXXXX) DTHD type connector (08192-XXXXX) Connector of type GT5 for coaxial cable of GPS antenna HD30 type connector (08191-XXXXX) Connector of KES1 type (08027-1XXXX) Connector of type L manufactured by YAZAKI (08056-2XXXX) Connector of type M manufactured by YAZAKI (08056-0XXXX) Connector of MIC type manufactured by NIPPON AMP L-connector of M type for coaxial cable Connector of PA type manufactured by YAZAKI Connector manufactured by SUMITOMO DENSO Connector of SWP type manufactured by YAZAKI (08055-1XXXX) Connector of X type manufactured by YAZAKI (08055-0XXXX) YAZAKI type connector 1-pole connector of pin type Round terminal or ordinary terminal Connector of PH166-05020 type manufactured by SHINAGAWA JIDOSHA DENSEN Connector manufactured by YAZAKI (For relay) D65EX. PX-15) Address Connector No. (G) = Green. (B) = Black. (Gr) = Gray. PX-15 20-321 (1) .Engine ST MON ment system system system drawing diagram diagram diagram SWG THL TL1 TL2 TL3 TM1 TMV TWH TWL Terminal DT HD-24 DT (B) DT DT HD-24 DT DT 1 3 23 8 6 2 23 2 2 Battery relay ground Fuel temperature sensor Intermediate connector [Console] Travel lever Intermediate connector [Shift switch] Transmission bevel speed sensor Intermediate connector [Transmission ECMV] Engine water temperature sensor (High temperature) Engine water temperature sensor (Low temperature) W5 AD3 V8 V8 V8 AJ6 AG7 Y6 AB9 J1 E8 J7 E1 I9 J9 J8 J6 J4 B9 B9 K8 K8 The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles) and (DT-12 poles) are as follows. Type Number of pins Location Arrange.

TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING CONNECTOR ARRANGEMENT DRAWING 20-322 (1) D65EX. PX-15 .

TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING D65EX. PX-15 20-323 (1) .

TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING 20-324 (1) D65EX. PX-15 .

TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING D65EX. PX-15 20-325 (1) .

PX-15 .TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING 20-326 (1) D65EX.

TROUBLESHOOTING CONNECTOR ARRANGEMENT DRAWING D65EX. PX-15 20-327 (1) .

PX-15 .TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT) CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT) 20-328 (1) D65EX.

PX-15 20-329 (1) . D65EX.TROUBLESHOOTING CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT) a This circuit diagram was drawn by extracting the engine controller system from the general electrical circuit diagram.

PX-15 .TROUBLESHOOTING CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (ST · TM CIRCUIT) CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (ST · TM CIRCUIT) 20-330 (1) D65EX.

PX-15 20-331 (1) .TROUBLESHOOTING CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (ST · TM CIRCUIT) a This circuit diagram was drawn by extracting the steering and transmission controller system from the general electrical circuit diagram. D65EX.

PX-15 .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-332 (1) D65EX.

PX-15 20-333 (1) . starting and filling systems. the lighting system and the communication network system from the general electrical circuit diagram.TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) a This circuit diagram was drawn by extracting the monitor panel system. D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) Connection table for connector pin numbers (Rev. 20-334 (8) D65EX. 2007.12) a The terms of male and female refer to the pins. while the terms of male housing and female housing refer to the mating portion of the housing. PX-15 .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX. PX-15 20-335 (8) .

PX-15 .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-336 (8) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX. PX-15 20-337 (8) .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-338 (8) D65EX. PX-15 .

PX-15 20-339 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-340 (8) D65EX. PX-15 .

PX-15 20-341 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-342 (8) D65EX. PX-15 .

PX-15 20-343 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

PX-15 .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-344 (8) D65EX.

PX-15 20-345 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-346 (8) D65EX. PX-15 .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX. PX-15 20-347 (8) .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-348 (8) D65EX. PX-15 .

PX-15 20-349 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-350 (8) D65EX. PX-15 .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX. PX-15 20-351 (8) .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-352 (8) D65EX. PX-15 .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX. PX-15 20-353 (8) .

PX-15 .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-354 (8) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX. PX-15 20-355 (8) .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-356 (8) D65EX. PX-15 .

PX-15 20-357 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-358 (8) D65EX. PX-15 .

PX-15 20-359 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-360 (8) D65EX. PX-15 .

PX-15 20-361 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-362 (8) D65EX. PX-15 .

PX-15 20-363 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

PX-15 .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-364 (8) D65EX.

PX-15 20-365 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-366 (8) D65EX. PX-15 .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX. PX-15 20-367 (8) .

TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 20-368 (8) D65EX. PX-15 .

PX-15 20-369 (8) .TROUBLESHOOTING CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) D65EX.

ECONO) 799-601-4360 Case 799-601-7010 Adapter for X (T-adapter) 799-601-7020 Adapter for X 799-601-7030 Adapter for X 799-601-7040 Adapter for X 799-601-7050 Adapter for SWP 799-601-7060 Adapter for SWP 799-601-7310 Adapter for SWP 799-601-7070 Adapter for SWP 799-601-7320 Adapter for SWP 799-601-7080 Adapter for M (T-adapter) 799-601-7090 Adapter for M 799-601-7110 Adapter for M 21 37 37 q q q q q 12 ECONO12P q q 12 ECONO12P q q 20-370 (8) D65EX. 2007.TROUBLESHOOTING T.BRANCH BOX AND T.12) a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly. Part name 799-601-2600 T-box (for ECONO) 799-601-3100 T-box (for MS) 799-601-3200 T-box (for MS) 799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS) 799-601-3420 Adapter for BENDIX (MS) 799-601-3430 Adapter for BENDIX (MS) 799-601-3440 Adapter for BENDIX (MS) 799-601-3450 Adapter for BENDIX (MS) 799-601-3460 Adapter for BENDIX (MS) 799-601-3510 Adapter for BENDIX (MS) 799-601-3520 Adapter for BENDIX (MS) 799-601-3530 Adapter for BENDIX (MS) 799-601-2910 Adapter for BENDIX (MS) 799-601-3470 Case 799-601-2710 Adapter for MIC 799-601-2720 Adapter for MIC 799-601-2730 Adapter for MIC 799-601-2740 Adapter for MIC 799-601-2950 Adapter for MIC 799-601-2750 Adapter for ECONO 799-601-2760 Adapter for ECONO 799-601-2770 Adapter for ECONO 799-601-2780 Adapter for ECONO 799-601-2790 Adapter for ECONO 799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI 799-601-2840 Extension cable (ECONO type) 799-601-2850 Case 799-601-4350 T-box (for DRC 60.BRANCH BOX AND T.BRANCH ADAPTER TABLE T.BRANCH ADAPTER TABLE (Rev. Number of pins T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4101 q q 1 2 3 4 6 8 12 14 16 1 2 3 M2P M3P X2P X3P X4P SW6P SW8P SW12P SW14P SW16P q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q 799-601-4201 Identification symbol Out of kit q q q 24 24 17 17 5 10 5 17 19 14 5 13 17 21 9 2 3 4 8 8 12 16 MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P MIC-5P MIC-13P MIC-17P MIC-21P MIC-9P ECONO2P ECONO3P ECONO4P ECONO8P DLI-8P DLI-12P DLI-16P q q q q q q q q q q q q q q q q 60 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q Part No. PX-15 .

Part name 799-601-7120 Adapter for M 799-601-7130 Adapter for M 799-601-7340 Adapter for M 799-601-7140 Adapter for S 799-601-7150 Adapter for S (White) 799-601-7160 Adapter for S (Blue) 799-601-7170 Adapter for S (Blue) 799-601-7330 Adapter for S (White) 799-601-7350 Adapter for S (White) 799-601-7180 Adapter for AMP040 799-601-7190 Adapter for AMP040 799-601-7210 Adapter for AMP040 799-601-7220 Adapter for AMP040 799-601-7230 Short connector for X 799-601-7240 Case 799-601-7270 Case 799-601-7510 Adapter for 070 799-601-7520 Adapter for 070 799-601-7530 Adapter for 070 799-601-7540 Adapter for 070 799-601-7550 Adapter for 070 799-601-7360 Adapter for relay 799-601-7370 Adapter for relay 799-601-7380 Adapter for JFC 799-601-9010 Adapter for DTM 799-601-9020 Adapter for DT 799-601-9030 Adapter for DT 799-601-9040 Adapter for DT 799-601-9050 Adapter for DT 799-601-9060 Adapter for DT (Gray) 799-601-9070 Adapter for DT (Black) 799-601-9080 Adapter for DT (Green) 799-601-9090 Adapter for DT (Brown) 799-601-9110 Adapter for DT (Gray) 799-601-9120 Adapter for DT (Black) 799-601-9130 Adapter for DT (Green) 799-601-9140 Adapter for DT (Brown) 799-601-9210 Adapter for HD30-18 799-601-9220 Adapter for HD30-18 799-601-9230 Adapter for HD30-18 799-601-9240 Adapter for HD30-18 799-601-9250 Adapter for HD30-24 799-601-9260 Adapter for HD30-24 799-601-9270 Adapter for HD30-24 799-601-9280 Adapter for HD30-24 799-601-9290 Adapter for HD30-24 799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO) 799-601-9330 Case 4 6 8 8 10 12 16 16 12 8 12 16 20 2 M4P M6P M8P S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P — q q q q q q q q 10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31 24 07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P — DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31 q q q q q D65EX. PX-15 20-371 (8) .BRANCH BOX AND T.BRANCH ADAPTER TABLE Number of pins T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4101 799-601-4201 Identification symbol Out of kit q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q Part No.TROUBLESHOOTING T.

20-372 (8) D65EX.3.3L 1.3A 1.3.2.4C 1. DRC-40 DRC-24 G A3 P 1.4T DTP4 DRC50 DRC60 — — HST16A HST16B HST26A — q q q 799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor 795-799-5540* Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM 795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE.TROUBLESHOOTING T. CAM Adapter for engine (CRI-T3) 799-601-4140 Atomosphere pressure 799-601-4150 Adapter for engine (CRI-T3) POIL Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA 799-601-4190* 799-601-4230* Socket for engine (CRI-T3) Commonrail pressure Socket for engine (CRI-T3) Air intake pressure/temperature 799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator 799-601-4380* Socket for engine (CRI-T3)(95) Air intake pressure/temperature 799-601-4260 Adapter for controller (ENG) 799-601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280 Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9730 Adapter for controller (HST) 799-601-9890 Multi-adapter for DT2 – 4 and DTM2 “*” Shows not T-adapter but socket.3.2.2.3 S C A — — — ITT3N FCIN FCIG FCIB 4160 4180 1. 4.2. PX-15 .2.2.G 2.BRANCH BOX AND T.2.PA 1. Part name 799-601-9340 Case 799-601-9350 Adapter for DRC 799-601-9360 Adapter for DRC 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor 799-601-9430* Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV 40 24 2 3 2 3 2 2 2 3 3 3 4 3 3 3 2 3 3 4 3 3 3 2 4 4 50 60 60 121 16 16 26 2.BRANCH ADAPTER TABLE Number of pins T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4101 q q q q q q q q 799-601-4201 Identification symbol Out of kit q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q Part No.3B 1. 3.

.............. (L1) See the list. (LH) See the list... 20-406 Trouble code table ... 20-407 Action code Troubleshooting page Error code 1500L0 15SAL1 15SALH 15SBL1 15SBLH 15SEL1 15SELH 15SFL1 15SFLH 15SGL1 15SGLH A000N1 AB00MA AD00L2 AD00MA AD10L3 AD10MA AD10MB AD11KA AD11KB AD51KA AD51KB ADA1KA ADAZKB Failed section Transmission clutch Forward clutch Forward clutch Reverse clutch Reverse clutch 1st clutch 1st clutch 2nd clutch 2nd clutch 3rd clutch 3rd clutch Engine Alternator Common rail Common rail Fuel supply pump Fuel supply pump Fuel supply pump Fuel supply pump solenoid 1 Fuel supply pump solenoid 1 Fuel supply pump solenoid 2 Fuel supply pump solenoid 2 No.. (L1) See the list............... (LH) Overrun (N1) Malfunction (MA) See the list.................................. (L1) See the list..... (LH) See the list.....TROUBLESHOOTING TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE) Information described in troubleshooting list ......................................... (L2) Defective function (MA) See the list.... (L1) See the list.............1.1 injector solenoid No............ PX-15 20-401 (1) .. (LH) See the list.................. (L1) See the list......... (LH) See the list....................................... (L0) See the list... (L3) Defective function (MA) Function reduction (MB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) CALL E03 20-408 CALL E03 20-409 CALL E03 20-410 CALL E03 20-411 CALL E03 20-412 CALL E03 20-413 CALL E03 20-414 CALL E03 20-415 CALL E03 20-416 CALL E03 20-417 CALL E03 20-418 — — 20-419 20-420 CALL E03 20-420 CALL E03 20-421 CALL E03 20-421 CALL E03 20-423 CALL E03 20-423 CALL E03 20-424 CALL E03 20-425 CALL E03 20-426 CALL E03 20-427 E02 20-428 CALL E03 20-429 D65EX......... and 3 injector solenoids Trouble See the list...... 2..

6 fuel injector solenoid Engine oil Radiator coolant Power train oil Hydraulic oil Battery relay Battery relay Neutral safety relay Neutral safety relay Back-up alarm relay Back-up alarm relay Preheater relay coil Engine controller load power supply relay Transmission neutral signal Transmission neutral signal Monitor panel CAN communication Steering and transmission controller Steering and transmission controller Steering and transmission controller sensor 5 V power supply Steering and transmission controller sensor 24 V power supply Steering and transmission controller type collation Steering and transmission controller CAN communication Engine controller type collation Engine controller Trouble Disconnection (KA) Disconnection (KA) Disconnection (KA) Short circuit (KB) Disconnection (KA) Disconnection (KA) Oil pressure reduction (ZG) Overheat (NS) Overheat (NS) Overheat (NS) Short circuit (KA) Disconnection (KB) Short circuit (KA) Disconnection (KB) Short circuit (KA) Disconnection (KB) Disconnection or short circuit (KZ) Short circuit (KB) Disconnection (KA) Short circuit (KB) Defective communication (KR) Source voltage reduction/input (KK) Abnormality in controller (KT) Source voltage reduction/input (KK) Source voltage reduction/input (KK) Action code E02 E02 E02 Troubleshooting page 20-431 20-432 20-433 CALL E03 20-434 E02 E02 — — — — — — E02 E02 E01 E01 E01 E02 E01 E01 20-436 20-437 20-438 20-438 20-439 20-439 20-440 20-441 20-442 20-444 20-446 20-448 20-450 20-452 20-454 20-455 CALL E03 20-456 CALL E04 20-458 E02 20-459 CALL E03 20-460 CALL E03 20-462 Type select signal inconsistency (KQ) CALL E04 20-463 Defective communication (KR) CALL E03 20-464 Type select signal inconsistency (KQ) CALL E03 20-466 Abnormality in controller (KT) CALL E03 20-467 20-402 (1) D65EX. PX-15 .3 injector solenoid No.4 injector solenoid No. and 6 injector solenoids No.5 fuel injector solenoid No.2 injector solenoid No.TROUBLESHOOTING Error code to display at the same time Error code ADB1KA ADC1KA ADD1KA ADDZKB ADE1KA ADF1KA B@BAZG B@BCNS B@CENS B@HANS D110KA D110KB D130KA D130KB D161KA D161KB D182KZ D1D0KB D5ZFKA D5ZFKB DAFRKR DAQ0KK DB30KK DAQ0KT DAQ5KK DB35KK DAQ6KK DB36KK DAQ9KQ DB39KQ DB3RKR DB20KQ DB20KT Failed section No.4. 5.

PX-15 20-403 (1) .TROUBLESHOOTING Error code to display at the same time Error code DB22KK DB29KQ DB2AMA DB2RKR DB2RMC DB30KK DAQ0KK DB35KK DAQ5KK DB36KK DAQ6KK DB39KQ DAQ9KQ DD11KB DD12KA DD12KB DD13KA DD13KB DD14KA DDQ2KA DD14KB DDQ2KB DDE2L6 DDN7KA DDN7KB DDQ2KA DD14KA DDQ2KB DD14KB DGE2KX DGE3L6 DGE4KX DGS1KX DH30KX DH40KX DK10KX DK12KX Failed section Engine controller load power supply Engine controller type select Trouble Source voltage reduction/input (KK) Action code Troubleshooting page CALL E04 20-468 Type select signal inconsistency (KQ) CALL E03 20-470 E02 20-471 Fuel injection amount adjustment switch signal Malfunction (MA) Steering and transmission controller CAN communication Engine controller CAN communication Steering and transmission controller Steering and transmission controller sensor 5 V power supply Steering and transmission controller sensor 24 V power supply Steering and transmission controller type collation Starting switch Shift up switch Shift up switch Shift down switch Shift down switch Parking lever switch Parking lever switch Engine oil pressure switch Pitch control switch Pitch control switch Parking lever switch Parking lever switch Engine water temperature sensor (for high temperature) Engine water temperature sensor (for low temperature) Fuel temperature sensor Hydraulic oil temperature sensor Boost pressure sensor Common rail pressure sensor Fuel control dial Deceleration potentiometer Defective communication (KR) Defective communication (MC) Source voltage reduction/input (KK) Source voltage reduction/input (KK) Source voltage reduction/input (KK) CALL E04 20-472 CALL E03 20-474 CALL E04 20-476 CALL E03 20-476 CALL E03 20-476 Type select signal inconsistency (KQ) CALL E04 20-476 Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Refer to table (L6) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Input signal is out of normal range (KX) See table (L6) Input signal is out of normal range (KX) Input signal is out of normal range (KX) Input is out of normal range (KX) Input is out of normal range (KX) Input is out of normal range (KX) Input is out of normal range (KX) CALL E04 20-477 E02 E02 E02 E02 20-478 20-480 20-482 20-484 CALL E03 20-486 CALL E03 20-488 E01 E02 E02 20-490 20-492 20-494 CALL E03 20-496 CALL E03 20-496 E01 E02 E01 — E02 20-497 20-498 20-499 20-500 20-502 CALL E03 20-504 CALL E03 20-506 CALL E03 20-508 D65EX.

TROUBLESHOOTING Error code DK30KA DK30KB DK30KX DK30KZ DK30L8 DK31KA DK31KB DK40KA DK40KB DK55KX DK55KZ DK55L8 DK56KA DK56KB DK57KA DK57KB DKH1KA DKH1KB DLE3LC DLF1KA DLH1LC DV00KB DW5AKA DW5AKB DW7BKA DW7BKB DWN1KA DWN1KB DWN2KA Failed section Steering potentiometer 1 Steering potentiometer 1 Steering potentiometer Steering potentiometer Steering potentiometer 1 Steering potentiometer 2 Steering potentiometer 2 Brake potentiometer Brake potentiometer Forward-reverse potentiometer Forward-reverse potentiometer Forward-reverse potentiometer Forward-reverse potentiometer 1 Forward-reverse potentiometer 1 Forward-reverse potentiometer 2 Forward-reverse potentiometer 2 Pitch angle sensor Pitch angle sensor Engine Ne speed sensor Transmission output speed sensor Engine G speed sensor Caution buzzer Pitch control solenoid Pitch control solenoid Fan reverse solenoid Fan reverse solenoid HSS EPC solenoid right HSS EPC solenoid right HSS EPC solenoid left Trouble Disconnection (KA) Short circuit (KB) Action code Troubleshooting page CALL E03 20-510 CALL E03 20-511 Input signal is out of normal range (KX) CALL E04 20-512 Disconnection or short circuit (Double trouble) (KZ) See table (L8) Short circuit (KA) Disconnection (KB) Disconnection (KA) Short circuit (KB) CALL E04 20-512 CALL E03 20-513 CALL E03 20-514 CALL E03 20-515 CALL E03 20-516 CALL E03 20-517 Input signal is out of normal range (KX) CALL E04 20-518 Disconnection or short circuit (Double trouble) (KZ) See table (L8) Short circuit (KA) Disconnection (KB) Short circuit (KA) Disconnection (KB) Short circuit (KA) Disconnection (KB) See table (LC) Disconnection (KA) See table (LC) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) CALL E04 20-518 CALL E03 20-519 CALL E03 20-520 CALL E03 20-522 CALL E03 20-524 CALL E03 20-526 CALL E03 20-528 CALL E03 20-529 CALL E03 20-530 E01 20-531 CALL E03 20-532 — E02 E02 E01 E01 20-533 20-534 20-535 20-536 20-537 CALL E03 20-538 CALL E03 20-539 CALL E03 20-540 20-404 (1) D65EX. PX-15 .

PX-15 20-405 (1) .TROUBLESHOOTING Error code DWN2KB DWN5KA DWN5KB DXH4KA DXH4KB DXH5KA DXH5KB DXH6KA DXH6KB DXH7KA DXH7KB DXH8KA DXH8KB Failed section HSS EPC solenoid left Fan pump TVC solenoid Fan pump TVC solenoid 1st clutch ECMV 1st clutch ECMV 2nd clutch ECMV 2nd clutch ECMV 3rd clutch ECMV 3rd clutch ECMV Reverse clutch ECMV Reverse clutch ECMV Forward clutch ECMV Forward clutch ECMV Trouble Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Action code Troubleshooting page CALL E03 20-541 E01 E01 20-542 20-543 CALL E03 20-544 CALL E03 20-545 CALL E03 20-546 CALL E03 20-547 CALL E03 20-548 CALL E03 20-549 CALL E03 20-550 CALL E03 20-551 CALL E03 20-552 CALL E03 20-553 D65EX.

TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING LIST INFORMATION DESCRIBED IN TROUBLESHOOTING LIST a The troubleshooting list and related circuit diagram summarize the following information. disconnect the connector. and insert the T-junction adapter in 4 both the male and female. • Defective hot short A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit. connect the plus (+) and minus (–) leads as shown below unless especially specified. (2) Pin number description sequence and tester lead handling For troubleshooting.) (1) Method of indicating connector numbers and handling T-junction For troubleshooting. Understand their contents well to advance troubleshooting. 1 2 Possible causes and standard value in normal state Cause by which a trouble is assumed to be detected 3 (The order number indicates a serial number. • Connect the minus (–) lead to a pin or harness indicated in the rear. insert or connect the T-junction adapter as shown below unless especially specified. disconnect the connector. • Connect the plus (+) lead to a pin or harness indicated in the 5 front. Action code Panel display Contents of trouble Action of monitor panel or controller Problem that appears on machine Related information Error code Controller code Panel display Trouble Trouble that appeared on machine State where the monitor panel or controller detects the trouble Action to be taken to protect the system and equipment when the monitor panel or controller detects a trouble Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or controller (above) Information related to a detected trouble or troubleshooting Cause Standard value in normal state/Remarks on troubleshooting <Described contents> • Standard value in normal state required to judge the assumed cause (good or not) • Remarks required to judge whether the cause is good <Phenomenon of defective harness> • Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. 20-406 (1) D65EX. PX-15 . • Grounding fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit. not a priority <Notes on troubleshooting> sequence. • When “male” or “female” is not indicated for a connector number. and insert the T-junction adapter in only either the male or female. • When “male” or “female” is indicated for a connector number. • Defective short A harness of an independent circuit abnormally comes into contact with one of another circuit.

Engine rotation signal. D65EX.: Indicates (Model-No. Trouble code KA KB KK KQ KR KT KX KZ MA MB MW NS ZG ZK Contents of trouble Disconnection in wiring Short circuit Source voltage reduction/input Type select signal inconsistency Defective communication Abnormality in controller Outside input signal range Disconnection or short circuit (Double trouble) Malfunction Performance reduction Sliding Overheat Oil pressure reduction Coolant level reduction Trouble code L0 L1 L2 L3 L4 L6 L8 LC LD LH Contents of trouble Fill signals at two or more channels which are not set as combination are turned ON at the same time. Analog signals in two systems are inconsistent. Fuel pressure is above maxim specified value. water temperature sensor signal.TROUBLESHOOTING TROUBLE CODE TABLE Related circuit diagram This is the excerpted circuit diagram related to trouble • Connector No. etc. ON and OFF signals at two systems are inconsistent. Switch is pressed for usually unthinkable long time. Fill signal is ON when command current to ECMV is OFF. check it against table below. • Arrow ( ): Roughly indicates mounting place on machine. Fill signal is OFF when command current to ECMV is ON. oil pressure switch signal. Object part is uncontrollable. rpm signals in two systems are inconsistent. PX-15 20-407 (1) . of pins) (Color). terminal C signal. TROUBLE CODE TABLE a Regarding trouble code provided with instruction “Refer to table”. are inconsistent with operation state or stop state.

[DXH5KA]. • Method of reproducing error code: Engine start + Run Cause Standard value in normal state/Remarks on troubleshooting Confirm the error codes displayed at the same time. [DXH6KA]. the following codes were displayed at the same time. [15SEL1]. [15SBL1]. [DXH8KB] Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state 20-408 (1) D65EX. then carry out troubleshooting for the codes. • The auto shift down function does not start. [15SALH]. • Limits operation of engine and transmission. and [15SEL1] (7) [15SALH] and [15SBLH] (8) [15SALH] and [15SELH] (9) [15SBLH] and [15SELH] • Flashes caution lamp and turns on caution buzzer. • Once machine is stopped. [DXH8KA]. (L0)) Action code CALL E03 Error code Controller code Transmission clutch: See the list. [15SGLH] [DXH4KA]. [15SBLH]. • Machine cannot travel. [DXH7KB]. [DXH4KB]. [DXH7KA]. [15SFL1]. [15SELH]. (Machine cannot travel) (2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB] (3) Either of [DXH6KA] or [DXH6KB] and (1) above (4) [15SFL1] and [15SGL1] (5) [15SFLH] and [15SGLH] (6) [15SAL1]. [15SAL1]. running is limited to specific gear speeds.TROUBLESHOOTING ERROR CODE 1500L0 ERROR CODE 1500L0 (TRANSMISSION CLUTCH: SEE THE LIST. (L0) Trouble (Steering and transmission controller system) 1500L0 Steering • Of the error codes related to the transmission clutch. [15SFLH]. [DXH5KB]. (Gear speed is limited) (1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB] • Of the error codes related to the transmission clutch. [15SBL1]. PX-15 . engine speed is limited to medium (half). the following codes were displayed at the same time. • Once machine is stopped. [DXH6KB]. [15SGL1].

Carry out the related troubleshootsystem ing (H mode). Defective forward clutch fill FSW (male) PCCS lever Resistance switch (Internal short) N Min. • Limits operation of engine and transmission. 1 Mz Between (1) – chassis ground F (Forward) Max. • Decides that engine speed is neutral (N) at reverse operation. ing (Contact with ground Wiring harness between ST2 (female) (35) – circuit) Resistance Max. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting Defective harness groundwithout turning starting switch ON.TROUBLESHOOTING ERROR CODE 15SAL1 ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SAL1 Controller code Steering Trouble Forward clutch: See the list. • Once machine is stopped. 1 Mz FSW (female) (1) with chassis ground aPrepare with starting switch OFF. • The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode. 1 z aPrepare with starting switch OFF. running is limited to F1. PX-15 20-409 (1) . Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission forward clutch ECMV D65EX. engine speed is limited to medium (half). 1 V When no fault is detected in the electric system. • Once machine is stopped. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Neutral running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then start the engine for troubleshooting. Defective steering and ST2 PCCS lever Voltage transmission controller N 5 – 11 V Between (35) – chassis ground F (Forward) Max. (L1) (Steering and transmission controller system) • The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit. then start the engine for troubleshooting.

Defective steering and ST2 PCCS lever Voltage transmission controller N 5 – 11 V Between (35) – chassis ground F (Forward) Max. then start the engine for troubleshooting. (LH) (Steering and transmission controller system) • The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.TROUBLESHOOTING ERROR CODE 15SALH ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST. 1 z connector) FSW (female) (1) aPrepare with starting switch OFF. • Once machine is stopped. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Forward running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 z aPrepare with starting switch OFF. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. running is limited to R1. Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission forward clutch ECMV 20-410 (1) D65EX. • The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode. • Decides that engine speed is neutral (N) at forward operation. engine speed is limited to medium (half). • Limits operation of engine and transmission. 1 Mz Between (1) – chassis ground F (Forward) Max. Carry out the related troubleshootsystem ing (H mode). • Flashes caution lamp and turns on caution buzzer. then start the engine for troubleshooting. 1 V When no fault is detected in the electric system. PX-15 . Defective forward clutch fill FSW (male) PCCS lever Resistance switch (Internal short) N Min. harness (Disconnection in wiring or defective contact in Wiring harness between ST2 (female) (35) – Resistance Max. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. • Once machine is stopped. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SALH Controller code Steering Trouble Forward clutch: See the list.

engine speed is limited to medium (half). • Once machine is stopped. 1 z aPrepare with starting switch OFF. 1 Mz Between (1) – chassis ground R (Reverse) Max. ing (Contact with ground Wiring harness between ST2 (female) (25) – circuit) Resistance Max. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. • Limits operation of engine and transmission. then start the engine for troubleshooting. then start the engine for troubleshooting. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting Defective harness groundwithout turning starting switch ON. 1 Mz RSW (female) (1) with chassis ground aPrepare with starting switch OFF. PX-15 20-411 (1) . Carry out the related troubleshootsystem ing (H mode). • The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode. • Decides that engine speed is neutral (N) at forward operation. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SBL1 Controller code Steering Trouble Reverse clutch: See the list. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Forward running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE 15SBL1 ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST. Defective steering and ST2 PCCS lever Voltage transmission controller N 5 – 11 V Between (24) and (25) – chassis ground R (Reverse) Max. Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission reverse clutch ECMV D65EX. • Once machine is stopped. 1 V When no fault is detected in the electric system. running is limited to R1. Defective reverse clutch fill RSW (male) PCCS lever Resistance switch (Internal short) N Min. (L1) (Steering and transmission controller system) • The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.

Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission reverse clutch ECMV 20-412 (1) D65EX. Defective steering and ST2 PCCS lever Voltage transmission controller N 5 – 11 V Between (25) – chassis ground R (Reverse) Max. PX-15 . engine speed is limited to medium (half). harness (Disconnection in wiring or defective contact in Wiring harness between ST2 (female) (25) – Resistance Max. • Once machine is stopped. 1 Mz Between (1) – chassis ground R (Reverse) Max. then start the engine for troubleshooting. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SBLH Controller code Steering Trouble Reverse clutch: See the list. • Decides that engine speed is neutral (N) at reverse operation. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. running is limited to F1. 1 Mz connector) RSW (female) (1) aPrepare with starting switch OFF. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. • Limits operation of engine and transmission. 1 V When no fault is detected in the electric system. • Flashes caution lamp and turns on caution buzzer. (LH) (Steering and transmission controller system) • The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit. • Once machine is stopped. then start the engine for troubleshooting. Defective reverse clutch fill RSW (male) PCCS lever Resistance switch (Internal short) N Min. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Forward running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 z aPrepare with starting switch OFF. • The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode. Carry out the related troubleshootsystem ing (H mode).TROUBLESHOOTING ERROR CODE 15SBLH ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST.

the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. 1 Mz Between (1) – chassis ground F1·R1 Max. Defective steering and ST3 PCCS lever Voltage transmission controller Other than F1/R1 5 – 11 V Between (19) – chassis ground F1·R1 Max. then carry out troubleshooting Defective harness groundwithout turning starting switch ON. Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 1st clutch ECMV D65EX. (L1) (Steering and transmission controller system) • The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit. Carry out the related troubleshootsystem ing (H mode). 1 V When no fault is detected in the electric system. then start the engine for troubleshooting. • The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SEL1 Controller code Steering Trouble 1st clutch: See the list. Defective 1st clutch fill 1SW (male) PCCS lever Resistance switch (Internal short) Other than F1/R1 Min. then start the engine for troubleshooting. • Flashes caution lamp and turns on caution buzzer. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Forward running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. running is limited to F1 and R1. • Limits operation of engine and transmission. engine speed is limited to medium (half). 1 Mz 1SW (female) (1) with chassis ground aPrepare with starting switch OFF. 1 z aPrepare with starting switch OFF. PX-15 20-413 (1) . • Once machine is stopped. • Once machine is stopped. ing (Contact with ground Wiring harness between ST3 (female) (19) – circuit) Resistance Max.TROUBLESHOOTING ERROR CODE 15SEL1 ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST.

(Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + F1 or R1 running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. running is limited to F2 and R2. Carry out the related troubleshootsystem ing (H mode). harness (Disconnection in wiring or defective contact in Wiring harness between ST3 (female) (19) – Resistance Max. Limits operation of engine and transmission. The auto shift down function does not start. 1 z aPrepare with starting switch OFF. (LH) (Steering and transmission controller system) • The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.TROUBLESHOOTING ERROR CODE 15SELH ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST. 1 Mz connector) 1SW (female) (1) aPrepare with starting switch OFF. PX-15 . then start the engine for troubleshooting. 1 Mz Between (1) – chassis ground F1·R1 Max. Once machine is stopped. Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 1st clutch ECMV 20-414 (1) D65EX. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SELH Controller code Steering Trouble 1st clutch: See the list. engine speed is limited to medium (half). Once machine is stopped. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. then start the engine for troubleshooting. The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode. Defective steering and ST3 PCCS lever Voltage transmission controller Other than F1/R1 5 – 11 V Between (19) – chassis ground F1·R1 Max. Defective 1st clutch fill 1SW (male) PCCS lever Resistance switch (Internal short) Other than F1/R1 Min. 1 V When no fault is detected in the electric system. • • • • • • Flashes caution lamp and turns on caution buzzer.

1 Mz 2SW (female) (1) with chassis ground aPrepare with starting switch OFF. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Neutral running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Carry out the related troubleshootsystem ing (H mode). • • • • • • Flashes caution lamp and turns on caution buzzer. Once machine is stopped. Defective 2nd clutch fill 2SW (male) PCCS lever Resistance switch (Internal short) Other than F2/R2 Min. Once machine is stopped. The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SFL1 Controller code Steering Trouble 2nd clutch: See the list. then carry out troubleshooting Defective harness groundwithout turning starting switch ON. Defective steering and ST3 PCCS lever Voltage transmission controller Other than F2/R2 5 – 11 V Between (29) – chassis ground F2·R2 Max. 1 Mz Between (1) – chassis ground F2·R2 Max. (L1) (Steering and transmission controller system) • The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit. 1 z aPrepare with starting switch OFF. Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 2nd clutch ECMV D65EX. running is limited to F2 and R2. then start the engine for troubleshooting. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. then start the engine for troubleshooting. 1 V When no fault is detected in the electric system. engine speed is limited to medium (half). Limits operation of engine and transmission.TROUBLESHOOTING ERROR CODE 15SFL1 ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST. PX-15 20-415 (1) . ing (Contact with ground Wiring harness between ST3 (female) (29) – circuit) Resistance Max. The auto shift down function does not operate.

Defective steering and ST3 PCCS lever Voltage transmission controller Other than F2/R2 5 – 11 V Between (29) – chassis ground F2·R2 Max. PX-15 . (LH) (Steering and transmission controller system) • The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit. then start the engine for troubleshooting. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + F2 or R2 running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. engine speed is limited to medium (half). 1 V When no fault is detected in the electric system. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SFLH Controller code Steering Trouble 2nd clutch: See the list. • Once machine is stopped. Defective 2nd clutch fill 2SW (male) PCCS lever Resistance switch (Internal short) Other than F2/R2 Min. Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 2nd clutch ECMV 20-416 (1) D65EX. Carry out the related troubleshootsystem ing (H mode). 1 Mz connector) 2SW (female) (1) aPrepare with starting switch OFF. then start the engine for troubleshooting. running is limited to F1 and R1. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. harness (Disconnection in wiring or defective contact in Wiring harness between ST3 (female) (29) – Resistance Max.TROUBLESHOOTING ERROR CODE 15SFLH ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST. 1 Mz Between (1) – chassis ground F2·R2 Max. • Once machine is stopped. 1 z aPrepare with starting switch OFF. • The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode. • Limits operation of engine and transmission.

Defective steering and ST3 PCCS lever Voltage transmission controller Other than F3/R3 5 – 11 V Between (39) – chassis ground F3·R3 Max. Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 3rd clutch ECMV D65EX. (L1)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SGL1 Controller code Steering Trouble 3rd clutch: See the list. then start the engine for troubleshooting. Defective 3rd clutch fill 3SW (male) PCCS lever Resistance switch (Internal short) Other than F3/R3 Min. ing (Contact with ground Wiring harness between ST3 (female) (39) – circuit) Resistance Max. 1 Mz 3SW (female) (1) with chassis ground aPrepare with starting switch OFF. The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode. 1 V When no fault is detected in the electric system. Carry out the related troubleshootsystem ing (H mode). • • • • • • Flashes caution lamp and turns on caution buzzer.TROUBLESHOOTING ERROR CODE 15SGL1 ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST. Once machine is stopped. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + Neutral running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Limits operation of engine and transmission. Once machine is stopped. (L1) (Steering and transmission controller system) • The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. 1 z aPrepare with starting switch OFF. then start the engine for troubleshooting. engine speed is limited to medium (half). 1 Mz Between (1) – chassis ground F3·R3 Max. PX-15 20-417 (1) . then carry out troubleshooting Defective harness groundwithout turning starting switch ON. running is limited to F3 and R3. The auto shift down function does not operate.

1 z aPrepare with starting switch OFF. Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 3rd clutch ECMV 20-418 (1) D65EX. • Once machine is stopped. • The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode. • Limits operation of engine and transmission. then start the engine for troubleshooting. Defective steering and ST3 PCCS lever Voltage transmission controller Other than F3/R3 5 – 11 V Between (39) – chassis ground F3·R3 Max. 1 z connector) 3SW (female) (1) aPrepare with starting switch OFF. 1 Mz Between (1) – chassis ground F3·R3 Max. Defective 3rd clutch fill 3SW (male) PCCS lever Resistance switch (Internal short) Other than F3/R3 Min. then start the engine for troubleshooting. harness (Disconnection in wiring or defective contact in Wiring harness between ST3 (female) (39) – Resistance Max. (LH) (Steering and transmission controller system) • The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit. (LH)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code 15SGLH Controller code Steering Trouble 3rd clutch: See the list. • Flashes caution lamp and turns on caution buzzer. running is limited to F1 and R1. • Once machine is stopped. (Code 31520: Transmission fill switch input state) • Method of reproducing error code: Engine start + F3 or R3 running Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 V When no fault is detected in the electric system. the hydraulic pressure Defective hydraulic pressure system is assumed to be abnormal. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. engine speed is limited to medium (half). Carry out the related troubleshootsystem ing (H mode). PX-15 .TROUBLESHOOTING ERROR CODE 15SGLH ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST.

• Stops fuel injection until the engine speed lowers below the specified speed.TROUBLESHOOTING ERROR CODE A000N1 ERROR CODE A000N1 (ENGINE: OVERRUN (N1)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Engine: Overrun (N1) Trouble (Engine controller system) A000N1 Engine • All the segments of the engine speed bar graph of the monitor panel lighted up to the red range and the engine speed exceeded the specified speed (2. • Saves the trouble but does not make any alarm. Cause Standard value in normal state/Remarks on troubleshooting If any other error code is displayed and recorded at the same time. carry out troubleshooting for that 1 error code first. (Code 01000: Engine speed) • Method of reproducing error code: Turn starting switch ON. Possible causes and standard value in normal state D65EX. PX-15 20-419 (1) . • Engine speed (rpm) can be checked in monitoring mode.750 rpm). • Engine speed can be checked in monitoring mode. • None in particular. Check that engine speed is displayed normally. 2 Improper use 3 Defective engine controller Instruct the using procedure again.

Cause Defective battery charge 1 (When system is in normal state) 2 Defective charge level caution lamp system Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing defective battery charge is occurring at present or occurred in past. The fuel used may be inappropriate. ERROR CODE AD00L2 ERROR CODE AB00MA ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code AB00MA Controller code — Trouble Alternator: Malfunction (MA) (Mechanical system) • During rotation of engine. sensor Defective mechanical The common rail pressure sensor is assumed to be defective mechan4 system of common rail ically. • If machine is operated as it is. • Limits output for operation. battery may be discharged. charge level caution lamp flashes. or ball 5 Defective overflow valve fixing. directly check it. emergency caution item flashes” in E mode.TROUBLESHOOTING ERROR CODE AB00MA. Possible causes and standard value in normal state ERROR CODE AD00L2 (COMMON RAIL: SEE THE LIST. directly check it. (Code 36400: Common rail pressure) • Method of reproducing error code: Engine start Cause 1 Defective related system Standard value in normal state/Remarks on troubleshooting Check the displayed error code. directly 7 Defective pressure limiter check it. (L2)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code AD00L2 Controller code Engine Trouble Common rail: See the list. • Flashes caution lamp and turns on caution buzzer. • Method of reproducing error code: Start engine. If another code is displayed. pressure sensor The overflow valve may cause spring damage. The pressure limiter is assumed to be defective mechanically. • Engine output reduces. • The fuel state (fuel pressure) of common rail can be checked in monitoring mode. directly check it. PX-15 . Carry out troubleshooting of charge level caution lamp system in accordance with “During running of engine. 20-420 (1) D65EX. sheet abrasion. Possible causes and standard value in normal state 2 Inappropriate fuel Defective electric system of 3 common rail pressure Carry out troubleshooting for error code [DH40KX]. 6 Clogged overflow pipe The overflow pipe is assumed to be clogged. (L2) (Engine controller system) • The fuel pressure of common rail became high (level 1). and correct it. • Flashes caution lamp. Investigate cause and damage condition. first carry out troubleshooting for the code. directly check it.

• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring mode. (MA) (Engine controller system) • The fuel pressure of common rail became high (level 2). • Engine output and speed reduces. see circuit equipment Note 2 for troubleshooting. • Limits output for operation. Inappropriate fuel The fuel used may be inappropriate. • Flashes caution lamp and turns on caution buzzer. and [AD51KB]. Defective common rail The common rail pressure sensor is assumed to be defective. PX-15 20-421 (1) . The filter strainer is assumed to be clogged. Cause 1 2 3 Possible causes and standard value in normal state 4 5 6 7 8 9 D65EX. (Code 36400: Common rail pressure) • Method of reproducing error code: Engine start Standard value in normal state/Remarks on troubleshooting Check the displayed error code. The fuel injector is assumed to be defective. (L3) (Engine controller system) • Non-pressure transmission (level 1) occurred in fuel supply pump. • The fuel state (fuel pressure) of common rail can be checked in monitoring mode. • Limits output and engine speed for operation. If another code is displayed. • Engine output reduces. directly pressure sensor check it. directly Defective pressure limiter check it. (Code 36400: Common rail pressure) • Method of reproducing error code: Engine start Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for error code [AD00L2]. directly check it. ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST. first carry Defective related system out troubleshooting for the code. Defective electric system of Carry out troubleshooting for error codes [AD11KA]. see Note 1 for troubleClogged filter strainer shooting. fuel supply pump PCV [AD51KA]. Defective fuel supply pump The fuel supply pump is assumed to be defective. [AD11KB]. directly check it. ERROR CODE AD00MA ERROR CODE AD10L3 ERROR CODE AD00MA (COMMON RAIL: DEFECTIVE FUNCTION (MA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code AD00MA Controller code Engine Trouble Common rail: See the list. see Note 3 for troubleDefective fuel injector shooting. • Flashes caution lamp and turns on caution buzzer. The pressure limiter is assumed to be defective mechanically. (L3)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code AD10L3 Controller code Engine Trouble Fuel supply pump: See the list. Defective low-pressure The low-pressure circuit equipment is assumed to be defective.TROUBLESHOOTING ERROR CODE AD00MA.

2) Upstream strainer of gauze filter If the gauze filter is clogged. clean. 1) Gauze filter Disassemble and check the filter. 1) Disconnect the hose from the collection part of the return spill tube (at the rear of the engine). Note 2.900 2. Limit of fuel spill rate (Total of quantity spilling from 6 cylinders) Stall speed (rpm) 1.TROUBLESHOOTING ERROR CODE AD10L3 Note 1. Check the low-pressure circuit parts for the following items. PX-15 . 1) Remaining fuel 2) Sticking and wear of feed pump 3) Leakage and clogging of low-pressure fuel piping 4) Defective operation of bypass valve or installation of wrong parts to bypass valve (See Fig. take care. 2) Connect a hose to the spill tube end to receive the spilling fuel.020 1.700 1.800 1. too. clean. 1: Locations of overflow valve 1 bypass valve 2 . Check. and replace the filters and strainers according to the following procedure.080 1. If it is clogged. 90ºC). clean the upstream strainer. • Fuel inlet joint 3 : Gauze filter is seen through both holes. 3) Start the engine and stall at each speed and measure the quantity of the fuel spilling in 1 minute. Method of measuring fuel spill rate k Since the spilling fuel is hot (max.000 Limit of spill rate (cc/min) 960 1. and fuel inlet joint (gauze filter) • Overflow valve 1 : Spring is seen through one hole (on nut side).140 1. replace the fuel filter. • Bypass valve 2 : Spring is seen through both holes. 3 Note 3. 1) 5) Oil pan oil mixed with fuel (fuel leakage in head cover) Fig.200 20-422 (1) D65EX. 3) Fuel filter If the trouble is not solved by performing 1) and 2) above.600 1.

ERROR CODE AD10MA AD10MB ERROR CODE AD10MA (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code AD10MA Controller code Engine Trouble Fuel supply pump: Defective function (MA) (Engine controller system) • An abnormal pressure occurred in the common rail fuel pressure.TROUBLESHOOTING ERROR CODE AD10MA. • Limits output and engine speed for operation. (Code 36400: Common rail pressure) • Method of reproducing error code: Engine start Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for error code [AD10L3]. • Runs in normal control state. PX-15 20-423 (1) . • Flashes caution lamp and turns on caution buzzer. (Code 36400: Common rail pressure) • Method of reproducing error code: Engine start Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for error code [AD10L3]. • Engine output reduces. D65EX. • Flashes caution lamp and turns on caution buzzer. ERROR CODE AD10MB (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code AD10MB Controller code Engine Trouble Fuel supply pump: Function reduction (MB) (Engine controller system) • Non-pressure transmission (level 2) occurred in the fuel supply pump. • The fuel state (fuel pressure) of common rail can be checked in monitoring mode. • The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring mode. • Engine output and speed reduces.

3 z Between (1) – chassis ground Min. engine speed is limited to medium (half). then carry out troubleshooting without turning starting switch ON. The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 1. EN3 (female) Resistance 4 Defective engine controller Between (12) – (22) 2. running is limited to F1 and R1. PX-15 . Once machine is stopped. 1 Mz chassis ground Circuit diagram related to fuel supply pump solenoid 1 20-424 (1) D65EX. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (12) – Resistance Max.TROUBLESHOOTING ERROR CODE AD11KA ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code AD11KA Controller code Engine Trouble Fuel supply pump solenoid 1: Disconnection (KA) (Engine controller system) • Disconnection in wiring occurred in fuel supply pump solenoid 1 (PCV1). 1 z PCV1 (female) (2) aPrepare with starting switch OFF. 1 Mz aPrepare with starting switch OFF. engine stops. If codes [AD51KA] and [AD51KB] are displayed at the same time. Limits engine and transmission operation. Once machine is stopped.3 z Between (12) (22) – Min. then carry out troubleshooting without turning starting switch ON. 1 z 2 wiring or defective contact in PCV1 (female) (1) connector) Wiring harness between EN3 (female) (22) – Resistance Max. Stops output to fuel supply pump solenoid 1 circuit. • • • • • • • • Flashes caution lamp and turns on caution buzzer. Defective fuel supply pump PCV1 (male) Resistance 1 solenoid 1 (Internal disconnection in wiring) Between (1) – (2) 2.3 – 5. Method of reproducing error code: Engine start Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz PCV1 (female) (2) with chassis ground aPrepare with starting switch OFF.3 – 5. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Defective harness groundwithout turning starting switch ON. 3 ing (Contact with ground Wiring harness between EN3 (female) (22) – circuit) Resistance Min.

Limits operation of engine and transmission. engine stops. then carry out troubleshooting without turning starting switch ON. 1 Mz aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. When code [AD51KA] and [AD51KB] appear at the same time. For troubleshooting of fuel supply pump solenoid 1.3 – 5. engine speed is limited to medium (half). then carry out troubleshooting Short circuit with chassis without turning starting switch ON. PX-15 20-425 (1) . 1 V PCV1 (female) (2) with chassis ground aPrepare with starting switch OFF.3 z Between (1) – chassis ground Min. Hot short circuit in wiring Wiring harness between EN3 (female) (12) – harness Voltage Max. Once machine is stopped. 1 Mz chassis ground Cause 1 2 Possible causes and standard value in normal state 3 4 Circuit diagram related to fuel supply pump solenoid 1 D65EX. special adaptor (799-601-9430) is required. ground in wiring harness Wiring harness between EN3 (female) (12) – (Contact with ground circuit) Resistance Max. then turn starting switch ON and carry out troubleshooting. 1 Mz PCV1 (female) (1) with chassis ground aPrepare with starting switch OFF. • • • • • • • • Flashes caution lamp and turns on caution buzzer.3 – 5. Once machine is stopped.3 z Between (12) (22) – Min. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Defective fuel supply pump PCV1 (male) Resistance solenoid 1 (Internal short circuit) Between (1) – (2) 2. Method of reproducing error code: Start engine. travel is limited to F1 and R1. EN3 (female) Resistance Defective engine controller Between (12) – (22) 2. Stops output to fuel supply pump solenoid 1 circuit. 1 V PCV1 (female) (1) with chassis ground (Contact with 24 V circuit) Wiring harness between EN3 (female) (22) – Voltage Max.TROUBLESHOOTING ERROR CODE AD11KB ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code AD11KB Controller code Engine Trouble Fuel supply pump solenoid 1: Short circuit (KB) (Engine controller system) • Overcurrent flowed in fuel supply pump solenoid 1 (PCV1) circuit.

TROUBLESHOOTING ERROR CODE AD51KA ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code AD51KA Controller code Engine Trouble Fuel supply pump solenoid 2: Disconnection (KA) (Engine controller system) • Disconnection in wiring occurred in fuel supply pump solenoid 2 (PCV2). then carry out troubleshooting Defective harness groundwithout turning starting switch ON. EN3 (female) Resistance 4 Defective engine controller Between (13) – (23) 2. If codes [AD11KA] and [AD11KB] are displayed at the same time. 1 Mz aPrepare with starting switch OFF. 1 z 2 wiring or defective contact in PCV2 (female) (1) connector) Wiring harness between EN3 (female) (23) – Resistance Max. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (13) – Resistance Max.3 – 5. The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 2. engine stops.3 – 5. then carry out troubleshooting without turning starting switch ON. 1 z PCV2 (female) (2) aPrepare with starting switch OFF. Once machine is stopped. then carry out troubleshooting without turning starting switch ON. Once machine is stopped. engine speed is limited to medium (half). running is limited to F1 and R1. 1 Mz PCV2 (female) (2) with chassis ground aPrepare with starting switch OFF. • • • • • • • • Flashes caution lamp and turns on caution buzzer. 1 Mz chassis ground Circuit diagram related to fuel supply pump solenoid 2 20-426 (1) D65EX.3 z Between (1) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. Method of reproducing error code: Engine start Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. PX-15 . Limits engine and transmission operation. Defective fuel supply pump PCV2 (male) Resistance 1 solenoid 2 (Internal disconnection in wiring) Between (1) – (2) 2.3 z Between (13) (23) – Min. Stops output to fuel supply pump solenoid 2 circuit. 3 ing (Contact with ground Wiring harness between EN3 (female) (23) – circuit) Resistance Min.

3 z Between (1) – chassis ground Min. Defective harness hot short Wiring harness between EN3 (female) (13) – 3 Voltage Max. Once machine is stopped. 2 ing (Contact with ground Wiring harness between EN3 (female) (13) – circuit) Resistance Max. Once machine is stopped. then carry out troubleshooting without turning starting switch ON.3 – 5. Method of reproducing error code: Engine start Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz PCV2 (female) (1) aPrepare with starting switch OFF. 1 V PCV2 (female) (2) with chassis ground aPrepare with starting switch OFF.3 – 5. Limits engine and transmission operation. running is limited to F1 and R1. Defective fuel supply pump PCV2 (male) Resistance 1 solenoid 2 (Internal disconnection in wiring) Between (1) – (2) 2. EN3 (female) Resistance 4 Defective engine controller Between (13) – (23) 2. • • • • • • • • Flashes caution lamp and turns on caution buzzer. engine speed is limited to medium (half). then carry out troubleshooting without turning starting switch ON. 1 Mz aPrepare with starting switch OFF. The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 2. Stops output to fuel supply pump solenoid 2 circuit.TROUBLESHOOTING ERROR CODE AD51KB ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code AD51KB Controller code Engine Trouble Fuel supply pump solenoid 2: Short circuit (KB) (Engine controller system) • Overcurrent occurred in fuel supply pump solenoid 2 (PCV2). engine stops. then carry out troubleshooting without turning starting switch ON. If codes [AD11KA] and [AD11KB] are displayed at the same time. 1 V (Contact with 24 V circuit) PCV2 (female) (1) with chassis ground Wiring harness between EN3 (female) (23) – Voltage Max. then carry out troubleshooting Defective harness groundwithout turning starting switch ON.3 z Between (13) (23) – Min. PX-15 20-427 (1) . 1 Mz chassis ground Circuit diagram related to fuel supply pump solenoid 2 D65EX.

1 INJECTOR SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code ADA1KA Controller code Engine Trouble No.1 z Cause Possible causes and standard value in normal state Circuit diagram related to No. 1 noid (Internal disconnection CN-1 (male) Resistance in wiring) Between (1) and (2) 0. then carry out troubleshooting Defective No. then carry out troubleshooting without turning starting switch ON.4 – 1.1 injector solenoid 20-428 (1) D65EX. PX-15 .TROUBLESHOOTING ERROR CODE ADA1KA ERROR CODE ADA1KA (NO. • Method of reproducing error code: Engine start Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (14) – Resistance Max.1 z aPrepare with starting switch OFF. 3 Defective engine controller EN3 (female) Resistance Between (14) and (24) 0. • Stops output to the No.1 injector solenoid (TWV#1) circuit.without turning starting switch ON. 1 z CN-1 (female) (2) aPrepare with starting switch OFF. 1 z 2 wiring or defective contact in CN-1 (female) (1) connector) Wiring harness between EN3 (female) (24) – Resistance Max.1 injector solenoid circuit. • Flashes caution lamp and turns on caution buzzer. • Engine output reduces.1 injector solenoid: Disconnection (KA) (Engine controller system) • Disconnection in wiring occurred in the No. then carry out troubleshooting without turning starting switch ON.1 injector sole.4 – 1.

then carry out troubleshooting without turning starting switch ON. 1 Mz aPrepare with starting switch OFF.2 injector solenoid (TWV#2). and 3 injector solenoids: Short circuit (KB) Trouble (Engine controller system) ADAZKB Engine • Overcurrent occurred in the No.3 injector solenoid (TWV#3). 1 Mz CN-3 (female) 1) with chassis ground Wiring harness between EN3 (female) (15) – Resistance Min. 2. running is limited to F1 and R1.1 z Between (1) (2) – chassis ground Min. then carry out troubleshooting without turning starting switch ON.TROUBLESHOOTING ERROR CODE ADAZKB ERROR CODE ADAZKB (NO. • Limits engine and transmission operations. 2. and 3 injector solenoid circuits. 1 Mz aPrepare with starting switch OFF. or No.1. engine speed is limited to medium (half). then carry out troubleshooting without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer. • Method of reproducing error code: Engine start Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. No.1. 1 Mz CN-3 (female) (2) with chassis ground 1 Defective No.1. 1 Mz CN-2 (female) (2) with chassis ground Wiring harness between EN3 (female) (5) – Resistance Min.4 – 1.1 injector solenoid (TWV#1). CN-1 (male) Resistance Between (1) – (2) 0.1 z Between (1) (2) – chassis ground Min. • Stops output to the No.2 injector solenoid (Internal short) Possible causes and standard value in normal state 3 Defective No. 1 Mz CN-1 (female) 1) with chassis ground Wiring harness between EN3 (female) (24) – Resistance Min. CN-2 (male) Resistance Between (1) – (2) 0. • Engine output reduces extremely. 1 Mz aPrepare with starting switch OFF. CN-3 (male) Resistance Between (1) – (2) 0.1 z Between (1) (2) – chassis ground Min. PX-15 20-429 (1) .4 – 1. 1 Mz CN-1 (female) (2) with chassis ground Wiring harness between EN3 (female) (6) – Resistance Min. 1 Mz CN-2 (female) 1) with chassis ground Wiring harness between EN3 (female) (16) – Resistance Min.3 injector solenoid (Internal short) Defective harness ground4 ing (Contact with ground circuit) D65EX.4 – 1. Wiring harness between EN3 (female) (14) – Resistance Min.1 injector solenoid (Internal short) 2 Defective No. then carry out troubleshooting without turning starting switch ON. AND 3 INJECTOR SOLENOIDS: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code No. • Once machine is stopped. • Once machine is stopped. 2.

1 V CN-1 (female) (1) with chassis ground Wiring harness between EN3 (female) (24) – Voltage Max.1 z Between EN3 (female) (14) – (24) 6 Defective engine controller Resistance 0. 1 V CN-1 (female) (2) with chassis ground Defective harness hot short Wiring harness between EN3 (female) (6) – 5 Voltage Max. and 3 injector solenoids 20-430 (1) D65EX.4 – 1. and take care of an electric shock and an electric leak. 1 V CN-3 (female) (1) with chassis ground Wiring harness between EN3 (female) (15) – Voltage Max. then turn starting switch ON for troubleshooting.TROUBLESHOOTING ERROR CODE ADAZKB Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.1 z Between EN3 (female) (6) – (16) Resistance 0. Circuit diagram related to No. 2.4 – 1.1. 1 V CN-2 (female) (2) with chassis ground Wiring harness between EN3 (female) (5) – Voltage Max. Resistance 0.4 – 1. PX-15 . 1 V CN-3 (female) (2) with chassis ground aPrepare with starting switch OFF. Handling of high-voltage circuit of engine controller. 1 V (Contact with 24 V circuit) CN-2 (female) (1) with chassis ground Wiring harness between EN3 (female) (16) – Voltage Max.1 z Between EN3 (female) (5) – (15) Cause k Since high voltage (100 – 150 V) is used for the electric circuit of the fuel injector. then carry out troubleshooting without turning starting switch ON. Wiring harness between EN3 (female) (14) – Voltage Max. refer to TESTING AND ADJUSTING.

3 Defective engine controller EN3 (female) Resistance Between (6) and (16) 0. then carry out troubleshooting Defective No. 1 noid (Internal disconnection CN-2 (male) Resistance in wiring) Between (1) and (2) 0. • Method of reproducing error code: Engine start Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.4 – 1.4 – 1.2 injector solenoid D65EX.1 z Cause Possible causes and standard value in normal state Circuit diagram related to No.2 injector solenoid: Disconnection (KA) (Engine controller system) • Disconnection in wiring occurred in the No.1 z aPrepare with starting switch OFF. • Engine output reduces.TROUBLESHOOTING ERROR CODE ADB1KA ERROR CODE ADB1KA (NO.2 INJECTOR SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code ADB1KA Controller code Engine Trouble No. then carry out troubleshooting without turning starting switch ON. 1 z CN-2 (female) (2) aPrepare with starting switch OFF. • Stops output to the No.2 injector solenoid circuit. then carry out troubleshooting without turning starting switch ON. PX-15 20-431 (1) .2 injector sole.without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer.2 injector solenoid (TWV#2) circuit. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (6) – Resistance Max. 1 z 2 wiring or defective contact in CN-2 (female) (1) connector) Wiring harness between EN3 (female) (16) – Resistance Max.

• Flashes caution lamp and turns on caution buzzer.3 injector solenoid (TWV#3) circuit. then carry out troubleshooting without turning starting switch ON.1 z Cause Possible causes and standard value in normal state Circuit diagram related to No.3 INJECTOR SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code ADC1KA Controller code Engine Trouble No.without turning starting switch ON. 1 z 2 wiring or defective contact in CN-3 (female) (1) connector) Wiring harness between EN3 (female) (15) – Resistance Max. 1 noid (Internal disconnection CN-3 (male) Resistance in wiring) Between (1) and (2) 0.3 injector solenoid 20-432 (1) D65EX.3 injector solenoid circuit.3 injector sole.1 z aPrepare with starting switch OFF. PX-15 . • Stops output to the No.TROUBLESHOOTING ERROR CODE ADC1KA ERROR CODE ADC1KA (NO.4 – 1. • Method of reproducing error code: Engine start Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.3 injector solenoid: Disconnection (KA) (Engine controller system) • Disconnection in wiring occurred in the No. 1 z CN-3 (female) (2) aPrepare with starting switch OFF. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (5) – Resistance Max. then carry out troubleshooting without turning starting switch ON. • Engine output reduces. then carry out troubleshooting Defective No.4 – 1. 3 Defective engine controller EN3 (female) Resistance Between (5) and (15) 0.

4 – 1.4 injector solenoid: Disconnection (KA) (Engine controller system) • Disconnection in wiring occurred in the No.4 injector solenoid circuit. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (26) – Resistance Max. • Engine output reduces.TROUBLESHOOTING ERROR CODE ADD1KA ERROR CODE ADD1KA (NO.4 INJECTOR SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code ADD1KA Controller code Engine Trouble No.without turning starting switch ON.1 z aPrepare with starting switch OFF. 3 Defective engine controller EN3 (female) Resistance Between (26) and (36) 0. then carry out troubleshooting Defective No. • Method of reproducing error code: Engine start Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.4 injector sole.4 – 1. 1 z 2 wiring or defective contact in CN-4 (female) (1) connector) Wiring harness between EN3 (female) (36) – Resistance Max. PX-15 20-433 (1) . 1 noid (Internal disconnection CN-4 (male) Resistance in wiring) Between (1) and (2) 0.4 injector solenoid D65EX. then carry out troubleshooting without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer. • Stops output to the No.1 z Cause Possible causes and standard value in normal state Circuit diagram related to No. then carry out troubleshooting without turning starting switch ON. 1 z CN-4 (female) (2) aPrepare with starting switch OFF.4 injector solenoid (TWV#4) circuit.

1 z Between (1) (2) – chassis ground Min. • Once machine is stopped. No. then carry out troubleshooting without turning starting switch ON. 5. PX-15 . 5. or No. 1 Mz CN-5 (female) (1) with chassis ground Wiring harness between EN3 (female) (33) – Resistance Min.1 z Between (1) (2) – chassis ground Min. 1 Mz CN-4 (female) (2) with chassis ground Wiring harness between EN3 (female) (34) – Resistance Min. engine speed is limited to medium (half). CN-5 (male) Resistance Between (1) – (2) 0.6 injector solenoid (Internal short) Defective harness ground4 ing (Contact with ground circuit) 20-434 (1) D65EX. 1 Mz CN-4 (female) (1) with chassis ground Wiring harness between EN3 (female) (36) – Resistance Min. • Flashes caution lamp and turns on caution buzzer.TROUBLESHOOTING ERROR CODE ADDZKB ERROR CODE ADDZKB (NO. running is limited to F1 and R1. then carry out troubleshooting without turning starting switch ON.5 injector solenoid (TWV#5). CN-6 (male) Resistance Between (1) – (2) 0.4 – 1. • Limits engine and transmission operations.5 injector solenoid (Internal short) Possible causes and standard value in normal state 3 Defective No. CN-4 (male) Resistance Between (1) – (2) 0. 1 Mz CN-6 (female) (1) with chassis ground Wiring harness between EN3 (female) (35) – Resistance Min. then carry out troubleshooting without turning starting switch ON.4 – 1.4 – 1.6 injector solenoid (TWV#6). • Once machine is stopped.1 z Between (1) (2) – chassis ground Min. • Engine output reduces extremely. 1 Mz CN-5 (female) (2) with chassis ground Wiring harness between EN3 (female) (25) – Resistance Min. 1 Mz aPrepare with starting switch OFF. • Stops output to the No. 5. and 6 injector solenoids: Short circuit (KB) Trouble (Engine controller system) ADDZKB Engine • Overcurrent occurred in the No. then carry out troubleshooting without turning starting switch ON. • Method of reproducing error code: Engine start Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz aPrepare with starting switch OFF.4. AND 6 INJECTOR SOLENOIDS: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code No. Wiring harness between EN3 (female) (26) – Resistance Min. 1 Mz aPrepare with starting switch OFF.4. 1 Mz CN-6 (female) (2) with chassis ground 1 Defective No.4 injector solenoid (Internal short) 2 Defective No.4.4 injector solenoid (TWV#4). and 6 injector solenoid circuits.

4 – 1. Handling of high-voltage circuit of engine controller.4. 1 V CN-6 (female) (2) with chassis ground aPrepare with starting switch OFF. 1 V CN-4 (female) (2) with chassis ground Defective harness hot short Wiring harness between EN3 (female) (34) – 5 Voltage Max. 5. PX-15 20-435 (1) .4 – 1.1 z Between EN3 (female) (34) – (33) Resistance 0.TROUBLESHOOTING ERROR CODE ADDZKB Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 V (Contact with 24 V circuit) CN-5 (female) (1) with chassis ground Wiring harness between EN3 (female) (33) – Voltage Max. Resistance 0. 1 V CN-4 (female) (1) with chassis ground Wiring harness between EN3 (female) (36) – Voltage Max. then carry out troubleshooting without turning starting switch ON. and take care of an electric shock and an electric leak. Wiring harness between EN3 (female) (26) – Voltage Max. refer to TESTING AND ADJUSTING. 1 V CN-6 (female) (1) with chassis ground Wiring harness between EN3 (female) (35) – Voltage Max.4 – 1. then turn starting switch ON for troubleshooting. and 6 injector solenoids D65EX.1 z Between EN3 (female) (26) – (36) 6 Defective engine controller Resistance 0. Circuit diagram related to No.1 z Between EN3 (female) (25) – (35) Cause k Since high voltage (100 – 150 V) is used for the electric circuit of the fuel injector. 1 V CN-5 (female) (2) with chassis ground Wiring harness between EN3 (female) (25) – Voltage Max.

5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code ADE1KA Controller code Engine Trouble No. 1 z 2 wiring or defective contact in CN-5 (female) (1) connector) Wiring harness between EN3 (female) (33) – Resistance Max.4 – 1. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (34) – Resistance Max. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting Defective No. 3 Defective engine controller EN3 (female) Resistance Between (34) – (33) 0. PX-15 .TROUBLESHOOTING ERROR CODE ADE1KA ERROR CODE ADE1KA (NO. 1 z CN-5 (female) (2) aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. • Stops output to No.1 z Cause Possible causes and standard value in normal state Circuit diagram related to No. • Engine output lowers.5 fuel injector solenoid circuit.5 fuel injector solenoid 20-436 (1) D65EX. 1 solenoid (Internal disconCN-5 (male) Resistance nection) Between (1) – (2) 0.5 fuel injector solenoid: Disconnection (KA) (Engine controller system) • Disconnection occurred in No.5 fuel injector solenoid (TWV#5) circuit. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON.4 – 1.1 z aPrepare with starting switch OFF. • Method of reproducing error code: Start engine.5 fuel injector without turning starting switch ON.

TROUBLESHOOTING ERROR CODE ADF1KA ERROR CODE ADF1KA (NO. then carry out troubleshooting without turning starting switch ON.1 z aPrepare with starting switch OFF.1 z Cause Possible causes and standard value in normal state Circuit diagram related to No.6 fuel injector solenoid (TWV#6) circuit. 1 solenoid (Internal disconCN-6 (male) Resistance nection) Between (1) – (2) 0. 3 Defective engine controller EN3 (female) Resistance Between (25) – (35) 0.6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code ADF1KA Controller code Engine Trouble No. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (25) – Resistance Max. • Stops output to No.6 fuel injector solenoid circuit. then carry out troubleshooting without turning starting switch ON.4 – 1. PX-15 20-437 (1) . 1 z CN-6 (female) (2) aPrepare with starting switch OFF.6 fuel injector solenoid: Disconnection (KA) (Engine controller system) • Disconnection occurred in No. • Method of reproducing error code: Start engine. then carry out troubleshooting Defective No. • Flashes caution lamp and turns on caution buzzer.4 – 1. 1 z 2 wiring or defective contact in CN-6 (female) (1) connector) Wiring harness between EN3 (female) (35) – Resistance Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.6 fuel injector solenoid D65EX. • Engine output lowers.6 fuel injector without turning starting switch ON.

Cause Engine oil pressure reduc1 tion (When system is in normal state) Defective engine oil 2 pressure caution lamp system Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing engine oil pressure reduction is occurring at present or occurred in past. • Method of reproducing error code: Start engine. emergency caution item flashes” in E mode. (Function of monitor panel) • If machine is operated as it is. Investigate cause and damage condition. and correct it. and correct it. radiator coolant temperature caution lamp flashes. emergency caution item flashes” in E mode. PX-15 . engine may be damaged. • Flashes caution lamp and turns on caution buzzer. (Function of monitor panel) • If machine is operated as it is. Possible causes and standard value in normal state 20-438 (1) D65EX. Carry out troubleshooting of engine oil pressure caution lamp system in accordance with “During running of engine. • Flashes caution lamp and turns on caution buzzer. Cause Engine water temperature 1 overheat (When system is in normal state) Defective engine water 2 temperature caution lamp system Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing engine water temperature overheat is occurring at present or occurred in past. ERROR CODE B@BCNS B@BAZG ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code B@BAZG Controller code Engine Trouble Engine oil: Oil pressure reduction (ZG) (Mechanical system) • During rotation of engine.TROUBLESHOOTING ERROR CODE B@BAZG. engine oil pressure caution lamp flashes. • Method of reproducing error code: Start engine. Possible causes and standard value in normal state ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT (NS)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code B@BCNS Controller code Engine Trouble Radiator coolant: Overheat (NS) (Mechanical system) • During rotation of engine. Investigate cause and damage condition. engine may be damaged. Carry out troubleshooting of engine water temperature caution lamp system in accordance with “During running of engine.

(Function of monitor panel) • If machine is operated as it is. • Flashes caution lamp and turns on caution buzzer. work equipment circuit units may be damaged. Cause Hydraulic oil temperature 1 overheat (When system is in normal state) Defective hydraulic oil 2 temperature caution lamp system Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing hydraulic oil temperature overheat is occurring at present or occurred in past. emergency caution item flashes” in E mode. Investigate cause and damage condition. • Method of reproducing error code: Start engine.TROUBLESHOOTING ERROR CODE B@CENS. Investigate cause and damage condition. • Flashes caution lamp and turns on caution buzzer. emergency caution item flashes” in E mode. Possible causes and standard value in normal state D65EX. power train may be damaged. Carry out troubleshooting of power train oil temperature caution lamp system in accordance with “During running of engine. • Method of reproducing error code: Start engine. Cause Power train oil temperature 1 overheat (When system is in normal state) Defective power train oil 2 temperature overheat caution lamp system Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing power train oil temperature overheat is occurring at present or occurred in past. PX-15 20-439 (1) . hydraulic oil temperature caution lamp flashes. ERROR CODE B@HANS B@CENS ERROR CODE B@CENS (POWER TRAIN OIL: OVERHEAT (NS)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code B@CENS Controller code Steering Trouble Power train oil: Overheat (NS) (Mechanical system) • During rotation of engine. and correct it. and correct it. (Function of monitor panel) • If machine is operated as it is. Possible causes and standard value in normal state ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code B@HANS Controller code Steering Trouble Hydraulic oil: Overheat (NS) (Mechanical system) • During rotation of engine. power train oil temperature caution lamp flashes. Carry out troubleshooting of hydraulic oil temperature caution lamp system in accordance with “During running of engine.

TROUBLESHOOTING ERROR CODE D110KA ERROR CODE D110KA (BATTERY RELAY: SHORT CIRCUIT (KA)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code D110KA Controller code Steering Trouble Battery relay: Short circuit (KA) (Steering and transmission controller system) • Abnormal current flowed to battery relay circuit when outputting it. • Output state (voltage) to battery relay can be checked in monitoring mode. 1 Mz with chassis ground aPrepare with starting switch OFF. Short circuit with chassis 2 ground in wiring harness Wiring harness between ST3 (female) (4) – (Contact with ground circuit) battery relay terminal SW – S13 (female) (10) Resistance Min. Defective steering and 3 ST3 Starting switch Voltage transmission controller Between (4) – ON 20 – 30 V chassis ground Cause Possible causes and standard value in normal state Circuit diagram related to battery relay 20-440 (1) D65EX. (Code 60600: Battery relay drive voltage) • Method of reproducing error code: Switch starting switch from ON to OFF. • Stops output to battery relay circuit. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. PX-15 . Battery relay Continuity/resistance Defective battery relay 1 Between terminals SW – (Internal short circuit) Continue SWG terminal Between terminal SW – Min. 1 Mz chassis ground aPrepare with starting switch OFF. • Problem may occur in data writing to ROM (nonvolatile storage) of each controller. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting.

• Stops output to battery relay circuit. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (4) – Resistance Max. (Code 60600: Battery relay drive voltage) • Method of reproducing error code: Switch starting switch from ON to OFF. 1 z 2 wiring or defective contact in battery relay SW terminal connector) Wiring harness between SWG terminal – Resistance Max. then carry out troubleshooting without turning starting switch ON. 1 z chassis GND03 aPrepare with starting switch OFF. 1 V with chassis ground aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE D110KB ERROR CODE D110KB (BATTERY RELAY: DISCONNECTION (KB)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code D110KB Controller code Steering Trouble Battery relay: Disconnection (KB) (Steering and transmission controller system) • Current does not flow when outputting it to battery relay circuit. Defective steering and 4 transmission controller ST3 (female) Continuity Between (4) – chassis ground Continue Cause Possible causes and standard value in normal state Circuit diagram related to battery relay D65EX. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. • Problem may occur in data writing to ROM (nonvolatile storage) of each controller. PX-15 20-441 (1) . then carry out troubleshooting without turning starting switch ON. Defective battery relay 1 Battery relay Continuity (Internal disconnection) Between terminals SW – Continue SWG terminal aPrepare with starting switch OFF. Hot short circuit in wiring 3 harness (Contact with 24 V Wiring harness between ST3 (female) (4) – circuit) battery relay terminal SW – S13 (female) (10) Voltage Max. • Output state (voltage) to battery relay can be checked in monitoring mode. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.

then turn starting switch ON and Hot short circuit in wiring carry out troubleshooting. 2 harness (Contact with 24 V Wiring harness between ST2 (female) (8) – NSF circuit) Voltage Max. • Flashes caution lamp and turns on caution buzzer. 1 V Cause Possible causes and standard value in normal state 20-442 (1) D65EX. • Engine does not start. aThis error code detects abnormality in primary side (coil side) of neutral safety relay. • Output state (voltage) to neutral safety relay can be checked in monitoring mode. (Code 50900: Neutral safety relay drive voltage) • Method of reproducing error code: Turn starting switch ON and operate parking lever (Lock position). then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. • Stops ground output to neutral safety relay circuit. PX-15 . Defective neutral safety 1 relay (Internal short circuit) NSF (male) Resistance Between (1) – (2) 200 – 400 z aPrepare with starting switch OFF. but not in secondary side (contact side) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 V (female) (2) with chassis ground aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE D130KA ERROR CODE D130KA (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code D130KA Controller code Steering Trouble Neutral safety relay: Short circuit (KA) (Steering and transmission controller system) • Abnormal current flowed in neutral safety relay circuit at the time of ground output. Defective steering and ST2 Parking lever Voltage 3 transmission controller Free position 20 – 30 V Between (8) – chassis ground Lock position Max.

TROUBLESHOOTING ERROR CODE D130KA Circuit diagram related to neutral safety relay D65EX. PX-15 20-443 (1) .

• Output state (voltage) to neutral safety relay can be checked in monitoring mode. then carry out troubleshooting without turning starting switch ON. Defective disconnection in wiring harness (Disconnec. • Engine can be started. then carry out troubleshooting without turning starting switch ON. 1 z starting switch ACC (270) aPrepare with starting switch OFF. regardless of position of parking brake lever. then carry out troubleshooting without turning starting switch ON. PX-15 . 1 V Cause 1 2 Possible causes and standard value in normal state 3 4 20-444 (1) D65EX.Wiring harness between ST2 (female) (8) – Resistance Max. Defective neutral safety relay (Internal disconnection) NSF (male) Resistance Between (1) – (2) 200 – 400 z aPrepare with starting switch OFF. 1 Mz starting switch ACC (270) with chassis ground aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE D130KB ERROR CODE D130KB (NEUTRAL SAFETY RELAY: DISCONNECTION (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code D130KB Controller code Steering Trouble Neutral safety relay: Disconnection (KB) (Steering and transmission controller system) • 24 V is not generated when ground of neutral safety relay circuit is interrupted. 1 z tion in wiring or defective NSF (female) (2) contact in connector) Wiring harness between NSF (female) (1) – Resistance Max. Short circuit with chassis Wiring harness between ST2 (female) (8) – Resistance Min. (Code 50900: Neutral safety relay drive voltage) • Method of reproducing error code: Turn starting switch ON and operate parking lever (Free position). Defective steering and ST2 Parking lever Voltage transmission controller Free position 20 – 30 V Between (8) – chassis ground Lock position Max. aThis error code detects abnormality in primary side (coil side) of neutral safety relay. then turn starting switch ON and carry out troubleshooting. • Stops ground output to neutral safety relay circuit. 1 Mz ground in wiring harness NSF (female) (2) with chassis ground (Contact with ground circuit) Wiring harness between NSF (female) (1) – Resistance Min. • Engine does not start. but not in secondary side (contact side) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. • Flashes caution lamp and turns on caution buzzer.

TROUBLESHOOTING ERROR CODE D130KB Circuit diagram related to neutral safety relay D65EX. PX-15 20-445 (1) .

but not in secondary side (contact side) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 20-446 (1) D65EX. then turn starting switch ON and carry out troubleshooting. aThis error code detects abnormality in primary side (coil side) of back-up alarm relay. • Back-up alarm is not turned on. 1 V Cause Possible causes and standard value in normal state a PCCS: Abbreviation for Palm Command Control System. Defective steering and ST2 Parking lever Voltage 3 transmission controller Neutral position 20 – 30 V Between (18) – chassis ground Reverse position Max. Defective back-up alarm 1 relay (Internal short circuit) BKA (male) Resistance Between (1) – (2) 200 – 400 z aPrepare with starting switch OFF. (Code 70400: Back-up alarm relay drive voltage) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever NEUTRAL. 1 V BKA (female) (2) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. • Output state (voltage) to back-up alarm relay can be checked in monitoring mode. PX-15 . • Stops output to back-up alarm relay circuit. 2 harness (Contact with 24 V Wiring harness between ST2 (female) (18) – circuit) Voltage Max.TROUBLESHOOTING ERROR CODE D161KA ERROR CODE D161KA (BACK-UP ALARM RELAY: SHORT CIRCUIT (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code D161KA Controller code Steering Trouble Back-up alarm relay: Short circuit (KA) (Steering and transmission controller system) • Abnormal current flowed in back-up alarm relay circuit at the time of ground output. then turn starting switch ON and Hot short circuit in wiring carry out troubleshooting.

PX-15 20-447 (1) .TROUBLESHOOTING ERROR CODE D161KA Circuit diagram related to back-up alarm relay D65EX.

aThis error code detects abnormality in primary side (coil side) of back-up alarm relay. • Output state (voltage) to back-up alarm relay can be checked in monitoring mode. aPrepare with starting switch OFF. 1 Mz BKA (female) (2) with chassis ground Wiring harness between BKA (female) (1) – Resistance Min. then carry out troubleshooting without turning starting switch ON. circuit probably has short circuit with chassis ground. BKA (male) Resistance Between (1) – (2) 200 – 400 z aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. • Back-up alarm is not turned on. regardless of positions of steering and forward-reverse lever and gearshift lever. 1 z BKA (female) (2) Wiring harness between BKA (female) (1) – Resistance Max.TROUBLESHOOTING ERROR CODE D161KB ERROR CODE D161KB (BACK-UP ALARM RELAY: DISCONNECTION (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code D161KB Controller code Steering Trouble Back-up alarm relay: Disconnection (KB) (Steering and transmission controller system) • 24 V is not generated when ground output of neutral safety relay circuit is interrupted. • Stops output to back-up alarm relay circuit. 20-448 (1) D65EX. 1 Mz FS2-9 outlet port with chassis ground aPrepare with starting switch OFF. 1 z FS2-9 outlet port aPrepare with starting switch OFF. PX-15 . but not in secondary side (contact side) Cause 1 Defective fuse FS2-9 Defective back-up alarm relay (Internal disconnection) Standard value in normal state/Remarks on troubleshooting If fuse is burnout. ST2 PCCS lever Voltage Neutral position 20 – 30 V Between (18) – chassis ground Reverse position Max. then carry out troubleshooting without turning starting switch ON. 1 V 2 Possible causes and standard value in normal state Defective disconnection in wiring harness (Disconnec3 tion in wiring or defective contact in connector) Short circuit with chassis 4 ground in wiring harness (Contact with ground circuit) 5 Defective steering and transmission controller a PCCS: Abbreviation for Palm Command Control System. • Back-up alarm is turned on. Wiring harness between ST2 (female) (18) – Resistance Min. then turn starting switch ON and carry out troubleshooting. Wiring harness between ST2 (female) (18) – Resistance Max. (Code 70400: Back-up alarm relay drive voltage) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever NEUTRAL.

PX-15 20-449 (1) .TROUBLESHOOTING ERROR CODE D161KB Circuit diagram related to back-up alarm relay D65EX.

TROUBLESHOOTING ERROR CODE D182KZ ERROR CODE D182KZ (PREHEATER RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code D182KZ Controller code Engine Trouble Preheater relay coil: Disconnection or short circuit (KZ) (Engine controller system) • The drive circuit of the preheater relay has a trouble of disconnection or short circuit. Defective preheater relay 1 (RHR) (Internal disconnec200 – Resistance Between RHR (female) (1) – (2) tion or grounding fault) 400 z Resistance Min. • Stops ground output to preheater relay. then turn starting switch ON and carry out troubleshooting. 1 Mz EN1 (female) (13). Voltage 4 Defective controller Max. but not in secondary side (contact side). Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Wiring harness between RHR (female) (2) – Resistance Min. 1 z connector) 270 Wiring harness between RHR (female) (1) – Resistance Max. (19) aPrepare with starting switch OFF. PX-15 . (19) with chassis ground aPrepare with starting switch OFF. aThis error code detects abnormality in primary side (coil side) of preheater relay. • Preheater relay cannot be driven. then carry out troubleshooting without turning starting switch ON. • Preheater relay is driven. 1 V Between EN1 (female) When relay is driven (12) – ground When relay is 20 – 30 V not driven Cause Possible causes and standard value in normal state 20-450 (1) D65EX. Wiring harness between RHR (female) (2) – Disconnection in wiring Resistance Max. 1 z EN1 (female) (13). then carry out troubleshooting without turning starting switch ON. regardless of atmospheric temperature. 1 Mz Between RHR (female) (1) – ground aPrepare with starting switch OFF. 1 z harness (Disconnection in EN1 (female) (12) 2 wiring or defective contact in Wiring harness between RHR (female) (1) – Resistance Max. 1 Mz 3 ground in wiring harness EN1 (female) (12) with chassis ground (Contact with ground circuit) Wiring harness between RHR (female) (1) – Resistance Min.

TROUBLESHOOTING ERROR CODE D182KZ Circuit diagram related to preheater relay coil D65EX. PX-15 20-451 (1) .

EN3 Starting switch Voltage 4 Defective engine controller OFF position Max. 1 load power supply relay PPR (male) Resistance (Internal short circuit) Between (3) – (5) Min. 3 harness (Contact with 24 V Voltage Max. harness (Disconnection in 2 wiring or defective contact in Wiring harness between EN1 (female) (13) Resistance Max. 1 V Between (1). Hot short circuit in wiring Wiring harness between EN3 (female) (1). • None in particular. • Flashes caution lamp and turns on caution buzzer. (21) – chassis ground ON position Max. 1 V 270 with chassis ground aPrepare with starting switch OFF. but not in primary side (coil side) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 8 V Cause Possible causes and standard value in normal state 20-452 (1) D65EX. (2). then carry out troubleshooting Disconnection in wiring without turning starting switch ON.TROUBLESHOOTING ERROR CODE D1D0KB ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code D1D0KB Controller code Engine Trouble Engine controller load power supply relay: Short circuit (KB) (Engine controller system) • Voltage is generated in controller load power supply circuit when starting switch is turned OFF. 1 V (21) – PPR (female) (3) with chassis ground circuit) Wiring harness between PPR (female) (1) – Voltage Max. (2). aThis error code detects abnormality in secondary side (contact side) of engine controller load power supply relay. 1 Mz aPrepare with starting switch OFF. then carry out troubleshooting Defective engine controller without turning starting switch ON. PX-15 . 1 z connector) (19) – 270 aPrepare with starting switch OFF. • Method of reproducing error code: Turn starting switch OFF. then turn starting switch ON and carry out troubleshooting. then carry out troubleshooting with starting switch OFF or ON.

PX-15 20-453 (1) .TROUBLESHOOTING ERROR CODE D1D0KB Circuit diagram related to engine controller D65EX.

(17) aPrepare with starting switch OFF. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. harness (Disconnection in 1 wiring or defective contact in Wiring harness between ST2 (female) (19) – Resistance Max. then turn starting switch ON and carry out troubleshooting. 1 z connector) EN3 (female) (7). • The state of the transmission neutral signal (ON/OFF) can be checked in monitoring mode (Code: 40909 Transmission-related controller output signal) (Code: 40901 Engine controller input signal 2). PX-15 . 1 Mz EN3 (female) (7). then carry out troubleshooting Disconnection in wiring without turning starting switch ON. • Method of reproducing error code: Turn starting switch ON and shift transmission in N position. • None in particular. • This signal line is for backing up (The main signal is transmitted through the CAN communication network). (17) with chassis ground aPrepare with starting switch OFF. 1 V Between ST2 (19) – ground Lever in F or R Voltage 5 – 11 V aPrepare with starting switch OFF. Defective steering and 3 transmission controller Lever in N Voltage Max.TROUBLESHOOTING ERROR CODE D5ZFKA ERROR CODE D5ZFKA (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code D5ZFKA Controller code Steering Trouble Transmission neutral signal: Disconnection (KA) (Steering and transmission controller system) • Voltage is not generated when ground of transmission neutral safety relay circuit is interrupted. (17) – ground Voltage 5 – 11 V Cause Possible causes and standard value in normal state Circuit diagram related to transmission neutral signal 20-454 (1) D65EX. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 2 ground in wiring harness Wiring harness between ST2 (female) (19) – (Contact with ground circuit) Resistance Min. 4 Defective engine controller Between EN3 (7). • Stops outputting the transmission neutral signal. then turn starting switch ON and carry out troubleshooting.

1 V Between ST2 (19) – ground Lever in F or R Voltage 5 – 11 V aPrepare with starting switch OFF. • None in particular. • Stops outputting the transmission neutral signal. then turn starting switch ON and carry out troubleshooting. 1 V connector) EN3 (female) (7). • This signal line is for backing up (The main signal is transmitted through the CAN communication network). (17) – ground Voltage 5 – 11 V Cause Possible causes and standard value in normal state Circuit diagram related to transmission neutral signal D65EX.TROUBLESHOOTING ERROR CODE D5ZFKB ERROR CODE D5ZFKB (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code D5ZFKB Controller code Steering Trouble Transmission neutral signal: Short circuit (KB) (Steering and transmission controller system) • Abnormal current flowed when ground signal of transmission neutral safety relay circuit is output. then turn starting switch ON and carry out troubleshooting. Defective steering and 2 transmission controller Lever in N Voltage Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then turn starting switch ON and Hot short circuit in wiring carry out troubleshooting. PX-15 20-455 (1) . 3 Defective engine controller Between EN3 (7). • Method of reproducing error code: Turn starting switch ON and shift transmission in N position. harness (Disconnection in 1 wiring or defective contact in Wiring harness between ST2 (female) (19) – Voltage Max. (17) with chassis ground aPrepare with starting switch OFF. • The state of the transmission neutral signal (ON/OFF) can be checked in monitoring mode (Code: 40909 Transmission-related controller output signal) (Code: 40901 Engine controller input signal 2).

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. (2) Disconnection in wiring – ST2 (female) (32) – EN2 (female) (32) – CA2 Resistance Max. 1 V (female) (A) – CA2 (female) (A) – G01 (female) 3 harness (Contact with 24 V (8) with chassis ground circuit) Wiring harness between S04 (female) (3). PX-15 . travel is limited to F1 and R1. engine speed is limited to medium (half). 1 z harness (Disconnection in (female) (A) – CA2 (female) (A) – G01 (female) 1 wiring or defective contact in (8) connector) Wiring harness between S04 (female) (3) (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Resistance Max. Once machine is stopped. Wiring harness between S04 (female) (1). (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Voltage Max. • • • • • Flashes caution lamp and turns on caution buzzer. • Method of reproducing error code: Turn starting switch ON. CA2 (male) Resistance Between (A) – (B) 100 – 140 z Defective monitor panel or If no problem is found in causes 1 to 4.) Cause Possible causes and standard value in normal state 20-456 (1) D65EX. (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Resistance Min. then carry out troubleshooting without turning starting switch ON. System may not operate normally. 1 V (female) (B) – CA2 (female) (B) – G01 (female) (7) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 z (female) (B) – CA2 (female) (B) – G01 (female) (7) aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DAFRKR ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DAFRKR Controller code MON Trouble Monitor panel CAN communication: Defective communication (KR) (Monitor panel system) • Monitor panel cannot recognize steering and transmission controller with CAN communication circuit. 1 Mz Short circuit with chassis (female) (A) – CA2 (female) (A) – G01 (female) 2 ground in wiring harness (8) with chassis ground (Contact with ground circuit) Wiring harness between S04 (female) (3). (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Resistance Min. Wiring harness between S04 (female) (1). 1 Mz (female) (B) – CA2 (female) (B) – G01 (female) (7) with chassis ground aPrepare with starting switch OFF. (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Hot short circuit in wiring Voltage Max. (Troubleshooting transmission controller cannot be carried out since it is internal defect. Once machine is stopped. it is suspected that monitor pan5 defective steering and el or steering and transmission controller is defective. Wiring harness between S04 (female) (1). Limits operation of engine and transmission. Defective CAN terminal 4 resistance CA2 (male).

TROUBLESHOOTING ERROR CODE DAFRKR Circuit diagram related to CAN communication D65EX. PX-15 20-457 (1) .

then turn starting switch ON and carry out troubleshooting. Resistance Min. (22) – FS1-9 2 wiring or defective contact in Wiring harness between FS1-1 – battery relay Resistance Max. 1 z connector) terminal C Wiring harness between ST3 (female) (21) Resistance Max. • • • • • • • • Flashes caution lamp and turns on caution buzzer. (33) Cause Possible causes and standard value in normal state 20-458 (1) D65EX. Disconnection in wiring Resistance Max. circuit probably has short circuit with 1 Defective fuse FS1-9 chassis ground. Limits operation of engine and transmission. Once machine is stopped. (2). 1 Mz – battery relay terminal C with chassis ground aPrepare with starting switch OFF. engine speed is limited to medium (half). (22) – 20 – 30 V (21). (22) – FS1-9 with chassis ground (Contact with ground circuit) Wiring harness between inlet FS1 – fusible link Resistance Min. Once machine is stopped. aPrepare with starting switch OFF. PX-15 . 1 z (31) (32) (33) – chassis ground aPrepare with starting switch OFF. Monitor panel may not display normally. 1 Mz 3 ground in wiring harness (11).TROUBLESHOOTING ERROR CODE DAQ0KK DB30KK ERROR CODE DAQ0KK DB30KK (STEERING AND TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Error code DAQ0KK DB30KK Controller code Steering Trouble Steering and transmission controller: Source voltage reduction/input (KK) (Steering and transmission controller system) • Source voltage of steering and transmission controller is below 17 V. not allowing system operate normally. 1 z harness (Disconnection in (11). it cannot travel any more. then carry out troubleshooting without turning starting switch ON. (31). Both of DAQ0KK and DB30KK are displayed. Defective steering and 4 ST3 Voltage transmission controller Between (1). then carry out troubleshooting without turning starting switch ON. Charge level (voltage) of battery can be checked in monitoring mode. (32). Short circuit with chassis Wiring harness between ST3 (female) (1). (Code 03200: Battery voltage) • Method of reproducing error code: Turn starting switch ON. Standard value in normal state/Remarks on troubleshooting If any of fuses FS1-9 is broken. (12). Relays and solenoids cannot operate. (11). (2). (2). (12). (12). Wiring harness between ST3 (female) (1).

• Sets default internal adjustment value. • Adjust once in the adjustment mode (Code: 0002). ERROR CODE DAQ0KT Circuit diagram related to Steering and transmission controller power supply ERROR CODE DAQ0KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code DAQ0KT Controller code Steering Trouble Steering and transmission controller: Abnormality in controller (KT) (Steering and transmission controller system) • Information of ROM (nonvolatile storage) of steering and transmission controller is not normal. (It is no problem even if you use controller unless no visible problem appears on machine. • Flashes caution lamp and turns on caution buzzer. • Gear shift feeling of transmission may become worse.) D65EX.TROUBLESHOOTING ERROR CODE DAQ0KK DB30KK. Cause 1 Defective steering and transmission controller Standard value in normal state/Remarks on troubleshooting Troubleshooting cannot be carried out since it is internal defect. PX-15 20-459 (1) . • Method of reproducing error code: Turn starting switch ON.

– TL2 (female) (4). PX-15 .2 kz ± 20% circuit) Sensor Between (5) – Min. • Stops output to 5 V power supply circuit if abnormal voltage flows • Limits operation of engine and transmission. 1 Mz chassis ground aPrepare with starting switch OFF. if the service code is lighted up (to indicate returning to normal). • System may not operate normally. travel is limited to F1 an R1.5 V. • Once machine is stopped.5 V Cause Possible causes and standard value in normal state 20-460 (1) D65EX. Defective brake potentiomeBRK 1 the cause is an internal trouble. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON. • Method of reproducing error code: Turn starting switch ON. aPrepare with starting switch OFF. Standard value in normal state/Remarks on troubleshooting When the connector shown at right is disconnected. Defective steering and 6 transmission controller ST1 Voltage Between (22) – (21) 4. 1 V (female) (5). – BRK (female) (C) with chassis ground aPrepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. Defective forward-reverse TL2 (male) Resistance 2 potentiometer (Internal Between (4) – (1) 3.5 V or above 5. • Abnormal current flowed in 5 V power supply circuit of steering and transmission controller sensor. – TL2 (female) (4). • Both of DAQ5KK and DB35KK are displayed. Hot short circuit in wiring 5 harness (Contact with 24 V Wiring harness between ST1 (female) (22) – TL2 circuit) Voltage Max. engine speed is limited to medium (half). 1 Mz (C) with chassis ground aPrepare with starting switch OFF. – BRK (female) Resistance Min.5 – 5. • Once machine is stopped. 1 Mz chassis ground aPrepare with starting switch OFF. Short circuit with chassis 4 ground in wiring harness Wiring harness between ST1 (female) (22) – TL2 (Contact with ground circuit) (female) (5). Defective steering potentiTL1 (male) Resistance 3 ometer (Internal short Between (5) – (8) 3. • Flashes caution lamp and turns on caution buzzer.2 kz ± 20% short circuit) Sensor Between (4) – Min. then turn starting switch ON and carry out troubleshooting.TROUBLESHOOTING ERROR CODE DAQ5KK DB35KK ERROR CODE DAQ5KK DB35KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Steering and transmission controller sensor 5 V power supply: Error code Controller code Trouble Source voltage reduction/input (KK) DAQ5KK Steering DB35KK (Steering and transmission controller system) • Voltage of 5 V power supply circuit of steering and transmission controller sensor is below 4. ter (Internal short circuit) connector aPrepare with starting switch OFF.

PX-15 20-461 (1) .TROUBLESHOOTING ERROR CODE DAQ5KK DB35KK Circuit diagram related to steering and transmission controller 5 V power supply D65EX.

• Limits operation of engine and transmission. • Method of reproducing error code: Turn starting switch ON. Defective steering and 3 transmission controller ST1 Voltage (16) – (21) 20 – 30 V Cause Possible causes and standard value in normal state Circuit diagram related to steering and transmission controller 24 V power supply 20-462 (1) D65EX. • Stops output to 24 V power supply circuit if abnormal voltage flows. travel is limited to F1 and R1. • System may not operate normally. PT2 1 sensor (Internal short aDisconnect connector with starting switch OFF. PX-15 . then turn starting switch ON and carry out troubleshooting. • Both of DAQ6KK and DB36KK are displayed. Short circuit with chassis 2 ground in wiring harness Wiring harness between ST1 (female) (16) – (Contact with ground circuit) HHP (female) (B) – PT2 (female) (C) with Resistance Min. engine speed is limited to medium (half). • Abnormal current flowed in 24 V power supply circuit of steering and transmission controller sensor. Standard value in normal state/Remarks on troubleshooting It is internal defect if service code lights on (reset display) Defective angle of inclination when disconnecting right connector. aPrepare with starting switch OFF. 1 Mz chassis ground aPrepare with starting switch OFF. then turn connector circuit) starting switch ON and carry out troubleshooting. • Flashes caution lamp and turns on caution buzzer.TROUBLESHOOTING ERROR CODE DAQ6KK DB36KK ERROR CODE DAQ6KK DB36KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 24 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/ INPUT (KK)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Steering and transmission controller sensor 24 V power supError code Controller code Trouble ply: Source voltage reduction/input (KK) DAQ6KK Steering DB36KK (Steering and transmission controller system) • Voltage of 24 V power supply circuit of steering and transmission controller sensor is below 17 V or above 30 V. • Once machine is stopped. then carry out troubleshooting without turning starting switch ON. • Once machine is stopped.

aPrepare with starting switch OFF. • Adjustment code: 0002: Steering and transmission controller spec. • Stops all outputs to steering and transmission controller. • Machine does not operate at all. carry out troubleshooting without Disconnection in wiring turning starting switch ON. • Method of reproducing error code: Turn starting switch ON. (Steering and transmission controller cannot be recognized normally.TROUBLESHOOTING ERROR CODE DAQ9KQ DB39KQ ERROR CODE DAQ9KQ DB39KQ (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Steering and transmission controller type collation: Type select Error code Controller code Trouble signal inconsistency (KQ) DAQ9KQ Steering DB39KQ (Steering and transmission controller system) • Internal spec. 1 V Between (40) – chassis ground 5 – 11 V Possible causes and standard value in normal state Circuit diagram related to steering and transmission controller type select D65EX. Cause Defective steering and 1 transmission controller adjustment Standard value in normal state/Remarks on troubleshooting It is normal if error code lights on (reset display) after carrying out adjustment mode. • Limits operation of engine. • Once machine is stopped. PX-15 20-463 (1) . set signal. • Both of DAQ9KQ and DB39KQ are displayed. 3 ground in wiring harness Wiring harness between ST3 (female) (40) – (Contact with ground circuit) Resistance Max. it cannot travel any more. setting of steering and transmission controller is inconsistent with spec. • Once machine is stopped. 1 Mz PL2 (18) with chassis ground aPrepare with starting switch OFF. and brake. carry out troubleshooting without Short circuit with chassis turning starting switch ON. harness (Disconnection in 2 wiring or defective contact in Wiring harness between ST3 (female) (30) Resistance Max. engine speed is limited to medium (half).) • Flashes caution lamp and turns on caution buzzer. Defective steering and ST3 Voltage 4 transmission controller Between (30) – chassis ground Max. transmission. then turn starting switch ON and carry out troubleshooting. 1 z connector) with GND01 aPrepare with starting switch OFF.

Wiring harness between S04 (female) (1). (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Resistance Min. then carry out troubleshooting without turning starting switch ON. Flashes caution lamp and turns on caution buzzer. (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Hot short circuit in wiring Voltage Max. then turn starting switch ON and carry out troubleshooting. Controller code Trouble • Method of reproducing error code: Turn starting switch ON. If no problem is found in causes 1 to 4. 1 z harness (Disconnection in (female) (A) – CA2 (female) (A) – G01 (female) 1 wiring or defective contact in (8) connector) Wiring harness between S04 (female) (3) (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Resistance Max. then carry out troubleshooting without turning starting switch ON. Once machine is stopped. engine speed is limited to medium (half). 1 Mz Short circuit with chassis (female) (A) – CA2 (female) (A) – G01 (female) 2 ground in wiring harness (8) with chassis ground (Contact with ground circuit) Wiring harness between S04 (female) (3). 5 el. 1 z (female) (B) – CA2 (female) (B) – G01 (female) (7) aPrepare with starting switch OFF. Defective CAN terminal 4 resistance CA2 (male).TROUBLESHOOTING ERROR CODE DB3RKR ERROR CODE DB3RKR (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information • • • • • • Error code Steering and transmission controller CAN communication: Defective communication (KR) DB3RKR Steering (Steering and transmission controller system) Steering and transmission controller cannot recognize monitor panel. it is suspected that monitor pandefective engine controller. (Troubledefective steering and shooting cannot be carried out since it is internal defect. or steering and transmission controller. PX-15 . CA2 (male) Resistance Between (A) – (B) 100 – 140 z Defective monitor panel. (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Voltage Max. 1 V (female) (A) – CA2 (female) (A) – G01 (female) 3 harness (Contact with 24 V (8) with chassis ground circuit) Wiring harness between S04 (female) (3). Wiring harness between S04 (female) (1).) transmission controller Cause Possible causes and standard value in normal state 20-464 (1) D65EX. (2) Disconnection in wiring – ST2 (female) (32) – EN2 (female) (32) – CA2 Resistance Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Wiring harness between S04 (female) (1). or engine controller with CAN communication circuit. 1 Mz (female) (B) – CA2 (female) (B) – G01 (female) (7) with chassis ground aPrepare with starting switch OFF. Limits operation of engine and transmission. 1 V (female) (B) – CA2 (female) (B) – G01 (female) (7) with chassis ground aPrepare with starting switch OFF. Once machine is stopped. travel is limited to F1 and R1. then carry out troubleshooting without turning starting switch ON. System may not operate normally. engine controller. (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Resistance Min.

PX-15 20-465 (1) .TROUBLESHOOTING ERROR CODE DB3RKR Circuit diagram related to CAN communication D65EX.

Code 40901: Engine controller input signal 2) • Method of reproducing error code: Turn starting switch ON. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. (23) – 5 – 11 V chassis ground Possible causes and standard value in normal state Circuit diagram related to engine controller type select 20-466 (1) D65EX. Cause Standard value in normal state/Remarks on troubleshooting Installation of wrong engine 1 Check part No. PX-15 . turn starting switch ON and carry out troubleshooting. 1 z connector) chassis ground aPrepare with starting switch OFF. engine speed is limited to medium (half). • Machine does not provide normal output. 1 V Between (17).TROUBLESHOOTING ERROR CODE DB20KQ ERROR CODE DB20KQ (ENGINE CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Engine controller type collation: Type select signal inconsistenTrouble cy (KQ) (Engine controller system) DB20KQ Engine • Type select signal directly acquired by engine controller is inconsistent with type select signal acquired via communication. (Controller and wiring harness) controller aPrepare with starting switch OFF. • Input state (ON/OFF) of engine controller type select signal can be checked in monitoring mode. • Once machine is stopped. harness (Disconnection in 3 wiring or defective contact in Wiring harness between EN1 (female) (3) – Resistance Max. • Once machine is stopped. • Limits operation of engine and transmission. travel is limited to F1 and R1. • Flashes caution lamp and turns on caution buzzer. (Code 40900: Engine controller input signal 1. (Controller and wiring harness) controller Installation of wrong 2 steering and transmission Check part No. EN1 Voltage 4 Defective engine controller Between (3) – chassis ground Max. • Controls it as default-set type.

then carry out troubleshooting Disconnection in wiring without turning starting switch ON. Engine may stop during operation or engine may not start. • • • • • • Flashes caution lamp and turns on caution buzzer. 1 z connector) (31). (32) with chassis ground 2 Defective engine controller Troubleshooting cannot be carried out since it is internal defect. travel is limited to F1 and R1. Limits operation of engine and transmission. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. harness (Disconnection in 1 wiring or defective contact in Wiring harness between EN3 (female) (11).TROUBLESHOOTING ERROR CODE DB20KT ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DB20KT Controller code Engine Trouble Engine controller: Abnormality in controller (KT) (Engine controller system) • Problem occurred in engine controller. engine speed is limited to medium (half). Cannot operate fuel injector solenoid well or stops output. Resistance Max. Once machine is stopped. Once machine is stopped. • Method of reproducing error code: Turn starting switch ON. PX-15 20-467 (1) . Possible causes and standard value in normal state Circuit diagram related to engine controller power supply D65EX.

(Code 03200: Battery voltage) • Method of reproducing error code: Turn starting switch ON. (32) Cause 1 Defective fuse (FS2-7) • • • • • • Possible causes and standard value in normal state 20-468 (1) D65EX. Standard value in normal state/Remarks on troubleshooting If fuse is burnout. Resistance Min. (2). Engine may stop during operation or engine may not start. Resistance Max. (31). then carry out troubleshooting Hot short circuit in wiring without turning starting switch ON. Flashes caution lamp and turns on caution buzzer. (2). 1 z GND03 aPrepare with starting switch OFF. 1 z (21) – PPR (female) (3) Wiring harness between PPR (female) (5) – Disconnection in wiring Resistance Max. Once machine is stopped. engine controller load power supply PPR relay is defective. 1 z connector) battery relay terminal C Wiring harness between PPR (female) (1) – Resistance Max. (21) – 20 – 30 V (11). 1 V (19) – starting switch 270 with chassis ground aPrepare with starting switch OFF. PX-15 . it cannot travel any more. aPrepare with starting switch OFF. Charge level (voltage) of battery can be checked in monitoring mode. Defective engine controller 2 load power supply relay If error code lights on (reset display) by replacing right con(Internal disconnection) nector with other relay. 5 harness (Contact with 24 V Wiring harness between EN1 (female) (13) circuit) Voltage Max. 1 Mz 4 ground in wiring harness FS2-7 outlet port with chassis ground (Contact with ground circuit) Wiring harness between FS2-7 inlet port – Resistance Min. turn starting switch ON and carry out troubleshooting. 1 z starting switch 270 Wiring harness between PPR (female) (2) – Resistance Max. aPrepare with starting switch OFF. 1 z harness (Disconnection in FS2-7 outlet port 3 wiring or defective contact in Wiring harness between FS2-7 inlet port – Resistance Max. then carry out troubleshooting without turning starting switch ON. circuit probably has short circuit with chassis ground. 1 Mz (21) – PPR (female) (3) with chassis ground Short circuit with chassis Wiring harness between PPR (female) (5) – Resistance Min. 6 Defective engine controller EN3 Voltage Between (1). engine speed is limited to medium (half). Wiring harness between EN3 (female) (1). aThis error code detects abnormality in engine controller load power supply. Wiring harness between EN3 (female) (1). 1 Mz starting switch 270 with chassis ground aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DB22KK ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Error code DB22KK Controller code Engine Trouble Engine controller load power supply: Source voltage reduction/input (KK) (Engine controller system) • Load source voltage of engine controller is below 17 V. 1 Mz battery relay terminal C Wiring harness between PPR (female) (1) – Resistance Min. turn starting switch ON and carry out troubleshooting. Once machine is stopped. Limits operation of engine and transmission. (2). then carry out troubleshooting without turning starting switch ON.

TROUBLESHOOTING ERROR CODE DB22KK Circuit diagram related to engine controller power supply D65EX. PX-15 20-469 (1) .

EN1 Voltage 3 Defective engine controller Between (3) – chassis ground Max. (Code 40900: Engine controller input signal 1. harness (Disconnection in 2 wiring or defective contact in Wiring harness between EN1 (female) (3) – Resistance Max. 1 z connector) chassis ground aPrepare with starting switch OFF. • Input state (ON/OFF) of engine controller type select signal can be checked in monitoring mode. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. • Once machine is stopped. Cause Standard value in normal state/Remarks on troubleshooting Installation of wrong engine 1 Check part No. • Flashes caution lamp and turns on caution buzzer. PX-15 . (Controller and wiring harness) controller aPrepare with starting switch OFF. 1 V Between (7). travel is limited to F1 and R1. • Controls it as default-set type. turn starting switch ON and carry out troubleshooting. engine speed is limited to medium (half). • Machine does not provide normal output. • Limits operation of engine and transmission. Code 40901: Engine controller input signal 2) • Method of reproducing error code: Turn starting switch ON. (8) – chassis ground 5 – 11 V Possible causes and standard value in normal state Circuit diagram related to engine controller type select 20-470 (1) D65EX.TROUBLESHOOTING ERROR CODE DB29KQ ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Engine controller type select: Type select signal inconsistency Trouble (KQ) (Engine controller system) DB29KQ Engine • Type select signal directly acquired by engine controller is inconsistent with type select signal saved in controller. • Once machine is stopped.

it is suspected that engine controller is defective. fuel injection amount adjustment switch setting is defective. • Flashes caution lamp and turns on caution buzzer. Possible causes and standard value in normal state D65EX.TROUBLESHOOTING ERROR CODE DB2AMA ERROR CODE DB2AMA (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL: MALFUNCTION (MA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DB2AMA Controller code Engine Trouble Fuel injection amount adjustment switch signal: Malfunction (MA) (Engine controller system) • Fuel injection amount adjustment switch is not set at correct position. • Method of reproducing error code: Turn starting switch ON. • Fuel injection amount adjustment setting cannot be changed. PX-15 20-471 (1) . Cause Defective fuel injection 1 amount adjustment switch setting 2 Defective engine controller Standard value in normal state/Remarks on troubleshooting If both fuel injection amount adjustment switches 1 and 2 are set at [F]. If no problem is found in above cause.

Controller code Trouble • Method of reproducing error code: Turn starting switch ON. defective engine controller (Troubleshooting cannot be carried out since it is internal defect. (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Hot short circuit in wiring Voltage Max. 1 z (female) (B) – CA2 (female) (B) – G01 (female) (7) aPrepare with starting switch OFF. PX-15 . Wiring harness between S04 (female) (1). 1 V (female) (B) – CA2 (female) (B) – G01 (female) (7) with chassis ground aPrepare with starting switch OFF. Limits operation of engine and transmission.) Cause Possible causes and standard value in normal state 20-472 (1) D65EX. CA2 (male) Resistance Between (A) – (B) 100 – 140 z Defective steering and If no problem is found in causes 1 to 4. 1 Mz (female) (B) – CA2 (female) (B) – G01 (female) (7) with chassis ground aPrepare with starting switch OFF. Once machine is stopped. (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Resistance Max. Flashes caution lamp and turns on caution buzzer. 1 Mz Short circuit with chassis (female) (A) – CA2 (female) (A) – G01 (female) 2 ground in wiring harness (8) with chassis ground (Contact with ground circuit) Wiring harness between S04 (female) (3). 1 z harness (Disconnection in (female) (A) – CA2 (female) (A) – G01 (female) 1 wiring or defective contact in (8) connector) Wiring harness between S04 (female) (3). engine controller is defective. (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Resistance Min. Once machine is stopped. it is suspected that steering and 5 transmission controller. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Resistance Min. then carry out troubleshooting without turning starting switch ON. engine speed is limited to medium (half).TROUBLESHOOTING ERROR CODE DB2RKR ERROR CODE DB2RKR (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information • • • • • • Error code Steering and transmission controller CAN communication: Defective communication (KR) DB2RKR Steering (Steering and transmission controller system) Steering and transmission controller cannot recognize engine controller with CAN communication circuit. Wiring harness between S04 (female) (1). (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Voltage Max. turn starting switch ON and carry out troubleshooting. travel is limited to F1 and R1. then carry out troubleshooting without turning starting switch ON. transmission controller. Wiring harness between S04 (female) (1). Defective CAN terminal 4 resistance CA2 (male). 1 V (female) (A) – CA2 (female) (A) – G01 (female) 3 harness (Contact with 24 V (8) with chassis ground circuit) Wiring harness between S04 (female) (3). (2) Disconnection in wiring – ST2 (female) (32) – EN2 (female) (32) – CA2 Resistance Max. then carry out troubleshooting without turning starting switch ON. System may not operate normally.

PX-15 20-473 (1) .TROUBLESHOOTING ERROR CODE DB2RKR Circuit diagram related to CAN communication D65EX.

CA2 (male) Resistance Between (A) – (B) 100 – 140 z If no problem is found in causes 1 to 4. PX-15 . 1 Mz (female) (B) – CA2 (female) (B) – G01 (female) (7) with chassis ground aPrepare with starting switch OFF. Wiring harness between S04 (female) (1). 1 V (female) (B) – CA2 (female) (B) – G01 (female) (7) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. • System may not operate normally. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. • Once machine is stopped. 1 V (female) (A) – CA2 (female) (A) – G01 (female) (8) with chassis ground Wiring harness between S04 (female) (3). CA2 (male). (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Resistance Min. then carry out troubleshooting without turning starting switch ON. it is suspected that engine controller. (Troubleshooting cannot be carried out since it is internal defect. then carry out troubleshooting without turning starting switch ON. 1 z (female) (A) – CA2 (female) (A) – G01 (female) (8) Wiring harness between S04 (female) (3). steering and transmission controller is defective. engine speed is limited to medium (half). (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Resistance Min.TROUBLESHOOTING ERROR CODE DB2RMC ERROR CODE DB2RMC (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (MC)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Engine controller CAN communication: Defective communicaTrouble tion (MC) (Engine controller system) DB2RMC Engine • Engine controller cannot recognize steering and transmission controller with CAN communication circuit. (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Voltage Max.) Disconnection in wiring harness (Disconnection in 1 wiring or defective contact in connector) Short circuit with chassis 2 ground in wiring harness (Contact with ground circuit) Possible causes and standard value in normal state Hot short circuit in wiring 3 harness (Contact with 24 V circuit) 4 Defective CAN terminal resistance Defective engine controller. • Limits operation of engine and transmission. turn starting switch ON and carry out troubleshooting. • Once machine is stopped. (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Resistance Max. Wiring harness between S04 (female) (1). • Flashes caution lamp and turns on caution buzzer. travel is limited to F1 and R1. • Method of reproducing error code: Turn starting switch ON. (2) – ST2 (female) (32) – EN2 (female) (32) – CA2 Resistance Max. Wiring harness between S04 (female) (1). (4) – ST2 (female) (22) – EN2 (female) (22) – CA2 Voltage Max. 1 Mz (female) (A) – CA2 (female) (A) – G01 (female) (8) with chassis ground Wiring harness between S04 (female) (3). 1 z (female) (B) – CA2 (female) (B) – G01 (female) (7) aPrepare with starting switch OFF. 5 defective steering and transmission controller 20-474 (1) D65EX.

PX-15 20-475 (1) .TROUBLESHOOTING ERROR CODE DB2RMC Circuit diagram related to CAN communication D65EX.

CALL E03 ERROR CODE DB39KQ DAQ9KQ (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) a See DAQ9KQ. CALL E03 ERROR CODE DB36KK DAQ6KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 24 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/ INPUT (KK)) a See DAQ6KK. ERROR CODE DB39KQ DAQ9KQ ERROR CODE DB30KK DAQ0KK ERROR CODE DB30KK DAQ0KK (STEERING AND TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) a See DAQ0KK. PX-15 . ERROR CODE DB35KK DAQ5KK.TROUBLESHOOTING ERROR CODE DB30KK DAQ0KK. CALL E04 20-476 (1) D65EX. CALL E04 ERROR CODE DB35KK DAQ5KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 5 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) a See DAQ5KK. ERROR CODE DB36KK DAQ6KK.

1 V starting switch 280 with chassis ground aPrepare with starting switch OFF. Defective starting switch 1 Starting switch Starting switch Resistance (Internal short circuit) Between 250 (B) – When OFF/ON Min. 1 V 2 harness (Contact with 24 V NSF (female) (5) with chassis ground circuit) Wiring harness between NSF (female) (3) – Voltage Max. engine speed is limited to medium (half). 1 V Cause Possible causes and standard value in normal state Circuit diagram related to starting switch signal C D65EX. Limits operation of engine and transmission. turn starting switch ON and carry out troubleshooting. then carry out troubleshooting with starting switch OFF or ON. it cannot travel any more. • • • • • Flashes caution lamp and turns on caution buzzer. 3 Defective engine controller EN1 Voltage Between (20) – chassis ground Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. PX-15 20-477 (1) .TROUBLESHOOTING ERROR CODE DD11KB ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT (KB)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Error code DD11KB Controller code Engine Trouble Starting switch: Short circuit (KB) (Engine controller system) • Signal C of starting switch is input during running of engine. Hot short circuit in wiring Wiring harness between EN1 (female) (20) – Voltage Max. turn starting switch ON and carry out troubleshooting. 1 Mz 280 (C) aPrepare with starting switch OFF. Once machine is stopped. Once machine is stopped. • Method of reproducing error code: Start engine. Engine cannot be accelerated.

1 Mz (2) – (3) Resistance between Min. Shift up switch ST1.TROUBLESHOOTING ERROR CODE DD12KA ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DD12KA Controller code Steering Trouble Shift up switch: Disconnection (KA) (Steering and transmission controller system) • Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time. Wiring harness between ST1 (female) (12) – Disconnection in wiring Resistance Max. 1 z (2) – (1) aPrepare with starting switch OFF. 1 z Min. 1 Mz Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. 1 V TL1 (female) (3) with chassis ground circuit) Wiring harness between ST1 (female) (9) – Voltage Max. PX-15 . turn starting switch ON and carry out troubleshooting. • Auto shift down does not function. 1 V ST3 (9) – ST1 (4) Cause Possible causes and standard value in normal state 20-478 (1) D65EX. ST3 Defective steering and OFF (Release) ON (Press) 4 transmission controller Voltage between Max. • Shift up is not possible. NO is for operation detection and NC is for error detection. 1 z SFTU (female) (2) aPrepare with starting switch OFF. Hot short circuit in wiring Wiring harness between ST1 (female) (12) – 3 harness (Contact with 24 V Voltage Max. 1 z connector) SFTU (female) (1) Wiring harness between ST1 (female) (4) – Resistance Max. • Input state (ON/OFF) from shift up switch can be checked in monitoring mode. (Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate shift up switch. 1 V 5 – 11 V ST1 (12) – ST1 (4) Voltage between 5 – 11 V Max. Shift up switch SFTU (male) Defective shift up switch OFF (Release) ON (Press) 1 (Internal disconnection) Resistance between Max. • Of signals of two systems of switch. 1 z harness (Disconnection in SFTU (female) (3) 2 wiring or defective contact in Wiring harness between ST3 (female) (9) – Resistance Max. turn starting switch ON and carry out troubleshooting. 1 V TL1 (female) (1) with chassis ground aPrepare with starting switch OFF. • Recognizes that switch is not pressed. • Flashes caution lamp and turns on caution buzzer.

TROUBLESHOOTING ERROR CODE DD12KA Circuit diagram related to shift up switch and shift down switch D65EX. PX-15 20-479 (1) .

• Input state (ON/OFF) from shift up switch can be checked in monitoring mode. • Of signals of two systems of switch. Short circuit with chassis Wiring harness between ST1 (female) (12) – Resistance Min. then carry out troubleshooting without turning starting switch ON. • Auto shift down does not function. NO is for operation detection and NC is for error detection. then carry out troubleshooting without turning starting switch ON. • Shift up is not possible. 1 z Min. Shift up switch ST1.TROUBLESHOOTING ERROR CODE DD12KB ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DD12KB Controller code Steering Trouble Shift up switch: Short circuit (KB) (Steering and transmission controller system) • Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time. 1 z (2) – (1) aPrepare with starting switch OFF. 1 V ST3 (9) – ST1 (4) Cause Possible causes and standard value in normal state 20-480 (1) D65EX. • Recognizes that switch is not pressed. PX-15 . 1 Mz Max. ST3 Defective steering and OFF (Release) ON (Press) 3 transmission controller Voltage between Max. 1 V 5 – 11 V ST1 (12) – ST1 (4) Voltage between 5 – 11 V Max. 1 Mz 2 ground in wiring harness SFTU (female) (3) with chassis ground (Contact with ground circuit) Wiring harness between ST3 (female) (9) – Resistance Min. 1 Mz (2) – (3) Resistance between Min. 1 Mz SFTU (female) (1) with chassis ground aPrepare with starting switch OFF. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. (Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate shift up switch. turn starting switch ON and carry out troubleshooting. Shift up switch SFTU (male) Defective shift up switch OFF (Release) ON (Press) 1 (Internal disconnection) Resistance between Max. • Flashes caution lamp and turns on caution buzzer.

TROUBLESHOOTING ERROR CODE DD12KB Circuit diagram related to shift up switch and shift down switch D65EX. PX-15 20-481 (1) .

1 V ST1 (18) – ST1 (4) Cause Possible causes and standard value in normal state 20-482 (1) D65EX. then carry out troubleshooting without turning starting switch ON. 1 z harness (Disconnection in SFTD (male) (3) 2 wiring or defective contact in Wiring harness between ST1 (female) (18) – Resistance Max. turn starting switch ON and carry out troubleshooting. 1 z connector) SFTD (male) (1) Wiring harness between ST1 (female) (4) – Resistance Max. NO is for operation detection and NC is for error detection. (Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate shift down switch. • Auto shift down does not function. 1 Mz (2) – (3) Resistance between Min. • Recognizes that switch is not pressed. Hot short circuit in wiring Wiring harness between ST1 (female) (24) – 3 harness (Contact with 24 V Voltage Max. • Shift down is not possible. 1 Mz Max. 1 z (2) – (1) aPrepare with starting switch OFF. Shift down switch SFTD (female) Defective shift down switch OFF (Release) ON (Press) 1 (Internal disconnection) Resistance between Max. Wiring harness between ST1 (female) (24) – Disconnection in wiring Resistance Max. 1 V SFTD (male) (1) with chassis ground aPrepare with starting switch OFF. • Flashes caution lamp and turns on caution buzzer. 1 V 5 – 11 V ST1 (24) – ST1 (4) Voltage between 5 – 11 V Max. 1 z SFTD (male) (4) aPrepare with starting switch OFF. • Input state (ON/OFF) from shift down switch can be checked in monitoring mode. 1 V SFTD (male) (3) with chassis ground circuit) Wiring harness between ST1 (female) (18) – Voltage Max. turn starting switch ON and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON. 1 z Min.TROUBLESHOOTING ERROR CODE DD13KA ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DD13KA Controller code Steering Trouble Shift down switch: Disconnection (KA) (Steering and transmission controller system) • Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time. • Of signals of two systems of switch. PX-15 . Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Shift down switch ST1 Defective steering and OFF (Release) ON (Press) 4 transmission controller Voltage between Max.

PX-15 20-483 (1) .TROUBLESHOOTING ERROR CODE DD13KA Circuit diagram related to shift up switch and shift down switch D65EX.

(Code 40905: Transmission controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate shift up switch. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Shift down switch ST1 Defective steering and OFF (Release) ON (Press) 3 transmission controller Voltage between Max. • Flashes caution lamp and turns on caution buzzer. • Shift down is not possible. • Auto shift down does not function. • Recognizes that switch is not pressed. • Input state (ON/OFF) from shift down switch can be checked in monitoring mode. Shift down switch SFTD (female) Defective shift down switch OFF (Release) ON (Press) 1 (Internal disconnection) Resistance between Max. turn starting switch ON and carry out troubleshooting.TROUBLESHOOTING ERROR CODE DD13KB ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DD13KB Controller code Steering Trouble Shift down switch: Short circuit (KB) (Steering and transmission controller system) • Signals of two systems of shift down switch circuit were turned ON (CLOSE) or OFF at the same time. 1 Mz 2 ground in wiring harness SFTD (male) (3) with chassis ground (Contact with ground circuit) Wiring harness between ST1 (female) (18) – Resistance Min. 1 Mz Max. PX-15 . 1 Mz (2) – (3) Resistance between Min. 1 Mz SFTD (male) (1) with chassis ground aPrepare with starting switch OFF. Short circuit with chassis Wiring harness between ST1 (female) (24) – Resistance Min. NO is for operation detection and NC is for error detection. then carry out troubleshooting without turning starting switch ON. 1 z (2) – (1) aPrepare with starting switch OFF. 1 V 5 – 11 V ST1 (24) – ST1 (4) Voltage between 5 – 11 V Max. 1 z Min. • Of signals of two systems of switch. then carry out troubleshooting without turning starting switch ON. 1 V ST1 (18) – ST1 (4) Cause Possible causes and standard value in normal state 20-484 (1) D65EX.

PX-15 20-485 (1) .TROUBLESHOOTING ERROR CODE DD13KB Circuit diagram related to shift up switch and shift down switch D65EX.

PX-15 . Parking lever Parking lever switch NSW (male) 1 (Internal short circuit) Free position Lock position Between (A) – (B) Max. 1 z NSW (female) (A) aPrepare with starting switch OFF. turn starting switch ON and carry out troubleshooting. Limits operation of engine. turn starting switch ON and carry out troubleshooting. Parking lever ST2 Defective steering and Free position Lock position 4 transmission controller Between (15) – Max. Of signals of two systems of switch. Engine cannot be started. Once machine is stopped. 1 V chassis ground Cause Possible causes and standard value in normal state 20-486 (1) D65EX.TROUBLESHOOTING ERROR CODE DD14KA DDQ2KA ERROR CODE DD14KA DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DD14KA DDQ2KA Controller code Steering Trouble Parking lever switch: Disconnection (KA) (Steering and transmission controller system) • Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time. • • • • • • • • • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting without turning starting switch ON. and brake. 1 z connector) NSW (female) (B) Wiring harness between ST1 (female) (4) – Resistance Max. Both of DD14KA and DDQ2KA are displayed. 1 z Min. Once machine is stopped. travel is limited to F1 and R1. then carry out troubleshooting without turning starting switch ON. 1 V 3 harness (Contact with 24 V NSW (female) (C) with chassis ground circuit) Wiring harness between ST2 (female) (5) – Voltage Max. Wiring harness between ST2 (female) (15) – Disconnection in wiring Resistance Max. 1 V NSW (female) (B) with chassis ground aPrepare with starting switch OFF. 1 z aPrepare with starting switch OFF. 1 Mz Max. 1 Mz Between (A) – (C) Min. Input state (ON/OFF) from parking brake switch can be checked in monitoring mode. (Code 40910: Steering controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate parking lever. NO is for operation detection and NC is for error detection. 1 z harness (Disconnection in NSW (female) (C) 2 wiring or defective contact in Wiring harness between ST2 (female) (5) – Resistance Max. Recognizes parking lever is in Free position. 1 V 5 – 11 V chassis ground Between (5) – 5 – 11 V Max. Hot short circuit in wiring Wiring harness between ST2 (female) (15) – Voltage Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. transmission. engine speed is limited to medium (half).

TROUBLESHOOTING ERROR CODE DD14KA DDQ2KA Circuit diagram related to parking lever switch D65EX. PX-15 20-487 (1) .

Engine cannot be started. Parking lever ST2 Defective steering and Free position Lock position 3 transmission controller Between (15) – Max. engine speed is limited to medium (half). (Code 40910: Steering controller input signal 1) • Method of reproducing error code: Turn starting switch ON and operate parking lever. Once machine is stopped. Parking lever Parking lever switch NSW (male) 1 (Internal disconnection) Free position Lock position Between (A) – (B) Max. Both of DD14KB and DDQ2KB are displayed. 1 V chassis ground Cause Possible causes and standard value in normal state 20-488 (1) D65EX. • • • • • • • • • Flashes caution lamp and turns on caution buzzer. Limits operation of engine. PX-15 . then carry out troubleshooting without turning starting switch ON. Of signals of two systems of switch. Input state (ON/OFF) from parking brake switch can be checked in monitoring mode. then carry out troubleshooting without turning starting switch ON. 1 Mz Between (A) – (C) Min. travel is limited to F1 and R1. 1 Mz 2 ground in wiring harness ST2 (female) (5) with chassis ground (Contact with ground circuit) Wiring harness between NSW (female) (C) – Resistance Min. Short circuit with chassis Wiring harness between NSW (female) (B) – Resistance Min. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Recognizes parking lever is in Free position. NO is for operation detection and NC is for error detection. 1 Mz Max. and brake. 1 z aPrepare with starting switch OFF. 1 Mz ST2 (female) (15) with chassis ground aPrepare with starting switch OFF. turn starting switch ON and carry out troubleshooting. 1 V 5 – 11 V chassis ground Between (5) – 5 – 11 V Max.TROUBLESHOOTING ERROR CODE DD14KB DDQ2KB ERROR CODE DD14KB DDQ2KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DD14KB DDQ2KB Controller code Steering Trouble Parking lever switch: Short circuit (KB) (Steering and transmission controller system) • Signals of two systems of parking lever switch circuit were turned ON (CLOSE) at the same time. transmission. 1 z Min. Once machine is stopped.

TROUBLESHOOTING ERROR CODE DD14KB DDQ2KB Circuit diagram related to parking lever switch D65EX. PX-15 20-489 (1) .

1 V Between (15) – chassis ground Min. 1 z 3 wiring or defective contact in PSL connector) Wiring harness between EN1 (female) (15) – Resistance Max. 1 z PSH aPrepare with starting switch OFF. 600 rpm Min. 1 z Between terminal – chassis ground Min. caution signal is not output. 1 Mz PSL with chassis ground aPrepare with starting switch OFF. 1 V 5 Defective engine controller Between (21) – chassis ground Min. PX-15 . EN1 Engine Voltage Stop Max. (Code 40900: Engine controller input signal 1) • Method of reproducing error code: Turn starting switch ON or start engine. • When engine oil pressure lowers. 1 Mz aPrepare with starting switch OFF. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DDE2L6 ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code DDE2L6 Controller code Engine Trouble Engine oil pressure switch: Refer to table (L6) (Engine controller system) • Signals of engine oil pressure switch are inconsistent with engine state. Defective high engine oil PSH Engine Resistance 2 pressure switch (Internal disconnection/short circuit) Stop Max. • None in particular. 1.300 rpm 20 – 30 V Cause Possible causes and standard value in normal state 20-490 (1) D65EX. then carry out troubleshooting without turning starting switch ON or by starting engine. 1 Mz aPrepare with starting switch OFF. Disconnection in wiring harness (Disconnection in Wiring harness between EN1 (female) (21) – Resistance Max. 1 z Between terminal – chassis ground Min. then carry out troubleshooting without turning starting switch ON or by starting engine. 1 Mz 4 ground in wiring harness PSH with chassis ground (Contact with ground circuit) Wiring harness between EN1 (female) (21) – Resistance Min. 1. • Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode.300 rpm Min. Short circuit with chassis Wiring harness between EN1 (female) (15) – Resistance Min. then carry out troubleshooting without turning starting switch ON. Defective low engine oil PSL Engine Resistance 1 pressure switch (Internal disconnection/short circuit) Stop Max. then carry out troubleshooting without turning starting switch ON. 600 rpm 20 – 30 V Stop Max. then carry out troubleshooting without turning starting switch ON or by starting engine.

PX-15 20-491 (1) .TROUBLESHOOTING ERROR CODE DDE2L6 Circuit diagram related to low engine oil pressure switch & high engine oil pressure switch D65EX.

• Recognizes switch is not pushed. 1 V 5 – 11 V ST3 (10) – ST1 (4) Voltage between 5 – 11 V Max. Hot short circuit in wiring Wiring harness between ST3 (female) (10) – Voltage Max. 1 z P0B (male) (3) aPrepare with starting switch OFF. 1 z (2) – (1) aPrepare with starting switch OFF. (Code 70300: Work equipment-related controller input signal) • Method of reproducing error code: Turn starting switch ON and operate pitch control switch. • Of signals of two systems of switch. • Input state (ON/OFF) from pitch control switch can be checked in monitoring mode. 1 z P0B (male) (2) Wiring harness between P0A (female) (2) – Resistance Max. Pitch control switch ST1. 1 z Min. then carry out troubleshooting without turning starting switch ON. Defective pitch control P0B (female) OFF (Release) ON (Press) 1 switch (Internal disconnecResistance between tion) Max. Pitch control switch P0A (male). 1 Mz (2) – (3) Resistance between Min. turn starting switch ON and carry out troubleshooting. 1 z 2 wiring or defective contact in P0A (female) (1) – P0B (male) (1) connector) Wiring harness between ST1 (female) (4) – Resistance Max. NO is for operation detection and NC is for error detection. • Pitch control cannot be performed. turn starting switch ON and carry out troubleshooting. 1 V ground aPrepare with starting switch OFF. 1 V ST3 (20) – ST1 (4) Cause Possible causes and standard value in normal state 20-492 (1) D65EX. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting without turning starting switch ON. 1 V 3 harness (Contact with 24 V P0A (female) (3) with chassis ground circuit) Wiring harness between ST3 (female) (20) – P0A (female) (1) – P0B (male) (1) with chassis Voltage Max. PX-15 . 1 Mz Max.TROUBLESHOOTING ERROR CODE DDN7KA ERROR CODE DDN7KA (PITCH CONTROL SWITCH: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DDN7KA Controller code Steering Trouble Pitch control switch: Disconnection (KA) (Steering and transmission controller system) • Signals of two systems of pitch control switch were turned OFF (OPEN) at the same time. Wiring harness between ST3 (female) (10) – Resistance Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. ST3 Defective steering and OFF (Release) ON (Press) 4 transmission controller Voltage between Max. 1 z P0A (female) (3) Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (20) – Resistance Max.

PX-15 20-493 (1) .TROUBLESHOOTING ERROR CODE DDN7KA Circuit diagram related to pitch control switch D65EX.

• Of signals of two systems of switch. 1 V 5 – 11 V ST3 (10) – ST1 (4) Voltage between 5 – 11 V Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. • Flashes caution lamp and turns on caution buzzer. 1 z (2) – (1) aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. • Pitch control cannot be performed. then carry out troubleshooting without turning starting switch ON. 1 Mz P0B (male) (3) with chassis ground aPrepare with starting switch OFF. ST3 Defective steering and OFF (Release) ON (Press) 3 transmission controller Voltage between Max. Pitch control switch ST1. PX-15 . 1 z Min. (Code 70300: Work equipment-related controller input signal) • Method of reproducing error code: Turn starting switch ON and operate pitch control switch. 1 V ST3 (20) – ST1 (4) Cause Possible causes and standard value in normal state 20-494 (1) D65EX. turn starting switch ON and carry out troubleshooting. 1 Mz P0A (female) (3) with chassis ground Short circuit with chassis 2 ground in wiring harness Wiring harness between ST3 (female) (20) – (Contact with ground circuit) P0A (female) (1) – P0B (male) (1) with chassis Resistance Min. 1 Mz Max. Wiring harness between ST3 (female) (10) – Resistance Min. • Recognizes switch is not pushed. • Input state (ON/OFF) from pitch control switch can be checked in monitoring mode. P0B (female) Defective pitch control OFF (Release) ON (Press) 1 switch (Internal short circuit) Resistance between Max. 1 Mz ground Wiring harness between P0A (female) (2) – Resistance Min. Pitch control switch P0A (male). NO is for operation detection and NC is for error detection. 1 Mz (2) – (3) Resistance between Min.TROUBLESHOOTING ERROR CODE DDN7KB ERROR CODE DDN7KB (PITCH CONTROL SWITCH: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DDN7KB Controller code Steering Trouble Pitch control switch: Short circuit (KB) (Steering and transmission controller system) • Signals of two systems of pitch control switch were turned ON (CLOSE) at the same time.

PX-15 20-495 (1) .TROUBLESHOOTING ERROR CODE DDN7KB Circuit diagram related to pitch control switch D65EX.

TROUBLESHOOTING ERROR CODE DDQ2KA DD14KA. CALL E03 ERROR CODE DDQ2KB DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) a See DD14KB. DDQ2KB DD14KA ERROR CODE DDQ2KA DD14KB ERROR CODE DDQ2KA DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA)) a See DD14KA. CALL E03 20-496 (1) D65EX. PX-15 .

TROUBLESHOOTING ERROR CODE DGE2KX ERROR CODE DGE2KX (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code DGE2KX Controller code Engine Trouble Engine water temperature sensor (for high temperature): Input signal is out of normal range (KX) (Engine controller system) • High engine water temperature sensor signal is out of normal range. 1 Mz chassis ground Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Short circuit with chassis 3 ground in wiring harness (Contact with ground circuit) 4 Defective engine controller Circuit diagram related to high engine water temperature sensor D65EX. • • • • Monitor panel does not display engine water temperature normally. TWH (male) Resistance Between (1) – (2) 3. When engine water overheats. 1 z TWH (female) (2) aPrepare with starting switch OFF. PX-15 20-497 (1) . (39) – Min. • Fixes water temperature signal output for monitor panel at 90ºC. (2) – chassis ground Min. Wiring harness between EN2 (female) (27) – Resistance Min. Fan speed is limited to half. then carry out troubleshooting without turning starting switch ON. caution signal is not output. Wiring harness between EN2 (female) (27) – Resistance Max. then carry out troubleshooting without turning starting switch ON. (Code 04102: Engine water temperature (High temperature side)) • Method of reproducing error code: Start engine. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON.5 k – 90 kz (10 – 100ºC) Between (27). Engine water temperature (temperature) can be checked in monitoring mode. 1 z TWH (female) (1) Wiring harness between EN2 (female) (39) – Resistance Max. 1 Mz TWH (female) (1) with chassis ground aPrepare with starting switch OFF. EN2 (female) Resistance Between (27) – (39) 3.5 k – 90 kz (10 – 100ºC) Between (1). Cause Defective high engine water temperature sensor (Internal 1 disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz aPrepare with starting switch OFF.

1 z TWL (female) (B) aPrepare with starting switch OFF. PX-15 .3 k – 9 kz (10 – 100ºC) circuit) Between (A). then carry out troubleshooting without turning starting switch ON. 1 Mz TWL (female) (A) with chassis ground aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DGE3L6 ERROR CODE DGE3L6 (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE): SEE TABLE (L6)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DGE3L6 Controller code Engine Trouble Engine water temperature sensor (for low temperature): See table (L6) (Engine controller system) • Low engine water temperature sensor signal is inconsistent with engine state.3 k – 9 kz (10 – 100ºC) Between (37). • Engine water temperature (temperature) can be checked in monitoring mode. (B) – chassis ground Min. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 3 ground in wiring harness Wiring harness between EN2 (female) (37) – (Contact with ground circuit) Resistance Min. Disconnection in wiring harness (Disconnection in Wiring harness between EN2 (female) (37) – Resistance Max. then carry out troubleshooting without turning starting switch ON. (39) – Min. 1 Mz aPrepare with starting switch OFF. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. temperature sensor (Internal TWL (male) Resistance 1 disconnection or short Between (A) – (B) 0. • Exhaust gas color is bad at low temperature. EN2 (female) Resistance 4 Defective engine controller Between (37) – (39) 0. 1 z 2 wiring or defective contact in TWL (female) (A) connector) Wiring harness between EN2 (female) (39) – Resistance Max. (Code 04104: Engine water temperature (Low temperature side)) • Method of reproducing error code: Start engine. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting Defective low engine water without turning starting switch ON. 1 Mz chassis ground Cause Possible causes and standard value in normal state Circuit diagram related to low engine water temperature sensor 20-498 (1) D65EX. • Engine does not start easily at low temperature.

1 Mz aPrepare with starting switch OFF. 1 Mz THL (female) (A) with chassis ground aPrepare with starting switch OFF. 3 ground in wiring harness Wiring harness between EN2 (female) (17) – (Contact with ground circuit) Resistance Min. (Code 04204: Fuel temperature) • Method of reproducing error code: Start engine. then carry out troubleshooting without turning starting switch ON. • Operates with normal control. PX-15 20-499 (1) . then carry out troubleshooting without turning starting switch ON. Defective fuel temperature THL (male) Resistance 1 sensor (Internal disconnection or short circuit) Between (A) – (B) 0. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Disconnection in wiring harness (Disconnection in Wiring harness between EN2 (female) (17) – Resistance Max. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. • Engine output lowers a little at low temperature. (B) – chassis ground Min. EN2 (female) Resistance 4 Defective engine controller Between (17) – (39) 0. 1 z THL (female) (B) aPrepare with starting switch OFF. 1 z 2 wiring or defective contact in THL (female) (A) connector) Wiring harness between EN2 (female) (39) – Resistance Max. • Fuel temperature (temperature) can be checked in monitoring mode.3 k – 9 kz (10 – 100ºC) Between (A). 1 Mz chassis ground Cause Possible causes and standard value in normal state Circuit diagram related to fuel temperature sensor D65EX.3 k – 9 kz (10 – 100ºC) Between (17). then carry out troubleshooting without turning starting switch ON.TROUBLESHOOTING ERROR CODE DGE4KX ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code DGE4KX Controller code Engine Trouble Fuel temperature sensor: Input signal is out of normal range (KX) (Engine controller system) • Fuel temperature sensor signal is out of normal range. (39) – Min.

temperature sensor (Internal SDS (male) Resistance 1 disconnection or short Between (1) – (2) 3. 4 source in wiring harness Wiring harness between ST1 (female) (9) – (Contact with 24 V circuit) Voltage Max. then carry out troubleshooting Defective hydraulic oil without turning starting switch ON. • Hydraulic oil temperature (temperature) can be checked in monitoring mode.5 k – 90 kz (10 – 100ºC) circuit) Between (1) (2) – chassis ground Min. Defective steering and ST1 (female) Resistance 5 transmission controller Between (9) – (21) 3. turn starting switch ON and carry Short circuit with power out troubleshooting. then carry out troubleshooting without turning starting switch ON. (Code 04401: Hydraulic oil temperature) • Method of reproducing error code: Turn starting switch ON or start engine. 3 ground in wiring harness Wiring harness between ST1 (female) (9) – (Contact with ground circuit) Resistance Min. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.5 k – 90 kz (10 – 100ºC) Between (9) – chassis ground Min. Disconnection in wiring harness (Disconnection in Wiring harness between ST1 (female) (9) – Resistance Max. 1 Mz SDS (female) (1) with chassis ground aPrepare with starting switch OFF. 1 Mz aPrepare with starting switch OFF. 1 z 2 wiring or defective contact in SDS (female) (1) connector) Wiring harness between ST1 (female) (21) – Resistance Max. 1 z SDS (female) (2) aPrepare with starting switch OFF. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. • Hydraulic oil temperature gauge of monitor panel. then carry out troubleshooting without turning starting switch ON. • Fan speed is limited to half. PX-15 . 1 Mz Cause Possible causes and standard value in normal state 20-500 (1) D65EX.TROUBLESHOOTING ERROR CODE DGS1KX ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code DGS1KX Controller code Steering Trouble Hydraulic oil temperature sensor: Input signal is out of normal range (KX) (Steering and transmission controller system) • Hydraulic oil temperature sensor signal is out of normal range. 1 V SDS (female) (1) with chassis ground aPrepare with starting switch OFF.

PX-15 20-501 (1) .TROUBLESHOOTING ERROR CODE DGS1KX Circuit diagram related to hydraulic oil temperature sensor D65EX.

Wiring harness between EN2 (female) (19) – Disconnection in wiring Resistance Max.3 – 4. Defective boost pressure PIM Voltage 1 sensor (Internal trouble) Between (1) – (3) 4.6 – 5. Wiring harness between EN2 (female) (19) – Resistance Min. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.4 V Between (20) – (39) 0. • Flashes caution lamp and turns on caution buzzer.7 V aPrepare with starting switch OFF. • Machine is not affected seriously. (Code 36500: Boost pressure) • Method of reproducing error code: Turn starting switch ON or start engine.7 V Cause Possible causes and standard value in normal state 20-502 (1) D65EX. 1 Mz PIM (female) (3) with chassis ground aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DH30KX ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DH30KX Controller code Engine Trouble Boost pressure sensor: Input is out of normal range (KX) (Engine controller system) • Boost pressure sensor signal is out of normal range. 1 Mz PIM (female) (2) with chassis ground Wiring harness between EN2 (female) (39) – Resistance Min. then carry out troubleshooting without turning starting switch ON. 1 z PIM (female) (3) aPrepare with starting switch OFF. • Special adapter (799-601-9420) is necessary for troubleshooting for boost pressure sensor. EN2 Voltage 4 Defective engine controller Between (19) – (39) 4. 1 Mz Short circuit with chassis PIM (female) (1) with chassis ground 3 ground in wiring harness Wiring harness between EN2 (female) (20) – (Contact with ground circuit) Resistance Min.6 – 5. • Boost pressure (pressure) can be checked in monitoring mode.3 – 4. turn starting switch ON and carry out troubleshooting. 1 z harness (Disconnection in PIM (female) (1) 2 wiring or defective contact in Wiring harness between EN2 (female) (20) – Resistance Max.4 V Between (2) – (3) 0. then carry out troubleshooting without turning starting switch ON. 1 z connector) PIM (female) (2) Wiring harness between EN2 (female) (39) – Resistance Max. turn starting switch ON and carry out troubleshooting. PX-15 .

TROUBLESHOOTING ERROR CODE DH30KX Circuit diagram related to boost presure sensor D65EX. PX-15 20-503 (1) .

6 – 5. (Code 36400: Common rail pressure) • Method of reproducing error code: Turn starting switch ON or start engine. • Limits operation of engine and transmission. EN2 Voltage 4 Defective engine controller Between (19) – (39) 4. 1 z connector) PFUEL (female) (2) Wiring harness between EN2 (female) (39) – Resistance Max. Wiring harness between EN2 (female) (19) – Disconnection in wiring Resistance Max.7 – 4. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 Mz Short circuit with chassis PFUEL (female) (1) with chassis ground 3 ground in wiring harness Wiring harness between EN2 (female) (40) – (Contact with ground circuit) Resistance Min. 1 Mz PFUEL (female) (3) with chassis ground aPrepare with starting switch OFF. 1 Mz PFUEL (female) (2) with chassis ground Wiring harness between EN2 (female) (39) – Resistance Min. • Once machine is stopped. Wiring harness between EN2 (female) (19) – Resistance Min. • Flashes caution lamp and turns on caution buzzer.4 V Between (2) – (3) 0.5 V aPrepare with starting switch OFF.7 – 4.5 V Cause Possible causes and standard value in normal state 20-504 (1) D65EX. travel is limited to F1 and R1. • Special adapter (799-601-9420) is necessary for troubleshooting for common rail pressure sensor. Defective common rail PFUEL Voltage 1 pressure sensor (Internal trouble) Between (1) – (3) 4. 1 z harness (Disconnection in PFUEL (female) (1) 2 wiring or defective contact in Wiring harness between EN2 (female) (40) – Resistance Max.TROUBLESHOOTING ERROR CODE DH40KX ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DH40KX Controller code Engine Trouble Common rail pressure sensor: Input is out of normal range (KX) (Engine controller system) • Common rail pressure sensor signal is out of normal range.6 – 5. PX-15 . 1 z PFUEL (female) (3) aPrepare with starting switch OFF. engine speed is limited to medium (half). turn starting switch ON and carry out troubleshooting. • Once machine is stopped.4 V Between (40) – (39) 0. • Common rail pressure (pressure) can be checked in monitoring mode. turn starting switch ON and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON.

TROUBLESHOOTING ERROR CODE DH40KX Circuit diagram related to common rail presure sensor D65EX. PX-15 20-505 (1) .

then carry out troubleshooting without turning starting switch ON. travel is limited to F1 and R1.5 V. • Once machine is stopped. Wiring harness between EN2 (female) (9) – Disconnection in wiring Resistance Max. 1 z DIAL (female) (C) aPrepare with starting switch OFF.4 V Between (10) – (29) 0.5 – 4.0 – 6. EN2 Voltage 5 Defective engine controller Between (9) – (29) 4.5 – 4. Defective fuel control dial DIAL (male) Resistance 1 (Internal disconnection or Between (A) – (C) 4. then carry out troubleshooting without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer. 1 V DIAL (female) (B) with chassis ground aPrepare with starting switch OFF.5 V Cause Possible causes and standard value in normal state 20-506 (1) D65EX. then turn starting switch ON and carry out troubleshooting. engine speed is limited to medium (half). • Continues controlling with signal of decelerator pedal potentiometer.5 kz Between (B) – (C) 0. Short circuit with power Wiring harness between EN2 (female) (9) – 4 source in wiring harness Voltage Max. 1 Mz 3 ground in wiring harness DIAL (female) (A) with chassis ground (Contact with ground circuit) Wiring harness between EN2 (female) (10) – Resistance Min.5 kz aPrepare with starting switch OFF. PX-15 . (Code 03000: Voltage of fuel control dial) • Method of reproducing error code: Turn starting switch ON. Short circuit with chassis Wiring harness between EN2 (female) (9) – Resistance Min. 1 Mz DIAL (female) (B) with chassis ground aPrepare with starting switch OFF. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 z harness (Disconnection in DIAL (female) (A) 2 wiring or defective contact in Wiring harness between EN2 (female) (10) – Resistance Max.TROUBLESHOOTING ERROR CODE DK10KX ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK10KX Controller code Engine Trouble Fuel control dial: Input is out of normal range (KX) (Engine controller system) • Signal voltage of fuel control dial circuit is below 0. • Once machine is stopped.0 kz short circuit) Between (A) – (B) 0. 1 z connector) DIAL (female) (B) Wiring harness between EN2 (female) (29) – Resistance Max. then carry out troubleshooting without turning starting switch ON.5 V or above 4.6 – 5. 1 V DIAL (female) (A) with chassis ground (Contact with 24 V circuit) Wiring harness between EN2 (female) (10) – Voltage Max. • Limits operation of engine and transmission. • Inputting from fuel control dial (Voltage) can be checked in monitoring mode.5 – 4. then turn starting switch ON and carry out troubleshooting.

TROUBLESHOOTING ERROR CODE DK10KX Circuit diagram related to fuel control dial D65EX. PX-15 20-507 (1) .

5 kz aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. Short circuit with power Wiring harness between EN2 (female) (9) – Voltage Max.5 – 4.0 kz connection or short circuit) Between (A) – (B) 0. then carry out troubleshooting without turning starting switch ON. 1 V DCL (female) (B) with chassis ground aPrepare with starting switch OFF. 1 z connector) DCL (female) (B) Wiring harness between EN2 (female) (29) – Resistance Max. • Once machine is stopped. 1 V source in wiring harness DCL (female) (A) with chassis ground (Contact with 24 V circuit) Wiring harness between EN2 (female) (38) – Voltage Max.6 – 5. 1 Mz ground in wiring harness DCL (female) (A) with chassis ground (Contact with ground circuit) Wiring harness between EN2 (female) (38) – Resistance Min. • Continues controlling with signal of fuel control dial. 1 z harness (Disconnection in DCL (female) (A) wiring or defective contact in Wiring harness between EN2 (female) (38) – Resistance Max. travel is limited to F1 and R1.3 – 4. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. Wiring harness between EN2 (female) (9) – Disconnection in wiring Resistance Max. engine speed is limited to medium (half). (Code 50001: Voltage of deceleration potentiometer) • Method of reproducing error code: Turn starting switch ON. Short circuit with chassis Wiring harness between EN2 (female) (9) – Resistance Min. 1 z DCL (female) (C) aPrepare with starting switch OFF. EN2 Voltage Defective engine controller Between (9) – (29) 4.5 kz Between (B) – (C) 0. then carry out troubleshooting without turning starting switch ON. Defective deceleration DCL (male) Resistance potentiometer (Internal disBetween (A) – (C) 4.4 V Between (38) – (29) 0.3 V or above 4.5 V. PX-15 . • Limits operation of engine and transmission. • Flashes caution lamp and turns on caution buzzer. 1 Mz DCL (female) (B) with chassis ground aPrepare with starting switch OFF.0 – 6.TROUBLESHOOTING ERROR CODE DK12KX ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE (KX)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK12KX Controller code Engine Trouble Fuel control dial: Input is out of normal range (KX) (Engine controller system) • Signal voltage of deceleration potentiometer circuit is below 0. then turn starting switch ON and carry out troubleshooting.5 – 4.5 V Cause 1 2 Possible causes and standard value in normal state 3 4 4 20-508 (1) D65EX. • Inputting from deceleration potentiometer (Voltage) can be checked in monitoring mode. • Once machine is stopped. then turn starting switch ON and carry out troubleshooting.

TROUBLESHOOTING ERROR CODE DK12KX Circuit diagram related to decel potentiometer D65EX. PX-15 20-509 (1) .

then carry out troubleshooting without turning starting switch ON. 1 z TL2 (female) (7) aPrepare with starting switch OFF. PX-15 . 1 source system carry out troubleshooting for it first. If it is displayed. • Limits operation of engine and transmission.TROUBLESHOOTING ERROR CODE DK30KA ERROR CODE DK30KA (STEERING POTENTIOMETER 1: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK30KA Controller code Steering Trouble Steering potentiometer 1: Disconnection (KA) (Steering and transmission controller system) • Signal voltage of steering potentiometer 1 system is above 4. • Input (Voltage) from steering potentiometer 1 can be checked in monitoring mode.5 V. travel is limited to F1 and R1.2 kz ± 20% nection or short circuit) Between (7) – (5) 1 – 6 kz (Right – Left steering) Between (7) – (8) 6 – 1 kz (Right – Left steering) aPrepare with starting switch OFF. (Code 50300: Voltage of steering potentiometer 1) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). aPrepare with starting switch OFF. Defective steering and 5 transmission controller ST1 Voltage Between (2) – (21) 0. 4 harness (Contact with 24 V Wiring harness between ST1 (female) (2) – circuit) Voltage Max. Disconnection in wiring harness (Disconnection in Wiring harness between ST1 (female) (21) – Resistance Max. • Continues controlling with signal of steering potentiometer 2 system. then turn starting switch ON and Hot short circuit in wiring carry out troubleshooting. • Once machine is stopped. then turn starting switch ON and carry out troubleshooting.5 – 4. 1 z 3 wiring or defective contact in TL2 (female) (8) connector) Wiring harness between ST1 (female) (2) – Resistance Max. Defective steering potentiTL2 (male) Resistance 2 ometer 1 (Internal disconBetween (5) – (8) 3. then carry out troubleshooting without turning starting switch ON. • Once machine is stopped. engine speed is limited to medium (half). • Flashes caution lamp and turns on caution buzzer. Cause Standard value in normal state/Remarks on troubleshooting Defective 5 V sensor power See if error code [DAQ5KK] [DB35KK] is displayed.5 V Possible causes and standard value in normal state Circuit diagram related to steering potentiometer 20-510 (1) D65EX. 1 V TL2 (female) (7) with chassis ground aPrepare with starting switch OFF.

• Continues controlling with signal of steering potentiometer 2 system. Defective steering potentiTL2 (male) Resistance 2 ometer 1 (Internal disconBetween (5) – (8) 3. (Code 50300: Voltage of steering potentiometer 1) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). If it is displayed. • Limits operation of engine and transmission. aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. harness (Disconnection in 5 wiring or defective contact in Wiring harness between ST1 (female) (22) – Resistance Max. • Once machine is stopped. • Once machine is stopped. Cause Standard value in normal state/Remarks on troubleshooting Defective 5 V sensor power See if error code [DAQ5KK] [DB35KK] is displayed. then turn starting switch ON and carry out troubleshooting.5 V aPrepare with starting switch OFF. 3 ground in wiring harness Wiring harness between ST1 (female) (2) – (Contact with ground circuit) Resistance Min. PX-15 20-511 (1) .5 V. 1 source system carry out troubleshooting for it first. 1 Mz TL2 (female) (7) with chassis ground aPrepare with starting switch OFF. travel is limited to F1 and R1. • Input (Voltage) from steering potentiometer 1 can be checked in monitoring mode. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. Defective steering and 4 transmission controller ST1 Voltage Between (2) – (21) 0. engine speed is limited to medium (half).2 kz ± 20% nection or short circuit) Between (7) – (5) 1 – 6 kz (Right – Left steering) Between (7) – (8) 6 – 1 kz (Right – Left steering) aPrepare with starting switch OFF. 1 z connector) TL2 (female) (5) Possible causes and standard value in normal state Circuit diagram related to steering potentiometer D65EX.5 – 4.TROUBLESHOOTING ERROR CODE DK30KB ERROR CODE DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK30KB Controller code Steering Trouble Steering potentiometer 1: Short circuit (KB) (Steering and transmission controller system) • Signal voltage of steering potentiometer 1 system is below 0.

• Once machine is stopped. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for error codes [DK30KA]. [DK30KB]. • Limits operation of engine. (Code 50300: Voltage of steering potentiometer 1) (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). engine speed is limited to medium (half). [DK30KB]. DK30KZ ERROR CODE DK30KX ERROR CODE DK30KX (STEERING POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code Controller code Steering potentiometer: Input signal is out of normal range Trouble (KX) (Steering and transmission controller system) DK30KX Steering • Either of error codes [DK30KA] and [DK30KB] of steering potentiometer systems 1 and 2 and either of error codes [DK31KA] and [DK31KB] are displayed simultaneously. • Flashes caution lamp and turns on caution buzzer. then either of error codes [DK30KA] and [DK30KB] and either of error codes [DK31KA] and [DK31KB] are displayed simultaneously. • Limits operation of engine. • Once machine is stopped. it cannot travel any more. • Once machine is stopped. • Input (Voltage) from steering potentiometers can be checked in monitoring mode. transmission. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for error codes [DK30KA]. engine speed is limited to medium (half). [DK31KA]. transmission. • Input (Voltage) from steering potentiometers can be checked in monitoring mode. • Flashes caution lamp and turns on caution buzzer. either of steering potentiometer systems 1 and 2 is abnormal. and brake. and [DK31KB]. (Code 50300: Voltage of steering potentiometer 1) (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). [DK31KA]. 20-512 (1) D65EX. • Once machine is stopped. ERROR CODE DK30KZ (STEERING POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (Double trouble) (KZ)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code Controller code Steering potentiometer: Disconnection or short circuit (KZ) Trouble (Steering and transmission controller system) DK30KZ Steering • When starting switch is turned ON. and [DK31KB]. it cannot travel any more. and brake. PX-15 .TROUBLESHOOTING ERROR CODE DK30KX.

travel is limited to F1 and R1. and [DK31KB].59 V. • Input (Voltage) from steering potentiometers can be checked in monitoring mode. PX-15 20-513 (1) . • Once machine is stopped. • Limits operation of engine and transmission. • Flashes caution lamp and turns on caution buzzer. [DK31KA]. • Once machine is stopped. D65EX.TROUBLESHOOTING ERROR CODE DK30L8 ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code Controller code Steering potentiometer 1: See table (L8) Trouble (Steering and transmission controller system) DK30L8 Steering • Total signal voltage of each of steering potentiometer 1 system and 2 system is below 4. • Continues controlling with signal of normal one of steering potentiometer 1 system and 2. [DK30KB]. Cause Standard value in normal state/Remarks on troubleshooting Carry out troubleshooting for error codes [DK30KA].41 V or above 5. (Code 50300: Voltage of steering potentiometer 1) (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). engine speed is limited to medium (half).

• Once machine is stopped. harness (Disconnection in wiring or defective contact in Wiring harness between ST1 (female) (21) – Resistance Max. (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). Defective steering potentiTL2 (male) Voltage ometer 2 (Internal disconBetween (5) – (8) 3. carry out troubleshooting for it first. • Once machine is stopped. PX-15 . aPrepare with starting switch OFF.5 V. Defective steering and transmission controller ST1 Voltage Between (19) – (21) 0. • Flashes caution lamp and turns on caution buzzer. 1 V TL2 (female) (6) with chassis ground aPrepare with starting switch OFF. • Limits operation of engine and transmission. • Continues controlling with signal of steering potentiometer 1 system. travel is limited to F1 and R1.TROUBLESHOOTING ERROR CODE DK31KA ERROR CODE DK31KA (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK31KA Controller code Steering Trouble Steering potentiometer 2: Short circuit (KA) (Steering and transmission controller system) • Signal voltage of steering potentiometer 2 system is above 4. If it is displayed.5 V aPrepare with starting switch OFF. 1 z connector) TL2 (female) (8) 2 Possible causes and standard value in normal state 3 4 5 Circuit diagram related to steering potentiometer 20-514 (1) D65EX. then turn starting switch ON and Short circuit with power carry out troubleshooting. source in wiring harness Wiring harness between ST1 (female) (19) – (Contact with 24 V circuit) Voltage Max. engine speed is limited to medium (half). then carry out troubleshooting without turning starting switch ON. • Input (Voltage) from steering potentiometer 2 can be checked in monitoring mode.5 – 4. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. then turn starting switch ON and carry out troubleshooting.2 kz ± 20% nection or short circuit) Between (6) – (5) 6 – 1 kz (Right – Left steering) Between (6) – (8) 1 – 6 kz (Right – Left steering) aPrepare with starting switch OFF. Cause Defective sensor power 1 source system Standard value in normal state/Remarks on troubleshooting See if error code [DAQ5KK] [DB35KK] is displayed.

5 V. • Once machine is stopped. then carry out troubleshooting without turning starting switch ON.2 kz ± 20% nection or short circuit) Between (6) – (5) 6 – 1 kz (Right – Left steering) Between (6) – (8) 1 – 6 kz (Right – Left steering) aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DK31KB ERROR CODE DK31KB (STEERING POTENTIOMETER 2: DISCONNECTION (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK31KB Controller code Steering Trouble Steering potentiometer 2: Disconnection (KB) (Steering and transmission controller system) • Signal voltage of steering potentiometer 2 system is below 0. 1 z TL2 (female) (6) aPrepare with starting switch OFF. Defective steering and 5 transmission controller ST1 Voltage Between (19) – (21) 0.5 V Cause Defective sensor power 1 source system Possible causes and standard value in normal state Circuit diagram related to steering potentiometer D65EX. Standard value in normal state/Remarks on troubleshooting See if error code [DAQ5KK] [DB35KK] is displayed. carry out troubleshooting for it first.5 – 4. • Limits operation of engine and transmission. 1 z 3 wiring or defective contact in TL2 (female) (5) connector) Wiring harness between ST1 (female) (19) – Resistance Max. 4 ground in wiring harness Wiring harness between ST1 (female) (19) – (Contact with ground circuit) Resistance Min. Disconnection in wiring harness (Disconnection in Wiring harness between ST1 (female) (22) – Resistance Max. • Continues controlling with signal of steering potentiometer 1 system. 1 Mz TL2 (female) (6) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. engine speed is limited to medium (half). travel is limited to F1 and R1. PX-15 20-515 (1) . (Code 50301: Voltage of steering potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering). • Once machine is stopped. aPrepare with starting switch OFF. Defective steering potentiTL2 (male) Resistance 2 ometer 2 (Internal disconBetween (5) – (8) 3. • Flashes caution lamp and turns on caution buzzer. • Input (Voltage) from steering potentiometer 2 can be checked in monitoring mode. If it is displayed. then carry out troubleshooting without turning starting switch ON.

5 – 4. ometer (Internal disconBRK (male) Resistance 2 nection or short circuit) Between (A) – (C) 4.5 – 1. Once machine is stopped. engine speed is limited to medium (half). travel is limited to F1 and R1. aPrepare with starting switch OFF.0 – 6. Cause Standard value in normal state/Remarks on troubleshooting Defective 5 V sensor power See if error code [DAQ5KK] [DB35KK] is displayed. PX-15 . Once machine is stopped.5 kz (Free – Stroke end) potentiometer Between (B) – (C) 4. Limits operation of engine and transmission. Auto shift-down mechanism does not work normally.0 kz • Defective installation of Between (A) – (B) 1. 1 source system carry out troubleshooting for it first. 1 Mz BRK (female) (B) with chassis ground aPrepare with starting switch OFF.5 V. 4 ground in wiring harness Wiring harness between ST1 (female) (3) – (Contact with ground circuit) Resistance Min.TROUBLESHOOTING ERROR CODE DK40KA ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK40KA Controller code Steering Trouble Brake potentiometer: Disconnection (KA) (Steering and transmission controller system) • Signal voltage of brake potentiometer circuit is below 0. Input (Voltage) from brake potentiometer can be checked in monitoring mode. 1 z 3 wiring or defective contact in BRK (female) (C) connector) Wiring harness between ST1 (female) (3) – Resistance Max. Defective steering and 5 transmission controller ST1 Voltage Between (3) – (21) 1.5 kz (Free – Stroke end) aPrepare with starting switch OFF.5 – 4. • • • • • • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting without turning starting switch ON. (Code 50400: Voltage of brake potentiometer) • Method of reproducing error code: Turn starting switch ON and operate brake pedal. If it is displayed.5 V Possible causes and standard value in normal state Circuit diagram related to brake potentiometer 20-516 (1) D65EX. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. 1 z BRK (female) (B) aPrepare with starting switch OFF. Disconnection in wiring harness (Disconnection in Wiring harness between ST1 (female) (22) – Resistance Max. then carry out troubleshooting • Defective brake potentiwithout turning starting switch ON.

aPrepare with starting switch OFF. 1 source system carry out troubleshooting for it first. Auto shift-down mechanism does not work normally. Input (Voltage) from brake potentiometer can be checked in monitoring mode. • • • • • • Flashes caution lamp and turns on caution buzzer. Limits operation of engine and transmission. then turn starting switch ON and carry out troubleshooting. travel is limited to F1 and R1.0 kz • Defective installation of (A) – (B) 1.5 kz (Free – Stroke end) aPrepare with starting switch OFF. (Code 50400: Voltage of brake potentiometer) • Method of reproducing error code: Turn starting switch ON and operate brake pedal. 3 source in wiring harness Wiring harness between ST1 (female) (3) – (Contact with 24 V circuit) Voltage Max. harness (Disconnection in 5 wiring or defective contact in Wiring harness between ST1 (female) (21) – Resistance Max. then carry out troubleshooting Disconnection in wiring without turning starting switch ON.5 V.5 V aPrepare with starting switch OFF. Defective steering and 4 transmission controller ST1 Voltage Between (3) – (21) 1. engine speed is limited to medium (half). If it is displayed. then turn starting switch ON and Short circuit with power carry out troubleshooting.5 V or above 4. 1 z connector) BRK (female) (A) Possible causes and standard value in normal state Circuit diagram related to brake potentiometer D65EX. Cause Standard value in normal state/Remarks on troubleshooting Defective 5 V sensor power See if error code [DAQ5KK] [DB35KK] is displayed. 1 V BRK (female) (B) with chassis ground aPrepare with starting switch OFF. PX-15 20-517 (1) .5 – 4.5 kz (Free – Stroke end) potentiometer (B) – (C) 4. then carry out troubleshooting • Defective brake potentiwithout turning starting switch ON. Once machine is stopped.0 – 6.5 – 1.TROUBLESHOOTING ERROR CODE DK40KB ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK40KB Controller code Steering Trouble Brake potentiometer: Short circuit (KB) (Steering and transmission controller system) • Signal voltage of brake potentiometer circuit is below 0. ometer (Internal disconBRK (male) Resistance 2 nection or short circuit) (A) – (C) 4. Once machine is stopped.5 – 4.

it cannot travel any more. it cannot travel any more. transmission. and brake. Cause Standard value in normal state/Remarks on troubleshooting Possible causes and standard value in normal state Carry out troubleshooting for error codes [DK56KA]. • Limits operation of engine. • Limits operation of engine. [DK57KA]. (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel). (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel). transmission. • Once machine is stopped. and [DK57KB]. • Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. engine speed is limited to medium (half). • Flashes caution lamp and turns on caution buzzer.TROUBLESHOOTING ERROR CODE DK55KX. • Once machine is stopped. Cause Standard value in normal state/Remarks on troubleshooting Possible causes and standard value in normal state Carry out troubleshooting for error codes [DK56KA]. • Once machine is stopped. PX-15 . then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and [DK57KB] are displayed simultaneously. either of forward-reverse potentiometer systems 1 and 2 is abnormal. engine speed is limited to medium (half). • Once machine is stopped. [DK57KA]. ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (Double trouble) (KZ)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Forward-reverse potentiometer: Disconnection or short circuit Trouble (KZ) (Steering and transmission controller system) DK55KZ Steering • When starting switch is turned ON. and [DK57KB]. 20-518 (1) D65EX. DK55KZ ERROR CODE DK55KX ERROR CODE DK55KX (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Forward-reverse potentiometer: Input signal is out of normal Trouble range (KX) (Steering and transmission controller system) DK55KX Steering • Either of error codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and either of error codes [DK57KA] and [DK57KB] are displayed simultaneously. • Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. [DK56KB]. [DK56KB]. and brake. • Flashes caution lamp and turns on caution buzzer.

TROUBLESHOOTING ERROR CODE DK55L8 ERROR CODE DK55L8 (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Forward-reverse potentiometer: See table (L8) Trouble (Steering and transmission controller system) DK55L8 Steering • Total signal voltage of each of forward-reverse potentiometer 1 system and 2 system is below 4. [DK56KB]. • Once machine is stopped. • Flashes caution lamp and turns on caution buzzer. • Once machine is stopped.41 V or above 5. Cause Standard value in normal state/Remarks on troubleshooting Possible causes and standard value in normal state Carry out troubleshooting for error codes [DK56KA]. D65EX. • Limits operation of engine and transmission. and [DK57KB]. travel is limited to F1 and R1.59 V. engine speed is limited to medium (half). (Code 50200: Voltage of forward-reverse potentiometer 1) (Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel). [DK57KA]. PX-15 20-519 (1) . • Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode. • Continues controlling with signal of normal one of forward-reverse potentiometer 1 system and 2.

then turn starting switch ON and Short circuit with power carry out troubleshooting. then carry out troubleshooting without turning starting switch ON.5 kz (Forward – Reverse) Between (3) – (1) 1. travel is limited to F1 and R1. • Input (Voltage) from forward-reverse potentiometer 1 can be checked in monitoring mode. • Continues controlling with signal of forward-reverse potentiometer 2 system. • Once machine is stopped. engine speed is limited to medium (half). Cause Standard value in normal state/Remarks on troubleshooting Defective 5 V sensor power See if error code [DB35KK] [DAQ5KK] is displayed. Defective forward-reverse TL2 (male) Resistance potentiometer 1 (Internal 2 disconnection or short Between (4) – (1) 3.5 V aPrepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. 1 z connector) TL2 (female) (1) Possible causes and standard value in normal state 20-520 (1) D65EX.2 kz ± 20% circuit) Between (3) – (4) 5. • Flashes caution lamp and turns on caution buzzer. harness (Disconnection in 5 wiring or defective contact in Wiring harness between ST1 (female) (21) – Resistance Max.5 V.5 – 1.5 – 5. (Code 50200: Voltage of forward-reverse potentiometer 1) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel). PX-15 .5 – 4. aPrepare with starting switch OFF. 3 source in wiring harness Wiring harness between ST1 (female) (13) – (Contact with 24 V circuit) Voltage Max. If it is displayed. Defective steering and 4 ST1 Voltage transmission controller Between (13) – (21) 0.TROUBLESHOOTING ERROR CODE DK56KA ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK56KA Controller code Steering Trouble Forward-reverse potentiometer 1: Short circuit (KA) (Steering and transmission controller system) • Signal voltage of forward-reverse potentiometer 1 system is above 4. • Once machine is stopped. • Limits operation of engine and transmission. 1 source system carry out troubleshooting for it first.5 kz (Forward – Reverse) aPrepare with starting switch OFF. 1 V TL2 (female) (3) with chassis ground aPrepare with starting switch OFF.

TROUBLESHOOTING ERROR CODE DK56KA Circuit diagram related to forward-reverse potentiometer D65EX. PX-15 20-521 (1) .

1 z TL2 (female) (3) aPrepare with starting switch OFF. 4 ground in wiring harness Wiring harness between ST1 (female) (13) – (Contact with ground circuit) Resistance Min.5 – 5.5 V Possible causes and standard value in normal state 20-522 (1) D65EX.5 – 1. • Once machine is stopped. • Input (Voltage) from forward-reverse potentiometer 1 can be checked in monitoring mode. • Once machine is stopped. aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer. 1 z 3 wiring or defective contact in TL2 (female) (4) connector) Wiring harness between ST1 (female) (13) – Resistance Max. Cause Standard value in normal state/Remarks on troubleshooting Defective 5 V sensor power See if error code [DAQ5KK] is displayed. If it is displayed. 1 Mz TL2 (female) (3) with chassis ground aPrepare with starting switch OFF. carry out 1 source system troubleshooting for it first.5 – 4. • Continues controlling with signal of forward-reverse potentiometer 2 system.5 V. PX-15 .TROUBLESHOOTING ERROR CODE DK56KB ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK56KB Controller code Steering Trouble Forward-reverse potentiometer 1: Disconnection (KB) (Steering and transmission controller system) • Signal voltage of forward-reverse potentiometer 1 system is below 0. engine speed is limited to medium (half). Defective steering and 5 transmission controller ST1 Voltage Between (13) – (21) 0.2 kz ± 20% circuit) Between (3) – (4) 5. (Code 50200: Voltage of forward-reverse potentiometer 1) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).5 kz (Forward – Reverse) Between (3) – (1) 1. then carry out troubleshooting Short circuit with chassis without turning starting switch ON.5 kz (Forward – Reverse) aPrepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. • Limits operation of engine and transmission. travel is limited to F1 and R1. Defective forward-reverse TL2 (male) Resistance potentiometer 1 (Internal 2 disconnection or short Between (4) – (1) 3. Disconnection in wiring harness (Disconnection in Wiring harness between ST1 (female) (22) – Resistance Max. then carry out troubleshooting without turning starting switch ON.

TROUBLESHOOTING ERROR CODE DK56KB Circuit diagram related to forward-reverse potentiometer D65EX. PX-15 20-523 (1) .

(Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).5 V aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DK57KA ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK57KA Controller code Steering Trouble Forward-reverse potentiometer 2: Short circuit (KA) (Steering and transmission controller system) • Signal voltage of forward-reverse potentiometer 2 system is above 4. 1 wiring or defective contact in carry out troubleshooting for it first. then carry out troubleshooting Disconnection in wiring without turning starting switch ON. travel is limited to F1 and R1. then turn starting switch ON and carry out troubleshooting. • Once machine is stopped. then carry out troubleshooting without turning starting switch ON.5 kz (Forward – Reverse) aPrepare with starting switch OFF. harness (Disconnection in 5 wiring or defective contact in Wiring harness between ST1 (female) (21) – Resistance Max. PX-15 .5 kz (Forward – Reverse) Between (2) – (1) 5.5 – 4. 3 source in wiring harness Wiring harness between ST1 (female) (7) – (Contact with 24 V circuit) Voltage Max.5 – 5. • Flashes caution lamp and turns on caution buzzer. then turn starting switch ON and Short circuit with power carry out troubleshooting. 1 V TL2 (female) (2) with chassis ground aPrepare with starting switch OFF. 1 z connector) TL2 (female) (1) Possible causes and standard value in normal state 20-524 (1) D65EX. engine speed is limited to medium (half). Defective forward-reverse TL2 (male) Resistance potentiometer 2 (Internal 2 disconnection or short Between (4) – (1) 2 kz ± 20% circuit) Between (2) – (4) 1.5 V. Cause Standard value in normal state/Remarks on troubleshooting Disconnection in wiring harness (Disconnection in See if error code [DB35KK] [DAQ5KK] is displayed. • Limits operation of engine and transmission. Defective steering and 4 transmission controller ST1 Voltage Between (7) – (21) 0. • Input (Voltage) from forward-reverse potentiometer 2 can be checked in monitoring mode. • Once machine is stopped. • Continues controlling with signal of forward-reverse potentiometer 1 system. connector) aPrepare with starting switch OFF.5 – 1. If it is displayed.

TROUBLESHOOTING ERROR CODE DK57KA Circuit diagram related to forward-reverse potentiometer D65EX. PX-15 20-525 (1) .

then carry out troubleshooting without turning starting switch ON. 4 ground in wiring harness Wiring harness between ST1 (female) (7) – (Contact with ground circuit) Resistance Min. 1 z TL2 (female) (3) aPrepare with starting switch OFF. Cause Standard value in normal state/Remarks on troubleshooting Defective 5 V sensor power See if error code [DB35KK] [DAQ5KK] is displayed. then carry out troubleshooting without turning starting switch ON. If it is displayed. (Code 50201: Voltage of forward-reverse potentiometer 2) • Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel). • Continues controlling with signal of forward-reverse potentiometer 1 system.2 kz ± 20% circuit) Between (2) – (4) 1. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. then turn starting switch ON and carry out troubleshooting.5 – 1.TROUBLESHOOTING ERROR CODE DK57KB ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK57KB Controller code Steering Trouble Forward-reverse potentiometer 2: Disconnection (KB) (Steering and transmission controller system) • Signal voltage of forward-reverse potentiometer 2 system is below 0.5 – 5. PX-15 . aPrepare with starting switch OFF. • Input (Voltage) from forward-reverse potentiometer 2 can be checked in monitoring mode.5 V Possible causes and standard value in normal state 20-526 (1) D65EX. • Once machine is stopped. travel is limited to F1 and R1.5 – 4.5 V. Disconnection in wiring harness (Disconnection in Wiring harness between ST1 (female) (22) – Resistance Max. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. Defective steering and 5 transmission controller ST1 Voltage Between (7) – (21) 0. • Once machine is stopped. 1 source system carry out troubleshooting for it first.5 kz (Forward – Reverse) Between (2) – (1) 5. Defective forward-reverse TL2 (male) Resistance potentiometer 2 (Internal 2 disconnection or short Between (4) – (1) 3. engine speed is limited to medium (half).5 kz (Forward – Reverse) aPrepare with starting switch OFF. 1 Mz TL2 (female) (2) with chassis ground aPrepare with starting switch OFF. 1 z 3 wiring or defective contact in TL2 (female) (4) connector) Wiring harness between ST1 (female) (13) – Resistance Max.

TROUBLESHOOTING ERROR CODE DK57KB Circuit diagram related to forward-reverse potentiometer D65EX. PX-15 20-527 (1) .

engine speed is limited to medium (half).15 – 4. 1 system carry out troubleshooting for it first. Input (Voltage) from pitch angle sensor can be checked in monitoring mode. 1 V PT1 (female) (B) with chassis ground aPrepare with starting switch OFF. 3 source in wiring harness Wiring harness between ST1 (female) (8) – (Contact with 24 V circuit) Voltage Max.TROUBLESHOOTING ERROR CODE DKH1KA ERROR CODE DKH1KA (PITCH ANGLE SENSOR: SHORT CIRCUIT (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DKH1KA Controller code Steering Trouble Pitch angle sensor: Short circuit (KA) (Steering and transmission controller system) • Signal voltage of pitch angle sensor is above 4. Limits operation of engine and transmission. Defective pitch angle sensor 2 (Internal trouble) PT1 Voltage Between (B) – (A) 0. then turn starting switch ON and Short circuit with power carry out troubleshooting. Cannot recognize pitch angle. then turn starting switch ON and carry out troubleshooting. • • • • • • • Flashes caution lamp and turns on caution buzzer.85 V Possible causes and standard value in normal state Circuit diagram related to pitch angle sensor 20-528 (1) D65EX. Defective steering and 4 transmission controller ST1 Voltage Between (8) – (21) 0.85 V aPrepare with starting switch OFF. (Code 60100: Voltage of pitch angle sensor) • Method of reproducing error code: Turn starting switch ON. If it is displayed. Cause Standard value in normal state/Remarks on troubleshooting Defective 24 V power source See if error code [DAQ6KK] [DB36KK] is displayed.85 V. Once machine is stopped. Shocks are made when gear is shifted on slope. aPrepare with starting switch OFF. PX-15 . then turn starting switch ON and carry out troubleshooting.15 – 4. travel is limited to F1 and R1. Once machine is stopped.

85 V aPrepare with starting switch OFF. engine speed is limited to medium (half). Shocks are made when gear is shifted on slope. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 1 z PT1 (female) (B) aPrepare with starting switch OFF. If it is displayed.85 V Possible causes and standard value in normal state Circuit diagram related to pitch angle sensor D65EX. travel is limited to F1 and R1. 4 ground in wiring harness Wiring harness between ST1 (female) (8) – (Contact with ground circuit) Resistance Min. Defective steering and 5 transmission controller ST1 Voltage Between (8) – (21) 0. Defective pitch angle sensor 2 (Internal trouble) PT1 Voltage Between (B) – (A) 0.15 – 4. (Code 60100: Voltage of pitch angle sensor) • Method of reproducing error code: Turn starting switch ON. Input (Voltage) from pitch angle sensor can be checked in monitoring mode.TROUBLESHOOTING ERROR CODE DKH1KB ERROR CODE DKH1KB (PITCH ANGLE SENSOR: DISCONNECTION (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DKH1KB Controller code Steering Trouble Pitch angle sensor: Disconnection (KB) (Steering and transmission controller system) • Signal voltage of pitch angle sensor is below 0. then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between ST1 (female) (16) – Resistance Max.15 V. PX-15 20-529 (1) . Cannot recognize pitch angle. aPrepare with starting switch OFF. 1 z 3 wiring or defective contact in PT1 (female) (C) connector) Wiring harness between ST1 (female) (8) – Resistance Max. Limits operation of engine and transmission. then turn starting switch ON and carry out troubleshooting. then turn starting switch ON and carry out troubleshooting. Once machine is stopped. • • • • • • • Flashes caution lamp and turns on caution buzzer. Cause Standard value in normal state/Remarks on troubleshooting Defective 24 V power source See if error code [DAQ6KK] [DB36KK] is displayed. 1 Mz PT1 (female) (B) with chassis ground aPrepare with starting switch OFF. Once machine is stopped. 1 system carry out troubleshooting for it first.15 – 4.

then carry out troubleshooting without turning starting switch ON. Limits operation of engine and transmission. Wiring harness between EN2 (female) (36) – Resistance Min. PX-15 . 1 z NE (female) (1) Wiring harness between EN2 (female) (26) – Resistance Max. then carry out troubleshooting without turning starting switch ON. (2) – chassis ground Min. Cause Defective engine Ne speed 1 sensor (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 Mz NE (female) (2) with chassis ground aPrepare with starting switch OFF. • • • • • • • Flashes caution lamp and turns on caution buzzer. Special adapter (799-601-9410) is necessary for troubleshooting for engine Ne speed sensor. travel is limited to F1 and R1. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. 1 Mz NE (female) (1) with chassis ground Wiring harness between EN2 (female) (26) – Resistance Min. NE (male) Resistance Between (1) – (2) 85 – 210 z Between (1). (26) – Min. Engine speed may become unstable or engine may stop. EN2 Resistance Between (36) – (26) 85 – 210 z Between (36). Method of reproducing error code: Start engine. 1 Mz chassis ground Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in 2 wiring or defective contact in connector) Short circuit with chassis 3 ground in wiring harness (Contact with ground circuit) 4 Defective engine controller Circuit diagram related to engine Ne speed sensor 20-530 (1) D65EX. Wiring harness between EN2 (female) (36) – Resistance Max. engine speed is limited to medium (half). 1 z NE (female) (2) aPrepare with starting switch OFF. Once machine is stopped. Once machine is stopped. 1 Mz aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DLE3LC ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: SEE TABLE (LC)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DLE3LC Controller code Engine Trouble Engine Ne speed sensor: See table (LC) (Engine controller system) • Cylinders cannot be identified by signal of engine Ne speed sensor.

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. • Transmission output speed can be checked in monitoring mode. (Code 31400: Transmission speed) • Method of reproducing error code: Start engine and travel machine actually. then turn starting switch ON and Defective transmission carry out troubleshooting.TROUBLESHOOTING ERROR CODE DLF1KA ERROR CODE DLF1KA (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code DLF1KA Controller code Steering Trouble Transmission output speed sensor: Disconnection (KA) (Steering and transmission controller system) • Signal is not input from transmission output speed sensor. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer. Disconnection in wiring harness (Disconnection in Wiring harness between ST2 (female) (30) – Resistance Max. PX-15 20-531 (1) . 3 ground in wiring harness Wiring harness between ST2 (female) (30) – (Contact with ground circuit) Resistance Min. 1 z 2 wiring or defective contact in TM1 (female) (1) connector) Wiring harness between ST2 (female) (29) – Resistance Max. output speed sensor TM1 (male) Resistance 1 (Internal disconnection or Between (1) – (2) 400 – 1. 1 z TM1 (female) (2) aPrepare with starting switch OFF. • Transmission speed cannot be monitored. 1 Mz aPrepare with starting switch OFF. Defective steering and ST2 (female) Resistance 4 transmission controller Between (30) – (29) 400 – 1. • Assumes that transmission output speed is 0 rpm. 1 z Cause Possible causes and standard value in normal state Circuit diagram related to transmission output speed sensor D65EX. 1 Mz TM1 (female) (1) with chassis ground aPrepare with starting switch OFF. • Traction force cannot be calculated.000 z Between (30) – chassis ground Min.000 z short circuit) Between (1) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON.

(2) – chassis ground Min. Short circuit with chassis Wiring harness between EN2 (female) (35) – G Resistance Min. • Limits operation of engine and transmission.TROUBLESHOOTING ERROR CODE DLH1LC ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: SEE TABLE (LC)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DLH1LC Controller code Engine Trouble Engine G speed sensor: See table (LC) (Engine controller system) • Cylinder cannot be identified from signal of engine G speed sensor. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. 1 Mz 3 ground in wiring harness (female) (1) with chassis ground (Contact with ground circuit) Wiring harness between EN2 (female) (25) – G Resistance Min. • Once machine is stopped. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.5 kz Between (35). then carry out troubleshooting without turning starting switch ON.4 k – 3. travel is limited to F1 and R1. 1 Mz aPrepare with starting switch OFF. Defective engine G speed G (male) Resistance 1 sensor (Internal disconnection or short circuit) Between (1) – (2) 1. PX-15 . 1 z 2 wiring or defective contact in (female) (1) connector) Wiring harness between EN2 (female) (25) – G Resistance Max. 1 z (female) (2) aPrepare with starting switch OFF. (25) – Min.5 kz Between (1). • Once machine is stopped. EN2 (female) Resistance 4 Defective engine controller Between (35) – (25) 1. 1 Mz (female) (2) with chassis ground aPrepare with starting switch OFF. Disconnection in wiring harness (Disconnection in Wiring harness between EN2 (female) (35) – G Resistance Max.4 k – 3. • Special adapter (799-601-9410) is necessary for troubleshooting for engine G speed sensor. engine speed is limited to medium (half). 1 Mz chassis ground Cause Possible causes and standard value in normal state Circuit diagram related to engine G speed sensor 20-532 (1) D65EX. then turn starting switch ON and carry out troubleshooting. • Method of reproducing error code: Start engine.

then turn starting switch ON and carry out troubleshooting. • Caution buzzer does not sound. Wiring harness between 217 (female) (1) – Voltage Max. then carry out troubleshooting without turning starting switch ON. 3 V (sounding) 1 Possible causes and standard value in normal state Short circuit with power 2 source in wiring harness (Contact with 24 V circuit) 3 Defective monitor panel Circuit diagram related to caution buzzer D65EX. buzzer sounds for 1 second). 1 V S03 (female) (18) with chassis ground aPrepare with starting switch OFF. • Stops caution buzzer circuit from outputting ground signal. 217 (male) Resistance Between (1) – (2) 200 z aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DV00KB ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB)) Action code — Contents of trouble Action of controller Problem that appears on machine Related information Error code DV00KB Controller code MON Trouble Caution buzzer: Short circuit (KB) (Monitor panel system) • Abnormal current flowed when caution buzzer circuit output ground signal. then turn starting switch ON and carry out troubleshooting. • Method of reproducing error code: Turn starting switch ON (When it is turned ON. Cause Defective caution buzzer (Internal short circuit) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. PX-15 20-533 (1) . S03 Caution buzzer Voltage When turned OFF 20 – 30 V Between (18) – When turned ON chassis ground Max.

• Output state (ON/OFF) to pitch control solenoid can be checked in monitoring mode. then turn starting switch ON and carry out troubleshooting. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (17) – Resistance Max. source in wiring harness Wiring harness between ST3 (female) (17) – (Contact with 24 V circuit) Voltage Max. 1 V 52 (female) (1) with chassis ground aPrepare with starting switch OFF. • Flashes caution lamp and turns on caution buzzer. Defective pitch control solenoid (Internal disconnection) 52 (male) Resistance Between (1) – (2) 20 – 30 z aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. PX-15 . (Code 70304: Work equipment-related controller output signal) • Method of reproducing error code: Turn starting switch ON and operate pitch control switch. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 1 z wiring or defective contact in 52 (female) (1) connector) Wiring harness between ST3 (female) (3) – Resistance Max. • Stops outputting power to pitch control solenoid circuit. Defective steering and transmission controller ST3 Voltage Between (17) – (3) 20 – 30 V Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to pitch control solenoid 20-534 (1) D65EX. • Pitch control cannot be performed.TROUBLESHOOTING ERROR CODE DW5AKA ERROR CODE DW5AKA (PITCH CONTROL SOLENOID: DISCONNECTION (KA)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DW5AKA Controller code Steering Trouble Pitch control solenoid: Disconnection (KA) (Steering and transmission controller system) • Any current does not flow when power is output to pitch control solenoid circuit. then carry out troubleshooting without turning starting switch ON. 1 z 52 (female) (2) aPrepare with starting switch OFF. then turn starting switch ON and Short circuit with power carry out troubleshooting.

2 ground in wiring harness Wiring harness between ST3 (female) (17) – (Contact with ground circuit) Resistance Min. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. PX-15 20-535 (1) . 1 Mz aPrepare with starting switch OFF. • Output state (ON/OFF) to pitch control solenoid can be checked in monitoring mode. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer. • Stops outputting power to pitch control solenoid circuit. Defective steering and ST3 (female) Resistance 4 transmission controller Between (17) – (3) 20 – 30 z Between (17) – chassis ground Min. 1 Mz 52 (female) (1) with chassis ground aPrepare with starting switch OFF. 1 Mz Cause Possible causes and standard value in normal state Circuit diagram related to pitch control solenoid D65EX. 1 Mz 52 (female) (1) with wiring harness between ST3 (female) (3) – 52 (female) (2) aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DW5AKB ERROR CODE DW5AKB (PITCH CONTROL SOLENOID: SHORT CIRCUIT (KB)) Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Error code DW5AKB Controller code Steering Trouble Pitch control solenoid: Short circuit (KB) (Steering and transmission controller system) • Abnormal current flowed when power is output to pitch control solenoid circuit. • Pitch control cannot be performed. (Code 70304: Work equipment-related controller output signal) • Method of reproducing error code: Turn starting switch ON and operate pitch control switch. Defective pitch control sole52 (male) Resistance 1 noid (Internal short circuit) Between (1) – (2) 20 – 30 z Between (1) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness (with another wiring Wiring harness between ST3 (female) (17) – harness) Resistance Min.

source in wiring harness Wiring harness between ST3 (female) (18) – (Contact with 24 V circuit) Voltage Max. Defective fan reverse solenoid (Internal disconnection) FAR (male) Resistance Between (1) – (2) 34 – 44 z aPrepare with starting switch OFF. 1 z wiring or defective contact in FAR (female) (1) connector) Wiring harness between ST3 (female) (13) – Resistance Max. PX-15 . 1 V FAR (female) (1) with chassis ground aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DW7BKA ERROR CODE DW7BKA (FAN REVERSE SOLENOID: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code DW7BKA Controller code Steering Trouble Fan reverse solenoid: Disconnection (KA) (Steering and transmission controller system) • When signal is output to fan reverse solenoid circuit. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. • Stops outputting to fan reverse solenoid circuit. then turn starting switch ON and carry out troubleshooting. Defective steering and transmission controller ST3 (female) Voltage Between (18) – (13) 15 – 25 V Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to fan reverse solenoid 20-536 (1) D65EX. then carry out troubleshooting without turning starting switch ON. (Code 40914: Steering-related controller output signal) • Method of reproducing service code: Turn starting switch ON and operate fan in reverse/cooling position. • Output (ON/OFF) to fan reverse solenoid can be checked in monitoring mode. then turn starting switch ON and Short circuit with power carry out troubleshooting. any current does not flow. then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (18) – Resistance Max. 1 z FAR (female) (2) aPrepare with starting switch OFF. • The fan reversing function cannot be used.

TROUBLESHOOTING ERROR CODE DW7BKB ERROR CODE DW7BKB (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code DW7BKB Controller code Steering Trouble Fan reverse solenoid: Short circuit (KB) (Steering and transmission controller system) • When signal was output to fan reverse solenoid circuit. 1 Mz Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to fan reverse solenoid D65EX. then carry out troubleshooting without turning starting switch ON. abnormal current flowed. Short circuit in wiring harness (with another wiring Wiring harness between ST3 (female) (18) – harness) FAR (female) (1) with wiring harness between Resistance Min. Defective fan reverse soleFAR (male) Resistance noid (Internal short circuit) Between (1) – (2) 34 – 44 z Between (1) – chassis ground Min. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. • Output (ON/OFF) to fan reverse solenoid can be checked in monitoring mode. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 Mz ST3 (female) (13) – FAR (female) (2) aPrepare with starting switch OFF. 1 Mz aPrepare with starting switch OFF. • The fan reversing function cannot be used. (Code 40914: Steering-related controller output signal) • Method of reproducing service code: Turn starting switch ON and operate fan in reverse/cooling position. PX-15 20-537 (1) . Defective steering and ST3 (female) Resistance transmission controller Between (18) – (13) 34 – 44 z Between (18) – chassis ground Min. 1 Mz FAR (female) (1) with chassis ground aPrepare with starting switch OFF. • Stops outputting to fan reverse solenoid circuit. ground in wiring harness (Contact with ground circuit) Wiring harness between ST3 (female) (18) – Resistance Min.

source in wiring harness Wiring harness between ST3 (female) (35) – (Contact with 24 V circuit) Voltage Max. (Code 50603: Right HSS solenoid output current) • Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to right). then turn starting switch ON and Short circuit with power carry out troubleshooting. • Output (Current) to HSS EPC solenoid right can be checked in monitoring mode. PX-15 . travel is limited to F1 and R1. • Flashes caution lamp and turns on caution buzzer. • Once machine is stopped. 1 V HSB (female) (1) with chassis ground aPrepare with starting switch OFF. noid right (Internal disconHSB (male) Resistance nection) Between (1) – (2) 5 – 15 z aPrepare with starting switch OFF. Defective steering and transmission controller ST3 Resistance Between (35) – (3) 5 – 15 z Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to HSS EPC solenoid right 20-538 (1) D65EX. engine speed is limited to medium (half). Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. any current does not flow. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Defective HSS EPC solewithout turning starting switch ON. then carry out troubleshooting without turning starting switch ON. 1 z wiring or defective contact in HSB (female) (1) connector) Wiring harness between ST3 (female) (3) – Resistance Max. • Once machine is stopped. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (35) – Resistance Max. • Stops outputting to HSS EPC solenoid right circuit. • Limits operation of engine and transmission. 1 z HSB (female) (2) aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DWN1KA ERROR CODE DWN1KA (HSS EPC SOLENOID RIGHT: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DWN1KA Controller code Steering Trouble HSS EPC solenoid right: Disconnection (KA) (Steering and transmission controller system) • When signal is output to HSS EPC solenoid right circuit.

PX-15 20-539 (1) . • Once machine is stopped. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. (Code 50603: Right HSS solenoid output current) • Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to right). travel is limited to F1 and R1. engine speed is limited to medium (half). Defective HSS EPC soleHSB (male) Resistance noid right (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. 1 Mz HSB (female) (1) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. • Stops outputting to HSS EPC solenoid right circuit. • Output (Current) to HSS EPC solenoid right can be checked in monitoring mode. • Limits operation of engine and transmission.TROUBLESHOOTING ERROR CODE DWN1KB ERROR CODE DWN1KB (HSS EPC SOLENOID RIGHT: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DWN1KB Controller code Steering Trouble HSS EPC solenoid right: Short circuit (KB) (Steering and transmission controller system) • When signal was output to HSS EPC solenoid right circuit. Defective steering and ST3 Resistance transmission controller Between (35) – (3) 5 – 15 z Between (35) – chassis ground Min. 1 Mz ST3 (female) (3) – HSB (female) (2) aPrepare with starting switch OFF. • Once machine is stopped. 1 Mz Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to HSS EPC solenoid right D65EX. abnormal current flowed. 1 Mz aPrepare with starting switch OFF. Short circuit in wiring harness (with another wiring Wiring harness between ST3 (female) (35) – harness) HSB (female) (1) with wiring harness between Resistance Min. ground in wiring harness Wiring harness between ST3 (female) (35) – (Contact with ground circuit) Resistance Min. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON.

engine speed is limited to medium (half).TROUBLESHOOTING ERROR CODE DWN2KA ERROR CODE DWN2KA (HSS EPC SOLENOID LEFT: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DWN2KA Controller code Steering Trouble HSS EPC solenoid left: Disconnection (KA) (Steering and transmission controller system) • When signal is output to HSS EPC solenoid left circuit. noid left (Internal disconnecHSA (male) Resistance tion) Between (1) – (2) 5 – 15 z aPrepare with starting switch OFF. Defective steering and transmission controller ST3 Resistance Between (25) – (3) 5 – 15 z Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to HSS EPC solenoid left 20-540 (1) D65EX. PX-15 . then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. 1 z wiring or defective contact in HSA (female) (1) connector) Wiring harness between ST3 (female) (3) – Resistance Max. then turn starting switch ON and Short circuit with power carry out troubleshooting. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. any current does not flow. then carry out troubleshooting Defective HSS pump solewithout turning starting switch ON. • Stops outputting to HSS EPC solenoid left circuit. (Code 50602: Left HSS solenoid output current) • Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to left). • Once machine is stopped. 1 z HSA (female) (2) aPrepare with starting switch OFF. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (25) – Resistance Max. travel is limited to F1 and R1. • Once machine is stopped. 1 V HSA (female) (1) with chassis ground aPrepare with starting switch OFF. • Output (Current) to HSS EPC solenoid left can be checked in monitoring mode. • Limits operation of engine and transmission. • Flashes caution lamp and turns on caution buzzer. source in wiring harness Wiring harness between ST3 (female) (25) – (Contact with 24 V circuit) Voltage Max.

engine speed is limited to medium (half). 1 Mz Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to HSS EPC solenoid left D65EX. 1 Mz aPrepare with starting switch OFF. • Limits operation of engine and transmission. • Output (Current) to HSS EPC solenoid left can be checked in monitoring mode. • Once machine is stopped. • Stops outputting to HSS EPC solenoid left circuit. ground in wiring harness Wiring harness between ST3 (female) (25) – (Contact with ground circuit) Resistance Min.TROUBLESHOOTING ERROR CODE DWN2KB ERROR CODE DWN2KB (HSS EPC SOLENOID LEFT: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DWN2KB Controller code Steering Trouble HSS EPC solenoid left: Short circuit (KB) (Steering and transmission controller system) • When signal was output to HSS EPC solenoid left circuit. then carry out troubleshooting without turning starting switch ON. 1 Mz HSA (female) (1) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 1 Mz ST3 (female) (3) – HSA (female) (2) aPrepare with starting switch OFF. (Code 50602: Left HSS solenoid output current) • Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to left). Defective HSS EPC soleHSA (male) Resistance noid left (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. abnormal current flowed. Defective steering and ST3 (female) Resistance transmission controller Between (25) – (3) 5 – 15 z Between (25) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. PX-15 20-541 (1) . • Once machine is stopped. then carry out troubleshooting without turning starting switch ON. • Flashes caution lamp and turns on caution buzzer. travel is limited to F1 and R1. Short circuit in wiring harness (with another wiring Wiring harness between ST3 (female) (25) – harness) HSA (female) (1) with wiring harness between Resistance Min. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.

any current does not flow. 31624: Cooling fan solenoid output current) • Method of reproducing service code: Turn starting switch ON. • Stops outputting to fan pump TVC solenoid circuit. • Output (Current) to fan pump TVC solenoid can be checked in monitoring mode. 1 z 2 wiring or defective contact in FAC (female) (1) connector) Wiring harness between ST3 (female) (23) – Resistance Max. 1 V FAC (female) (1) with chassis ground aPrepare with starting switch OFF. 3 source in wiring harness Wiring harness between ST3 (female) (36) – (Contact with 24 V circuit) Voltage Max. (Code 31623. PX-15 . • Fan speed is kept at maximum level. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (36) – Resistance Max. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. 1 z FAC (female) (2) aPrepare with starting switch OFF. Defective fan pump solenoid 1 (Internal disconnection) FAC (male) Resistance Between (1) – (2) 5 – 15 z aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DWN5KA ERROR CODE DWN5KA (FAN PUMP TVC SOLENOID: DISCONNECTION (KA)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code DWN5KA Controller code Steering Trouble Fan pump TVC solenoid: Disconnection (KA) (Steering and transmission controller system) • When signal is output to fan pump TVC solenoid circuit. Defective steering and 4 transmission controller ST3 (female) Resistance Between (36) – (23) 5 – 15 z Cause Possible causes and standard value in normal state Circuit diagram related to fan pump TVC solenoid 20-542 (1) D65EX. then turn starting switch ON and Short circuit with power carry out troubleshooting. then carry out troubleshooting without turning starting switch ON.

then carry out troubleshooting without turning starting switch ON. Defective steering and ST3 (female) Resistance 4 transmission controller Between (36) – (23) 5 – 15 z Between (36) – chassis ground Min. PX-15 20-543 (1) . 1 Mz Cause Possible causes and standard value in normal state Circuit diagram related to fan pump TVC solenoid D65EX. 1 Mz ST3 (female) (23) – FAC (female) (2) aPrepare with starting switch OFF. 2 ground in wiring harness Wiring harness between ST3 (female) (36) – (Contact with ground circuit) Resistance Min. abnormal current flowed. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness (with another wiring Wiring harness between ST3 (female) (36) – harness) FAC (female) (1) with wiring harness between Resistance Min. • Stops outputting to fan pump TVC solenoid circuit.TROUBLESHOOTING ERROR CODE DWN5KB ERROR CODE DWN5KB (FAN PUMP TVC SOLENOID: SHORT CIRCUIT (KB)) Action code E01 Contents of trouble Action of controller Problem that appears on machine Related information Error code DWN5KB Controller code Steering Trouble Fan pump TVC solenoid: Short circuit (KB) (Steering and transmission controller system) • When signal was output to fan pump TVC solenoid circuit. 1 Mz FAC (female) (1) with chassis ground aPrepare with starting switch OFF. • Fan speed is kept at maximum level. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 1 Mz aPrepare with starting switch OFF. Defective fan pump solenoid FAC (male) Resistance 1 (Internal short circuit) Between (1) – (2) 5 – 15 z Between (1) – chassis ground Min. (Code 31623. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. • Output (Current) to fan pump TVC solenoid can be checked in monitoring mode. 31624: Cooling fan solenoid output current) • Method of reproducing service code: Turn starting switch ON.

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. PX-15 . Automatic shift-down function does not work. Output (Current) to 1st clutch solenoid can be checked in monitoring mode. any current does not flow.TROUBLESHOOTING ERROR CODE DXH4KA ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH4KA Controller code Steering Trouble 1st clutch ECMV: Disconnection (KA) (Steering and transmission controller system) • When signal is output to 1st clutch solenoid circuit. then carry out troubleshooting without turning starting switch ON. source in wiring harness Wiring harness between ST3 (female) (6) – (Contact with 24 V circuit) Voltage Max. Limits operation of engine and transmission. (Code 31602. travel is limited to F2 and R2. Defective steering and transmission controller ST3 (female) Resistance Between (6) – (23) 5 – 25 z Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 1st clutch ECMV 20-544 (1) D65EX. Once machine is stopped. 31612: Output current of 1st clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F1 or R1. Stops outputting to transmission 1st clutch solenoid circuit. • • • • • • • Flashes caution lamp and turns on caution buzzer. engine speed is limited to medium (half). Defective 1st clutch ECMV (Internal disconnection) 1SOL (male) Resistance Between (1) – (2) 5 – 25 z aPrepare with starting switch OFF. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (6) – Resistance Max. 1 z 1SOL (female) (2) aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. Once machine is stopped. then turn starting switch ON and Short circuit with power carry out troubleshooting. 1 V 1SOL (female) (1) with chassis ground aPrepare with starting switch OFF. 1 z wiring or defective contact in 1SOL (female) (1) connector) Wiring harness between ST3 (female) (23) – Resistance Max.

TROUBLESHOOTING ERROR CODE DXH4KB ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH4KB Controller code Steering Trouble 1st clutch ECMV: Short circuit (KB) (Steering and transmission controller system) • When signal was output to transmission 1st clutch solenoid circuit. then carry out troubleshooting without turning starting switch ON. Defective steering and ST3 (female) Resistance transmission controller Between (6) – (23) 5 – 25 z Between (6) – chassis ground Min. Once machine is stopped. Short circuit in wiring harness (with another wiring Wiring harness between ST3 (female) (6) – harness) Resistance Min. Once machine is stopped. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. ground in wiring harness (Contact with ground circuit) Wiring harness between ST3 (female) (6) – Resistance Min. (Code 31602. Limits operation of engine and transmission. Output (Current) to 1st clutch solenoid can be checked in monitoring mode. 31612: Output current of 1st clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F1 or R1. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 1 Mz 1SOL (female) (1) with wiring harness between ST3 (female) (23) – 1SOL (female) (2) aPrepare with starting switch OFF. 1 Mz Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 1st clutch ECMV D65EX. abnormal current flowed. 1 Mz aPrepare with starting switch OFF. 1 Mz 1SOL (female) (1) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. travel is limited to F2 and R2. PX-15 20-545 (1) . Defective 1st clutch ECMV 1SOL (male) Resistance (Internal short circuit) Between (1) – (2) 5 – 25 z Between (1) – chassis ground Min. • • • • • • • Flashes caution lamp and turns on caution buzzer. engine speed is limited to medium (half). Stops outputting to transmission 1st clutch solenoid circuit. Automatic shift-down function does not work.

• Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission 2nd clutch solenoid circuit. travel is limited to F1 and R1. Defective steering and transmission controller ST3 (female) Resistance Between (16) – (23) 5 – 25 z Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 2nd clutch ECMV 20-546 (1) D65EX. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (16) – Resistance Max. • Once machine is stopped. PX-15 . then turn starting switch ON and Short circuit with power carry out troubleshooting. source in wiring harness Wiring harness between ST3 (female) (16) – (Contact with 24 V circuit) Voltage Max. 31613: Output current of 2nd clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F2 or R2.TROUBLESHOOTING ERROR CODE DXH5KA ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH5KA Controller code Steering Trouble 2nd clutch ECMV: Disconnection (KA) (Steering and transmission controller system) • When signal is output to 2nd clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped. 1 V 2SOL (female) (1) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. (Code 31603. Defective 2nd clutch ECMV (Internal disconnection) 2SOL (male) Resistance Between (1) – (2) 5 – 25 z aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. 1 z wiring or defective contact in 2SOL (female) (1) connector) Wiring harness between ST3 (female) (23) – Resistance Max. any current does not flow. engine speed is limited to medium (half). • Output (Current) to 2nd clutch solenoid can be checked in monitoring mode. 1 z 2SOL (female) (2) aPrepare with starting switch OFF.

1 Mz aPrepare with starting switch OFF. ground in wiring harness (Contact with ground circuit) Wiring harness between ST3 (female) (16) – Resistance Min. • Output (Current) to 2nd clutch solenoid can be checked in monitoring mode. 1 Mz 2SOL (female) (1) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. travel is limited to F1 and R1. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 31613: Output current of 2nd clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F2 or R2. abnormal current flowed. 1 Mz Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 2nd clutch ECMV D65EX.TROUBLESHOOTING ERROR CODE DXH5KB ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH5KB Controller code Steering Trouble 2nd clutch ECMV: Short circuit (KB) (Steering and transmission controller system) • When signal was output to transmission 2nd clutch solenoid circuit. 1 Mz 2SOL (female) (1) with wiring harness between ST3 (female) (23) – 2SOL (female) (2) aPrepare with starting switch OFF. Short circuit in wiring harness (with another wiring Wiring harness between ST3 (female) (16) – harness) Resistance Min. Defective 2nd clutch ECMV 2SOL (male) Resistance (Internal short circuit) Between (1) – (2) 5 – 25 z Between (1) – chassis ground Min. (Code 31603. • Limits operation of engine and transmission. PX-15 20-547 (1) . then carry out troubleshooting without turning starting switch ON. • Once machine is stopped. • Stops outputting to transmission 2nd clutch solenoid circuit. Defective steering and ST3 (female) Resistance transmission controller Between (16) – (23) 5 – 25 z Between (16) – chassis ground Min. • Flashes caution lamp and turns on caution buzzer. engine speed is limited to medium (half). • Once machine is stopped. then carry out troubleshooting without turning starting switch ON.

travel is limited to F1 and R1. then carry out troubleshooting without turning starting switch ON. 1 z wiring or defective contact in 3SOL (female) (1) connector) Wiring harness between ST3 (female) (23) – Resistance Max. source in wiring harness Wiring harness between ST3 (female) (26) – (Contact with 24 V circuit) Voltage Max. then carry out troubleshooting without turning starting switch ON. • Once machine is stopped. 31614: Output current of 3rd clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F3 or R3. • Limits operation of engine and transmission. 1 V 3SOL (female) (1) with chassis ground aPrepare with starting switch OFF. • Output (Current) to 3rd clutch solenoid can be checked in monitoring mode. PX-15 . any current does not flow. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and Short circuit with power carry out troubleshooting. engine speed is limited to medium (half). 1 z 3SOL (female) (2) aPrepare with starting switch OFF. Defective steering and transmission controller ST3 (female) Resistance Between (26) – (23) 5 – 25 z Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 3rd clutch ECMV 20-548 (1) D65EX. (Code 31604. • Once machine is stopped. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (26) – Resistance Max. Defective 3rd clutch ECMV (Internal disconnection) 3SOL (male) Resistance Between (1) – (2) 5 – 25 z aPrepare with starting switch OFF. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission 3rd clutch solenoid circuit.TROUBLESHOOTING ERROR CODE DXH6KA ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH6KA Controller code Steering Trouble 3rd clutch ECMV: Disconnection (KA) (Steering and transmission controller system) • When signal is output to 3rd clutch solenoid circuit.

• Once machine is stopped. then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness (with another wiring Wiring harness between ST3 (female) (26) – harness) Resistance Min. 31614: Output current of 3rd clutch ECMV) • Method of reproducing service code: Start engine and drive machine in F3 or R3. • Flashes caution lamp and turns on caution buzzer. ground in wiring harness (Contact with ground circuit) Wiring harness between ST3 (female) (26) – Resistance Min. abnormal current flowed. then carry out troubleshooting without turning starting switch ON. Defective steering and ST3 Resistance transmission controller Between (26) – (23) 5 – 25 z Between (26) – chassis ground Min. • Limits operation of engine and transmission. Defective 3rd clutch ECMV 3SOL (male) Resistance (Internal short circuit) Between (1) – (2) 5 – 25 z Between (1) – chassis ground Min. travel is limited to F1 and R1. • Output (Current) to 3rd clutch solenoid can be checked in monitoring mode. 1 Mz Cause 1 Possible causes and standard value in normal state 2 3 4 Circuit diagram related to transmission 3rd clutch ECMV D65EX. (Code 31604. 1 Mz aPrepare with starting switch OFF. 1 Mz 3SOL (female) (1) with chassis ground aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. engine speed is limited to medium (half). Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. • Stops outputting to transmission 3rd clutch solenoid circuit. then carry out troubleshooting Short circuit with chassis without turning starting switch ON.TROUBLESHOOTING ERROR CODE DXH6KB ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH6KB Controller code Steering Trouble 3rd clutch ECMV: Short circuit (KB) (Steering and transmission controller system) • When signal was output to transmission 3rd clutch solenoid circuit. 1 Mz 3SOL (female) (1) with wiring harness between ST3 (female) (23) – 3SOL (female) (2) aPrepare with starting switch OFF. PX-15 20-549 (1) . • Once machine is stopped.

then carry out troubleshooting Defective reverse clutch without turning starting switch ON. 1 z RSOL (female) (2) aPrepare with starting switch OFF.TROUBLESHOOTING ERROR CODE DXH7KA ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH7KA Controller code Steering Trouble Reverse clutch ECMV: Disconnection (KA) (Steering and transmission controller system) • When signal is output to reverse clutch solenoid circuit. travel is limited to F1. engine speed is limited to medium (half). • Stops outputting to transmission reverse clutch solenoid circuit. • Output (Current) to reverse clutch solenoid can be checked in monitoring mode. then carry out troubleshooting without turning starting switch ON. • Once machine is stopped. 31616: Output current of reverse clutch ECMV) • Method of reproducing service code: Start engine and drive machine in reverse. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (37) – Resistance Max. • Flashes caution lamp and turns on caution buzzer. any current does not flow. then turn starting switch ON and Short circuit with power carry out troubleshooting. 1 V RSOL (female) (1) with chassis ground aPrepare with starting switch OFF. • Once machine is stopped. (Code 31606. 1 z 2 wiring or defective contact in RSOL (female) (1) connector) Wiring harness between ST3 (female) (13) – Resistance Max. 3 source in wiring harness Wiring harness between ST3 (female) (37) – (Contact with 24 V circuit) Voltage Max. then carry out troubleshooting without turning starting switch ON. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. PX-15 . 1 ECMV (Internal disconnecRSOL (male) Resistance tion) Between (1) – (2) 5 – 25 z aPrepare with starting switch OFF. • Limits operation of engine and transmission. Defective steering and 4 transmission controller ST3 (female) Resistance Between (37) – (13) 5 – 25 z Cause Possible causes and standard value in normal state Circuit diagram related to transmission reverse clutch ECMV 20-550 (1) D65EX.

then carry out troubleshooting without turning starting switch ON. 1 Mz aPrepare with starting switch OFF. 31616: Output current of reverse clutch ECMV) • Method of reproducing service code: Start engine and drive machine in reverse. PX-15 20-551 (1) . Defective reverse clutch RSOL (male) Resistance 1 ECMV (Internal short circuit) Between (1) – (2) 5 – 25 z Between (1) – chassis ground Min. 2 ground in wiring harness (Contact with ground circuit) Wiring harness between ST3 (female) (37) – Resistance Min. travel is limited to F1. • Output (Current) to reverse clutch solenoid can be checked in monitoring mode. (Code 31606. 1 Mz Cause Possible causes and standard value in normal state Circuit diagram related to transmission reverse clutch ECMV D65EX. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 1 Mz RSOL (female) (1) with wiring harness between ST3 (female) (13) – RSOL (female) (2) aPrepare with starting switch OFF. abnormal current flowed.TROUBLESHOOTING ERROR CODE DXH7KB ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB)) Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH7KB Controller code Steering Trouble Reverse clutch ECMV: Short circuit (KB) (Steering and transmission controller system) • When signal was output to transmission reverse clutch solenoid circuit. • Stops outputting to transmission reverse clutch solenoid circuit. Defective steering and ST3 (female) Resistance 4 transmission controller Between (37) – (13) 5 – 25 z Between (37) – chassis ground Min. 1 Mz RSOL (female) (1) with chassis ground aPrepare with starting switch OFF. • Flashes caution lamp and turns on caution buzzer. • Limits operation of engine and transmission. engine speed is limited to medium (half). Short circuit in wiring har3 ness (with another wiring Wiring harness between ST3 (female) (37) – harness) Resistance Min. • Once machine is stopped. • Once machine is stopped. then carry out troubleshooting without turning starting switch ON.

TROUBLESHOOTING

ERROR CODE DXH8KA

ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH8KA Controller code Steering Trouble Forward clutch ECMV: Disconnection (KA) (Steering and transmission controller system)

• When signal is output to forward clutch solenoid circuit, any current does not flow. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission forward clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output current of forward clutch ECMV) • Method of reproducing service code: Start engine and drive machine forward. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward clutch ECMV (Internal short circuit) FSOL (male) Resistance Between (1) – (2) 5 – 25 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (27) – Resistance Max. 1 z wiring or defective contact in FSOL (female) (1) connector) Wiring harness between ST3 (female) (13) – Resistance Max. 1 z FSOL (female) (2) aPrepare with starting switch OFF, then turn starting switch ON and Short circuit with power carry out troubleshooting. source in wiring harness Wiring harness between ST3 (female) (27) – (Contact with 24 V circuit) Voltage Max. 1 V FSOL (female) (1) with chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering and transmission controller ST3 (female) Resistance Between (27) – (13) 5 – 25 z Cause

1

Possible causes and standard value in normal state

2

3

4

Circuit diagram related to transmission forward clutch ECMV

20-552
(1)

D65EX, PX-15

TROUBLESHOOTING

ERROR CODE DXH8KB

ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH8KB Controller code Steering Trouble Forward clutch ECMV: Short circuit (KB) (Steering and transmission controller system)

• When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed. • Flashes caution lamp and turns on caution buzzer. • Stops outputting to transmission forward clutch solenoid circuit. • Limits operation of engine and transmission. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1. • Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output current of forward clutch ECMV) • Method of reproducing service code: Start engine and drive machine forward. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward clutch FSOL (male) Resistance 1 ECMV (Internal short circuit) Between (1) – (2) 5 – 25 z Between (1) – chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 2 ground in wiring harness (Contact with ground circuit) Wiring harness between ST3 (female) (27) – Resistance Min. 1 Mz FSOL (female) (1) with chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness (with another wiring Wiring harness between ST3 (female) (27) – harness) Resistance Min. 1 Mz FSOL (female) (1) with wiring harness between ST3 (female) (13) – FSOL (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering and ST3 (female) Resistance 4 transmission controller Between (27) – (13) 5 – 25 z Between (27) – chassis ground Min. 1 Mz Cause

Possible causes and standard value in normal state

Circuit diagram related to transmission forward clutch ECMV

D65EX, PX-15

20-553
(1)

TROUBLESHOOTING

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)

Information described in troubleshooting list ........................................................................................... E- 1 The engine does not start .............................................................................................................. E- 2 The preheater does not operate. ................................................................................................... E- 3 The monitor panel does not come on at all when the starting switch is turned on. ....................... E- 4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out. ...................................................................................................................... E- 5 While the engine is operating, the battery charge level caution lamp flashes. ............................... E- 6 While the engine is operating, the emergency warning item flashes. ............................................ E- 7 While the preheater is operating, the preheating pilot lamp does not come on. ............................ E- 8 The engine water temperature gauge does not indicate normally. ................................................ E- 9 Indication of the power train temperature gauge is abnormal. ....................................................... E-10 The hydraulic oil temperature gauge does not indicate normally. .................................................. E-11 Indication of the fuel gauge is abnormal. ....................................................................................... E-12 Indications of gear speed and engine speed are abnormal. .......................................................... E-13 Indication of the preset mode service meter is abnormal. ............................................................. E-14 The warning lamp does not flash or does not go out. .................................................................... E-15 The alarm buzzer does not sound or does not stop. ...................................................................... E-16 Auto shift down is not possible or is not released. ......................................................................... E-17 The buzzer cancel switch does not work. ...................................................................................... E-18 The information switch does not work. ........................................................................................... E-19 The preset mode does not operate or cannot be reset. ................................................................. E-20 The monitor panel cannot be set in the service mode or cannot be set out of the service mode. . E-21 The back-up alarm does not sound. .............................................................................................. E-22 The head lamp and rear lamp do not light up. ............................................................................... E-23 Malfunction of wipers ..................................................................................................................... E-24 Washing water does not come out. ................................................................................................ E-25 The air conditioner does not operate. ............................................................................................

20-602 20-603 20-606 20-608 20-609 20-610 20-612 20-615 20-617 20-618 20-619 20-620 20-621 20-621 20-621 20-622 20-623 20-624 20-625 20-626 20-627 20-629 20-630 20-632 20-648 20-653

D65EX, PX-15

20-601
(1)

TROUBLESHOOTING

INFORMATION DESCRIBED IN TROUBLESHOOTING LIST

INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
a Troubleshooting lists and related circuit diagrams contain the following information all together. Understand the contents carefully and troubleshoot the machine.
Trouble Related information Problem that appears on the machine. Information related to problems occurred or troubleshooting Cause Standard value in normal state/Remarks on troubleshooting <Described contents> • Standard value in normal state required to judge the assumed cause (good or not) • Remarks required to judge whether the cause is good 1 <Phenomenon of defective harness> • Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. • Grounding fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit. • Defective hot short A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit. • Defective short A harness of an independent circuit abnormally comes into contact with one of another circuit.

2 Possible causes and standard value in normal state

Cause by which a trouble is assumed to be detected (The order number indicates a serial number, not a priority <Notes on troubleshooting> sequence.) (1) Method of indicating connector numbers and handling T-junction For troubleshooting, insert or connect the T-junction adapter as shown below unless especially specified. 3 • When “male” or “female” is not indicated for a connector number, disconnect the connector, and insert the T-junction adapter in both the male and female. • When “male” or “female” is indicated for a connector number, disconnect the connector, and insert the T-junction adapter in only either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless especially specified. 4 • Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus (–) lead to a pin or harness indicated in the rear.

Related circuit diagram

This is the excerpted circuit diagram related to trouble • Connector No.: Indicates (Model-No. of pins) (Color). • Arrow ( ): Roughly indicates mounting place on machine.

20-602
(1)

D65EX, PX-15

TROUBLESHOOTING

E-1

E-1 THE ENGINE DOES NOT START
Trouble Related information • The engine does not start. • The engine start circuit has the neutral safety function, and the engine does not start unless the parking lever is set to the lock position or the travel lever is in the neutral position. • If “the monitor panel does not come on” or “the battery relay does not cause operating sound” when the starting switch is set to ON, the main electric power supply system is supposed to be out of order. So, inspect the main electric power supply system. Cause 1 Insufficient battery capacity Standard value in normal state/Remarks on troubleshooting Battery voltage Battery specific gravity Min. 25 V Min. 1.26 aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Starting switch Switch position Resistance OFF Min. 1 Mz Between 250 (B) and 280 (C) START Max. 1 z aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Parking lever Free position Lock position Monitor panel Other than “P” is “P” is displayed displayed aPrepare with the starting switch OFF, then start the engine and carry out troubleshooting. If the engine starts in accordance with the engine starting arrangement after the neutral safety relay (NSF) is replaced with another one while the starting switch is set to OFF, the relay is defective. aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Alternator Voltage Between Terminal R and ground Max. 12 V aPrepare with the starting switch OFF, then start the engine and carry out troubleshooting. Starting motor Voltage Electric power supply: between 20 – 30 V Terminal B and ground Charge: between ST (2) and Max. 12 V ground Starting: between ST (1) and 20 – 30 V ground When the voltages of electric power supply, for charging and starting are normal but the starting motor does not rotate, the starting motor is defective. aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between 280 (C) and NFS (feResistance Max. 1 z male) (3) Wiring harness between NSF (female) (5) and Resistance Max. 1 z ST (female) (1) Wiring harness between NSF (female) (5) and Resistance Max. 1 z EN1 (female) (20)

2

Defective starting switch (internal disconnection)

Defective parking lever 3 switch (Internal trouble defect or defective adjustment)

4

Defective neutral safety relay (internal disconnection)

Possible causes and standard value in normal state

5

Defective alternator (internal short circuit)

6

Detective starting motor (internal defect)

Disconnection in wiring harness (disconnection in 7 wiring or defective contact in connector)

D65EX, PX-15

20-603
(1)

TROUBLESHOOTING

E-1

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Hot short circuit of wiring 8 harness (Contact with 24 V Wiring harness between alternator R terminal circuit) and ST (female) (2) or ST1 (female) (15) or Voltage Max. 1 V S04 (female) (9) with ground aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between 280 (C) – NSF (feResistance Min. 1 Mz Short circuit with chassis male) (3) and chassis ground 9 ground in wiring harness Wiring harness between NSF (female) (5) – ST (Contact with ground circuit) Resistance Min. 1 Mz (female) (1) and chassis ground Wiring harness between NSF (female) (5) – Resistance Min. 1 Mz EN1 (female) (20) and chassis ground

Cause

20-604
(1)

D65EX, PX-15

TROUBLESHOOTING

E-1

Engine start/charge-related circuit diagram

D65EX, PX-15

20-605
(1)

TROUBLESHOOTING

E-2

E-2 THE PREHEATER DOES NOT OPERATE.
Trouble • The preheater does not operate. aThis troubleshooting describes the procedures to be followed when the manual preheating function cannot heat the electrical intake air heater mounting section. (When the preheating lamp only does not come on, carry out the troubleshooting of “The preheating lamp does not come on”.) • For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are available. When either function is performed, the preheating lamp comes on. • If “the monitor panel does not come on” or “the battery relay does not cause operating sound” hen the starting switch is turned ON, the main electric power supply system supposed to be out of order. So, inspect the main electric power supply system. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Starting switch Switch position Resistance OFF Min. 1 Mz Between 250 (B) and 280 (C) HEAT Max. 1 z If fuse is broken, circuit probably has a grounding fault, etc.

Related information

1

Defective starting switch (Internal disconnection)

2

Defective fuse (FUSE, FS1, 2)

3

4

Possible causes and standard value in normal state

5

6

7

aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective preheater relay Disconnect coolant sensor TWL with starting switch OFF and replace (Internal disconnection) preheater relay with another one, and then turn starting switch ON. If preheating is started, preheater relay RHR is defective. aPrepare with the starting switch OFF, then set the starting switch to HEAT and carry out troubleshooting. Heater relay Voltage Electric power supply: between 20 – 30 V Defective heater relay Terminal HT/B (B) and ground (internal defect) Signal: between Terminal 20 – 30 V HT/S (C) and ground When the both voltages of electric power supply and signal are normal and no operating sound is caused, the heater relay is defective. aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective electrical intake air Electrical intake air heater Continuity heater (internal defect) Between terminals Continue aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between starting switch 255 Resistance Max. 1 z (R1) and RHR (female) (3) and HT/S (C) Disconnection in wiring harness (Disconnection in Wiring harness between RHR (female) (5) – Resistance Max. 1 z wiring or defective contact in FS1 (7) connector) Wiring harness between battery relay and CN-C Resistance Max. 1 z and ST/B and HT/B Wiring harness between heater relay HT/A (A) Resistance Max. 1 z terminal and electrical intake air heater aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between starting switch 255 Resistance Min. 1 Mz (R1) – RHR (3) – HT/S (C) terminal and ground Short circuit with chassis Wiring harness between RHR (female) (5) – Resistance Min. 1 Mz ground in wiring harness FS1 (7) and ground (Contact with ground circuit) Wiring harness between battery relay C – Resistance Min. 1 Mz ST/B terminal – HT/B and ground Wiring harness between heater relay HT/A – Resistance Min. 1 Mz intake air heater terminal and ground

20-606
(1)

D65EX, PX-15

TROUBLESHOOTING

E-2

Engine preheat-related circuit diagram

D65EX, PX-15

20-607
(1)

TROUBLESHOOTING

E-3

E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON.
Trouble Related information • If “operation sound of the battery is not heard” when the starting switch is turned ON, the main power supply system may be defective. Accordingly, check the may power supply system. • The monitor panel does not come on at all when the starting switch is turned ON. • When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge section and the lamp section come on for approximately 2 sec. and go out. Standard value in normal state/Remarks on troubleshooting When the fuse FS2-(6) is cut off, the circuit may have possibly been Defective fuse FS2-(6) short-circuited with ground. aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection of wiring harness (Disconnection in Wiring harness between S03 (female) (1) (2) Resistance Max. 1 z wiring or defective contact in and fuse FS2-(6) connector) Wiring harness between S03 (female) (3) (4) Resistance Max. 1 z and GND01 and ground aPrepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring without turning the starting switch ON. harness (Contact with Wiring harness between S03 (female) (1), (2) ground circuit) Resistance Min. 1 Mz – fuse FS2-(6) with ground aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel S03 Voltage Between (1) (2) and (3) (4) 20 – 30 V Cause

1

2 Possible causes and standard value in normal state 3

4

Circuit diagram related to ripper pin puller solenoid

20-608
(1)

D65EX, PX-15

TROUBLESHOOTING

E-4

E-4 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
Trouble Related information Possible causes and standard value in normal state • When the starting switch is turned ON, the monitor panel completely remains lighted and does not go out. • When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge section and the lamp section come on for approximately 2 sec. and go out. Cause 1 Defective monitor panel Standard value in normal state/Remarks on troubleshooting This internal defect cannot be diagnosed.

D65EX, PX-15

20-609
(1)

TROUBLESHOOTING

E-5

E-5 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES.
Trouble Related information • The battery charge level caution lamp flashes. • When any abnormality is detected during engine operation, the battery charge level caution lamp will flash. Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then start the engine and carry out troubleshooting. Defective alternator (insuffiAlternator Engine speed Voltage cient power generation) Between Terminal R Min. medium speed 20 – 30 V and ground (half) aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection of wiring harness (Disconnection in Wiring harness between S04 (female) (9) and Resistance Max. 1 z wiring or defective contact in alternator R terminal connector) Between wiring harness AL/F and GND03 and Resistance Max. 1 z ground aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring harness (Contact with Between wiring harness (between S04 (female) ground circuit) Resistance Min. 1 Mz (9) and alternator R terminal, or STC1 (1) (female) (15)) and ground aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel S04 Engine speed Voltage Between (9) and Medium speed (half) 20 – 30 V ground Cause

1

Possible causes and standard value in normal state

2

3

4

20-610
(1)

D65EX, PX-15

TROUBLESHOOTING

E-5

Engine start/charge-related circuit diagram

D65EX, PX-15

20-611
(1)

TROUBLESHOOTING

E-6

E-6 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES.
Trouble (1) • The engine oil pressure caution lamp flashes. • When any abnormality is detected during engine operation, the engine oil pressure caution lamp will flash and sound the alarm buzzer. • The engine oil pressure switch signal is sent and received from the engine controller through communication. • Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode. (Code 40900: Engine controller input signal 1) Cause Standard value in normal state/Remarks on troubleshooting Drop of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is de1 (when the system is normal) tected. aPrepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the engine. The engine oil low pressure PSL Engine Resistance 2 switch is defective. (Internal short circuit) Stop Max. 1 z Between terminal and ground Min. 600 rpm Min. 1 Mz aPrepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the engine. The engine oil high pressure PSH Engine Resistance 3 switch is defective. (Internal short circuit) Stop Max. 1 z Between terminal and ground Min. 1,300 rpm Min. 1 Mz aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring Between wiring harness (between EN1 (female) Resistance Min. 1 Mz 4 harness (Contact with (21) and PSL) and ground ground circuit) Between wiring harness (between EN1 (female) Resistance Min. 1 Mz (15) and PSH) and ground aPrepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the engine. EN1 Engine Voltage Stop Max. 1 V 5 Defective engine controller Between (21) and ground Min. 600 rpm 5 – 11 V Stop Max. 1 V Between (15) and ground Min. 1,300 rpm 5 – 11 V 6 Defective monitor panel This is an internal defect, which cannot be troubleshot.

Related information

Possible causes and standard value in normal state

Circuit diagram related to engine oil low pressure switch and engine oil high pressure switch

20-612
(1)

D65EX, PX-15

TROUBLESHOOTING

E-6

Trouble (2)

Related information

• The engine water temperature caution lamp flashes. • When any abnormality is detected during engine operation, the engine water temperature caution lamp will flash and sound the alarm buzzer. • The engine water temperature caution lamp flashes or goes out as it links with indication on the engine water temperature gauge. • Input state (temperature) from engine water temperature (high temperature side) sensor can be checked in monitoring mode. (Code 04102: Engine water temperature (high temperature side)) Cause Overheated engine water 1 temperature (when the system is normal) Standard value in normal state/Remarks on troubleshooting As overheated engine water was detected, check the engine water temperature. (When the water temperature is over 108ºC, the lamp flashes.) Check the indication on the engine water temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the engine water temperature gauge is abnormal”. aWater temperatures are guides for selecting indications.

Possible causes and standard value in normal state

The engine water temperature sensor system is 2 defective. (Engine controller system)

Water temperature gauge

3 Defective monitor panel

Red range Goes out. Flashes. When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.) Water temperature lamp
White range/Green range

Trouble (3)

Related information

• The power train oil temperature caution lamp flashes. • When any abnormality is detected during engine operation, the power tlain oil temperature caution lamp will flash and sound the alarm buzzer. • The power train oil temperature caution lamp flashes or goes out as it links with indication on the power train oil temperature gauge. • Input state (temperature) from power train oil temperature sensor can be checked in monitoring mode. (Code 30100: Torque converter oil temperature) Cause Standard value in normal state/Remarks on troubleshooting Overheated oil temperature As an overheated power train oil temperature was detected, check the 1 of power train (when the power train oil temperature. (When the oil temperature is over 130ºC, system is normal) the lamp flash and sound the buzzer, over 120ºC, the lamp flashes.) Check the indication on the power train oil temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the power train oil temperature gauge is abnormal”. aOil temperatures are guides for selecting indications. The power train oil tempera2 ture sensor system is defective. (Monitor panel system)

Possible causes and standard value in normal state

Oil temperature gauge

3 Defective monitor panel

Red range Goes out. Flashes. When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.) Oil temperature lamp
White range/Green range

D65EX, PX-15

20-613
(1)

TROUBLESHOOTING

E-6

Trouble (4)

Related information

• The hydraulic oil temperature caution lamp flashes. • When any abnormality is detected during engine operation, the hydraulic oil temperature caution lamp will flash and sound the alarm buzzer. • The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydraulic oil temperature gauge. • Input state (temperature) from hydraulic oil temperature sensor can be checked in monitoring mode. (Code 04401: Hydraulic oil temperature) Cause Overheated hydraulic oil 1 temperature (when the system is normal) Standard value in normal state/Remarks on troubleshooting As an overheated hydraulic oil temperature was detected, check the hydraulic oil temperature. (When the oil temperature is over 130ºC, the lamp flash and sound the buzzer, over 120ºC, the lamp flashes.) Check the indication on the engine water temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the hydraulic oil temperature gauge is abnormal”. aOil temperatures are guides for selecting indications.

Possible causes and standard value in normal state

The hydraulic oil tempera2 ture sensor system is defective. (Monitor panel system)

Oil temperature gauge

3 Defective monitor panel

Red range Goes out. Flashes. When Causes 1 and 2 are not applicable, the monitor panel is supposed to be defective. (This is an internal defect, which cannot be troubleshot.) Oil temperature lamp
White range/Green range

20-614
(1)

D65EX, PX-15

TROUBLESHOOTING

E-7

E-7 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON.
Trouble Related information • While the preheater is operating, the preheating pilot lamp does not come on. aThis troubleshooting describes the procedures to be followed when the preheating lamp doe not come on. (When the preheater mounting section is not heated, carry out the troubleshooting of “The preheater does not work”.) • For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are available. Even when either function is performed, the preheating lamp comes on. Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring without turning the starting switch ON. harness (Disconnection in 1 wiring or defective contact in Wiring harness between S03 (female) (9) and Resistance Max. 1 z connector) heater relay HT/A (A) terminal aPrepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring without turning the starting switch ON. 2 harness (Contact with Wiring harness between S03 (female) (9) and ground circuit) Resistance Min. 1 Mz heater relay HT/A (A) terminal and ground aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. S03 Voltage 3 Defective monitor panel ON Max. 1 V Between (9) and ground R1 Min. 7 V Cause

Possible causes and standard value in normal state

D65EX, PX-15

20-615
(1)

TROUBLESHOOTING

E-7

Engine preheat-related circuit diagram

20-616
(1)

D65EX, PX-15

1 z and TWH (female) (2) aPrepare with the starting switch OFF. 1 Mz (27) and TWH (female) (1)) and ground aPrepare with the starting switch OFF. then carry out troubleshooting without turning the starting switch ON. Wiring harness between EN2 (female) (27) Resistance Max. Disconnection of wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and standard value in normal state Ground fault of wiring 3 harness (Contact with ground circuit) Hot short circuit of wiring 4 harness (Contact with 24 V circuit) 5 Defective engine controller 6 Defective monitor panel Circuit diagram related to engine water high temperature sensor D65EX. Cause The engine water high temperature sensor is defective. then carry out troubleshooting without turning the starting switch ON.TROUBLESHOOTING E-8 E-8 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY. then carry out troubleshooting without turning the starting switch ON. 1 V (27) and TWH (female) (1)) and ground Wiring harness between EN2 (female) (39) – Voltage Max. EN2 (female) Resistance Between (27) and (39) 3. 1 z and TWH (female) (1) Wiring harness between EN2 (female) (39) Resistance Max. PX-15 20-617 (1) . 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. 1 V TWH (female) (2) and ground aPrepare with the starting switch OFF. 1 Mz aPrepare with the starting switch OFF.5 k – 90 kz (10 – 100ºC) This is an internal defect. Between wiring harness (between EN2 (female) Voltage Max. • When any abnormality occurred in the engine hot water temperature sensor system. then carry out troubleshooting without turning the starting switch ON. which cannot be troubleshot.5 k – 90 kz (10 – 100ºC) Between (1) (2) and ground Min. Between wiring harness (between EN2 (female) Resistance Min. TWH (male) Resistance Between (1) and (2) 3. Trouble (1) Related information • The engine water temperature gauge does not indicate normally. the failure code [DGE2KX] is displayed sometimes. • Signals of the engine water high temperature sensor are sent and received from the engine controller through communication. then turn the starting switch ON and carry out troubleshooting.

then carry out troubleshooting without turning the starting switch ON. Disconnection of wiring harness (Disconnection in Wiring harness between S04 (female) (12) and Resistance Max. 1 Mz ground aPrepare with the starting switch OFF.5 k – 90 kz short circuit) 10 – 100ºC Between (1) and Min. then carry out troubleshooting without turning the starting switch ON. then carry out troubleshooting without turning the starting switch ON. 1 z S03 (female) (3) aPrepare with the starting switch OFF. 3 harness (Contact with Between wiring harness (between S04 (female) ground circuit) Resistance Min. Torque converter oil 5 Defective monitor panel S04 (female) Resistance temperature Between (12) and 10 – 100ºC 3. Trouble Related information • Indication of the power train temperature gauge is abnormal. temperature 1 (Internal disconnection or Between (1) and (2) 3. PX-15 . then carry out troubleshooting Ground fault of wiring without turning the starting switch ON.5 k – 90 kz ground Cause Possible causes and standard value in normal state Circuit diagram related to power train oil temperature sensor 20-618 (1) D65EX. then turn the starting switch ON and carry out troubleshooting. The power train oil temperaTorque converter oil 453 (male) Resistance ture sensor is defective. 1 V (12) and 453 (female) (1)) and ground circuit) Wiring harness between 453 (female) (2) – Voltage Max. Hot short circuit of wiring Between wiring harness (between S04 (female) 4 harness (Contact with 24 V Voltage Max. 1 V S03 (female) (3) and ground aPrepare with the starting switch OFF. 1 Mz (12) and 453 (female) (1)) and ground aPrepare with the starting switch OFF.TROUBLESHOOTING E-9 E-9 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL. • Signals of the power train oil temperature sensor are sent and received through communication by the monitor panel. Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. 1 z 2 wiring or defective contact in 453 (female) (1) connector) Wiring harness between 453 (female) (2) and Resistance Max.

which cannot be troubleshot. then carry out troubleshooting without turning the starting switch ON. Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. PX-15 20-619 (1) . then carry out troubleshooting The hydraulic oil temperawithout turning the starting switch ON. then carry out troubleshooting Ground fault of wiring without turning the starting switch ON. then turn the starting switch ON and carry out troubleshooting. the failure code [DGS1KX] is displayed sometimes. • When any abnormality occurred in the hydraulic oil temperature sensor system. 1 z 2 wiring or defective contact in SDS (female) (1) connector) Wiring harness between ST1 (female) (21) and Resistance Max. then carry out troubleshooting without turning the starting switch ON. 1 Mz (9) and SDS (female) (1)) and ground aPrepare with the starting switch OFF. Cause Possible causes and standard value in normal state Circuit diagram related to hydraulic oil temperature sensor D65EX.5 k – 90 kz short circuit) Between (1) and ground Min. Hot short circuit of wiring Between wiring harness (between ST1 (female) 4 harness (Contact with 24 V Voltage Max. SDS (male) Resistance 1 (Internal disconnection or Between (1) and (2) 3.TROUBLESHOOTING E-10 E-10 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY. Disconnection of wiring harness (Disconnection in Wiring harness between ST1 (female) (9) and Resistance Max. 1 V (9) and SDS (female) (1)) and ground circuit) Wiring harness between ST1 (female) (21) – Voltage Max. • Signals of the hydraulic oil temperature sensor are received from the steering and transmission controller through communication. 1 V SDS (female) (2) and ground aPrepare with the starting switch OFF. 1 z SDS (female) (2) aPrepare with the starting switch OFF. ture sensor is defective. Defective transmission 5 controller ST1 (female) Resistance Between (9) and (21) 3. 1 Mz aPrepare with the starting switch OFF.5 k – 90 kz 6 Defective monitor panel This is an internal defect. 3 harness (Contact with Between wiring harness (between ST1 (female) ground circuit) Resistance Min. Trouble Related information • The hydraulic oil temperature gauge does not indicate normally.

1 z 2 wiring or defective contact in 423 (female) (1) connector) Wiring harness between 423 (female) (2) – Resistance Max. Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. (4) and ground 5 Defective monitor panel This is an internal defect. Defective fuel level sensor. then carry out troubleshooting without turning the starting switch ON. 3 harness (Contact with Between wiring harness (between S04 (female) ground circuit) Resistance Min. (4) with ground aPrepare with the starting switch OFF. 423 (male) Remained fuel level Resistance 1 (Internal disconnection or short circuit) Full About 4 z Between (1) and (2) (ground) Empty About 85 z aPrepare with the starting switch OFF. 1 V S03 (female) (3). PX-15 . 1 z S03 (female) (3). then carry out troubleshooting Ground fault of wiring without turning the starting switch ON. 1 V (10) and 423 (female) (1)) and ground circuit) Wiring harness between 423 (female) (2) – Voltage Max. Cause Possible causes and standard value in normal state Circuit diagram related to fuel level sensor 20-620 (1) D65EX.TROUBLESHOOTING E-11 E-11 INDICATION OF THE FUEL GAUGE IS ABNORMAL. then turn the starting switch ON and carry out troubleshooting. which cannot be troubleshooting. Trouble Related information • Indication of the fuel gauge is abnormal. 1 Mz (10) and 423 (female) (1)) and ground aPrepare with the starting switch OFF. Disconnection of wiring harness (Disconnection in Wiring harness between S04 (female) (10) and Resistance Max. • Signals of the fuel level sensor are sent and received through communication by the monitor panel. Hot short circuit of wiring Between wiring harness (between S04 (female) 4 harness (Contact with 24 V Voltage Max. then carry out troubleshooting without turning the starting switch ON.

(Gauge or lamp module) Cause Possible causes and standard value in normal state Trouble (2) Related information Possible causes and standard value in normal state • Shift mode and service meter are not displayed at all.TROUBLESHOOTING E-12. Trouble Related information Possible causes and standard value in normal state • Indications of gear speed and engine speed are abnormal. which cannot be troubleshot. Cause 1 Defective monitor panel Standard value in normal state/Remarks on troubleshooting This is an internal defect. Cause 1 Defective monitor panel Standard value in normal state/Remarks on troubleshooting This is an internal defect. Standard value in normal state/Remarks on troubleshooting When the battery charge level caution lamp flashes during engine opDefective alternator signals 1 eration. system caution items flash”. E-14 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT. Defective monitor panel 2 This is an internal defect. which cannot be troubleshot. • Signals of gear speed and engine speed are sent and received through communication by the monitor panel. E-14 E-12 E-12 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL. • The display data of the preset mode and service meter are sent and received through communication by the steering and transmission controller. Cause 1 Defective monitor panel Standard value in normal state/Remarks on troubleshooting This is an internal defect. carry out the troubleshooting of “While the engine is operating. the service meter does not advance. Trouble (1) Related information • During engine operation. which cannot be troubleshot. which cannot be troubleshot. D65EX. PX-15 20-621 (1) . E-13. • The service meter measures time while the monitor panel is receiving engine drive signals (alternator signals). Trouble Related information Possible causes and standard value in normal state • The warning lamp does not flash or does not go out. E-13 INDICATION OF THE PRESET MODE SERVICE METER IS ABNORMAL. • The display data are sent and received through communication by the steering and transmission controller.

1 z wiring or defective contact in 217 (female) (1) connector) Wiring harness between 217 (female) (2) and Resistance Max. Trouble Related information • The alarm buzzer does not sound or does not stop. 1 z FS2-(6) aPrepare with the starting switch OFF. then turn the starting switch ON and carry out troubleshooting. Defective alarm buzzer 217 (male) Resistance (Internal disconnection or short circuit) Between (2) and (1) Min.TROUBLESHOOTING E-15 E-15 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP. 3 V 2 Possible causes and standard value in normal state 3 4 5 Circuit diagram related to alarm buzzer 20-622 (1) D65EX. 1 Mz harness (Contact with male) (2) with ground ground circuit) Wiring harness between 217 (female) (1) – Resistance Min. PX-15 . Cause Defective circuit breaker 1 fuse FS2-(6) Standard value in normal state/Remarks on troubleshooting When the fuse FS2-(6) is cut off. • When a short circuit occurs in the alarm buzzer system. 1 Mz aPrepare with the starting switch OFF. Disconnection of wiring harness (Disconnection in Wiring harness between S03 (female) (18) and Resistance Max. then carry out troubleshooting without turning the starting switch ON. a ground fault may have possibly occurred in the circuit. then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring Wiring harness between FS2-(6) – 217 (feResistance Min. 1 Mz S03 (female) (18) and ground aPrepare with the starting switch OFF. the failure code is displayed but no other failure codes are displayed. 1 kz Between (1). Defective monitor panel S03 Alarm buzzer Voltage (Gauge/lamp module) At stop 20 – 30 V Between (18) and ground At operation (sounding) Max. (2) and ground Min. then carry out troubleshooting without turning the starting switch ON. aPrepare with the starting switch OFF.

then carry out troubleshooting without turning the starting switch ON.TROUBLESHOOTING E-16 E-16 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED. 1 Mz Between (2) and (3) ON (1) Max. the steering and transmission controller controller may be restricting the function because of other causes. wiring harness (Contact with Between wiring harness (between ST2 (female) ground circuit) Resistance Min. Defective auto shift down ASD (male) Auto shift down switch Resistance switch (Internal disconnection or short circuit) OFF (0) Min. 1 2 Possible causes and standard value in normal state 3 4 5 Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. Disconnection of wiring harness (Disconnection in Wiring harness between ST2 (female) (37) and Resistance Max. 1 z ground aPrepare with the starting switch OFF. 1 z aPrepare with the starting switch OFF. OFF (0) 5 – 11 V (32). (31). Cause Circuit diagram related to auto shift down switch D65EX. Defective steering and Voltage Between ST2 (37) Auto shift down switch transmission controller and ST3 (21). 1 V Restriction of function by When Causes 1 to 4 are not applicable. then turn the starting switch Ground steering and fault of ON and carry out troubleshooting. then turn the starting switch ON and carry out troubleshooting. 1 z wiring or defective contact in ADS (female) (2) connector) Wiring harness between ADS (female) (3) and Resistance Max. PX-15 20-623 (1) . (33) ON (1) Max. then carry out troubleshooting without turning the starting switch ON. Trouble Related information • Auto shift down is not possible or is not released. 1 Mz (37) and ASD (female) (2)) and ground aPrepare with the starting switch OFF.

1 z GND04 aPrepare with the starting switch OFF. 1 Mz Between (1) and (3) Max. PX-15 . 1 z t OFF (0) Min. then carry out troubleshooting without turning the starting switch ON. Steering and Buzzer cancel switch Voltage transmission controller Defective steering and Between ST2 (female) OFF (0) 5 – 11 V transmission controller (36) and ST3 (female) Max. 1 Mz and BUZ (female) (3)) and ground aPrepare with the starting switch OFF. (32). (33) Cause Circuit diagram related to buzzer cancel switch 20-624 (1) D65EX. (33) Between ST2 (female) OFF (0) 5 – 11 V (26) and ST3 (female) Max. Disconnection of wiring Wiring harness between ST2 (36) and BUZ Resistance Max. 1 z U aPrepare with the starting switch OFF. (32). 1 Mz and BUZ (female) (2)) and ground ground circuit) Between wiring harness (between ST2 (26) Resistance Min. Ground fault of wiring Between wiring harness (between ST2 (36) harness (Contact with Resistance Min. then carry out troubleshooting without turning the starting switch ON. 1 z harness (Disconnection in (female) (2) wiring or defective contact in Wiring harness between ST2 (26) and BUZ Resistance Max. then turn the starting switch ON and carry out the troubleshooting. Trouble Related information • The buzzer cancel switch does not work. 1 z connector) (female) (3) Wiring harness between BUZ (female) (1) and Resistance Max. (31). 1 Mz switch (Internal disconnecBetween (1) and (2) tion or short circuit) Max. 1 V t (21).TROUBLESHOOTING E-17 E-17 THE BUZZER CANCEL SWITCH DOES NOT WORK. BUZ (male) Buzzer cancel switch Resistance Defective buzzer cancel OFF (0) Min. 1 2 Possible causes and standard value in normal state 3 4 Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. then carry out troubleshooting without turning the starting switch ON. 1 V U (21). (31).

Steering controller Buzzer cancel switch Voltage Defective steering and Between ST2 (16) OFF (0) 5 – 11 V 4 transmission controller and ST3 (21). 1 Mz CUR (female) (3)) and ground aPrepare with the starting switch OFF. then carry out troubleshooting without turning the starting switch ON. then turn the starting switch ON and carry out troubleshooting.TROUBLESHOOTING E-18 E-18 THE INFORMATION SWITCH DOES NOT WORK. Trouble Related information • The information switch does not work. Ground fault of wiring Between wiring harness (between ST2 (16) and Resistance Min. 1 V (32). 1 z aPrepare with the starting switch OFF. 1 Mz 1 (Internal short circuit or Between (1) and (2) disconnection) Max. 1 z GND04 aPrepare with the starting switch OFF. 1 z harness (Disconnection in (female) (2) 2 wiring or defective contact in Wiring harness between ST2 (6) and CUR Resistance Max. (33) OFF (0) 5 – 11 V Between (6) and ground Max. Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. CUR (male) Information switch Resistance Defective information switch OFF (0) Min. then carry out troubleshooting without turning the starting switch ON. 1 z OFF (0) Min. (31). 1 Mz Between (1) and (3) Max. PX-15 20-625 (1) . 1 V Cause Circuit diagram related to information switch D65EX. 1 z connector) (female) (3) Wiring harness between CUR (female) (1) and Resistance Max. then carry out troubleshooting without turning the starting switch ON. Max. 1 Mz 3 harness (Contact with CUR (female) (2)) and ground ground circuit) Between wiring harness (between ST2 (6) and Resistance Min. Wiring harness between ST2 (16) and CUR Disconnection of wiring Resistance Max.

steering and transmission concontroller troller may be limiting function because of another reason. Disconnection of wiring harness (Disconnection in Wiring harness between ST2 (female) (10) – Resistance Max. then carry out troubleshooting without turning the starting switch ON.TROUBLESHOOTING E-19 E-19 THE PRESET MODE DOES NOT OPERATE OR CANNOT BE RESET. 1 z ground aPrepare with starting switch OFF. Defective steering and ST2 Preset mode switch Voltage transmission controller OFF (0) 5 – 11 V Between (10) and ground ON (1) Max. Cause Circuit diagram related to preset mode 20-626 (1) D65EX. 1 Mz Between (2) – (3) ON (1) Max. 1 2 Possible causes and standard value in normal state 3 4 5 Standard value in normal state/Remarks on troubleshooting aPreare with the starting OFF. then carry out troubleshooting Ground fault of wiring without turning starting switch ON. Trouble Related information • The preset mode does not operate or cannot be reset. then carry out troubleshooting without turning the starting switch ON. 1 z wiring or defective contact in MAM (female) (2) connector) Wiring harness between MAM (female) (3) and Resistance Max. harness (Contact with Wiring harness between ST2 (female) (10) – ground circuit) Resistance Min. Defective manual mode MAM (male) Preset mode switch Resistance switch (Internal disconnection) OFF (0) Min. PX-15 . 1 z MAM (female) (2) with ground aPrepare with the starting switch OFF. then turn the starting switch ON and carry out troubleshooting. 1 z aPrepare with the starting switch OFF. 1 V Limitation of function by When Causes 1 to 4 are not applicable.

Between (5) and (4) ON Max. 1 z S24 (2) Wiring harness between ST1 (female) (6) and Resistance Max. Defective monitor panel S03 Service switch Voltage 8 (Gauge/lamp module) OFF Max. Trouble Related information • The monitor panel cannot be set in the service mode or cannot be set out of the service mode. 1 V male) (16) and ground aPrepare with the starting switch OFF. 1 Mz male) (6) and ground aPrepare with the starting switch OFF. 1 V Cause Defective buzzer cancel 1 switch system Defective information switch 2 system D65EX. 1 z S24 (5) aPrepare with the starting switch OFF. Since the information switch system is supposed to be out of order. Defective steering and ST1 Service switch Voltage 9 transmission controller OFF 5 – 11 V Between (6) and ground ON Max.TROUBLESHOOTING E-20 E-20 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE OR CANNOT BE SET OUT OF THE SERVICE MODE. (6) with ground ground circuit) Wiring harness between S24 (5) – ST1 (feResistance Min. 1 z Disconnection of wiring S24 (1) harness (Disconnection in Wiring harness between S24 (4) and ground Resistance Max. PX-15 20-627 (1) . then carry out troubleshooting without turning the starting switch ON. a ground fault may have possibly oc3 Defective fuse FS1 (10) curred in the circuit. then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring Wiring harness between FS1 (10) – S24 (1) – Resistance Min. When the fuse FS1 (10) is cut off. carry out the troubleshooting of “The information switch does not work”. 1 Mz Between (1) and (2). then carry out troubleshooting without turning the starting switch ON. carry out the troubleshooting of “The buzzer cancel switch does not work”. 1 z aPrepare with the starting switch OFF. Wiring harness between FS1 (10) outlet and Resistance Max. 7 harness (Contact with 24 V Wiring harness between S24 (2) – S03 (fecircuit) Voltage Max. 1 V Between (16) and ground ON 20 – 30 V aPrepare with the starting switch OFF. 1 z 5 wiring or defective contact in Wiring harness between S03 (female) (16) and connector) Resistance Max. Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Since the buzzer cancel switch system is supposed to be out of order. 1 Mz 6 harness (Contact with S03 (female) (5). Defective service switch S24 Service switch Resistance 4 (Internal short circuit or disconnection) OFF Min. then turn the starting switch ON and carry out troubleshooting. then turn the starting switch ON and carry out troubleshooting. then turn the starting switch Hot short circuit of wiring ON and carry out troubleshooting. aPrepare with the starting switch OFF.

TROUBLESHOOTING E-20 Circuit diagram related to monitor panel 20-628 (1) D65EX. PX-15 .

then turn the starting switch ON and carry out troubleshooting.Resistance Min. the back-up alarm is supposed (internal defect) to be defective. PX-15 20-629 (1) . (3) Disconnection of wiring harness (Disconnection in Wiring harness between BKA (female) (2) – Resistance Max. 1 z back-up alarm positive (+) terminal Wiring harness between back-up alarm negaResistance Max. 1 Mz wiring or defective contact in ST2 (female) (18) connector) Wiring harness between BKA (female) (5) and Resistance Max. 1 Mz harness (Contact with BKA (female) (1). Cause 1 2 Possible causes and standard value in normal state 3 4 5 Circuit diagram related to back-up alarm D65EX. Trouble Related information • The back-up alarm does not sound. a relevant failure code is displayed. (3) and ground ground circuit) Between wiring harness (between BKA (female) (5) and back-up alarm positive (+) termi. • When a failure occurs on the primary side (coil side) of the back-up alarm relay. Standard value in normal state/Remarks on troubleshooting When the fuse is blown. but in case of failure on the secondary side (contact side).TROUBLESHOOTING E-21 E-21 THE BACK-UP ALARM DOES NOT SOUND. Wiring harness between FS2-(9) and BKA (feResistance Max. then carry out troubleshooting without turning the starting switch ON. no failure code is displayed. aPrepare with the starting switch OFF. 1 z tive (–) terminal – and GND03 aPrepare with the starting switch OFF. Defective back-up relay When the relay is replaced with another relay while the starting switch (internal disconnection) is set to OFF and the alarm sounds after the starting switch is turned on and the machine is operated in reverse. 1 Mz nal) and ground Defective back-up alarm When Causes 1 to 4 are not applicable. a ground fault may have probably occurred in Defective fuse (FS2-(9)) the circuit. Ground fault of wiring Between wiring harness related to FS2-(9) and Resistance Min. aPrepare with the starting switch OFF. then carry out troubleshooting without turning the starting switch ON. 1 z male) (1). the back-up alarm relay (BKA) is defective.

then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. the circuit probably has a grounding fault. etc. 228 (female) (1) and ground Cause Defective rear lamp 1 (Breakage of bulb) 2 Defective fuse (FS1-(8)) Standard value in normal state/Remarks on troubleshooting Since the rear lamp may be defective. Possible causes and standard value in normal state If the fuse is broken. then carry out troubleshooting without turning starting switch ON. aPrepare with starting switch OFF. Short circuit with chassis Wiring harness between FWL (female) (2) – Resistance Min. 1 z 228 (female) (2) and GND03 aPrepare with starting switch OFF. aPrepare with starting switch OFF. 1 Mz 5 ground in wiring harness FS1-(8) with ground (Contact with ground circuit) Wiring harness between FWL (female) (3) – Resistance Min. 1 Mz Between (2) – (3) ON Max. then carry out troubleshooting without turning starting switch ON. 1 Mz 5 ground in wiring harness FS1-(8) with ground (Contact with ground circuit) Wiring harness between RWL (female) (3) – Resistance Min. 1 z harness (Disconnection in FS1-(8) 4 wiring or defective contact in Wiring harness between FWL (female) (3) – Resistance Max. 1 z connector) 203 (female) (2) and 204 (female) (2) Wiring harness between 203 (female) (1) – Resistance Max. the circuit probably has a grounding fault. 1 Mz 224 (female) (2). Wiring harness between FWL (female) (2) – Disconnection in wiring Resistance Max. Defective rear lamp switch RWL (male) Switch Resistance 3 (Internal disconnection) OFF Min. then carry out troubleshooting without turning starting switch ON. PX-15 . 1 z 204 (female) (1) and GND04 aPrepare with starting switch OFF. Trouble (2) Related information • The rear lamp does not light up.TROUBLESHOOTING E-22 E-22 THE HEAD LAMP AND REAR LAMP DO NOT LIGHT UP. Possible causes and standard value in normal state If the fuse is broken. Wiring harness between RWL (female) (2) – Disconnection in wiring Resistance Max. 204 (female) (2) and ground Cause Defective head lamp 1 (Breakage of bulb) 2 Defective fuse (FS1-(8)) Standard value in normal state/Remarks on troubleshooting Since the head lamp may be defective. then carry out troubleshooting without turning starting switch ON. Trouble (1) Related information • The head lamp does not light up. 1 Mz Between (2) – (3) ON Max. 1 Mz 203 (female) (2). check its bulb for breakage. Short circuit with chassis Wiring harness between RWL (female) (2) – Resistance Min. Defective head lamp switch FWL (male) Switch Resistance 3 (Internal disconnection) OFF Min. check its bulb for breakage. 1 z harness (Disconnection in FS1-(8) 4 wiring or defective contact in Wiring harness between RWL (female) (3) – Resistance Max. 1 z aPrepare with starting switch OFF. 1 z aPrepare with starting switch OFF. etc. 20-630 (1) D65EX. 1 z connector) 224 (female) (2) and 228 (female) (1) Wiring harness between 224 (female) (1) – Resistance Max.

TROUBLESHOOTING E-22 Circuit diagram related to panel lamp. head lamp and rear lamp D65EX. PX-15 20-631 (1) .

then carry out troubleshooting without turning starting switch ON. CN30. 1 z Between (3) – (4) OFF Min. then carry out troubleshooting without turning starting switch ON. PX-15 . CN14 (male) Position of switch Resistance Defective front wiper switch ON Max. 1 z ground aPrepare with starting switch OFF. or CN32. CN31. Defective fusible link (FL1) etc. If any wiper does not operate. then turn starting switch ON and carry out troubleshooting.TROUBLESHOOTING E-23 E-23 MALFUNCTION OF WIPERS Trouble (1) Related information • • • • • The front wiper does not operate (Continuous operation is defective). the relay is defective. 1 Mz CN28 (female) (4) with ground Cause 1 2 3 4 Possible causes and standard value in normal state 5 6 7 20-632 (1) D65EX. 1 Mz CN29 (female) (3) with ground tion in wiring or defective contact in connector or Wiring harness between CN29 (female) (6) – Resistance Max. Since fuse (5) in the cab is used for the front wiper system and intermittent Defective fuse (5) in cab switch system. intermittent selector relay Between CN29 (3) – ground Voltage 20 – 30 V Between CN29 (6) – ground Voltage 20 – 30 V Between CN29 (1) – ground Voltage Max. the circuit probably has a grounding fault. If fuse (5) in the cab is broken. Carry out the following troubleshooting when only the front wiper is defective. Standard value in normal state/Remarks on troubleshooting If the fusible link is broken. intermittent operation of the all wipers becomes defective.Wiring harness between CN14 (female) (4) – Resistance Min. the relay is defective. then turn starting switch ON and Defective front wiper carry out troubleshooting. 1 z contact with ground circuit) CN28 (female) (4) Wiring harness between CN29 (female) (6) – Resistance Min. then turn starting switch ON and Defective front wiper carry out troubleshooting. then carry out troubleshooting without turning starting switch ON. Between CN23 (6) – ground Voltage 20 – 30 V Defective front wiper motor aPrepare with starting switch OFF. 1 z circuit with chassis ground in CN29 (female) (3) wiring harness (Disconnec. 1 Mz • If the trouble is repaired by replacing the relay with relay CN27. aPrepare with starting switch OFF. aPrepare with starting switch OFF. those systems probably have a grounding fault. 1 V • If the trouble is repaired by replacing the relay with relay CN26. etc. intermittent relay Between CN28 (4) – ground Voltage 20 – 30 V Between CN28 (3) – ground Voltage 20 – 30 V Between CN28 (5) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. Wiring harness between CN23 (female) (1) – Resistance Max. check the fusible link (FL1). or CN33. Wiring harness between CN14 (female) (4) – Disconnection or short Resistance Max. When carrying out the troubleshooting. turn the intermittent switch OFF and turn the wiper switch ON. aPrepare with starting switch OFF.

1 z 7 CN23 (female) (6) tion in wiring or defective contact in connector or Wiring harness between CN28 (female) (5) – Resistance Min. (3) and between CN23 (female) (3) Resistance Min.Wiring harness between CN28 (female) (5) – Resistance Max. (3) and between CN23 (female) (3) Resistance Max. 1 Mz contact with ground circuit) CN23 (female) (6) with ground Wiring harness between CN28 (female) (6) – Resistance Max. 1 Mz Disconnection or short circuit with chassis ground in – CN28 (female) (3) with ground wiring harness (Disconnec.TROUBLESHOOTING E-23 Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Wiring harness between fuse (5) – CN14 (female) (2). 1 z ground Wiring harness between CN23 (female) (1) – Resistance Max. 1 z – CN28 (female) (3) Wiring harness between fuse (5) – CN14 (female) (2). 1 z ground Cause D65EX. PX-15 20-633 (1) .

then turn starting switch ON and Defective front wiper carry out troubleshooting. Carry out the following troubleshooting when the ordinary operation is normal. Between CN28 (2) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. or CN32. turn the wiper switch and intermittent switch ON. When carrying out the troubleshooting. the relay is defective. 1 z contact in connector or CN28 (female) (2) contact with ground circuit) Wiring harness between CN29 (female) (5) – Resistance Min. CN30. CN31. Defective front wiper aPrepare with starting switch OFF.CN29 (female) (1) with ground tion in wiring or defective Wiring harness between CN29 (female) (5) – Resistance Max. 1 z CN29 (female) (1) Disconnection or short circuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance Min. 1 z ground Cause 1 2 Possible causes and standard value in normal state 3 4 20-634 (1) D65EX. Wiring harness between CN11 (female) (2) – Resistance Max. Standard value in normal state/Remarks on troubleshooting • If the ordinary operation is normal and the other wiper do not operate intermittently either. then carry out troubleshooting without turning starting switch ON.TROUBLESHOOTING E-23 Trouble (2) Related information • • • • The front wiper does not operate intermittently. 1 z Between (1) – (2) OFF Min. aPrepare with starting switch OFF. intermittent selector relay Between CN29 (1) – ground Voltage 20 – 30 V Between CN29 (5) – ground Voltage 20 – 30 V • If the trouble is repaired by replacing the relay with relay CN26. the intermittent switch is probably defective. or CN33. PX-15 . aPrepare with starting switch OFF. then carry out troubleshooting Defective intermittent switch without turning starting switch ON. CN11 (male) Position of switch Voltage ON Max. 1 Mz • If the trouble is repaired by replacing the relay with relay CN27. 1 Mz wiring harness (Disconnec. Stop about 5 seconds after the wiper goes and returns once. then turn starting switch ON and intermittent relay carry out troubleshooting. 1 Mz CN28 (female) (2) with ground Wiring harness between CN29 (female) (2) – Resistance Max. the relay is defective.

PX-15 20-635 (1) .TROUBLESHOOTING E-23 Circuit diagram related to wiper system D65EX.

Defective fusible link (FL1) etc.TROUBLESHOOTING E-23 Trouble (3) Related information • • • • The rear wiper does not operate (Continuous operation is defective). etc. then carry out troubleshooting without turning starting switch ON. CN29. intermittent relay Between CN32 (4) – ground Voltage 20 – 30 V Between CN32 (3) – ground Voltage 20 – 30 V Between CN32 (5) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. aPrepare with starting switch OFF.Wiring harness between CN12 (female) (4) – Resistance Min. the relay is defective. aPrepare with starting switch OFF. 1 Mz CN32 (female) (4) with ground Cause 1 2 3 4 Possible causes and standard value in normal state 5 6 7 20-636 (1) D65EX. the relay is defective. then carry out troubleshooting without turning starting switch ON. 1 Mz • If the trouble is repaired by replacing the relay with relay CN27. then turn starting switch ON and Defective rear wiper carry out troubleshooting. or CN31. Since fuse (4) in the cab is used for only the rear wiper system. 1 Mz CN33 (female) (3) with ground tion in wiring or defective contact in connector or Wiring harness between CN33 (female) (6) – Resistance Max. then carry out troubleshooting without turning starting switch ON. CN28. Between CN37 (1) – ground Voltage 20 – 30 V Defective rear wiper motor aPrepare with starting switch OFF. check the fusible link (FL1). 1 z ground aPrepare with starting switch OFF. When carrying out the troubleshooting. 1 V • If the trouble is repaired by replacing the relay with relay CN26. Carry out the following troubleshooting when only the rear wiper is defective. CN12 (male) Position of switch Resistance Defective rear wiper switch ON Max. intermittent selector relay Between CN33 (3) – ground Voltage 20 – 30 V Between CN33 (6) – ground Voltage 20 – 30 V Between CN33 (1) – ground Voltage Max. then turn starting switch ON and carry out troubleshooting. this sysDefective fuse (4) in cab tem probably has a grounding fault. 1 z Between (3) – (4) OFF Min. If any wiper does not operate. PX-15 . Wiring harness between CN37 (female) (2) – Resistance Max. 1 z circuit with chassis ground in CN33 (female) (3) wiring harness (Disconnec. 1 z contact with ground circuit) CN32 (female) (4) Wiring harness between CN33 (female) (6) – Resistance Min. the circuit probably has a grounding fault. Standard value in normal state/Remarks on troubleshooting If the fusible link is broken. or CN30. turn the intermittent switch OFF and turn the wiper switch ON. Wiring harness between CN12 (female) (4) – Disconnection or short Resistance Max. then turn starting switch ON and Defective rear wiper carry out troubleshooting. aPrepare with starting switch OFF.

Resistance Min. 1 z male) (2). 1 z ground Wiring harness between CN37 (female) (2) – Resistance Max. (3) with ground Wiring harness between fuse (4) – CN32 (feResistance Max. 1 z male) (3) – CN37 (female) (3) Disconnection or short circuit with chassis ground in Wiring harness between fuse (4) – CN32 (fe.male) (3) – CN37 (female) (3) with ground 7 tion in wiring or defective Wiring harness between CN32 (female) (5) – Resistance Max. 1 z ground Cause D65EX. PX-15 20-637 (1) . 1 Mz CN37 (female) (1) with ground Wiring harness between CN32 (female) (6) – Resistance Max. (3) Wiring harness between fuse (4) – CN12 (feResistance Min. 1 Mz wiring harness (Disconnec. 1 z contact in connector or CN37 (female) (1) contact with ground circuit) Wiring harness between CN32 (female) (5) – Resistance Min.TROUBLESHOOTING E-23 Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Wiring harness between fuse (4) – CN12 (feResistance Max. 1 Mz male) (2).

intermittent selector relay Between CN33 (1) – ground Voltage 20 – 30 V Between CN33 (5) – ground Voltage 20 – 30 V • If the trouble is repaired by replacing the relay with relay CN26. or CN30.TROUBLESHOOTING E-23 Trouble (4) Related information • • • • The rear wiper does not operate intermittently. then carry out troubleshooting Defective intermittent switch without turning starting switch ON. 1 Mz CN32 (female) (2) with ground Wiring harness between CN33 (female) (2) – Resistance Max. then turn starting switch ON and intermittent relay carry out troubleshooting. CN29. 1 z CN33 (female) (1) Disconnection or short circuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance Min. CN28. the relay is defective. Stop about 5 seconds after the wiper goes and returns once. Wiring harness between CN11 (female) (2) – Resistance Max. 1 z Between (1) – (2) OFF Min. 1 z ground Cause 1 2 Possible causes and standard value in normal state 3 4 20-638 (1) D65EX. Carry out the following troubleshooting when the ordinary operation is normal. the relay is defective. turn the wiper switch and intermittent switch ON.CN33 (female) (1) with ground tion in wiring or defective Wiring harness between CN33 (female) (5) – Resistance Max. the intermittent switch is probably defective. aPrepare with starting switch OFF. 1 Mz • If the trouble is repaired by replacing the relay with relay CN27. When carrying out the troubleshooting. Defective rear wiper aPrepare with starting switch OFF. Standard value in normal state/Remarks on troubleshooting • If the ordinary operation is normal and the other wiper do not operate intermittently either. Between CN32 (2) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and Defective rear wiper carry out troubleshooting. 1 z contact in connector or CN32 (female) (2) contact with ground circuit) Wiring harness between CN33 (female) (5) – Resistance Min. or CN31. 1 Mz wiring harness (Disconnec. aPrepare with starting switch OFF. PX-15 . CN11 (female) Position of switch Voltage ON Max.

TROUBLESHOOTING E-23 Circuit diagram related to wiper system D65EX. PX-15 20-639 (1) .

then carry out troubleshooting without turning starting switch ON. • When carrying out the troubleshooting. or CN33. Since fuse (6) in the cab is used for the right door wiper system and left Defective fuse (6) in cab door wiper system. (If fuse (6) in the cab is broken.) • If any wiper does not operate. 1 z Between (3) – (4) OFF Min. 1 z contact with ground circuit) CN30 (female) (4) Wiring harness between CN31 (female) (6) – Resistance Min. or CN32.Wiring harness between CN13 (female) (4) – Resistance Min. the left door wiper does not operate either. then turn starting switch ON and Defective right door wiper carry out troubleshooting. either of those systems probably has a grounding fault. 1 Mz • If the trouble is repaired by replacing the relay with relay CN27. PX-15 . turn the intermittent switch OFF and turn the wiper switch ON.TROUBLESHOOTING E-23 Trouble (5) Related information • The right door wiper does not operate (Continuous operation is defective). the relay is defective. Wiring harness between CN13 (female) (4) – Disconnection or short Resistance Max. CN29. the circuit probably has a grounding fault. 1 z fore motor – ground aPrepare with starting switch OFF. aPrepare with starting switch OFF. 1 z circuit with chassis ground in CN31 (female) (3) wiring harness (Disconnec. • Carry out the following troubleshooting when only the right door wiper is defective. then turn starting switch ON and Defective right door wiper carry out troubleshooting. Standard value in normal state/Remarks on troubleshooting If the fusible link is broken. Defective right door wiper CN13 (male) Position of switch Resistance switch ON Max. etc. CN28. then carry out troubleshooting without turning starting switch ON. 1 Mz CN30 (female) (4) with ground Cause 1 2 3 4 Possible causes and standard value in normal state 5 6 7 20-640 (1) D65EX. intermittent selector relay Between CN31 (3) – ground Voltage 20 – 30 V Between CN31 (6) – ground Voltage 20 – 30 V Between CN31 (1) – ground Voltage Max. 1 V • If the trouble is repaired by replacing the relay with relay CN26. Wiring harness between connector (1) just beResistance Max. 1 Mz CN31 (female) (3) with ground tion in wiring or defective contact in connector or Wiring harness between CN31 (female) (6) – Resistance Max. intermittent relay Between CN30 (4) – ground Voltage 20 – 30 V Between CN30 (3) – ground Voltage 20 – 30 V Between CN30 (5) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. Defective fusible link (FL1) etc. aPrepare with starting switch OFF. check the fusible link (FL1). the relay is defective. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. Between connector (3) just before motor – Voltage 20 – 30 V ground Defective right door wiper motor aPrepare with starting switch OFF. aPrepare with starting switch OFF.

(3) – CN17 (4) – connector (female) Resistance Min. PX-15 20-641 (1) . 1 z circuit with chassis ground in male) (3) wiring harness (Disconnec. 1 z contact with ground circuit) just before motor – CN17 (3) – CN30 (female) (5) Wiring harness between connector (female) Resistance Min. 1 Mz (4) just before motor – CN13 (female) (2).Wiring harness between fuse (6) – CN30 (fe. 1 Mz 7 male) (3) with ground tion in wiring or defective contact in connector or Wiring harness between connector (female) (3) Resistance Max. (3) – CN17 (4) – connector (female) Resistance Max.Resistance Min. 1 Mz (3) just before motor – CN17 (3) – CN30 (female) (5) with ground Wiring harness between CN30 (female) (6) – Resistance Max. (3) with ground Wiring harness between fuse (6) – CN30 (feDisconnection or short Resistance Max.TROUBLESHOOTING E-23 Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Wiring harness between fuse (6) – CN13 (female) (2). 1 z ground Wiring harness between connector (female) Resistance Max. 1 z (1) just before motor – CN17 (1) – ground Cause D65EX. (3) Wiring harness between fuse (6) – CN13 (female) (2). 1 z (4) just before motor – CN13 (female) (2).

1 Mz • If the trouble is repaired by replacing the relay with relay CN27. 1 z Between (1) – (2) OFF Min. Stop about 5 seconds after the wiper goes and returns once. aPrepare with starting switch OFF. then turn starting switch ON and intermittent relay carry out troubleshooting. turn the wiper switch and intermittent switch ON. 1 z ground 20-642 (1) D65EX. CN29. or CN32. 1 Mz CN30 (female) (2) with ground Wiring harness between CN31 (female) (2) – Resistance Max. 1 z contact in connector or CN30 (female) (2) contact with ground circuit) Wiring harness between CN31 (female) (5) – Resistance Min. Between CN30 (2) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. the relay is defective. Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting • If the ordinary operation is normal and the other wiper do not operate intermittently either. the relay is defective. Defective right door wiper 3 aPrepare with starting switch OFF. CN11 (female) Position of switch Voltage ON Max. 1 z CN31 (female) (1) Disconnection or short circuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance Min. then carry out troubleshooting 1 Defective intermittent switch without turning starting switch ON. Wiring harness between CN11 (female) (2) – Resistance Max. aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 Mz wiring harness (Disconnec. or CN33.CN31 (female) (1) with ground 4 tion in wiring or defective Wiring harness between CN31 (female) (5) – Resistance Max. When carrying out the troubleshooting. PX-15 . then turn starting switch ON and Defective right door wiper 2 carry out troubleshooting. CN28. Carry out the following troubleshooting when the ordinary operation is normal. intermittent selector relay Between CN31 (1) – ground Voltage 20 – 30 V Between CN31 (5) – ground Voltage 20 – 30 V • If the trouble is repaired by replacing the relay with relay CN26.TROUBLESHOOTING E-23 Trouble (6) Related information • • • • The right door wiper does not operate intermittently. the intermittent switch is probably defective.

TROUBLESHOOTING E-23 Circuit diagram related to wiper system D65EX. PX-15 20-643 (1) .

either of those systems probably has a grounding fault. then turn starting switch ON and Defective left door wiper carry out troubleshooting. 1 z circuit with chassis ground in CN27 (female) (3) wiring harness (Disconnec. CN30. or CN33. 1 z Between (3) – (4) OFF Min. 1 V • If the trouble is repaired by replacing the relay with relay CN28. turn the intermittent switch OFF and turn the wiper switch ON. 1 Mz CN26 (female) (4) with ground Cause 1 2 3 4 Possible causes and standard value in normal state 5 6 7 20-644 (1) D65EX. then carry out troubleshooting without turning starting switch ON. Defective fusible link (FL1) etc. then turn starting switch ON and Defective left door wiper carry out troubleshooting. check the fusible link (FL1). the relay is defective. the right door wiper does not operate either. aPrepare with starting switch OFF.) • If any wiper does not operate. CN31. the circuit probably has a grounding fault. intermittent selector relay Between CN27 (3) – ground Voltage 20 – 30 V Between CN27 (6) – ground Voltage 20 – 30 V Between CN27 (1) – ground Voltage Max. the relay is defective.Wiring harness between CN15 (female) (4) – Resistance Min. Wiring harness between CN15 (female) (4) – Disconnection or short Resistance Max. etc. Since fuse (6) in the cab is used for the left door wiper system and left Defective fuse (6) in cab door wiper system. 1 Mz • If the trouble is repaired by replacing the relay with relay CN29. aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. intermittent relay Between CN26 (4) – ground Voltage 20 – 30 V Between CN26 (3) – ground Voltage 20 – 30 V Between CN26 (5) – ground Voltage 20 – 30 V aPrepare with starting switch OFF.TROUBLESHOOTING E-23 Trouble (7) Related information • The left door wiper does not operate (Continuous operation is defective). Defective left door wiper CN15 (male) Position of switch Resistance switch ON Max. (If fuse (6) in the cab is broken. then turn starting switch ON and carry out troubleshooting. Between connector (3) just before motor – Voltage 20 – 30 V ground Defective left door wiper motor aPrepare with starting switch OFF. 1 z fore motor – ground aPrepare with starting switch OFF. 1 Mz CN27 (female) (3) with ground tion in wiring or defective contact in connector or Wiring harness between CN27 (female) (6) – Resistance Max. or CN32. • When carrying out the troubleshooting. Standard value in normal state/Remarks on troubleshooting If the fusible link is broken. Wiring harness between connector (1) just beResistance Max. aPrepare with starting switch OFF. PX-15 . • Carry out the following troubleshooting when only the left door wiper is defective. 1 z contact with ground circuit) CN26 (female) (4) Wiring harness between CN27 (female) (6) – Resistance Min. then carry out troubleshooting without turning starting switch ON.

TROUBLESHOOTING E-23 Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Wiring harness between fuse (6) – CN26 (female) (3) – CN24 (4) – connector (female) (4) Resistance Max. 1 z circuit with chassis ground in male) (2). 1 z just before motor Wiring harness between fuse (6) – CN26 (female) (3) – CN24 (4) – connector (female) (4) Resistance Min. 1 Mz just before motor – CN24 (3) – CN26 (female) (5) Wiring harness between CN26 (female) (6) – Resistance Max.Wiring harness between fuse (6) – CN15 (fe. 1 Mz 7 male) (2). PX-15 20-645 (1) .Resistance Min. 1 Mz just before motor with ground Wiring harness between fuse (6) – CN15 (feDisconnection or short Resistance Max. 1 z ground Wiring harness between connector (female) Resistance Max. (3) wiring harness (Disconnec. 1 z (1) just before motor – CN24 (1) – ground Cause D65EX. (3) tion in wiring or defective contact in connector or Wiring harness between connector (female) (3) Resistance Max. 1 z contact with ground circuit) just before motor – CN24 (3) – CN26 (female) (5) Wiring harness between connector (female) (3) Resistance Min.

Stop about 5 seconds after the wiper goes and returns once. or CN32. then carry out troubleshooting 1 Defective intermittent switch without turning starting switch ON. CN31. intermittent selector relay Between CN27 (1) – ground Voltage 20 – 30 V Between CN27 (5) – ground Voltage 20 – 30 V • If the trouble is repaired by replacing the relay with relay CN28. the intermittent switch is probably defective. CN11 (female) Position of switch Voltage ON Max. Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting • If the ordinary operation is normal and the other wiper do not operate intermittently either. Wiring harness between CN11 (female) (2) – Resistance Max. 1 Mz • If the trouble is repaired by replacing the relay with relay CN29. then carry out troubleshooting without turning starting switch ON. Carry out the following troubleshooting when the ordinary operation is normal. 1 z ground 20-646 (1) D65EX. PX-15 . CN30. 1 z contact in connector or CN26 (female) (2) contact with ground circuit) Wiring harness between CN27 (female) (5) – Resistance Min. 1 z CN27 (female) (1) Disconnection or short circuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance Min.CN27 (female) (1) with ground 4 tion in wiring or defective Wiring harness between CN27 (female) (5) – Resistance Max. aPrepare with starting switch OFF. then turn starting switch ON and Defective left door wiper 2 carry out troubleshooting. turn the wiper switch and intermittent switch ON. 1 Mz wiring harness (Disconnec. or CN33. When carrying out the troubleshooting. Between CN26 (2) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. 1 z Between (1) – (2) OFF Min.TROUBLESHOOTING E-23 Trouble (8) Related information • • • • The left door wiper does not operate intermittently. 1 Mz CN26 (female) (2) with ground Wiring harness between CN27 (female) (2) – Resistance Max. then turn starting switch ON and intermittent relay carry out troubleshooting. the relay is defective. Defective left door wiper 3 aPrepare with starting switch OFF. aPrepare with starting switch OFF. the relay is defective.

TROUBLESHOOTING E-23 Circuit diagram related to wiper system D65EX. PX-15 20-647 (1) .

1 Mz wiring harness (Disconnecmale) (2) with ground 3 tion in wiring or defective Wiring harness between CN14 (female) (1) – contact in connector or Resistance Max. 1 z Defective front washer 1 motor aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 Mz aDisconnection or short circuit with chassis ground in wiring harness (Disconnection in wiring or defective contact in connector or contact with ground circuit) Wiring harness between fuse (5) – CN14 (feResistance Max. CN14 (female) Position of switch Resistance 2 Defective front wiper switch W/ or W/ Max. 1 z ground Cause Possible causes and standard value in normal state 20-648 (1) D65EX. carry out troubleshooting in E-23 THE WIPER DOES NOT OPERATE first. 1 z Disconnection or short male) (2) circuit with chassis ground in Wiring harness between fuse (5) – CN14 (feResistance Min. 1 z contact with ground circuit) 19 (3) – 13 (3) – 11 (female) (2) Wiring harness between CN14 (female) (1) – Resistance Min. (If the wiper does not operate either. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. Trouble (1) Related information • Washing water of the front washer does not come out.TROUBLESHOOTING E-24 E-24 WASHING WATER DOES NOT COME OUT. PX-15 . (Switch position: W/ ) Wiring harness between 11 (female) (1) – ground Resistance Max. Between 11 (2) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. 1 Mz 19 (3) – 13 (3) – 11 (female) (2) and ground Wiring harness between 11 (female) (1) – Resistance Max. • Carry out the following troubleshooting when the front wiper operates normally. 1 z Between (2) – (1) OFF Min. then carry out troubleshooting without turning starting switch ON.

TROUBLESHOOTING E-24 Circuit diagram related to washer system D65EX. PX-15 20-649 (1) .

see Trouble (1). • Carry out the following troubleshooting when the rear wiper operates normally.male) (2) with ground 3 tion in wiring or defective Wiring harness between CN12 (female) (1) – Resistance Max. (Switch position: W/ ) Wiring harness between 12 (female) (1) – ground Resistance Max. carry out troubleshooting in E-23 THE WIPER DOES NOT OPERATE first. 1 z ground Cause Possible causes and standard value in normal state For the electric circuit diagram of each system. 1 z contact in connector or 19 (4) – 13 (4) – 12 (female) (2) contact with ground circuit) Wiring harness between CN12 (female) (1) – Resistance Min. CN12 (female) Position of switch Resistance 2 Defective rear wiper switch W/ or W/ Max. 1 z Between (2) – (1) OFF Min. 20-650 (1) D65EX. 1 Mz aPrepare with starting switch OFF. Between 12 (2) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. PX-15 . 1 z male) (2) Disconnection or short circuit with chassis ground in Wiring harness between fuse (4) – CN12 (fe. then carry out troubleshooting without turning starting switch ON. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. (If the wiper does not operate either. 1 Mz wiring harness (Disconnec. then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse (4) – CN12 (feResistance Max. then turn starting switch ON and carry out troubleshooting. 1 z 1 Defective rear washer motor aPrepare with starting switch OFF.TROUBLESHOOTING E-24 Trouble (2) Related information • Washing water of the rear washer does not come out.Resistance Min. 1 Mz 19 (4) – 13 (4) – 12 (female) (2) and ground Wiring harness between 12 (female) (1) – Resistance Max.

1 Mz 19 (1) – 13 (1) – 9 (female) (2) and ground Wiring harness between 9 (female) (1) – Resistance Max.Resistance Min. Defective left door wiper CN15 (female) Position of switch Resistance 2 switch W/ or W/ Max. (Switch position: W/ ) Defective left door washer Wiring harness between 9 (female) (1) – ground Resistance Max. 1 z contact in connector or 19 (1) – 13 (1) – 9 (female) (2) contact with ground circuit) Wiring harness between CN15 (female) (1) – Resistance Min. 1 Mz aPrepare with starting switch OFF. • Carry out the following troubleshooting when the left door wiper operates normally.TROUBLESHOOTING E-24 Trouble (3) Related information • Washing water of the left door washer does not come out. • Since the left door wiper switch and right door wiper switch use fuse (6) jointly. D65EX. 1 z male) (2) Disconnection or short circuit with chassis ground in Wiring harness between fuse (6) – CN15 (fe. 1 z Between (2) – (1) OFF Min. then carry out troubleshooting without turning starting switch ON. 1 z ground Cause Possible causes and standard value in normal state For the electric circuit diagram of each system. both wipers do not operate. then turn starting switch ON and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON. if fuse (6) is broken. Wiring harness between fuse (6) – CN15 (feResistance Max. then carry out troubleshooting without turning starting switch ON. (If the wiper does not operate either. PX-15 20-651 (1) . carry out troubleshooting in E-23 THE WIPER DOES NOT OPERATE first. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. see Trouble (1).male) (2) with ground 3 tion in wiring or defective Wiring harness between CN15 (female) (1) – Resistance Max. Between 9 (2) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. 1 Mz wiring harness (Disconnec. 1 z 1 motor aPrepare with starting switch OFF.

carry out troubleshooting in E-23 THE WIPER DOES NOT OPERATE first.TROUBLESHOOTING E-24 Trouble (4) Related information • Washing water of the right door washer does not come out. then carry out troubleshooting without turning starting switch ON. 1 Mz aPrepare with starting switch OFF. 1 Mz wiring harness (Disconnec. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. both wipers do not operate.male) (2) with ground 3 tion in wiring or defective Wiring harness between CN13 (female) (1) – Resistance Max. then turn starting switch ON and carry out troubleshooting. Between 10 (2) – ground Voltage 20 – 30 V aPrepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. (Switch position: W/ ) Defective right door washer Wiring harness between 10 (female) (1) – ground Resistance Max. 1 z ground Cause Possible causes and standard value in normal state For the electric circuit diagram of each system. if fuse (6) is broken. 20-652 (1) D65EX. 1 z 1 motor aPrepare with starting switch OFF. • Since the right door wiper switch and left door wiper switch use fuse (6) jointly. then carry out troubleshooting without turning starting switch ON. 1 z male) (2) Disconnection or short circuit with chassis ground in Wiring harness between fuse (6) – CN13 (fe.Resistance Min. 1 Mz 19 (2) – 13 (2) – 10 (female) (2) and ground Wiring harness between 10 (female) (1) – Resistance Max. Defective right door wiper CN13 (female) Position of switch Resistance 2 switch W/ or W/ Max. 1 z contact in connector or 19 (2) – 13 (2) – 10 (female) (2) contact with ground circuit) Wiring harness between CN13 (female) (6) – Resistance Min. PX-15 . • Carry out the following troubleshooting when the right door wiper operates normally. Wiring harness between fuse (6) – CN13 (feResistance Max. (If the wiper does not operate either. see Trouble (1). 1 z Between (2) – (1) OFF Min.

then carry out troubleshooting without turning the starting switch ON.TROUBLESHOOTING E-25 E-25 THE AIR CONDITIONER DOES NOT OPERATE. Defective blower main relay 2 (coil side) CN-R1 (male) Resistance Between (1) and (2) 240 ± 40 z aPrepare with the starting switch OFF. aPrepare with the starting switch OFF. then turn the starting switch ON and carry out troubleshooting. then turn the starting switch ON and carry out troubleshooting. 8 Defective blower motor The motor is in order when it rotates after the starting switch is turned ON and the blower Lo switch is turned on. aPrepare with the starting switch OFF. then carry out troubleshooting without turning the starting switch ON. then turn the starting switch ON and carry out troubleshooting. then carry out troubleshooting without turning the starting switch ON. Defective blower Mi1 relay 7 (contact side) The relay is in order when the motor rotates after the starting switch is turned ON and the blower Mi switch is turned on. 8 Defective blower motor The motor is in order when it rotates after the starting switch is turned ON and the blower Lo switch is turned on. a ground fault may have possibly occurred in the circuit. PX-15 20-653 (1) . Defective blower Hi relay 4 (coil side) CN-R2 (male) Resistance Between (1) and (2) 240 ± 40 z aPrepare with the starting switch OFF. Defective blower Mi2 relay 7 (contact side) The relay is in order when the motor rotates after the starting switch is turned ON and the blower Mi switch is turned on. aPrepare with the starting switch OFF. aPrepare with the starting switch OFF. Cause Defective circuit breaker 1 (CB2) D65EX. aPrepare with the starting switch OFF. Defective blower Mi1 relay 6 (coil side) CN-R3 (male) Resistance Between (1) and (2) 240 ± 40 z aPrepare with the starting switch OFF. then turn the starting switch ON and carry out troubleshooting. Trouble (1) Related information • No air flow. Defective blower Mi2 relay 6 (coil side) CN-R4 (male) Resistance Between (1) and (2) 240 ± 40 z aPrepare with the starting switch OFF. Defective blower main relay 3 (contact side) CN-R1 (male) Voltage Between (8C) and ground 20 – 30 V aPrepare with the starting switch OFF. then carry out troubleshooting without turning the starting switch ON. Defective blower Hi relay 5 (contact side) The relay is in order when the motor rotates after the starting switch is turned ON and the blower Hi switch is turned on. then turn the starting switch ON and carry out troubleshooting. then turn the starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting When the circuit breaker is cut off.

1 z and CN-R2 (female) (12B) or CN-R (female) (11C) Disconnection of wiring harness (Disconnection in Wiring harness between CB2 outlet and AC1 9 Resistance Max. the control panel is supposed 10 Defective control panel to be defective. 1 z wiring or defective contact in (female) (1A). CN-R (female) Resistance Max. 1 z (S141) or CN-R2 (female) (14E) or CN-R3 (female) (14N) and ground Wiring harness between CN-B (female) (11B) Resistance Max. CN-R1 (female) (1D). Carry out the troubleshooting of “Cooling is not possible”. Cause 20-654 (1) D65EX. Wiring harness between CN-R3 (female) (3B) Resistance Max. 1 z and AC1 (female) (4A) When Causes 1 to 9 are not applicable. Wiring harness between CN-R4 (female) (14C). then carry out troubleshooting without turning the starting switch ON. PX-15 . AC1 (female) (14A). 1 z and AC1 (female) (5A) Wiring harness between CN-R4 (female) (4B) Resistance Max.TROUBLESHOOTING E-25 Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. failure phenomenon may have been 11 Different failure phenomenon mistaken. 1 z and AC1 (female) (3B) Wiring harness between CN-R2 (female) (5B) Resistance Max. When any cause cannot be specified. 1 z and AC1 (female) (2A) aPrepare with the starting switch OFF. CN-R2 (female) (1E) or CN-R4 (female) (11) connector) Wiring harness between CN-R1 (female) (2B) Resistance Max. then carry out troubleshooting without turning the starting switch ON. 1 z and CN-R1 (female) (11A) Wiring harness between CN-B (female) (12A) Resistance Max.

The compressor is supposed to be out of order.TROUBLESHOOTING E-25 Trouble (2) Related information • Cooling is not possible. CN-R5 (male) Resistance Between (1) and (2) 240 ± 40 z aPrepare with the starting switch OFF. aStart the engine and carry out the troubleshooting. aPrepare with the starting switch OFF. then turn the starting switch ON and carry out troubleshooting. 1 z CN-R5 (female) (1K) Wiring harness between CN-T (female) (9B) Resistance Max. then turn the starting switch ON and carry out troubleshooting. Cause 1 Defective pressure switch 2 Defective compressor clutch relay (coil side) 3 Defective compressor clutch relay (contact side) 4 Defective condenser relay (contact side) 5 Defective thermistor Possible causes and standard value in normal state 6 Defective condenser blower resistor 7 Defective condenser motor 8 Defective compressor magnet clutch 9 Defective compressor Disconnection of wiring harness (Disconnection in 10 wiring or defective contact in connector) Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. so inspect it directly. aStart the engine and carry out the troubleshooting. then carry out troubleshooting without turning the starting switch ON. 1 z or CN-R1 (female) (8C) Wiring harness between CN-R5 (female) Resistance Max.500 z aPrepare with the starting switch OFF. Condenser blower resistor Resistance Between terminals 2. 1 z and AC1 (female) (9A) D65EX. 1 z (18A) and A/C (female) (1) Wiring harness between CB2 outlet and Resistance Max. then turn the starting switch ON and carry out troubleshooting. CN-R6 Voltage Between (23A) and ground 20 – 30 V aPrepare with the starting switch OFF. PX-15 20-655 (1) .8 z ± 5% aTurn the starting switch on and carry out the troubleshooting. then carry out troubleshooting without turning the starting switch ON. then carry out troubleshooting without turning the starting switch ON. The motor is in order if it is rotating when the air conditioner is switched ON. so inspect it directly. 3. Wiring harness between CB2 outlet and CN-R6 (female) (8B) or CN-R5 (female) (8D) Resistance Max. CN-P Blower switch Voltage Between (6B) and ON 20 – 30 V ground aPrepare with the starting switch OFF. The compressor magnet clutch is supposed to be out of order. AC1 (male) Resistance Between (9A) and (13A) Max. then carry out troubleshooting without turning the starting switch ON. CN-R5 (male) Voltage Between (18A) and ground 20 – 30 V aPrepare with the starting switch OFF.

Cause 20-656 (1) D65EX. 1 z and AC1 (female) (6A) When Causes 1 to 10 are not applicable.TROUBLESHOOTING E-25 Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF. then carry out troubleshooting without turning the starting switch ON. 1 z 10 wiring or defective contact in and CN-R5 (female) (7A) connector) Wiring harness between CN-P (female) (6B) Resistance Max. the control panel is supposed 11 Defective control panel to be defective. PX-15 . Disconnection of wiring harness (Disconnection in Wiring harness between CN-P (female) (7B) Resistance Max.

PX-15 20-657 (1) .TROUBLESHOOTING E-25 Circuit diagram related to air conditioner D65EX.

...................................................................9 Overheat of power train oil temperature ..................................................... H-18 Excessive hydraulic drift of ripper lift ..............................................1 No travel power (no drawbar pull) .................. H......................................4 Machine travels only in one direction forward or in reverse .TROUBLESHOOTING TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) Information described in troubleshooting list ................................................. H............................................................. H......................................................... H-17 Excessive hydraulic drift of blade tilt ........................................... H............................................................... H-15 Ripper lift speed is slow or lacks power .....8 Brake does not work .................................................................................................... H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor .................................................................. H............................................................................................ H-14 Blade tilt speed is slow or lacks power ..............................................................................................................................................................................................7 Steering speed or power is low .........................6 Machine does not turn (not turned rightward or leftward) .......................................................................................... H-13 Blade lift speed is slow or lacks power ...5 When gear is shifted or travel direction is changed................................................... PX-15 20-701 (1) ................................ H................................................................................................................ H-11 All work equipment speeds are slow .......................................2 Machine does not move (at 2nd or 3rd speed) ......... large time lag is made ..... H........................ H-16 Excessive hydraulic drift of blade lift .............................................................. 20-702 20-703 20-704 20-705 20-706 20-707 20-708 20-708 20-709 20-709 20-710 20-710 20-711 20-711 20-712 20-712 20-713 20-713 20-714 D65EX................. H........................................................................ H-12 Work equipment does not move ...................................3 Machine does not move in any speed range ......... H.................................................

) 4 20-702 (1) D65EX. PX-15 . Trouble Related information Problem that appears on the machine.TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING LIST INFORMATION DESCRIBED IN TROUBLESHOOTING LIST a Troubleshooting lists contain the following information all together. Information related to problems occurred or troubleshooting Cause 1 Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting 2 Cause supposed to have caused failure <Contents> (The sequence shows refer. Understand the contents carefully and troubleshoot the machine.• Standard values in normal state for judging possible causes ence numbers and does not • Remarks for making judgment 3 mean priority.

31 kg/cm2} Defective set pressure of aPrepare with the starting switch OFF. Defective brake valve Parking lever Brake pressure Min.84 MPa {Min.650 rpm Defective power train pump The power train pump is assumed to be defective. then carry out troubleshooting transmission main relief without turning the starting switch ON. 2.88 MPa 0.84 MPa {Min. Defective engine Measurement conditions Number of engine rotations F3 stall 1. Transmission clutch Clutch pressure FWD Min. the parking Defective parking lever or lever or brake pedal linkage is not assumed to be adjusted normally.84 MPa {Min. PCCS lever Transmission main relief pressure Full neutral Min. directly check mission it. 26 kg/cm2} If the result of the troubleshooting in cause 6 is abnormal.69 MPa Full neutral {Max.84 MPa {Min. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.55 MPa Free {Min. aPrepare with starting switch OFF. then drive the engine in high idling mode for troubleshooting. 29 kg/cm2} (ECMV) function 1ST Min. • Confirm that the oil quantity on the power train is normal before troubleshooting. 2. then drive the engine in low idling mode for troubleshooting. 2.84 MPa {Min. 2. 0.04 MPa {Min. • Free length of large spring: 128 mm • Free length of small spring: 108 mm • Number of shims: 6 aPrepare with starting switch OFF. Cause 1 2 3 4 Possible causes and standard value in normal state 5 6 7 8 D65EX. Original pressure of Torque converter Internally defective torque PCCS lever torque converter delivery pressure converter Max. 2. 29 kg/cm2} 3RD Min. 9 kg/cm2} {4 – 7 kg/cm2} aPrepare with starting switch OFF. 29 kg/cm2} Defective transmission valve REV Min. 29 kg/cm2} 2ND Min. then drive the engine in high idling mode for troubleshooting. (No drawbar pull). then drive the engine in high idling mode for troubleshooting. Internally defective transThe transmission is assumed to be defective internally. valve and internal defect Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly.TROUBLESHOOTING H-1 H-1 NO TRAVEL POWER (NO DRAWBAR PULL) Trouble Related information • There is no travel power. 29 kg/cm2} aPrepare with starting switch OFF. directly check it.39 – 0. then drive the engine in high idling mode for troubleshooting. 2. 3. PX-15 20-703 (1) . brake pedal linkage Directly check it.

0. brake drag occurs.) Internally defective transThe transmission is assumed to be defective internally. Defective transmission valve Transmission clutch Clutch pressure (ECMV) function 2ND Min. directly check mission it. • Confirm that the transmission main relief pressure is normal before troubleshooting. then drive the engine in high idling mode for troubleshooting.TROUBLESHOOTING H-2 H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED) Trouble Related information • Machine does not move.04 MPa {Min.04 MPa {Min. 9 kg/cm2} {4 – 7 kg/cm2} aPrepare with starting switch OFF. Defective parking brake The parking brake function is assumed to be defective (dragged). 3.88 MPa 0. 31 kg/cm2} Internally defective transThe transmission clutch (2nd or 3rd speed) is assumed to be defective mission clutch internally. (At 2nd or 3rd speed) • Confirm that the oil quantity on the power train is normal before troubleshooting. Original pressure of Torque converter Internally defective torque PCCS lever torque converter delivery pressure converter Max. (See H-1. PX-15 . Defective brake function (Drag) If the machine does not run by low idling + F2 operation.39 – 0. function (Drag) check the linkage valves. and start the engine for troubleshooting. (Carry out troubleshooting “Brake does not work”. aMove to a flat place (a hard road). Cause 1 Possible causes and standard value in normal state 2 3 4 5 6 20-704 (1) D65EX. directly check it. then drive the engine in low idling mode for troubleshooting.69 MPa Full neutral {Max.) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. 3. 31 kg/cm2} 3RD Min.

) Transmission clutch Clutch pressure Defective transmission valve FWD Min. and drive the engine in high idling mode for troubleshooting. • Free length of large spring: 128 mm • Free length of small spring: 108 mm • Number of shims: 6 aPrepare with starting switch OFF.04 MPa {Min.84 MPa {Min. 29 kg/cm2} 3RD Min.84 MPa {Min.84 MPa {Min. then carry out troubleshooting 2 fective set pressure of trans.) Brake hydraulic pressure Brake pedal (left/right) 5 Defective brake function Release Min. directly check it. 2. directly 4 mission clutch check it. aMove to a flat place. 29 kg/cm2} 3 (ECMV) function REV Min.without turning the starting switch ON. carry out troubleshooting “Brake does not work”. (Before this. 29 kg/cm2} 2ND Min. confirm that the transmission main relief pressure is normal. then drive the engine in low idling mode for troubleshooting. PCCS lever Transmission main relief pressure Full neutral Min. then drive the engine in high idling mode for troubleshooting. 29 kg/cm2} 1ST Min. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective power train pump The power train pump is assumed to be defective. 2. • Confirm that the oil quantity on the power train is normal before troubleshooting.84 MPa {Min. 3. PX-15 20-705 (1) . (Before this. 2.TROUBLESHOOTING H-3 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE Trouble Related information • Machine does not move in any speed range. aPrepare with starting switch OFF. 31 kg/cm2} Defective and Internally de.55 MPa {Min. 26 kg/cm2} Pedal 0 {0} When the hydraulic pressure is abnormal.84 MPa {Min. confirm that the transmission main relief pressure is normal. Possible causes and standard value in normal state D65EX.aPrepare with the starting switch OFF. 2. 2. mission main relief valve Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly. 2. 29 kg/cm2} Internally defective transThe transmission clutch is assumed to be defective internally.

• Confirm that the oil quantity on the power train is normal before troubleshooting. then carry out troubleshooting 2 transmission main relief without turning the starting switch ON. 2.) Defective transmission valve 3 Transmission clutch Clutch pressure (ECMV) function FWD Min. directly check it.TROUBLESHOOTING H-4 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE Trouble Related information • Machine travels only in one direction Forward or in reverse. • Free length of large spring: 128 mm • Free length of small spring: 108 mm • Number of shims: 6 aPrepare with starting switch OFF. confirm that the transmission main relief pressures is normal. PX-15 .84 MPa {Min. directly check it. (Before this.84 MPa {Min. 29 kg/cm2} Defective transmission When the troubleshooting in cause 3 is abnormal. valve or internal defect Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly. then drive the engine in high idling mode for troubleshooting. directly check it. 31 kg/cm2} Defective set pressure of aPrepare with the starting switch OFF. Internally defective transThe transmission clutch (forward or backward) is assumed to be defec5 mission clutch tive internally. 29 kg/cm2} REV Min.04 MPa {Min. 3. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective power train pump The power train pump is assumed to be defective. aPrepare with starting switch OFF. Possible causes and standard value in normal state 20-706 (1) D65EX. then drive the engine in low idling mode for troubleshooting. PCCS lever Transmission main relief pressure Full neutral Min. the clutch seal is as4 clutch seal sume to be defective. 2.

aPrepare with starting switch OFF.TROUBLESHOOTING H-5 H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED. 29 kg/cm2} 3RD Min. Defective brake function 6 (Drag) If the machine does not run by low idling + F2 operation. PCCS lever Transmission main relief pressure Full neutral Min. 3. PX-15 20-707 (1) . 29 kg/cm2} 3 (ECMV) function REV Min. (Before this.04 MPa {Min.84 MPa {Min. directly check it. then drive the engine in high idling mode for troubleshooting. 2. Internally defective transThe transmission clutch is assumed to be defective internally. then start the engine for troubleshooting. • Free length of large spring: 128 mm • Free length of small spring: 108 mm • Number of shims: 6 aPrepare with starting switch OFF.84 MPa {Min. 31 kg/cm2} Defective set pressure of aPrepare with the starting switch OFF. 2. directly 5 mission clutch check it. valve or internal defect Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly. directly check it. 2. confirm that the transmission main relief pressure is normal. aMove to a flat place (a hard road). 29 kg/cm2} 1ST Min. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective power train pump The power train pump is assumed to be defective.) Possible causes and standard value in normal state D65EX. then carry out troubleshooting 2 transmission main relief without turning the starting switch ON.84 MPa {Min. 2. the clutch seal is as4 clutch seal sume to be defective.84 MPa {Min. (Carry out troubleshooting “Brake does not work”. 29 kg/cm2} Defective transmission When the troubleshooting in cause 3 is abnormal.) Transmission clutch Clutch pressure Defective transmission valve FWD Min. 29 kg/cm2} 2ND Min. 2. then drive the engine in low idling mode for troubleshooting. LARGE TIME LAG IS MADE Trouble Related information • Time lag is excessive when shifting gear or changing direction. • Confirm that the oil quantity on the power train is normal before troubleshooting. brake drag occurs.84 MPa {Min.

then drive the engine in high idling Defective set pressure or mode for troubleshooting.) • Confirm that the oil quantity for function is normal before troubleshooting.TROUBLESHOOTING H-6.27 ± 0. defective function of self1 PCCS lever Original pressure of control circuit pressure reducing valve 4. • Confirm that the oil quantity on the power train is normal before troubleshooting. Defective set pressure or 1 defective function of HSS PCCS lever HSS relief pressure main relief valve 38. Standard value in normal state/Remarks on troubleshooting aPrepare with starting the engine. defective function of self2 PCCS lever Original pressure of control circuit pressure reducing valve 4.5 ± 2. Cause Possible causes and standard value in normal state 20-708 (1) D65EX. Standard value in normal state/Remarks on troubleshooting aPrepare with starting the engine.5 kg/cm2} If an abnormal sound occurs in the HSS peripheral equipment. H-7 H-6 H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD) Trouble Related information • Machine does not turn. Cause Possible causes and standard value in normal state H-7 STEERING SPEED OR POWER IS LOW Trouble Related information • Steering speed or power is insufficient.2 – 41.27 ± 0.5 kg/cm2} If an abnormal sound occurs in the HSS peripheral equipment. carry Abnormal sound from HSS 2 out troubleshooting “Abnormal Sound around HSS and Work Equipperipheral equipment ment Pump or HSS Motor”.25 MPa (PPC source pressure) Neutral {43. PX-15 .5 ± 2.7 MPa Left or right stroke end {390 – 425 kg/cm2} aPrepare with starting the engine.25 MPa (PPC source pressure) Neutral {43. then drive the engine in high idling Defective set pressure or mode for troubleshooting. carry Abnormal sound from HSS out troubleshooting “Abnormal Sound around HSS and Work Equip3 peripheral equipment ment Pump or HSS Motor”. (The machine does not turn leftward or rightward. then drive the engine in high idling mode for troubleshooting.

) • Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.TROUBLESHOOTING H-8. See if the machine moves (travels). Brake pedal Brake hydraulic pressure Min. Defective brake function 2. (Carry out troubleshooting “Brake does not work”. the adjustment of the brake pedal linkage is assumed to be abnormal. clutch function (Slip) directly check it. aPrepare with starting the engine for troubleshooting.55 MPa At release {Min. • Confirm that the value of the oil temperature of the power train matches the actual oil temperature before troubleshooting. 2. 1. If it does not move.) Standard value in normal state/Remarks on troubleshooting The engine cooling system is assumed to be defective or the engine Defective engine system output is assumed to be increased. 26 kg/cm2} At pedaling 0 {0} If the troubleshooting in cause 1 is abnormal. aPrepare with starting switch OFF. then drive the engine in high idling mode for troubleshooting. Defective power train pump The power train pump is assumed to be defective or aired from the sucor air from suction circuit tion circuit. If the troubleshooting in cause 1 is abnormal. Run the engine at low idling on a flat place (a hard road). 1 Possible causes and standard value in normal state Defective brake valve function 2 Defective adjustment of brake pedal linkage 3 Defective brake seal 4 Slipped or abrasive brake disk plate H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE Trouble Related information • The oil temperature of the power train overheats. brake drag occurs.69 MPa Max.) Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF.) Cause 1 2 Possible causes and standard value in normal state 3 4 5 D65EX. see the Shop Manual: Engine. 0. the brake seal is assumed to be defective. carry out troubleshooting “Abnormal Power Train Oil temperature”.88 MPa Full neutral {4 – 7 kg/cm2} {Max. then drive the engine in high idling mode for troubleshooting. H-9 H-8 H-8 BRAKE DOES NOT WORK Trouble Related information • Brake does not work. directly check it. (If they do not match. 9 kg/cm2} Defective transmission The transmission clutch is assumed to be defective internally (slipped). • Confirm that the oil quantity on the power train is normal before troubleshooting. • Confirm that the oil quantity on the power train is normal before troubleshooting. Set the gearshift lever in F2. directly check it. PX-15 20-709 (1) . directly check it. (See H-1.39 – 0. • Confirm that the main relief pressure for transmission is normal before troubleshooting. The brake disk plate is assumed to be slipped or abrasive. directly check it. Original pressure of Torque converter Internally defective torque PCCS lever torque converter delivery pressure converter 0. (Drag) 3.

19. the PPC valve is asvalve sumed to be defective internally. directly check it. directly check it. Internally defective HSS The HSS and work equipment pump is assumed to be defective inter4 pump nally. Defective function of selfpressure reducing valve Work equipment lever Original pressure of control circuit (PPC original pressure) 4. 200 kg/cm2} aPrepare with starting switch OFF. directly check it. tor Possible causes and standard value in normal state H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW Trouble Related information • All work equipment speeds are slow.27 ± 0. • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. directly check it. PX-15 .25 MPa Full neutral {43.5 ± 2.5 kg/cm2} Internally defective PPC When the troubleshooting in cause 5 is abnormal. 20-710 (1) D65EX. Defective unload valve funcWork equipment lever Unload pressure tion 3. 3 Possible causes and standard value in normal state 4 5 6 The pump of the HSS and work equipment is assumed to be defective. aPrepare with starting switch OFF. then drive the engine in high idling mode for troubleshooting.43 +1. Cause 1 Inappropriate oil Clogged hydraulic oil tank 2 strainer Standard value in normal state/Remarks on troubleshooting The oil used is assumed to be inappropriate. directly check the pipes. directly check it. then drive the engine in high idling mode for troubleshooting. directly check it.6 MPa Stroke end {Min. Cause Defective PTO (pump drive 1 unit of HSS and work equipment) Defective HSS and work 2 equipment pump Standard value in normal state/Remarks on troubleshooting The PTO pump drive unit of the work equipment is assumed to be defective. The strainer of the hydraulic oil tank is assumed to be clogged. Internally defective HSS mo5 The HSS motor is assumed to be defective internally. directly check it.37 MPa 0 Full neutral {35 +14 kg/cm2} 0 aPrepare with starting switch OFF. Defective set pressure or Work equipment lever Main relief pressure defective function of main relief valve Min. then drive the engine in high idling mode for troubleshooting. Air is assumed to be inhaled in the suction circuit of the HSS and work 3 Air inhaled in suction circuit equipment pump. H-11 H-10 H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR Trouble Related information • Abnormal noise from around HSS and work equipment pump.TROUBLESHOOTING H-10.

directly check it. Defective set pressure or Work equipment lever Main relief pressure 4 defective function of main relief valve Min.53 – 4. then drive the engine in high idling mode for troubleshooting.5 ± 2. Confirm whether the blade is remodeled.25 MPa Full neutral {43.41 MPa Lift stroke end {36 – 45 kg/cm2} The spool function of the blade lift operation valve is assumed to be defective. Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. The blade lift cylinder is assumed to be aired. then drive the engine in high idling mode for troubleshooting. 19. PX-15 20-711 (1) .37 MPa 0 Full neutral {35 +14 kg/cm2} 0 aPrepare with starting switch OFF. Possible causes and standard value in normal state The HSS and work equipment pump is assumed to be defective. directly check it. Blade lever PPC valve output pressure 3. H-13 H-12 H-12 WORK EQUIPMENT DOES NOT MOVE Trouble Related information • Work equipment does not move. 200 kg/cm2} aPrepare with starting switch OFF. carry out troubleshooting “High Hydraulic Drift Rate of Blade Lift”.27 ± 0.6 MPa Stroke end {Min. then drive the engine in high idling mode for troubleshooting. When the hydraulic drift rate of the blade lift is also high.TROUBLESHOOTING H-12. aPrepare with starting switch OFF.5 kg/cm2} H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER Trouble Related information • • • • Blade lift speed is slow or lacks power. Possible causes and standard value in normal state 1 Defective PPC valve function 2 Defective function of blade lift operation valve (Spool) 3 Aired blade lift cylinder D65EX. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. directly check it. • Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.43 +1. Cause Defective PTO (Pump drive 1 unit of HSS and work equipment) Defective HSS and work 2 equipment pump Standard value in normal state/Remarks on troubleshooting The PTO pump drive unit of the HSS and work equipment is assumed to be defective. carry out the air bleed and observe how the phenomenon changes. Defective function of self5 pressure reducing valve Work equipment lever Original pressure of control circuit (PPC original pressure) 4. then drive the engine in high idling mode for troubleshooting. Defective unload valve func3 Work equipment lever Unload pressure tion 3.

When the hydraulic drift rate of the ripper lift is also high.41 MPa Lift stroke end {36 – 45 kg/cm2} The spool function of the blade tilt operation valve is assumed to be defective. PX-15 . When the hydraulic drift rate of the blade tilt is also high.53 – 4. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. carry out the air bleed and observe how the phenomenon changes.TROUBLESHOOTING H-14. 1 Possible causes and standard value in normal state Defective PPC valve function 2 Defective function of ripper lift operation valve (Spool) Defective function of ripper 3 lift operation valve (suction valve) 4 Aired ripper lift cylinder 20-712 (1) D65EX. The blade tilt cylinder is assumed to be aired. The ripper lift cylinder is assumed to be aired. Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. then drive the engine in high idling mode for troubleshooting.41 MPa Lift stroke end {36 – 45 kg/cm2} The spool function of the ripper lift operation valve is assumed to be defective. carry out troubleshooting “High Hydraulic Drift Rate of Blade Tilt”. aReplace the suction valve in the head with one at the bottom. The suction valve of the ripper lift operation valve is assumed to be defective. Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting. carry out the air bleed and observe how the phenomenon changes. Blade lever PPC valve output pressure 3.53 – 4. directly check it. and observe how the phenomenon changes. Possible causes and standard value in normal state 1 Defective PPC valve function 2 Defective function of blade tilt operation valve (Spool) 3 Aired blade tilt cylinder H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER Trouble Related information • • • • Ripper lift speed is slow or lacks power. Confirm whether the blade is remodeled. directly check it. directly check it. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF. then drive the engine in high idling mode for troubleshooting. H-15 H-14 H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER Trouble Related information • • • • Blade tilt speed is slow or lacks power. Ripper lever PPC valve output pressure 3. carry out troubleshooting “High Hydraulic Drift Rate of Ripper Lift”. Confirm whether the ripper is remodeled.

Fully extend the blade tilt cylinder. • Confirm that no oil leaks the circuits in the work equipment before troubleshooting. • Confirm that no oil leaks the circuits in the work equipment before troubleshooting. Disconnect the hose on the cylinder head and block it. 3. • Confirm whether the blade is remodeled. Possible causes and standard value in normal state 1 Defective seal of blade lift operation valve (Spool) 2 Defective seal of blade lift cylinder H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT Trouble Related information • Excessive hydraulic drift of blade tilt. Blade tilt Hydraulic drift Block blade tilt circuit 200 mm/15 min The seal of the blade tilt cylinder is assumed to be defective. Blade lift Hydraulic drift Block blade lift circuit 100 mm/15 min The seal of the blade lift cylinder is assumed to be defective. Measure hydraulic drift of blade tip. then stop the engine for troubleshooting. Measure hydraulic drift of blade tip. Possible causes and standard value in normal state 1 Defective seal of blade tilt operation valve (Spool) 2 Defective seal of blade tilt cylinder D65EX.TROUBLESHOOTING H-16. 3. • Confirm whether the blade is remodeled. PX-15 20-713 (1) . H-17 H-16 H-16 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT Trouble Related information • Excessive hydraulic drift of blade lift. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting the engine. 1. directly check it. 2. directly check it. Raise the blade (about 800 mm). then stop the engine for troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting the engine. 2. 1. Disconnect the hose on the cylinder head and block it.

1.TROUBLESHOOTING H-18 H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT Trouble Related information • Excessive hydraulic drift of ripper lift. • Confirm whether the ripper is remodeled. Possible causes and standard value in normal state 1 Defective seal of ripper lift operation valve (Spool) 2 Defective seal of ripper lift cylinder 20-714 (1) D65EX. directly check it. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with starting the engine. PX-15 . Ripper lift Hydraulic drift Block ripper lift circuit 100 mm/15 min The seal of the ripper lift cylinder is assumed to be defective. Pull out the shank pin and raise the ripper to the maximum. Disconnect the hose on the cylinder head side and block it. • Confirm that no oil leaks the circuits in the work equipment before troubleshooting. 2. then stop the engine for troubleshooting.

.............. fuel in oil) ......................................7 Exhaust smoke is black (incomplete combustion) ................................................. or water level goes down) ........................................................................... S........................................... S-13 Oil level rises (water............................................................................................................................................ S......................................................8 Oil consumption is excessive (or exhaust smoke is blue) ............................................................................................................................... S-16 Vibration is excessive .................................... S-15 Abnormal noise is made ...............................6 Engine lacks output (or lacks power) .................................................... S............................................................................ PX-15 20-801 (1) .............. S-10 Fuel consumption is excessive ....................................... S..................5 Engine does not rotate smoothly (hunting) .......................9 Oil becomes contaminated quickly ......................................................................... S..................... S-14 Water temperature becomes too high (overheating) .................................TROUBLESHOOTING TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) Method of using troubleshooting charts ........................................................................................ S-12 Oil pressure caution lamp lights up (drop in oil pressure) ....4 Engine stops during operations ...................... S.........3 Engine does not pick up smoothly (follow-up is poor) .......................................................................................................................................................................................................................1 Starting performance is poor (starting always takes time) ...... S-11 Oil is in cooling water (or water spurts back................................................... 20-802 20-806 20-807 20-810 20-811 20-812 20-813 20-814 20-815 20-816 20-817 20-818 20-819 20-820 20-821 20-822 20-823 D65EX...................... S...... S.. S...............................................................2 Engine does not start ............................

check items. [Check items] The serviceman carries out simple inspection to narrow down the causes. PX-15 . The items in (B) are items that can be obtained from the user. Next. [Questions] Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items under (C) in the chart on the right correspond to this. [Troubleshooting] Troubleshooting is carried out in the order of probability.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions. and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. 20-802 (1) D65EX. depending on the user’s level. starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. The serviceman narrows down the causes from information (A) that he has obtained from the user and the results of (C) that he has obtained from his own inspection.

Check each of the [Questions] and [Check items] in turn. Use the E in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. For (Confirm recent repair history) in the [Questions] Section. 1 2 D65EX. However. and of these. do not use this when marking caluculations to narrow down causes. so start troubleshooting for that item to make final confirmation of the cause. PX-15 20-803 (1) . Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with Q. ask the user. 2. but it can be included if necessary to determine the order for troubleshooting. The vertical column (Causes) that has the highest number of applicable Q or w marks is the most probable cause.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS The basic method of using the troubleshooting chart is as follows. As a rule. do not use it when calculating the points for locating the cause. causes that have a high probability are marked with w. 1. taking note of the Q or w marks in the chart for the horizontal lines of symptoms applicable to the machine. and mark the Cause column with E to use as reference for locating the cause of the fairure.

and [Dust indicator is red]. If we look from these three symptoms to find the causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. we find that there is a relationship with five causes.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS • Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system. S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel.) Legend : Possible causes (judging from Questions and Check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items to confirm the cause. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. [Power gradually became weaker]. PX-15 . Three symptoms have a causal relationship with this problem: [Exhaust gas gradually became black]. 20-804 (1) D65EX.

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS 5 causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the 5 Cause items in the vertical column. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . (1) Clogged air cleaner element: (2) Air leakage between turbocharger and cyl. valve seat: (5) Worn piston ring. cylinder: Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. and the exhaust gas color should return to normal. Three symptoms Step 2 Add up the total of and marked where the horizontal limes for the three symptoms and the vertical columns for the causes intersect. D65EX. head: (3) Clogged. PX-15 20-805 (1) . seized injection nozzle: (4) Defective contact of valve. so carry out cleaning. The Remedy is given as [Clean].

the engine may not start until the crankshaft has completed two rotations.TROUBLESHOOTING S-1 S-1 Starting performance is poor (starting always takes time) General causes why starting performance is poor • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel a With the common rail fuel injection system. Causes Confirm recent repair history Degree of use of machine Ease of starting Operated for long period Gradually became worse Starts when warm E E E E Q w w Q Q w w Q Q Q Q w w Q Q Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Preheating indicator lamp does not light up during preheating or in low temperatures Charging caution lamp lights up while engine is running Dust indicator lamp is red Air breather hole in fuel tank cap is clogged Leakage of fuel from fuel piping When fuel priming pump is operated. this does not indicate any abnormality. temperature of some cylinders is low Engine does not pick up smoothly add combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Check air cleaner directly When compression pressure is measured. it is found to be low Remedy 20-806 (1) D65EX. spill flow is small (See error code “AD10L3”) When exhaust manifold is touched immediately after starting engine. air comes out Check fuel filter. However. so even when the starting operation is carried out. it is found to be low When air is bled from fuel line. there is no response. strainer directly Check fuel feed pump strainer directly Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed” Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Intake air heater mount does not become warm during operation of preheating Is voltage 26 – 30 V between alternator terminal B and terminal E with engine at low idling? w w q q q When specific gravity of electrolyte or voltage of battery is measured. or operation is too heavy Starting motor cranks engine slowly When engine is cranked with starting motor No fuel comes out even when fuel filter air bleed plug is removed w w w w w w w w Q w Q Q w w w w Q Q Q w Q Q w q q q q q q q q q Yes No When hose at collection portion for spill flow from fuel injector is disconnected. the fuel injection timing is recognized electrically. PX-15 .

engine starts Remedy Q w w Q Q w q q q q D65EX. PX-15 20-807 (1) . pinion moves out. engine starts When terminal B and terminal C of starting motor are connected. engine starts When terminal B and terminal C of safety relay are connected. there is no actuation sound from battery relay When starting switch is turned to START. pinion does not move out Speed of rotation is low When starting switch is turned to START.TROUBLESHOOTING S-2 S-2 Engine does not start a) Engine does not turn General causes why engine does not turn • Internal parts of engine seized a See “Engine stops during operations”. and carry out troubleshooting at ON When terminal B and terminal C of starting switch are connected. battery electrolyte is found to be low Battery terminal is loose When starting switch is turned to ON. but Makes grating noise Soon disengages again Makes rattling noise and does not turn Check flywheel ring gear directly When specific gravity of electrolyte or voltage of battery is measured. it is found to be low There is no voltage (20 – 30 V) between battery relay terminal B and terminal E Turn the starting switch OFF. Causes Confirm recent repair history Degree of use of machine Condition of horn when starting switch is turned ON Operated for long period Horn does not sound Horn volume is low E E w w w w Q Q w w Q q q q w Q w When battery is checked. connect the cord. engine starts When terminal of safety switch and terminal B of starting motor are connected. • Defective electrical system • Failure in power train a Carry out troubleshooting of the machine.

air comes out Check fuel filter directly Check fuel feed pump gauze filter directly Check fuel feed pump directly Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed” Carry out troubleshooting “Abnormality in fuel supply pump solenoid” in troubleshooting for monitor panel Check fuel overflow valve directly Possible to start in reduced cylinder mode Remedy q q 20-808 (1) D65EX. spill flow is small (See error code “AD10L3”) w Q w w w w w w Q w Q Q Q w w w w Q Q Q w Q Q q q q q q q q q q w w w w Q Q E E E Q Q Q When air is bled from fuel line. PX-15 . or operation is too heavy When engine is cranked with starting motor No fuel comes out even when fuel filter air bleed plug is removed When hose at collection portion for spill flow from fuel injector is disconnected.TROUBLESHOOTING S-2 b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out • Fuel is not being supplied • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter) Causes Confirm recent repair history Degree of use of machine Operated for long period E E E Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is removed. there is no fuel in filter There is leakage from fuel piping When fuel priming pump is operated. there is no response.

abnormal noise is heard from around cylinder head When engine is cranked with starting motor No fuel comes out even when fuel filter air bleed plug is removed Operated for long period E E E E w w w w w w Q Q Q w w Q w w w w w Q Q w w Q w w w w q q q q q q q q q q q Remedy When hose at collection portion for spill flow from fuel injector is disconnected. there is no response. air comes out Check fuel filter. or operation is too heavy Starting motor cranks engine slowly When engine is cranked. spill flow is small (See error code “AD10L3”) When exhaust manifold is touched immediately after starting engine. strainer directly Check fuel feed pump strainer directly Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed” Spray condition is poor when fuel injector is tested as individual part When specific gravity of electrolyte or voltage of battery is measured it is found to be low Defective water temperature gauge display on machine Intake air heater mount does not become warm during preheating D65EX.TROUBLESHOOTING S-2 c) Exhaust smoke comes out but engine does not start (Fuel is being injected) General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel Causes Confirm recent repair history Degree of use of machine Suddenly failed to start Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Preheating indicator lamp dies not light up during preheating or in low temperatures Dust indicator lamp is red Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is removed. there is no fuel in filter There is leakage from fuel piping When fuel priming pump is operated. temperature of some cylinders is low Check air cleaner element directly Remove head cover and check directly When compression pressure is measured. it is found to be low When air is bled from fuel line. PX-15 20-809 (1) .

PX-15 .) Causes Confirm recent repair history Degree of use of machine Operated for long period E E E E E Engine pick-up suddenly became poor Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Dust indicator lamp is red Air breather hole in fuel tank cap is clogged Rust and water are found when fuel is drained There is leakage from fuel piping When fuel priming pump is operated. there is no response. or operation is too heavy When exhaust manifold is touched immediately after starting engine. temperature of some cylinders is low Color of exhaust gas Blue under light load Black w w w w Q Q w w w w w Q w w w w w w Q Q Q w w Q w w Q Q w q q q q q q q q q q q w w Q w Q w w w Abnormal noise is heard from around cylinder head when engine is run Noise of interference is heard from around turbocharger High idling speed is normal. it is found to be low Check valve clearance directly When turbocharger is rotated by hand.TROUBLESHOOTING S-3 S-3 Engine does not pick up smoothly (follow-up is poor) General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system. but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive Check air cleaner element directly When compression pressure is measured. it is found to be heavy When air is bled from fuel line. air comes out Check fuel filter. strainer directly Check fuel feed pump strainer directly Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed” Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Remedy 20-810 (1) D65EX.

engine turns Remedy E E w w w w w Q w w Q Q Q Q w Q w Q w w Q Q Q Q Q Q w Q w w w w w Q Q w w Q Q w w w w w w w w w q q q q q q q q q q D65EX. there is no response. or operation is too heavy Rust and water are found when fuel tank is drained Metal particles are found when oil is drained Does not turn at all When it is attempted to turn engine by hand Turns in opposite direction Moves amount of backlash Fuel supply pump shaft does not turn Engine rotates. • Failure in power train a Carry out troubleshooting of the machine. pump. Causes Confirm recent repair history Degree of use of machine Operated for long period Abnormal noise was heard and engine stopped suddenly Condition when engine stopped Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Fuel level caution lamp lights up Fuel tank is found to be empty Air breather hole in fuel tank cap is clogged There is leakage from fuel piping When priming pump is operated.TROUBLESHOOTING S-4 S-4 Engine stops during operations General causes why engine stops • Internal part of engine seized • Insufficient supply of fuel • Engine overheating a See troubleshooting for [Overheat]. air compressor) is removed. strainer directly Check fuel feed pump strainer directly Check fuel feed pump directly Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed” When auxiliary equipment (Hyd. PX-15 20-811 (1) . but stops when load is applied to machine Check dynamic valve system directly Check piston and connecting rod directly Check crankshaft directly Check gear train directly Check fuel filter.

TROUBLESHOOTING S-5 S-5 Engine does not rotate smoothly (hunting) General causes why engine does not rotate smoothly • Air in fuel system • Speed sensor is not normal (abnormality not big enough to generate error display) Causes Confirm recent repair history Degree of use of machine Operated for long period Occurs at a certain speed range Condition of hunting Occurs at low idling Occurs even when speed is raised Occurs on slopes Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained There is leakage from fuel piping When fuel priming pump is operated. strainer directly Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Carry out troubleshooting for error code “DLH1LC: Abnormality in Ne revolution sensor” Carry out troubleshooting for error code “DLE3LC: Abnormality in G revolution sensor” Remedy E E Q w Q Q Q Q Q Q Q Q Q w Q w w w w Q Q w w Q Q q q q q q q Q Q Q Q q 20-812 (1) D65EX. or operation is too heavy When air is bled from fuel line. there is no response. PX-15 . air comes out Check fuel feed pump strainer directly Check fuel filter.

it is found to be low When compression pressure is measured.TROUBLESHOOTING S-6 S-6 Engine lacks output (or lacks power) General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. it is found to be clogged Check air intake piping directly When boost pressure is measured. strainer directly Check fuel feed pump gauze filter directly Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed” Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Check mounting of boost pressure sensor directly Carry out troubleshooting for error code “DH30KX: Abnormality in boost pressure sensor” Carry out troubleshooting for error code “DGE4KX: Abnormality in fuel temperature sensor” Remedy D65EX. PX-15 20-813 (1) . • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system. temperature of some cylinders is low Noise of interference is heard from around cylinder head when engine is run Abnormal noise is heard from around cylinder head when engine is run High idling speed of engine is low High idling speed is normal.) Causes Confirm recent repair history Degree of use of machine Power was lost Operated for long period Suddenly Gradually E E E E E Q Q w Q Q Q w w w Q Q Q Q Q Q Q Q Q Q Q Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Engine oil must be added more frequently Dust indicator lamp is red Air breather hole in fuel tank cap is clogged There is leakage from fuel piping Power is lacking after short stop in operations Color of exhaust gas Black Blue under light load w w w w w w w Q w w Q w w q q q q q q q q q q q q q q q q Q Q Q Q Q Q w When exhaust manifold is touched immediately after starting engine. it is found to be low Check valve clearance directly Check fuel filter. but speed suddenly drops when load is applied Engine pickup is poor and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive When air cleaner element is inspected directly.

PX-15 .) Causes Confirm recent repair history Degree of use of machine Operated for long period Suddenly became black Color of exhaust gas Gradually became black Blue under light load Non-specified fuel is being used Engine oil must be added more frequently Power was lost Dust indicator lamp is red Muffler is crushed Leakage of air between turbocharger and cylinder head. exhaust color returns to normal Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed” Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Check fuel spill piping directly Carry out troubleshooting for error code “DGE3L6: Abnormality in water temperature sensor” Remedy Suddenly Gradually E E E E w w Q w Q Q Q Q Q Q w w Q w Q Q Q Q w w Q Q Q Q Q Q w w w Q Q Q Q w Q Q Q w w q q q q q q q q q q Q Q w 20-814 (1) D65EX. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating a See troubleshooting for [Overheat]. it is found to be low Check valve clearance directly When muffler is removed. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system. temperature of some cylinders is low Noise of interference is heard from around turbocharger when engine is run Abnormal noise is heard from around cylinder head when engine is run Stall speed is too high (excessive injection of fuel) Exhaust noise is abnormal Engine pickup is poor and combustion is irregular Blow-by gas is excessive When hose from the injector to spill collection portion is disconnected. loose damp Operates in low-temperature mode even at normal temperatures When exhaust manifold is touched immediately after starting engine. spill flow is found to be abnormally high (See error code “AD10L3”) Check air cleaner directly When turbocharger is rotated by hand.TROUBLESHOOTING S-7 S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. it is found to be heavy When compression pressure is measured.

PX-15 20-815 (1) . • External leakage of oil • Wear of lubrication system Causes Confirm recent repair history Degree of use of machine Operated for long period E E E E Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Outside of engine is dirty with oil Loose piping clamp in air intake system Inside of turbocharger air supply pipe is dirty with oil Inside of exhaust pipe is dirty with oil There is oil in engine cooling water Oil level in clutch or damper chamber rises Exhaust smoke is blue under light load Amount of blow-by gas Excessive None w w Q Q w w w Q w Q Q w w w w w w w Q q q q q q q q q q q q q q q Remedy Q w w w w w When intake manifold is removed. dust is found inside When intake manifold is removed.TROUBLESHOOTING S-8 S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive • Abnormal combustion of oil • The engine has been run at low or high idling for a long time continuously (more than 20 minutes continuous operation is not allowed). inside is found to be extremely dirty Excessive play of turbocharger shaft Check breather element directly When compression pressure is measured. it is found to be low Check rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage There is external leakage of oil from engine D65EX.

it is found to be low Check breather. breather tube directly Check oil cooler is inspected directly Check oil filter directly Spring of oil filter safety valve catching or broken Check turbocharger drain tube directly Remedy Q w w Q Q w w w w Q Q w w q q q q q q q q Q w Q Amount of blow-by gas 20-816 (1) D65EX. PX-15 . oil filter caution lamp lights up When oil filter is inspected. metal particles are found Inside of exhaust pipe is dirty with oil Engine oil temperature rises quickly Color of exhaust gas Blue under light load Black Excessive None Excessive play of turbocharger shaft When compression pressure is measured.TROUBLESHOOTING S-9 S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly • Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Improper fuel used • Improper oil used • Operation under excessive load Causes Confirm recent repair history Degree of use of machine Operated for long period E E E Non-specified fuel is being used Engine oil must be added more frequently Even when oil temperature rises.

it is found to be excessive Carry out troubleshooting for error code “AD10L3: Abnormality in water low-temperature sensor” Check with monitoring function on machine q D65EX. PX-15 20-817 (1) .TROUBLESHOOTING S-10 S-10 Fuel consumption is excessive General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection (injection pressure. injection timing) • Excessive injection of fuel Causes Confirm recent repair history Degree of use of machine Condition of fuel consumption Operated for long period More than for other machines of same model Gradually increased Suddenly increased There is external leakage of fuel from engine There is irregular combustion Engine oil level rises and smells of diesel fuel When exhaust manifold is touched immediately after starting engine. temperature of some cylinders is low Low idling speed is high Engine stall speed is high Exhaust gas color Black White E E E Q Q Q Q w w w w w Q Q Q Q Q Q Q Q q q q q q q q Remedy Q Q Remove head cover and check directly Check fuel feed pump oil seal directly Carry out troubleshooting for error code “DGE3L6: Fuel supply pump non-force feed” Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode When flow of oil from fuel injector at spill return collection portion is measured.

liner directly Check cylinder liner directly Pressure-tightness test of oil cooler shows there is leakage Remedy w w q q q q q 20-818 (1) D65EX.TROUBLESHOOTING S-11 S-11 Oil is in cooling water (or water spurts back. or water level goes down) General causes why oil is in cooling water • Internal leakage in lubrication system • Internal leakage in cooling system Causes Confirm recent repair history Degree of use of machine Oil level Operated for long period Suddenly increased Gradually increased E E Q Q Q Q Q Q w w Q Q w Q Hard water is being used as cooling water Engine oil level has risen. oil is cloudy white Excessive air bubbles inside radiator. transmission oil is drained. transmission oil is cloudy white When hydraulic oil. PX-15 . spurts back Hydraulic oil. water is found Pressure-tightness test of cylinder head shows there is leakage Check cylinder block.

PX-15 20-819 (1) . wear of lubricating system • Defective oil pressure control • Improper oil used (improper viscosity) • Deterioration of oil due to overheating Causes Confirm recent repair history Degree of use of machine Operated for long period E E E Oil pressure caution lamp lights up Non-specified oil is being used Replacement of filters has not been carried out according to Operation Manual Lights up at low idling Condition when oil pressure lamp light up Lights up at low idling and high idling Lights up on slopes Sometimes lights up Oil temperature caution lamp lights up (machines equipped with lamp) Oil level in oil pan is low There is crushing. clogging.TROUBLESHOOTING S-12 S-12 Oil pressure caution lamp lights up (drop in oil pressure) General causes why oil pressure drops • Leakage. oil pressure caution lamp goes out Remedy Q w Q w w w Q w Q w Q w w w Q w Q Q w w w w w q q q Q q q q q q D65EX. spring in oil pump relief valve Check oil filter directly Carry out troubleshooting for error code “DDE2L6: Abnormality in oil pressure sensor” When oil level sensor is replaces. external leakage from hydraulic piping Oil is cloudy white or smells of diesel oil Metal particles are found when oil is drained Metal particles are found when oil inside oil filter is drained Metal particles are found in oil filter Check oil pan strainer pipe directly Oil pump rotation is heavy. there is play Deterioration. damage of valve.

water comes out Oil level goes down in clutch chamber or damper chamber Oil level goes down in hydraulic tank When compression pressure is measured. PX-15 . liner directly Check rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove water pump and check directly Remove thermostat cover and check directly Remove fuel supply pump and check directly Check auxiliary equipment seal directly Remedy w Q Q w Q Q w Q w w w w Q Q w Q Q w w w w q q q q q q q q q q 20-820 (1) D65EX. smells of diesel fuel) a If there is oil in the cooling water. carry out troubleshooting for “Oil is in cooling water”. or water spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned.TROUBLESHOOTING S-13 S-13 Oil level rises (water. drops of water come from muffler When radiator cap is left open and engine is run at idling. fuel in oil) General causes why oil level rises • Water in oil (cloudy white) • Fuel in oil (diluted. it is found to be low Remove head cover and check directly Check cylinder block. an abnormal number of bubbles appear. Causes Confirm recent repair history Degree of use of machine Operated for long period E E E E Fuel consumption has increased Water must be added more frequently There is oil in engine cooling water Oil smells of diesel fuel Oil is cloudy white When engine is started.

oil is cloudy white Fan belt tension is loose There is play when fan pulley is rotated Cloudy white oil is floating on cooling water Excessive air bubbles inside radiator. water spurts back When light bulb is held behind radiator. it is found to be low Check cylinder liner directly Check oil cooler directly Temperature difference between top and bottom radiator tanks is excessive When function test is carried out on thermostat. Causes Confirm recent repair history Degree of use of machine Condition of overheating Operated for long period Suddenly overheated Always tends to overheat Rises quickly Water temperature gauge Does not go down from red range E E E E Q w Q w w Q Q w w w Q Q w Radiator water level caution lamp lights up Engine oil level has risen. no light passes through Radiator shroud. damage of fan) • Drop in heat dissipation efficiency • Defective cooling circulation system • Rise in oil temperature in power train a Carry out troubleshooting for machine.TROUBLESHOOTING S-14 S-14 Water temperature becomes too high (overheating) General causes why water temperature becomes too high • Lack of cooling air (deformation. pulley directly When water temperature is measured. PX-15 20-821 (1) . inside of underguard are clogged with dirt or mud Water is leaking because of cracks in hose or loose clamps Cooling water flows out from radiator overflow hose Fan belt whines under sudden acceleration Power train oil temperature enters red range faster than engine water temperature When compression pressure is measured. it is found to be normal Remedy w w w w w w w w w w q q q q q q q q q w D65EX. it does not open even at cracking temperature Temperature difference between top and bottom radiator tanks is small Check radiator core directly When function test is carried out on radiator cap. cracking pressure is found to be low Check fan belt.

TROUBLESHOOTING S-15 S-15 Abnormal noise is made General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system a Judge if the noise is an internal noise or an external noise. but this is not an abnormality. abnormal noise disappears Check valve clearance directly When compression pressure is measured. but this is not an abnormality. temperature of some cylinders is low Color of exhaust gas Blue under light load Black w Q w Q w Q Q w q q q q q q q q q q q q Q w Q Q Engine pickup is poor and combustion is abnormal Abnormal noise is loud when accelerating Blow-by gas is excessive When turbocharger is rotated by hand. fan belt directly Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Abnormal noise is made only when starting Check with monitoring function on machine Remedy 20-822 (1) D65EX. PX-15 . it enters the acceleration mode and the engine noise is higher for 3 seconds. the engine sound becomes slightly louder because it is operated in the low temperature mode. a When the engine is accelerated. a If the engine is not thoroughly warmed up. it is found to be heavy Check dynamic valve system directly When muffler is removed. Causes Confirm recent repair history Degree of use of machine Condition of abnormal noise Operated for long period Gradually occurred Suddenly occurred E Q Q Q w w w w w w w Q Q Q w Non-specified fuel is being used Engine oil must be added more frequently Metal particles are found in oil drained from oil filter Leakage of air between turbocharger and cylinder head Noise of interference is heard from around turbocharger when engine is run Abnormal noise is heard from around cylinder head when engine is run Vibrating noise is heard from around muffler when engine is run When exhaust manifold is touched immediately after starting engine. it is found to be low Remove timing gear cover and check directly Check fan.

connecting rod bearing directly Check gear train directly Check cam bushing directly Check with monitoring function on machine Check engine mounting bolts directly When face runout and radial runout are inspected. PX-15 20-823 (1) . they are found to be incorrect Check support spigot joint portion directly Check inside of output shaft (damper) directly Remedy Q Q Q Q Q Q q D65EX. carry out troubleshooting also for “Abnormal noise is made”. Causes Confirm recent repair history Degree of use of machine Condition of vibration Operated for long period Suddenly increased Gradually increased E E E E Q Q Q w w Q Q w q q q q q q q q Q Q w w Q Q Q Q Non-specified fuel is being used Metal particles are found in oil drained from oil filter Metal particles are found when oil pan is drained Oil pressure is low at low idling Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Check dynamic valve system directly Check main bearing. breakage) • Improper alignment with machine • Abnormal combustion a If there is abnormal noise together with the vibration.TROUBLESHOOTING S-16 S-16 Vibration is excessive General causes why vibration is excessive • Defective parts (abnormal wear.

....... Removal .......................... REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY . 30REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY ...................19 303030303030303022 22 22 23 24 24 24 24 30....................................17 30.... Special tool ......................... Installation .....18 30...........................................................................................................................................................................4 30....................... 30........... 30Assembly .................................. SPECIAL TOOL LIST ................................................................. 30DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY ............ 30Removal .................................. Special tool ......... Removal ............................. Disassembly and assembly of assemblies ....................25 303030303030303026 26 26 26 29 29 29 32 D65EX............. REMOVAL AND INSTALLATION OF NOZZLE TIP ..........................................................................................18 30.........................................................................................................5 30...................... Special tool . 30Installation ..17 30...... 30Disassembly ................................................. 30- 34 34 35 36 36 37 38 38 38 41 43 43 45 46 46 49 50 50 50 57 68 68 68 75 86 86 88 92 92 94 97 97 97 30....................................................... REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY .......................DISASSEMBLY AND ASSEMBLY 30 DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL ...................... 30REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY ................................................................................... Removal .............. Installation ......................... REMOVAL AND INSTALLATION OF ENGINE REAR SEAL ................ 30Assembly ......................................................................................................................... Installation .................................. 30Special tool ........................................................ 30Installation .................... 30Connection .................................... Installation .....12 3030303013 13 13 14 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY ............................ 30Assembly .. Installation ........ 30DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY .. Removal ................................................................................................................. 30Assembly .............................................................................................. Removal ............................................... 30Removal ........ Installation ..............................................................17 30........................4 30............... REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY ... 30Disassembly ............... 30Installation ............................................................................................... 30Removal .......................................... COATING MATERIALS LIST ................................................................................... 30Disconnection .................................. SKETCHES OF SPECIAL TOOLS ................... 30DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY ............... 30Disassembly ................................................ Removal ..............................8 30.......... REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY .............. 30DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY ...6 30.......... 30REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY .................................... 30Removal ............. REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL .................................. Removal and installation of assemblies ............ Installation ..................................... 30DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY ....... 30Disassembly . 30Special tool ....25 30............ 30Installation ...................................... Removal .......... Installation ...............................................................25 30......... 30Installation ... 30Special tool .......................................................................... Removal .................. PX-15 30-1 (8) ........................... REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY ..................... Special tool .... 30Removal .................. Special tool ............ 30REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY ....................................................

............................ Special tool ................................................................................................................................................... Expansion of track shoe assembly (When track frame has internal trouble) ............ Installation .................................................. Installation .................. Expansion of track shoe assembly (Ordinary) .................... Installation ...... Assembly .......... Removal ............................................... Disassembly ....................... Special tool ....................................................................................