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FOREWORD

CEBM019102

Shop
Manual

D51EX-22
D51PX-22
CRAWLER TRACTOR

D51EX-22 B10001
SERIAL NUMBERS and UP
D51PX-22 B10001

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

D51EX-22 00-1 2
FOREWORD CONTENTS
12
CONTENTS 00

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2 1
FOREWORD

The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. m New page to be added Add

l Page to be replaced Replace

( ) Page to be deleted Discard

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l 00-1 c 00-21 10-8 10-37

l 00-2 b 00-22 10-9 10-38

l 00-2-1 c 00-23 10-10 10-39

m 00-2-2 b 00-24 10-11 10-40

m 00-2-3 b 00-25 10-12 10-41

m 00-2-4 b 00-26 10-13 10-42

m 00-2-5 b 00-27 10-14 10-43

m 00-2-6 b 00-28 10-15 10-44

m 00-2-7 b 10-16 10-45

m 00-2-8 b 01-1 10-17 10-46

l 00-2-9 c 01-2 10-18 10-47

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10-79 10-112 10-145 10-178

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10-81 10-114 10-147 10-180

10-82 10-115 10-148 10-181

10-83 10-116 10-149 10-182

10-84 10-117 10-150 10-183

10-85 10-118 10-151 10-184

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10-90 10-123 10-156

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10-93 10-126 10-159 20-3

10-94 10-127 10-160 20-4

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10-98 10-131 10-164 20-8

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30-3 30-36 30-69 30-102

30-4 30-37 30-70 30-103

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30-7 30-40 30-73 30-106

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30-11 30-44 30-77 30-110

30-12 30-45 30-78 30-111

30-13 30-46 30-79 30-112

30-14 30-47 30-80 30-113

30-15 30-48 30-81 30-114

30-16 30-49 30-82 30-115

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30-29 30-62 30-95 30-128

30-30 30-63 30-96 30-129

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30-130 40-122 l 40-203 b l 40-236 b

30-131 40-123 l 40-204 b l 40-237 b

30-132 40-124 l 40-205 b l 40-238 b

30-133 40-125 l 40-206 b l 40-239 b

30-134 40-126 l 40-207 b l 40-240 b

30-135 40-127 l 40-208 b l 40-241 b

30-136 40-128 l 40-209 b l 40-242 b

30-137 40-129 l 40-210 b l 40-243 b

30-138 40-130 l 40-211 b l 40-244 b

30-139 40-131 l 40-212 b l 40-245 b

30-140 40-132 l 40-213 b l 40-246 b

40-133 l 40-214 b l 40-247 b

40-101 40-134 l 40-215 b l 40-248 b

40-102 40-135 l 40-216 b l 40-249 b

40-103 40-136 l 40-217 b l 40-250 b

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40-105 40-138 l 40-219 b l 40-252 b

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40-111 40-144 l 40-225 b l 40-258 b

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40-114 40-147 l 40-228 b l 40-261 b

40-115 40-148 l 40-229 b l 40-262 b

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40-117 40-150 l 40-231 b l 40-264 b

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40-119 l 40-233 b l 40-266 b

40-120 l 40-201 b l 40-234 b l 40-267 b

40-121 l 40-202 b l 40-235 b l 40-268 b

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l 40-269 b l 40-302 b l 40-335 b l 40-368 b

l 40-270 b l 40-303 b l 40-336 b l 40-369 b

l 40-271 b l 40-304 b l 40-337 b l 40-370 b

l 40-272 b l 40-305 b l 40-338 b l 40-371 b

l 40-273 b l 40-306 b l 40-339 b l 40-372 b

l 40-274 b l 40-307 b l 40-340 b l 40-373 b

l 40-275 b l 40-308 b l 40-341 b l 40-374 b

l 40-276 b l 40-309 b l 40-342 b l 40-375 b

l 40-277 b l 40-310 b l 40-343 b l 40-376 b

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l 40-286 b l 40-319 b l 40-352 b m 40-385 b

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l 40-288 b l 40-321 b l 40-354 b m 40-387 b

l 40-289 b l 40-322 b l 40-355 b m 40-388 b

l 40-290 b l 40-323 b l 40-356 b m 40-389 b

l 40-291 b l 40-324 b l 40-357 b m 40-390 b

l 40-292 b l 40-325 b l 40-358 b m 40-391 b

l 40-293 b l 40-326 b l 40-359 b m 40-392 b

l 40-294 b l 40-327 b l 40-360 b m 40-393 b

l 40-295 b l 40-328 b l 40-361 b m 40-394 b

l 40-296 b l 40-329 b l 40-362 b m 40-395 b

l 40-297 b l 40-330 b l 40-363 b m 40-396 b

l 40-298 b l 40-331 b l 40-364 b m 40-397 b

l 40-299 b l 40-332 b l 40-365 b m 40-398 b

l 40-300 b l 40-333 b l 40-366 b m 40-399 b

l 40-301 b l 40-334 b l 40-367 b m 40-400 b

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l 40-401 b l 40-434 b l 40-467 b l 40-523 b

l 40-402 b l 40-435 b l 40-468 b l 40-524 b

l 40-403 b l 40-436 b m 40-469 b l 40-525 b

l 40-404 b l 40-437 b m 40-470 b m 40-526 b

l 40-405 b l 40-438 b m 40-471 b m 40-527 b

l 40-406 b l 40-439 b m 40-472 b m 40-528 b

l 40-407 b l 40-440 b m 40-473 b m 40-529 b

l 40-408 b l 40-441 b m 40-474 b m 40-530 b

l 40-409 b l 40-442 b m 40-475 b m 40-531 b

l 40-410 b l 40-443 b m 40-476 b m 40-532 b

l 40-411 b l 40-444 b m 40-533 b

l 40-412 b l 40-445 b l 40-501 b m 40-534 b

l 40-413 b l 40-446 b l 40-502 b m 40-535 b

l 40-414 b l 40-447 b l 40-503 b m 40-536 b

l 40-415 b l 40-448 b l 40-504 b m 40-537 b

l 40-416 b l 40-449 b l 40-505 b m 40-538 b

l 40-417 b l 40-450 b l 40-506 b m 40-539 b

l 40-418 b l 40-451 b l 40-507 b m 40-540 b

l 40-419 b l 40-452 b l 40-508 b m 40-541 b

l 40-420 b l 40-453 b l 40-509 b m 40-542 b

l 40-421 b l 40-454 b l 40-510 b m 40-543 b

l 40-422 b l 40-455 b l 40-511 b m 40-544 b

l 40-423 b l 40-456 b l 40-512 b m 40-545 b

l 40-424 b l 40-457 b l 40-513 b m 40-546 b

l 40-425 b l 40-458 b l 40-514 b m 40-547 b

l 40-426 b l 40-459 b l 40-515 b m 40-548 b

l 40-427 b l 40-460 b l 40-516 b m 40-549 b

l 40-428 b l 40-461 b l 40-517 b m 40-550 b

l 40-429 b l 40-462 b l 40-518 b m 40-551 b

l 40-430 b l 40-463 b l 40-519 b m 40-552 b

l 40-431 b l 40-464 b l 40-520 b m 40-553 b

l 40-432 b l 40-465 b l 40-521 b m 40-554 b

l 40-433 b l 40-466 b l 40-522 b m 40-555 b

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m 40-556 b l 40-614 b m 40-722 b m 50-30 b

m 40-557 b l 40-615 b m 40-723 b m 50-31 b

m 40-558 b l 40-616 b m 40-724 b m 50-32 b

m 40-559 b l 40-617 b m 50-33 b

m 40-560 b l 40-618 b m 50-1 b m 50-34 b

m 40-561 b l 40-619 b m 50-2 b m 50-35 b

m 40-562 b l 40-620 b m 50-3 b m 50-36 b

m 40-563 b l 40-621 b m 50-4 b m 50-37 b

m 40-564 b l 40-622 b m 50-5 b m 50-38 b

m 40-565 b l 40-623 b m 50-6 b m 50-39 b

m 40-566 b l 40-624 b m 50-7 b m 50-40 b

m 40-567 b m 50-8 b m 50-41 b

m 40-568 b m 40-701 b m 50-9 b m 50-42 b

m 40-569 b m 40-702 b m 50-10 b m 50-43 b

m 40-570 b m 40-703 b m 50-11 b m 50-44 b

m 40-571 b m 40-704 b m 50-12 b m 50-45 b

m 40-572 b m 40-705 b m 50-13 b m 50-46 b

m 40-573 b m 40-706 b m 50-14 b m 50-47 b

m 40-574 b m 40-707 b m 50-15 b m 50-48 b

m 40-708 b m 50-16 b m 50-49 b

l 40-601 b m 40-709 b m 50-17 b m 50-50 b

l 40-602 b m 40-710 b m 50-18 b m 50-51 b

l 40-603 b m 40-711 b m 50-19 b m 50-52 b

l 40-604 b m 40-712 b m 50-20 b m 50-53 b

l 40-605 b m 40-713 b m 50-21 b m 50-54 b

l 40-606 b m 40-714 b m 50-22 b m 50-55 b

l 40-607 b m 40-715 b m 50-23 b m 50-56 b

l 40-608 b m 40-716 b m 50-24 b m 50-57 b

l 40-609 b m 40-717 b m 50-25 b m 50-58 b

l 40-610 b m 40-718 b m 50-26 b m 50-59 b

l 40-611 b m 40-719 b m 50-27 b m 50-60 b

l 40-612 b m 40-720 b m 50-28 b m 50-61 b

l 40-613 b m 40-721 b m 50-29 b m 50-62 b

D51EX/PX-22 00-2-7 b
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m 50-63 b m 50-96 b m 50-129 b m 50-162 b

m 50-64 b m 50-97 b m 50-130 b m 50-163 b

m 50-65 b m 50-98 b m 50-131 b m 50-164 b

m 50-66 b m 50-99 b m 50-132 b m 50-165 b

m 50-67 b m 50-100 b m 50-133 b m 50-166 b

m 50-68 b m 50-101 b m 50-134 b m 50-167 b

m 50-69 b m 50-102 b m 50-135 b m 50-168 b

m 50-70 b m 50-103 b m 50-136 b m 50-169 b

m 50-71 b m 50-104 b m 50-137 b m 50-170 b

m 50-72 b m 50-105 b m 50-138 b m 50-171 b

m 50-73 b m 50-106 b m 50-139 b m 50-172 b

m 50-74 b m 50-107 b m 50-140 b m 50-173 b

m 50-75 b m 50-108 b m 50-141 b m 50-174 b

m 50-76 b m 50-109 b m 50-142 b m 50-175 b

m 50-77 b m 50-110 b m 50-143 b m 50-176 b

m 50-78 b m 50-111 b m 50-144 b m 50-177 b

m 50-79 b m 50-112 b m 50-145 b m 50-178 b

m 50-80 b m 50-113 b m 50-146 b m 50-179 b

m 50-81 b m 50-114 b m 50-147 b m 50-180 b

m 50-82 b m 50-115 b m 50-148 b m 50-181 b

m 50-83 b m 50-116 b m 50-149 b m 50-182 b

m 50-84 b m 50-117 b m 50-150 b m 50-183 b

m 50-85 b m 50-118 b m 50-151 b m 50-184 b

m 50-86 b m 50-119 b m 50-152 b m 50-185 b

m 50-87 b m 50-120 b m 50-153 b m 50-186 b

m 50-88 b m 50-121 b m 50-154 b m 50-187 b

m 50-89 b m 50-122 b m 50-155 b m 50-188 b

m 50-90 b m 50-123 b m 50-156 b m 50-189 b

m 50-91 b m 50-124 b m 50-157 b m 50-190 b

m 50-92 b m 50-125 b m 50-158 b m 50-191 b

m 50-93 b m 50-126 b m 50-159 b m 50-192 b

m 50-94 b m 50-127 b m 50-160 b m 50-193 b

m 50-95 b m 50-128 b m 50-161 b m 50-194 b

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m 50-195 b m 50-228 b m 50-261 b m 50-294 b

m 50-196 b m 50-229 b m 50-262 b m 50-295 b

m 50-197 b m 50-230 b m 50-263 b m 50-296 b

l 50-198 c m 50-231 b m 50-264 b m 50-297 b

l 50-199 c m 50-232 b m 50-265 b m 50-298 b

m 50-200 b m 50-233 b m 50-266 b

m 50-201 b m 50-234 b m 50-267 b 90-1

l 50-202 c m 50-235 b m 50-268 b 90-3

l 50-203 c m 50-236 b m 50-269 b 90-4

l 50-204 c m 50-237 b m 50-270 b 90-5

l 50-205 c m 50-238 b m 50-271 b 90-7

l 50-206 c m 50-239 b m 50-272 b 90-9

l 50-207 c m 50-240 b m 50-273 b 90-11

l 50-208 c m 50-241 b m 50-274 b 90-13

l 50-209 c m 50-242 b m 50-275 b 90-15

l 50-210 c m 50-243 b m 50-276 b 90-17

m 50-211 b m 50-244 b m 50-277 b 90-19

m 50-212 b m 50-245 b m 50-278 b 90-21

m 50-213 b m 50-246 b m 50-279 b 90-23

m 50-214 b m 50-247 b m 50-280 b 90-25

m 50-215 b m 50-248 b m 50-281 b 90-27

m 50-216 b m 50-249 b m 50-282 b 90-29

m 50-217 b m 50-250 b m 50-283 b 90-31

m 50-218 b m 50-251 b m 50-284 b 90-33

m 50-219 b m 50-252 b m 50-285 b 90-35

m 50-220 b m 50-253 b m 50-286 b 90-37

m 50-221 b m 50-254 b m 50-287 b

m 50-222 b m 50-255 b m 50-288 b

m 50-223 b m 50-256 b m 50-289 b

m 50-224 b m 50-257 b m 50-290 b

m 50-225 b m 50-258 b m 50-291 b

m 50-226 b m 50-259 b m 50-292 b

m 50-227 b m 50-260 b m 50-293 b

D51EX/PX-22 00-2-9 2
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00-2-10 b D51EX/PX-22
FOREWORD SAFETY
12
SAFETY 00

SAFETY NOTICE 00

IMPORTANT SAFETY NOTICE 00

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbols and are 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.

GENERAL PRECAUTIONS 00 PREPARATIONS FOR WORK 00

Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.

1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not
machine. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
Always wear safety glasses when hitting parts with 3. When disassembling or assembling, support the
a hammer. machine with blocks, jacks or stands before starting
Always wear safety glasses when grinding parts work.
with a grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00

before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or
before starting any step of the operation. Before starting hydraulic pressure measuring plugs, loosen them slowly
work, hang UNDER REPAIR signs on the controls in to prevent the oil from spurting out. Before
the operator's compartment. disconnecting or removing components of the oil, water
or air circuits, first remove the pressure completely from
5. Keep all tools in good condition and learn the correct the circuit.
way to use them.
2. The water and oil in the circuits are hot when the engine
6. Decide a place in the repair workshop to keep tools and is stopped, so be careful not to get burned. Wait for the
removed parts. Always keep the tools and parts in their oil and water to cool before carrying out any work on
correct places. Always keep the work area clean and the oil or water circuits.
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke 3. Before starting work, remove the leads from the battery.
while working. ALWAYS remove the lead from the negative (-)
terminal first.

00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.

5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.

8. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.

9. Be sure to assemble all parts again in their original places. Replace any damaged part 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 being operated.

10. 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. Also check that connecting parts are correctly installed.

11. When assembling or installing parts, always use the specified tightening 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.

12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.

14. 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.

00-4
FOREWORD GENERAL
12
GENERAL 00

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

This 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. In addition, this section gives the judgement standards
when inspecting disassembled parts.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.

TROUBLESHOOTING

Troubleshooting charts correlating Problems to Causes are also included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.

OTHER

This section has the foldout drawings for the machine.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.

00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00

VOLUMES 00

REVISIONS 00

Shop manuals are issued as a guide to carrying out repairs.


Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows:
between the title page and SAFETY page.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series SYMBOLS 00

Electrical volume: Each issued as one to cover all models So that the shop manual can be of ample practical use,
Attachment volume: Each issued as one to cover all models important places for safety and quality are marked with the
following symbols.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
be available. Special safety precautions are
Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00

Special technical precautions or


Any additions, amendments or other changes will be sent to other precautions for preserving
H Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems.
FILING METHOD 00
Caution necessary when
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number:
Example: Places that require special
Tightening
attention for tightening torque
torque
10 - 3 during assembly.
Places to be coated with
Item number (10. Structure and Function) Coat
adhesives and lubricants etc.
Consecutive page number for each item Places where oil, water or fuel
Fill
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as Places where oil or water must
in the example. Drain be drained, and quantity to be
Example: drained.
10-4
10-4-1
Added pages
10-4-2

10-5

REVISED EDITION MARK 00

When a manual is revised, an edition mark (123) is


recorded on the bottom outside corner of the pages.

00-6
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00

HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the
symbol.

l If a part cannot be smoothly removed from the machine


by hoisting, the following checks should be made: 3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load
WIRE ROPES 00

during hoisting, untwisting of


the rope, or slipping of the
1. Use adequate ropes depending on the weight of parts to rope from its original winding
be hoisted, referring to the table below: position on the load, which
Wire ropes can result in a dangerous
(Standard Z or S twist ropes without galvanizing) accident

Rope diameter Allowable load 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
mm kN tons
two or more ropes, the force subjected to each rope will
10 9.8 1.0 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
11.2 13.7 1.4
hoisting is made with two ropes, each of which is
12.5 15.7 1.6 allowed to sling up to 1000 kg vertically, at various
hanging angles. When two ropes sling a load vertically,
14 21.6 2.2
up to 2000 kg of total weight can be suspended. This
16 27.5 2.8 weight becomes 1000 kg when two ropes make a 120
hanging angle. On the other hand, two ropes are subject
18 35.3 3.6
to an excessive force as large as 4000 kg if they sling a
20 43.1 4.4 2000 kg load at a lifting angle of 150.
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

H The allowable load value is estimated to be 1/6 or 1/7 of


the breaking strength of the rope used.Sling wire ropes
from the middle portion of the hook.
2. Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident

00-7
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00

WARNING! Before carrying out the following work,


release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.

WARNING! Even if the residual pressure is released from


the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected.
Accordingly, prepare an oil receiving
container.

TYPE 1 00

DISCONNECTION 00

1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not
hold the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.

4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.

CONNECTION 00

1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.

00-8
FOREWORD PUSH PULL COUPLER

TYPE 2 00

DISCONNECTION 00

1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a
of the hexagonal portion at the male end.

2. Hold in the condition in Step 1, and turn the lever (4) to the
right - clockwise.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.

CONNECTION 00

1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.

00-9
FOREWORD PUSH PULL COUPLER
12
TYPE 3 00

DISCONNECTION 00

1. Hold the connector of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.

2. Hold in the condition in Step 1, and push until the cover (3)
contacts surface a of the hexagonal portion at the male end.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.

CONNECTION 00

1. Hold the connector of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of
the hexagonal portion at the male end to connect it.

00-10
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
EXPLANATION OF MAINTENANCE STANDARD TERMS 00

l 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 Tolerance
0.022
120
0.126

H 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:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0

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 size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference
between these sizes 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 shaft
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.

00-11
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
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.

00-12
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00

BOLTS AND NUTS 00

l Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench)
H The following table corresponds to the bolts in Figure A.
Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35

H The following table corresponds to the bolts in Figure B.


Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52

Figure A Figure B

00-13
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00

Use these torques for hose nuts.


Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 50.6
04 22 27 58.9 - 98.1 44.4 - 72.4
05 24 32 107.9 - 166.7 79.6 - 123.0
06 30 36 147.1 - 205.9 108.5 - 151.9
10 33 41 147.1 - 245.1 108.5 - 180.8
12 36 46 196.2 - 294.2 144.7 - 217.0
14 42 55 245.2 - 343.2 180.9 - 253.1

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00

Use these torques for split flange bolts.


Thread diameter Width across flat Tightening torque
mm mm Nm lbf ft
10 14 59 - 74 43.51 - 54.57

12 17 98 - 123 72.28 - 90.72

16 22 235 - 285 173.32 - 210.20

TIGHTENING TORQUE FOR FLARED NUTS 00

Use these torques for flared part of nut.

Thread diameter Width across flat Tightening torque


mm mm Nm lbf ft
14 19 24.5 4.9 18.0 3.6

18 24 49 19.6 36.1 14.4

22 27 78.5 19.6 57.8 14.4

24 32 137.3 29.4 101.2 21.6

30 36 176.5 29.4 130.1 21.6

33 41 196.1 49 144.6 36.1

36 46 245.2 49 180.8 36.1

42 55 294.2 49 216.9 36.1

00-14
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 00

H Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Width across flat Tightening torque Nm (lbf ft)


Norminal No.
mm mm Range Target
02 14 35 - 63 (25.81 - 46.46) 44 (32.45)
03, 04 20 84 - 132 (61.95 - 97.35) 103 (75.96)
Varies depending on
05, 06 24 128 - 186 (94.40 - 137.18) 157 (115.79)
type of connector.
10, 12 33 363 - 480 (267.73 - 354.02) 422 (311.25)
14 42 746 - 1010 (550.22 - 744.93) 883 (651.26)

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 00

H Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque Nm (lbf lb)


Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 (4.33 - 6.50) 7.35 (5.42)
10 10 17 9.8 - 12.74 (7.22 - 9.39) 11.27 (8.31)
12 12 19 14.7 - 19.6 (10.84 - 14.45) 17.64 (13.01)
14 14 22 19.6 - 24.5 (14.45 - 18.07) 22.54 (16.62)
16 16 24 24.5 - 34.3 (18.07 - 25.29) 29.4 (21.68)
18 18 27 34.3 - 44.1 (25.29 - 32.52) 39.2 (28.91)
20 20 30 44.1 - 53.9 (32.52 - 39.75) 49.0 (36.14)
24 24 32 58.8 - 78.4 (43.36 - 57.82) 68.6 (50.59)
30 30 32 93.1 - 122.5 (68.66 - 90.35) 107.8 (79.50)
33 33 _ 107.8 - 147.0 (79.50 - 108.42) 124.4 (91.75)
36 36 36 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03)
42 42 _ 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40)
52 52 _ 274.4 - 367.5 (202.38 - 271.05) 323.4 (238.52)

TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 00

H Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
H Apply the following torque when the threads are coated (wet) with engine oil.

Taper seal
Tightening torque (Nm (lbf ft)) Face seal type
type
Nominal Width Nominal thread
size of hose across flats Thread size size - Threads per Root diameter (mm)
Range Target
(mm) inch, Thread (Reference)
series
34 - 54 (25.0 - 39.8) 44 (32.4) - 9/16 - 18UN 14.3
02 19
34 - 63 (25.0 - 46.4) 44 (32.4) 14 - -
22 54 - 93 (39.8 - 68.5) 74 (54.5) - 11/16 -16UN 17.5
03
24 59 - 98 (43.5 - 72.2) 78 57.5) 18 - -
04 27 84 - 132 (61.9 - 97.3) 103 (75.9) 22 13/16 - 16UN 20.6
05 32 128 - 186 (94.4 - 137.1) 157 (115.7) 24 1 - 14UNS 25.4
06 36 177 - 245 (130.5 - 180.7) 216 (159.3) 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 (130.5 - 180.7) 216 (159.3) 33 - -
(12) 46 197 - 294 (145.3 - 216.8) 245 (180.7) 36 - -
(14) 55 246 - 343 (181.4 - 252.9) 294 (216.8) 42 - -

00-15
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS 00

Copper wire
Nominal Cable O.D. Current
Number of Dia. Of strand Cross section Applicable circuit
number (mm) rating (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE 00

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
Primary

1
Color White Black Black Red Yellow Green Blue
Code WR BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color
Red White White Red White White
Code WB BY RB YB GR LR
3 White & Black & Yellow & Green &
Color Red & Black Blue & Red
Black Yellow Black Red
Code WL BR RY YG GY LY
Auxiliary

4 White & Red & Yellow & Green & Blue &
Color Black & Red
Blue Yellow Green Yellow Yellow
Code WG RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color
Green Green Blue Black Black
Code RL YW GL
6 Yellow & Green &
Color Red & Blue
White Blue

00-16
FOREWORD ELECTRIC WIRE CODE
12
HOW TO READ ELECTRIC WIRE CODE 00

H 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)
Using
Type Symbol Material temperature Example of use
range C (F)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for AV appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
30 to +60
Thin-cover Annealed copper for electric (-22 to +140)
Conductor
low-voltage appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold
low-voltage appliance 50 to +110
AEX district, wiring at high-temperature
wire for Heat-resistant crosslinked (-58 to +230)
Insulator place
automobile polyethylene

00-17
FOREWORD 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/
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
Diameter of
Conductor strand
Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(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
Cover D

AV Standard 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
Diameter of
Conductor strand
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cover D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

H f of nominal No. denotes flexible.

00-18
FOREWORD ELECTRIC WIRE CODE
12
3. Color Codes Table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

l 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.

H Types of circuits and color codes

(Table 4)
Type of wire AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch

00-19
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00

METHOD OF USING THE CONVERSION TABLE 00

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.

EXAMPLE
l Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.

B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.

C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.


A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.

B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.

c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-20
FOREWORD CONVERSION TABLES
12

Millimeters to Inches 1 mm = 0.03937 in


0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1 kg = 2.2046 lb


0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-21
FOREWORD CONVERSION TABLES
12

Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal


0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal


0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-22
FOREWORD CONVERSION TABLES
12

kgm to ft. lb. 1 kgm = 7.233 ft. lb.


0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-23
FOREWORD CONVERSION TABLES
12

kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2


0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-24
FOREWORD CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
C F C F C F C F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-25
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00

H The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
l Used to prevent rubber gaskets, rubber cushions
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out
l Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 l Used for plastics (except polyethylene,
(2 pes.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.
l Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g l Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive l Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
500 g
Adhesives

Polyethylene
LT-4 790-129-9040 250 g l Used as sealant for machined holes.
container
Holtz l Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
l Quick hardening type adhesive.
Three bond Polyethylene l Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container l Used mainly for adhesion of metals, rubbers,
plastics and woods.
l Quick hardening type adhesive.
Aron-alpha Polyethylene l Quick cure type (max. strength after 30 minutes).
790-129-9130 50 g
201 container l Used mainly for adhesion of rubbers, plastics
and metals.
l Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc l Used at joint portions subject to high tempera-
648-50 container
ture.
l Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
Features: Resistance to heat
Gasket sealant

l
l Used as sealant for flange surfaces and bolts at
high temperature locations; used to prevent
LG-3 790-129-9070 1 kg Can seizure.
l Used as sealant for heat resistant gasket for at
high temperature locations such as engine
pre-combustion chamber, exhaust pipe.

00-26
FOREWORD COATING MATERIALS

Category Code Part No. Quantity Container Main applications, features


l Features: Resistance to water, oil
l Used as sealant for flange surface, thread.
l Also possible to use as sealant for flanges with
LG-4 790-129-9020 200 g Tube
large clearance.
l Used as sealant for mating surfaces of final drive
case, transmission case.
l Used as sealant for various threads, pipe joints,
Polyethylene con- flanges.
Gasket sealant

LG-5 790-129-9080 1 kg
tainer l Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
l Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, thread.
l Used as sealant for oil pan, final drive case, etc.
l Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube l Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three bond l Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
l Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
Molybdenum

squeaking).
disulphide
lubricant

l Used to prevent seizure or scuffing of the thread


LM-P 09940-00040 200 g Tube when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various l General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
l Used for normal temperature, light load bearing
G2-CA SYG2-400CA-A Various Various
Grease

at places in contact with water or steam.


SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum

400 g (10 per


SYG2-400M Belows type l Used for places with heavy load.
case)

00-27
FOREWORD COATING MATERIALS
12

MEMORANDUM

00-28
01 GENERAL

SPECIFICATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2


D51EX, PX-22 POWER ANGLE, POWER TIT DOZER WITH ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . 01-2
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
TABLE OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS . . . . . . . . . . . . . . . . . . . . 01-12

D51EX/PX-22 01-1
GENERAL SPECIFICATION DRAWING
12
SPECIFICATION DRAWING

D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB
D51EX-22 D51PX-22
Item Unit 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
12,600
Machine weight kg 13,100 13,000
(12,695)
Engine model --- Komatsu SAA6D107E-1 diesel engine
Engine rated horsepower kW {HP} /rpm 97 {130} / 2,200
A Overall length mm 7,800 4,820

B Overall height (not including antenna) 2,997 3,015


mm
(to tip of antenna pipe) 3,177 3,195
3,045
C Overall width mm 3,350
(2,350)
FORWARD km/h 3.4/5.6/9.0
Travel speed (1st/2nd/3rd)
(Quick shift mode) REVERSE km/h 4.1/6.5/9.0
(1st/2nd/3rd)

Travel speed FORWARD km/h 0 - 9.0


(Variable shift mode) REVERSE km/h 0 - 9.0

Values in (_) are for the machines equipped with wide blade.

01-2 D51EX/PX-22
GENERAL SPECIFICATION
12
SPECIFICATION
D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
Serial No. B10001 and up
Operating weight
l Bare tractor with ROPS cab 11,100 11,500 11,400
12,600 13,100 13,000
Weight

l With power angle tilt dozer + ROPS cab


kg (12,695)

l With power angle totalizer + ROPS canopy 12,240 12,740 12,640


(12,335)
Min. turning radius (bare tractor,counter-rotation) m 2.4 2.6 2.6

Gradeability deg 30 30 30
Stability (front, rear, left, right) deg 35 35 35
Quick shift mode
Forward (1st/2nd/3rd) km/h 3.4/5.6/9.0 3.4/5.6/9.0 3.4/5.6/9.0
Performance

Reverse (1st/2nd/3rd) 4.1/6.5/9.0 4.1/6.5/9.0 4.1/6.5/9.0


Travel
speed

Variable shift mode


Forward km/h 0 - 9.0 0 - 9.0 0 - 9.0
Reverse 0 - 9.0 0 - 9.0 0 - 9.0
Bare tractor with ROPS cab 38.9 28.9 28.3
(0.40) (0.30) (0.29)
pressure
Ground

With power angle tiltdozer + kPa 44.1 32.9 32.2


ROPS cab {kg/cm2} (0.45) (0.34) (0.33)
With power angle tiltdozer + 42.8 32.0 31.3
ROPS canopy (0.44) (0.43) (0.32)
Bare tractor 3,660 3,660 3,700
Overall
length

With power angle tiltdozer + mm 4,800 4,800 4,820


ROPS cab
With power angle tiltdozer + 4,800 4,800 4,820
ROPS canopy
Bare tractor 2,300 2,590 2,610
Overall
width

mm
Power angle tiltdozer 3,045 3,350 3,350
(3,350)
Dimensions

To tip of exhaust pipe 2,885 2,885 2,905


To top of operator's compartment with ROPS
Overall
height

cab/canopy mm
(not including antenna) 2,997 2,997 3,015
(including antenna) 3,117 3,177 3195
Track gauge 1,790 1,880 1,880
Length of track on ground 2,745 2,745 2,745

Width of track mm 510 710 720


(standard track shoe)

Min. ground clearance 385 385 455

Values in (_) are for the machines equipped with wide blade.

D51EX/PX-22 01-3
GENERAL SPECIFICATION
12

D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
Serial No. B10001 and up
--- SAA6D107E-1
Model --- 4-cycle, water-cooled, in-line vertical type, 6 cylinders,
Type direct injection, with turbocharger, air-cooled after cooler
No. of cylinders - bore x stroke mm 6-107x124
Piston displacement L {cc} 6.69 {6,690}

Rated horsepower kW {HP}/rpm 99 {133}


Performance
Engine

Max. torque Nm {kgm}/rpm 585.5 {59.7}


High idling rpm 2,270
Low idling rpm 850
Min. fuel consumption ratio g/kWh {g/HPh} 242 {181}
Starting motor --- 24 V, 5.5 kW
Alternator --- 24 V, 25 A
Battery (*1) --- 12 V, 140 Ah x 2
Radiator core type --- Aluminium bar plate 5.1/2
Type, number Variable displacement swash-plate piston type x 2
(main pump) --- Fix displacement gear type x 1
(charge pump)
HST pump

Discharge amount
(main pump) cm3/rev 95
Power train system

(charge pump) 55
Set pressure MPa
(main pump) {kg/cm2} 41.2 {420}
(charge pump) 3.6 {35}
Type, number --- Variable displacement angled piston type
HST motor

(with parking brake) x 2


Discharge amount cm3/rev 160

Planetary gear, 2-stage reduction type,


Final drive --- splash type lubrication
Suspension --- Semi-rigid, equalizer beam type
Carrier roller --- 2 on each side
Track roller --- 7 on each side
Undercarriage

Track shoe Width: 510 mm Width: 710 mm


l Assembly-type single grouser Q'ty on each side: Q'ty on each side: ---
44 pieces 44 pieces
Pitch: 175 mm Pitch: 175 mm
--- Width: 720 mm
l Assembly-type special swamp shoe --- --- Q'ty on each side:
44 pieces
Pitch: 175 mm

*1: The battery capacity (Ah) is the 5-hour rate valve.

01-4 D51EX/PX-22
GENERAL SPECIFICATION
12

D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
Serial No. B1001 and up
control Hydraulic

Type, number --- Variable displacement swash-plate piston type x 1


pump

Discharge amount cm3/rev 45


Max. discharge pressure MPa {kg/cm2} 27.4 {280}

Type, number --- 4-spool valve x 1


valve
Main

Operating method --- Hydraulic pilot type

Type --- Double-acting piston type


Cylinder bore mm 90
cylinder

Outside diameter of piston rod mm 50


Lift
Work equipment hydraulic system

Piston stroke mm 425


Max. distance between pins mm 1,165
Min. distance between pins mm 740
Type --- Double-acting piston type
Cylinder bore mm 100
cylinder

Outside diameter of piston rod mm 55


Tilt

Piston stroke mm 150


Max. distance between pins mm 675
Min. distance between pins mm 525
Type --- Double-acting piston type
Cylinder bore mm 90
cylinder

50
Angle

Outside diameter of piston rod mm


Piston stroke mm 465
Max. distance between pins mm 1,265
Min. distance between pins mm 800
Type --- Double-acting
piston type
Cylinder bore mm 110
cylinder
Ripper

Outside diameter of piston rod mm 60 --- ---


Piston stroke mm 294
Max. distance between pins mm 994
Min. distance between pins mm 700
Hydraulic tank --- Box type (externally mounted control valve type)
Hydraulic filter --- Tank return side
Oil cooler --- Air-cooled type (Aluminium bar-plate 5.1/2)

D51EX/PX-22 01-5
GENERAL SPECIFICATION
12

D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
Serial No. B10001 and up
Type --- Hydraulic type angle tilt dozer
Blade support method --- Hydraulic cylinder type
Dimensions Performance

Max. lifting height (from ground) mm 980 980 1055


Work equipment

Max. lowering depth (from ground) mm 520 520 445


Max. tilt mm 445 (490) 490 490
Max. angle deg 28.5 28.5 28.5

Blade width mm 3045 (3350) 3350 3350


Blade height mm 1110 1110 1110
Blade cutting angle deg 57 57 59

Type Parallelogram
Beam length mm 700
Number of shanks 3
Digging angle (at on the ground/at max. digging deg 53.5/53.5
Ripper

Performance

depth)
Adjustment of digging depth Changeable for 2 level
Max. digging depth mm 430
Max. lift mm 375
Shank interval mm 700

Values in (_) are for the machines equipped with wide blade.

01-6 D51EX/PX-22
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
H This Weight Table is for reference when handling components or when transporting the machine.

Unit: kg (lb)

Machine model D51EX-22 D51PX-22

Serial Number B10001 and up

Machine weight
with ROPS cab 12,600 (27,800) 13,100 (28,900)
with ROPS Canopy 12,240 (26,985) 12,740 (28,087)

Engine, damper assembly (not including water or oil) 585 (1,290) 585 (1,290)
l Engine assembly (including mount bracket, starter, alternator etc.) 548 (1,210) 548 (1,210)
l Damper assembly 37 (81.6) 37 (81.6)

Fan support bracket assembly (include fan, motor, guard and bracket) 67 (148) 67 (148)

Cooling core
l Radiator 36 (79.4) 36 (79.4)
l Oil cooler 25 (55.1) 25 (55.1)
l Charge air cooler 25 (55.1) 25 (55.1)

Fuel tank (not including fuel) 216 (476) 216 (476)

Hydraulic pump assembly (including fittings on pumps) 193 (425) 193 (425)
l HST pump 160 (353) 160 (353)
l Work equipment pump 26 (57.3) 26 (57.3)

Final drive assembly (including motor and sprockets) 496 (1,090) 496 (1,090)
l HST motor (each side) 180 (397) 180 (397)
l Final drive (each side) (including sprocket, bolts and nuts) 316 (697) 316 (697)
l Sprocket (each side) 5.6 (12.3) x9 5.6 (12.3) x9

Frame assembly (including plumbing mount brackets 1,498 (3,300) 1,498 (3,300)
l Main frame 1439 (3,170) 1439 (3,170)
l Underguard (inspection covers) 48 (106) 48 (106)

Track frame assembly (each side) 1473 (3,250) 1477 (3,260)


l Track frame (each side) (include guards and covers) 709 (1,560) 713 (1,570)
l Idler assembly (each side) 219 (483) 219 (483)
l Recoil spring assembly (each side) 221 (487) 221 (487)
l Track roller (each side)
39 (86) x 4, 44 (97) x 3 39 (86) x 4, 44 (97) x 3
18 (39.7) x 2 18 (39.7) x 2
l Carrier roller (each side)

Track shoe assembly


l Single grouser shoe (510 mm) 1,041 (2,300) x 2 ---
l Single grouser shoe (560 mm) 1,095 (2,410) x 2 ---
l Single grouser shoe (710 mm) --- 1,260 (2,780) x 2
l Swamp shoe (720 mm)
--- 1,065 (2,350) x 2

Hydraulic tank (not including hydraulic oil) (include washer tank) 173 (381) 173 (381)

Charge pump 15 (33.1) 15 (33.1)

Control valve
l 4-spool valve (including fittings and mount plate) 25 (55.1) 25 (55.1)
l 5-spool valve (with ripper) (include fittings and mount plate) 28 (61.7) ---

D51EX/PX-22 01-7
GENERAL WEIGHT TABLE

Unit: kg (lb)

Machine model D51EX-22 D51PX-22

Serial Number B10001 and up

Power angle tilt dozer assembly (include center ball, pitch link and pins) 1,415 (3,120) 1,513 (3,340)
l Blade 713 (1,570) 811 (1,790)
l Dozer frame 464 (1,020) 464 (1,020)
l Tilt cylinder assembly 37 (81.6) 37 (81.6)
l Angle cylinder assembly 32 (70.5) x 2 32 (70.5) x 2

Lift cylinder assembly 32 (70.5) x 2 32 (70.5) x 2

Ripper assembly (include ripper cylinder) 842 (1,860) ---

Ripper cylinder assembly 47 (104) ---

ROPS cab assembly (Include floor, seat, air conditioner) 1,176 ( (2,590) 1,176 ( (2,590)

ROPS canopy assembly (Include floor, seat) 814 (1,790) 814 (1,790)

Operators seat
l Standard seat 64 (141) 64 (141)
l Hi-back seat 67 (148) 67 (148)
74 (163) 74 (163)
l Air suspension seat
Rear mask assembly (include linkage) 78 (172) 78 (172)

Engine hood assembly (include doors, muffler, pre-cleaner, exhaust tubes) 252 (556) 252 (556)

Pivot shaft (each side) 150 (331) 162 (357)

Equalizer bar 89 (196) 93 (205)

01-8 D51EX/PX-22
GENERAL WEIGHT TABLE
12

MEMORANDUM

D51EX/PX-22 01-9
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
12
TABLE OF FUEL, COOLANT AND LUBRICANTS
Ambient Temperature Recommended
Fluid
Reservoir -22 -4 14 32 50 68 86 140 122 F Komatsu
Type
-30 -20 -10 0 10 20 30 40 50 C Fluids
Komatsu
SAE 0W30EOS and HTHS 3.5min. (Note 1) EOS0W30
Komatsu
SAE 5W40EOS and HTHS 3.5min. (Note 1) EOS5W40
Engine oil pan

Engine oil

Komatsu
SAE 10W30DH EO10W30DH
Komatsu
SAE 15W40DH EO15W40DH

SAE 30DH Komatsu EO30DH

Power
Final drive case train oil TO 30 (SEA30) TO30
(Note 2)

Idler Engine SAE 30 EO30DH


oil

Hydraulic
oil TOS5W30 (SEA5W30) TOS5W30
(synthetic
type oil)
Power
train TO 10 TO10
Hydraulic system oil

SAE10W30DH EO10W30DH
Engine SAE15W40DH EO15W40DH
oil
SAE10WDH EO10DH

Hyper GO-T (NLGI NO. 0) GO-T


white grease
(Note 4) G2-T (NLGI NO. 2) G2-T

Moly disul. LM-G (NLGI NO. 2) LM-G


grease

Grease
LM-G (NLGI NO. 2) GO-L1
Lithium LM-G (NLGI NO. 2) G2-L1
grease
LM-G (NLGI NO. 2) G2-L1-S

Bio grease G2-BT (NLGI NO.2) G2-BT

Engine Cooling Super


AF-NAC (Note 5) AF-NAC
system coolant

No.2-D ASTM N0. 2-D


Fuel tank Diesel fuel
No. 1-D ASTM No. 1-D

l API: American Petroleum Institute


l SAE: Society of Automotive Engineers
l ASTM: American Society of Testing and Material

01-10 D51EX/PX-22
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS

Final drive case Cooling


Engine oil pan Hydraulic system Idler (each) Fuel tank
(each) system
Specified liter 23 4.4 123 0.21 270 35
capacity US gal 6.08 1.16 32.5 --- 71.3 9.25
Refill liter 20 4.0 63 0.21 --- ---
capacity US gal 5.28 1.06 16.64 --- --- ---

REMARK
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine
mounted on this machine uses an electronically controlled high-pressure fuel injection device.
This device requires high precision parts and lubrication, so if low viscosity fuel with low
lubricating ability is used, the durability may drop markedly.

Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS (High-Temperature High-Shear Viscosity
150C [302F]) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
If these oils are not available, contact your Komatsu Distributor.

Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.

Note 3: Hyper white grease (G2-TE) has a high performance.


When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-TE is recommended.

Note 4: Hyper white grease (G2-TE) is a high performance white grease.


When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-TE is recommended.
When it is desired to preserve the external appearance of the machine and prevent it from becoming to dirty due to
black grease.

Load Friction Heat Water Biodegrad


Type of grease Remarks
performance resistance resistance resistance ability
Hyper white grease s s s s w Non-black high load
Moly. disul. grease l s l l w Molybdenum grease
Lithium grease m l l l w
Biodegradable grease m s l s Synthetic grease
s: Excellent l: Good m: Normal w: Poor

Note. 5: Supercoolant (AF-NAC)

1) The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.

2) For details of the ratio when diluting super coolant with water, see "CLEAN INSIDE OF COOLING SYSTEM (4-
26)" of your Operation and Maintenance Manual.
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant
(AF-NAC). In this case, no adjustment is needed for temperatures down to -10C (14F). (never dilute with water)

3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.

D51EX/PX-22 01-11
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS

RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS


When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to
the Komatsu web page or consult your Komatsu distributor.

01-12 D51EX/PX-22
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD

12
ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
ENGINE RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
COOLING FAN PUMP - SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP) . . . 10-8
COOLING FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
OIL COOLER BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
CHARGE SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
PATH OF POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
UNDER CARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
TRACK FRAME AND RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
HYDRAULIC SYSTEM 1 (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
HST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
SAFETY-SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
TOWING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
HST MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
MOTOR CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE . . . . . . . . . . . 10-70
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
CHARGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
UNLOAD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
LS BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
WORK EQUIPMENT AND FAN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
SERVO VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
QUICK DROP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
BLADE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
RIPPER/WINCH PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
HYDRAULIC TANK, FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127

D51EX/PX-22 10-1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
CUTTING EDGE AND END BIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
WORK EQUIPMENT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
ANGLE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
PISTON VALVE FOR ANGLE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
CAB AND ITS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
STEERING AND BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
WORK EQUIPMENT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
CAB DAMPER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147
AIR CONDITIONER AND FLOOR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
ENGINE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
COOLING CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
HST CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
GEAR SHIFT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
GEAR SHIFTING BY OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED . . . . . . . . . . . . 10-160
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
PARKING BRAKE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
KOMTRAX SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
HST CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
ELECTRIC LEVER (FOR TRAVEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
KOMTRAX TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
BRAKE OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
HYDRAULIC OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
HST CIRCUIT OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
DECELERATOR PEDAL POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
BRAKE PEDAL POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
CHARGE FILTER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
ENGINE ROTATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
BOOST PRESSURE AND TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
WIF SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
HST MOTOR SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188

10-2 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
ENGINE AND COOLING SYSTEM

ENGINE RELATED PARTS

1. Rear engine mount 5. Belt tensioner 9. HST charge pump

2. Front engine mount 6. Alternator 10. Fuel pump

7. Air conditioner compressor


3. Vibration damper 11. Engine controller
(Idler pulley for canopy spec.)

4. Water pump 8. Turbocharger

D51EX/PX-22 10-3
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Outline

1. Cooling cores and fan located at rear end of machine. Charged air and coolant water are directed to the rear of the machine
through pipes.

2. Compressor for air conditioner is located at the front of the engine and is driven by the alternator belt.

3. The air cleaner, pre-cleaner, muffler and exhaust pipe are located on or near the engine hood.

10-4 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
COOLING SYSTEM

13. Oil cooler bypass valve


1. Radiator 7. Coolant drain valve
assembly

2. Radiator cap 8. After cooler outlet port 14. Cooler fan motor

3. Oil cooler 9. Radiator inlet port hose 15. Air bleeder of engine block

4. After cooler 10. Reservoir tank 16. Water bypass line

5. Shroud 11. After cooler inlet port

6. Fan 12. Radiator outlet port hose

Item Unit Radiator Oil cooler After cooler

Aluminium brazed Aluminium brazed Aluminium brazed


Core type ---
bar-plate bar-plate bar-plate

Fin pitch mm/2p 5.08 5.08 5.08

Total heat dissipation area m2 (ft2) 27.9 (300) 18.6 (200) 14.0 (151)

kPa 110 15 490 50


Pressure valve cracking pressure kg/cm2 1.12 0.15 5 0.5 ---
(psi) (16 2.18) (71.1 16.7)

kPa 4.8 - 10.3


Vacuum valve cracking pressure kg/cm2 0.05 - 0.1 --- ---
(psi) (0.69 - 1.49)

D51EX/PX-22 10-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12

10-6 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12

1. Coolant inlet 7. Coolant flow to thermostat housing

2. Pump impeller 8. Coolant by-pass passage

3. Coolant flow past lubricating oil cooler 9. Coolant flow back to radiator

4. Coolant flow past cylinders 10. Bypass open

5. Coolant flow from cylinder block to cylinder head 11. Coolant bypass in cylinder head

6. Coolant flow between cylinders 12. Coolant flow to water pump inlet

During normal operating temperature.

1. The coolant flow thermostat opens and coolant flows through the return line to the radiator.

2. Coolant temperature deceases as coolant passes through radiator.

3. Coolant is returned to the pump inlet through the supply line.

During cold engine operating temperature.

1. The coolant flow thermostat is closed.

2. Coolant flows through coolant bypass in cylinder head back to water pump inlet.

D51EX/PX-22 10-7
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
COOLING FAN PUMP - SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT
AND FAN PUMP)

10-8 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
COOLING FAN MOTOR
Type: LMF16

1. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 - 74 Nm (43.5 - 54.5 lbf ft)


P: From fan pump
T: From cooler to tank
TC: To Tank

Specifications

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LMF16
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.0 cc/rev
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,500 rpm
Rated flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 L/min (6.3 gal/min)
Cracking pressure of check valve . . . . . . . . . . . . . . 0.13 kg/cm2 (1.84 psi)

D51EX/PX-22 10-9
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12

1. Output shaft 7. End cover


2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool
6. Valve plate

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installation Installation
Free length Installation
load Free length load
12 Spool return spring Outside diameter length
(N {kg}) (N {kg}) If damaged or
deformed, replace
58.8 N 47.1 N spring.
44.84 12 33
{6 kg} {4.8 kg}
3.04 N 2.45 N
13 Check valve spring 29.27 6.5 19.1
{0.31 kg} {0.25 kg}

14. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 - 12.7 Nm (7.2 - 9.3 lbf ft)

10-10 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
1. Hydraulic motor

Function
l This hydraulic motor is called a swash plate-type axial piston motor. It
converts the energy of the pressurized oil sent from the hydraulic
pump into rotary motion.

Principle of operation
l The oil sent from the hydraulic pump flows through valve plate (7)
into cylinder block (5).
l This oil can flow on only one side of the (Y Y) line connecting the
top dead center of the stroke of piston (4).
l The oil sent to one side of cylinder block (5) presses piston (4) and
generates force (F1) [F1 = P xD2/4].
l This force is applied to thrust plate (2). Since thrust plate (2) is fixed to
the angle of (a) to the output shaft (1), the force is divided into com-
ponents (F2) and (F3).
l The radial component (F3) generates torque [T = F3 ri] against the
(Y-Y) line connecting the top dead center and bottom dead center.
l The result of this torque [T = (F3 ri)] rotates cylinder block (5)
through the piston.
l Since this cylinder block (5) is splined to the output shaft, the output
shaft revolves to transmit the torque.

D51EX/PX-22 10-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
2. Suction valve

Function
l If the fan pump stops, the pressurized oil does not flow into the motor. Since the motor continues revolution because of the
force of inertia, however, the pressure on the outlet side of the motor rises.
l When the oil stops flowing in from inlet port (P), the suction valve sucks in the oil on the outlet side and supplies it to port
(MA) where there is not sufficient oil to prevent cavitation.

Operation

A. When starting
l If the pressurized oil from the pump is supplied to port (P)
and the pressure on (MA) side rises and starting torque is
generated in the motor, the motor starts revolution. The oil on
motor outlet (MB) side of the motor returns through port (T)
to the tank.

B. When stopping
l If the engine is stopped and the input revolution of the fan
pump lowers to 0 rpm, the pressurized oil from the pump is
not supplied to port (P) any more. As the pressurized oil is
not supplied to (MA) side of the motor, the motor speed
lowers gradually to stop.
l If the motor shaft is revolved by the force of inertia while the
oil flow in port (P) is reducing, the oil in port (T) on the outlet
side is sent by suction valve (1) to (MA) side to prevent
cavitation.

10-12 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
3. Operation of reversible valve

A. When the ON-OFF solenoid for the reversible valve is


de-energized
l If ON-OFF solenoid (1) for the reversible valve is
de-energized, the pressurized oil from the pump is blocked
by ON-OFF selector valve (2), and port (C) opens for the
tank circuit.
l Accordingly, reversible valve spool (3) is pushed by
reversible valve spring (4) to the right to open motor port
(MA) and then the pressurized oil flows in to revolve the
motor forward (clockwise).

B. When ON-OFF solenoid for reversible valve is energized


l If ON-OFF solenoid (1) for reversible valve is "energized",
ON-OFF selector valve (2) changes to let the pressurized oil
from the pump flow through port (C) into spool chamber (D).
l The pressurized oil in chamber (D) pushes reversible valve
spool (3) to the left against reversible valve spring (4). As a
result, motor port (MB) opens and pressurized oil flows in to
revolve the motor in reverse (counterclockwise).

D51EX/PX-22 10-13
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12

MEMORANDUM

10-14 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
OIL COOLER BYPASS VALVE
H This valve consists of oil cooler bypass valve and charge safety valve

.
P1: From charge filter 1. Oil cooler bypass valve
P2: From fan motor 2. Charge safety valve
C1: To oil cooler inlet 3. Torque ........................ 147 - 186.3 Nm (108 - 137 lbf ft)
C2: From oil cooler outlet 4. Torque ........................ 49 - 59 Nm (36.0 - 43.5 lbf ft)
T: To hydraulic tank
Ts: To HST pump T1

D51EX/PX-22 10-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Oil cooler bypass valve

1. Charge pump 4. Oil cooler bypass valve


2. HST pump 4A. Poppet
3. Charge safety valve 4B. Ring
4C. Plug
5. Oil cooler

10-16 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Function
l The oil cooler bypass valve controls the maximum pressure in the oil cooler to protect the oil cooler.

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length Installed Free
load load Replace spring if damaged or
6 Cooler bypass valve spring Outside diameter length length
N {kg} N {kg} deformed
86.1 N 68.9 N
43.8 13.2 30.8
{8.78 kg} {7.0 kg}

D51EX/PX-22 10-17
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
CHARGE SAFETY VALVE

1. Charge pump 3C. Valve seat


2. HST pump 3D. Poppet
3. Charge safety valve 3E Spring
3A. Valve 3F. Adjustment screw
3B. Spring

10-18 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Function
l The charge safety valve is installed to the oil cooler bypass valve and controls the maximum pressure in the charge circuit
to protect the charge circuit.

Operation
l Port (A) is connected to the charge circuit, port (B) to the drain circuit,
and port (C) to the tank drain circuit through the oil cooler. The oil
also fills chamber (D) through orifice (a) of valve (3A). Poppet (3D) is
fitted to valve seat (3C).

l When abnormal pressure is generated in the circuit or the shuttle valve


of the HST motor is in neutral, if the oil in port (A) and chamber (C)
rises to the pressure set with spring (3E), poppet (3D) is pushed to the
right and the oil in chamber (D) is relieved to port (B) and the oil
pressure in chamber (D) lowers.

l If the oil pressure in port (D) lowers, differential pressure is generated


between ports (A) and (D) by orifice (a) of valve (3A) and then valve
(3A) is pushed to the right by the oil pressure in port (A) and the oil in
port (A) is relieved. As a result, the pressure in the charge circuit does
not rise any more.

D51EX/PX-22 10-19
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN

POWER TRAIN

Outline

l The power generated by engine (1) has its torsional vibration reduced by damper (2), and is then transmitted to the input
shaft of the HST pump.
l HST pump (3) consists of swash plate type piston pumps for the left travel and right travel joined in tandem. The
hydraulic power passes from each pump through high-pressure hoses (4) and is transmitted to left and right HST motors
(5).
l HST pump (3) changes the discharge direction and discharge amount continuously in accordance with the movement of
the swash plate of each pump to match the movement of the steering, direction, and speed lever. This changes the
direction of rotation and speed of the left and right HST motors and controls the forward and reverse travel and turning of
the machine.
l The hydraulic power transmitted to HST motor (5) is output from the motor output shaft as mechanical power, and is
transmitted to final drive (6).
l Final drive (6) is a 2-stage planetary gear mechanism. It reduces the speed and rotates sprocket (7) to drive track shoe (8).

REMARK
HST is an abbreviation for Hydrostatic Transmission.

10-20 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN SYSTEM

1. Engine 6. HST motor

2. Damper 7. Final drive

3. HST pump 8. Sprocket

4. Charge pump 9. Track shoe

5. High pressure hose 10. Work equipment pump

D51EX/PX-22 10-21
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
DAMPER

Unit: mm
No. Check item Criteria Remedy

Distance between HST pump Standard size Repair limit


1. Adjust
mounting surface and tip of boss 82.5 0.5
Wear of inner teeth of coupling
2. Repair limit: 1.0 Replace
(resin)

Coupling
3.
4. Boss
5. HST pump input shaft
6. Cover
7. Flywheel

8. Torque . . . . . . . . . . . . . . . . . . . . . . . . 55.8 - 73.5 Nm (41.1 - 54.2 lbf ft)


9. Torque . . . . . . . . . . . . . . . . . . . . . . . . 44.1 - 53.9 Nm (32.5 - 39.7 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 123 Nm (72.2 - 90.7 lbf ft)
11. Torque . . . . . . . . . . . . . . . . . . . . . . 490 - 608 Nm (361.4 - 448.4 lbf ft)

Outline
l The damper reduces the torsional vibration caused by variations in the engine torque, and acts to protect the engine and
downstream drive system from the torsional vibration.
l The power from the engine is transmitted from flywheel (7) to coupling (3). Coupling (3) absorbs the torsional vibration
and transmits the power through boss (4) to the HST pump.

10-22 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

FINAL DRIVE

1. Oil level plug


2. Drain plug

Outline

l The final drive is a planetary gear, 2-stage reduction type. It provides splash lubrication when the gear rotates.
l It is also possible to remove or install the final drive as a single unit.
l A floating seal is installed to the rotating and sliding portion of the sprocket to prevent the entry of sand or soil from
outside and to prevent leakage of lubricating oil.

Specifications

Reduction ratio: . . . . . . ((14 + 97) / 14) ((20 + 97) / 20) + 1 = 45.382

D51EX/PX-22 10-23
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12

3. No. 1 sun gear (No. of teeth: 14) 9. Floating seal


4. No. 2 sun gear (No. of teeth: 20) 10. HST motor
5. No. 1 planetary carrier 11. Hub
6. Cover 12. No. 2 planetary pinion (No. of teeth: 37)
7. Sprocket 13. Ring gear (No. of teeth: 97)
8. No. 2 planetary carrier 14. No. 1 planetary pinion (No. of teeth: 41)

10-24 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12

Unit: mm
No. Check item Criteria Remedy
Backlash of No. 1 sun gear and No. Standard clearance Clearance limit
15
1 planetary pinion 0.13 0.35 1.00
Backlash of No. 1 planetary pinion
16 0.17 0.53 1.10
and ring gear
Backlash of No. 1 planetary carrier Replace
17 0.27 0.49 1.00
and No. 2 sun gear
Backlash of No. 2 sun gear and No.
18 0.14 0.38 1.00
2 planetary pinion
Backlash of No. 2 planetary pinion
19 0.17 0.53 1.10
and ring gear

20. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 461 - 559 Nm (340 - 412 lbf ft)


21. Torque . . . . . . . . . . . . . . . . . . . . . . . 245 - 308.7 Nm (181 - 228 lbf ft)
22. Torque . . . . . . . . . . . . . . . . . . . . . . . 58.8 - 73.5 Nm (43.4 - 54.2 lbf ft)
23. Torque . . . . . . . . . . . . . . . . . . . . . . . 98 - 122.5 Nm (72.3 - 90.4 lbf ft)
24. Torque . . . . . . . . . . . . . . . . . . . . . . . 58.5 - 78.4 Nm (43.1 - 57.8 lbf ft)

D51EX/PX-22 10-25
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
PATH OF POWER TRANSMISSION

l The power from the HST motor goes from No. 1 sun gear (1) through No. 1 planetary pinion (2), is reduced and rotates in
the opposite direction from the rotation of the HST motor, and is then transmitted to ring gear (6).
l When this happens, No. 1 planetary pinion (2) forms one unit with No. 1 planetary carrier (3), and the power from No. 1
planetary carrier (3) is transmitted to No. 2 sun gear (4).
l The power transmitted to No. 2 sun gear (4) passes through No. 2 planetary pinion (5), has its speed reduced, and is
transmitted to ring gear (6).
l The rotating power undergoes two-stage reduction, is transmitted to ring gear (6), passes through hub (7), and is
transmitted to sprocket (8).

10-26 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
UNDER CARRIAGE AND FRAME

MAIN FRAME

1. Engine mount
2. Frame assembly
3. Rear underguard
4. Middle underguard
5. Engine underguard
6. Oil drain guard

Outline
l A hull frame structure with the main frame, track frame, and underguard forming one unit is used.

D51EX/PX-22 10-27
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
TRACK FRAME AND RECOIL SPRING

1. Idler 9. Rod
2. Carrier roller 10.Recoil spring
3. Track frame 11. Wear ring
4. Sprocket teeth 12. U-packing
5. Track roller end guard 13. Nut
6. Track roller center guard (if equipped) 14. Lubricator
7. Track roller 15. Cylinder
8. Seal 16. Bushing
17. Holder

10-28 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12

Unit: mm
No. Check item Criteria Remedy
Check item Repair limit
18 Deformation of track frame 7(in length of 3,000) Repair
Bend, twist, opening of idler section 3(in length of 300)
5
Standard size Repair limit
Free length x Installed Installed Free Installed
19 Recoil spring O.D. length load length load
Replace
110.2 kN 99.2 kN
563 x 196 438 551
11,238 kg 10,114 kg

Standard Tolerance Standard Clearance


Clearance between piston size Shaft Hole clearance limit
20 Replace bushing
and bushing
+0.120 0.55
60 -0.60 1.0
+0.0 0.720
- Quantity of grease 270cc(grease: G2-LI) ---

21. Torque . . . . . . . . . . . . . . . . . . . . . . 235 - 285 Nm (173.3 - 210.2 lbf ft)


22. Torque . . . . . . . . . . . . . . . . . . . . . . . 58.8 - 88.2 Nm (43.3 - 65.2 lbf ft)
23. Min. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 147.1 Nm (108.4 lbf ft)

Outline
l Recoil spring (10) is used to adjust the track shoe tension by supplying grease through lubricator (14) or discharge
existing grease and moving rod (9) forward or in reverse. It also damps sudden shocks applied to idler (1)

Q'ty on each Flange type and arrangement


side
D51EX-22, D51PX-22 7 pcs. S, D, S, D, S, D, S
S: Single flange
W: Double flange

D51EX/PX-22 10-29
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
SUSPENSION

10-30 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12

1. Equalizer bar 5. Bushing 9. Bushing (large)

2. Center pin 6. Seal 10. Plug (oil filler)

3. Side pin 7. Seal 11. Bushing (small)

4. Pivot shaft 8. Bushing 12. Cover

13. Seal

Outline
l The track frame moves the front part of the track frame up and down around pivot shaft (4) in its rear.
l Equalizer bar (1) rocks around center pin (2) and is connected to both track frames by side pin (3).

D51EX-22 D51PX-22
Displacement at center Upward 46.1 49.4
of equalizer bar side pin
(mm) Downward 46.1 49.4

D51EX/PX-22 10-31
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance


Clearance between pivot shaft size Shaft Hole clearance limit
14 and bushing (large)
-0.145 +0.063 0.145-
123 1.0
-0.208 0 0.271
Clearance between pivot shaft -0.120 +0.054 0.120- Replace
15 85 1.0 bushing
and bushing (small) -0.174 0 0.228
Clearance between center pin -0.100 +0.174 0.200-
16 60 0.5
and bushing -0.146 +0.100 0.320
Clearance between side pin and -0.100 +0.010 0.080-
17 50 0.5
bushing -0.146 -0.020 0.156
Press-fitting force of pivot shaft
18 48.0kN {4.9ton}
bushing (large)
Press-fitting force of pivot shaft
19 33.3kN {3.4ton}
bushing (small)
Quantity of oil in pivot shaft
- 4.0 L (enging oil: SAE30)
section

20. Torque . . . . . . . . . . . . . . . . . . . . 490 - 607.6 Nm (361.4 - 448.1 lbf ft)


21. Torque . . . . . . . . . . . . . . . . . . . . 245 - 308.4 Nm (180.7 - 227.4 lbf ft)
22. Torque . . . . . . . . . . . . . . . . . . . 2245 - 308.7 Nm (180.9 - 227.6 lbf ft)

10-32 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12

MEMORANDUM

D51EX/PX-22 10-33
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
IDLER

10-34 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Unit: mm
No Check Item Criteria Remedy

Standard size Repair limit


1 Guide rib outer diameter
541 ---

2 Idler tread outer diameter 505 487


Build-up
3 Guide rib height 18 27 welding or
replace
4 Idler tread thickness 21 12

5 Tread section width 42 ---

6 Idler over width 167 ---

Standard Tolerance Standard Clearance


Clearance between shaft size Shaft Hole clearance limit
7
and bushing
-0.250 +0.074 0.250
54 ---
-0.280 -0 0.354 Replace

Clearance between shaft -0.250 +0.046 0.250


8 54 ---
and support -0.280 -0 0.326

9 Axial play of idler 0.26 ~ 0.66

Clearance between guide


10 2 6 Shim
plate and side plate adjustment or
plate
Clearance between guide
11 1 replacement
plate and side plate

Thickness of guide plate


12 2
shim pack

Thickness of guide plate


13 4 Adjust
shim pack

Thickness of guide plate


14 4
shim pack

15 Thickness of guide plate 9 6

16 Thickness of support plate 6 3

17 Thickness off support plate 6 3


Replace
18 Thickness off guide plate 6 3

19 Thickness off guide plate 6 3

20 Thickness of side plate 6 3

D51EX/PX-22 10-35
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
TRACK ROLLER
D51EX/PX-22
Single flange type

Double flange type (If equipped)

10-36 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange (outside)
213
2 Outside diameter of flange (inside) 205
3 Outside diameter of tread 185 160
4 Thickness of tread 42.5 30
Repair by
5 Width of flange (outside) 18 13 buildup weld-
6 Width of flange (inside) 15 10 ing or replace
Width of tread
7 42
(Single-flange type)
Width of tread
8 44.5
(Double-flange type)
9 Overall width 208
Tolerance Standard Clearance
Standard size
Clearance between shaft and Shaft Hole clearance limit
10
bushing 0.250 +0.074 0.250
54
0.280 0 0.344
Replace
0.250 0.160 0.044
11 Clearance between shaft and collar 53.7
0.300 0.206 0.140
Standard clearance Clearance limit
12 Axial play of roller
0.43 0.72

13. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 245 - 309 Nm (181 - 227 lbf ft)

D51EX/PX-22 10-37
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
CARRIER ROLLER

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
170
2 Outside diameter of tread 150 126 Rebuild or
3 Thickness of tread 17.5 5.5 replace
4 Width of tread 42 47
5 Width of flange 15 10
Tolerance Standard Clearance
Standard size
Clearance between shaft and Shaft Hole clearance limit
6
support 0.100 +0.250 0.100
41
0.200 0 0.450
Tolerance Standard Clearance
Standard size Replace
Interference between shaft and seal Shaft Hole clearance limit
7
guard +0.170 +0.025 0.115
41.5
+0.140 0 0.170
Standard clearance Clearance limit
8 Play in axial direction of shaft
0 0.50

9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 245 - 309 Nm (181 - 227 lbf ft)

10-38 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12

MEMORANDUM

D51EX/PX-22 10-39
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
SPROCKET

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Wear of tooth root Rebuild or
74 65
replace
2 Thickness of tooth root 22.7 13.7

10-40 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Full-scale drawing of sprocket tooth profile

H Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.

D51EX/PX-22 10-41
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
TRACK SHOE
D51EX/PX-22

*1. Single shoe


*2. Swamp shoe

H Port (P) is the link on the bushing fitting side.

10-42 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch
175.3 178.3
Turning over Turn over or
Standard size
2 Outside diameter of bushing Light load Heavy load replace
63 52.8 55.4
3 Thickness of bushing 13.1 2.9 5.5
Standard size Repair limit Repair or
4 Height of link
106 95 replace
Thickness of link
5 32 21 Replace
(Bushing fitting part)
a. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Shoe bolt Regular link 196 20 {20 2} 120 10
6 (Single shoe) Retighten
(Swamp shoe) b. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Master link 196 20 {20 2} 180 10
Tolerance
Standard size Standard clearance
Interference between bushing and Shaft Hole
7
link +0.304 +0.074
59 0.190 0.304
+0.264 0
Adjust or
Interference between regular pin +0.372 +0.062
8 36.2 0.210 0.372 replace
and link +0.272 0
Standard clearance
9 Clearance of link mating face Each side Both sides
1.2 2.4

D51EX/PX-22 10-43
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Single shoe
D51EX/PX-22

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height of grouser Rebuild or
55 25
replace
2 Thickness of grouser 67 37

D51PX-22
Swap shoe

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height of grouser Rebuild or
83 70
replace
2 Thickness of grouser 20 7

10-44 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
HYDRAULIC SYSTEM 1 (HST)

HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM


H HST: Abbreviation for Hydrostatic Transmission

1. HST pump 4. L.H. HST motor

2. R.H. HST motor 5. Motor control solenoid valve

3. HST charge filter 6. Charge pump

D51EX/PX-22 10-45
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
HST PUMP
H HST: Abbreviation for HydroStatic Transmission
Type: HPV95 + 95

10-46 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
Outline

This pump consists of a variable displacement swash plate tandem piston pump, servo valve, EPC valve and safety-suction
valve.

A1: . . . . . . . . . . . . . Max. displacement adjustment screw (Forward L.H.)


A2: . . . . . . . . . . . . . Max. displacement adjustment screw (Forward R.H.)
B1: . . . . . . . . . . . . . . Max. displacement adjustment screw (Reverse L.H.)
B2: . . . . . . . . . . . . . .Max. displacement adjustment screw (Reverse R.H.)
CPA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Charge pressure input port
CSA1: . . . . . . . . . . . . Pressure pickup port (Forward L.H. EPC pressure)
CSA2: . . . . . . . . . . . . Pressure pickup port (Forward R.H. EPC pressure)
CSB1: . . . . . . . . . . . . .Pressure pickup port (Reverse L.H. EPC pressure)
CSB2: . . . . . . . . . . . . .Pressure pickup port (Reverse R.H. EPC pressure)
ESA1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot current (Forward L.H.)
ESA2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot current (Forward R.H.)
ESB1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot current (Reverse L.H.)
ESB2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot current (Reverse R.H.)
PA1: . . . . . . . . . . . . . . . . . . . . . . . . . .Pump discharge port (Forward L.H.)
PA2: . . . . . . . . . . . . . . . . . . . . . . . . . Pump discharge port (Forward R.H.)
PB1:. . . . . . . . . . . . . . . . . . . . . . . . . . Pump discharge port (Reverse L.H.)
PB2:. . . . . . . . . . . . . . . . . . . . . . . . . . Pump discharge port (Reverse R.H.)
PH1:. . . . . . . . . . . . . Pressure pickup port (L.H. pump high pressure side)
PH2:. . . . . . . . . . . . . Pressure pickup port (R.H. pump high pressure side)
RP1:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing valve
T3: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drain port
T4: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil cooler return port
TS1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drain port
TS2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drain port

1. EPC valve

2. Piston pump

3. Servo valve

4. Safety-suction valve

5. Torque . . . . . . . . . . . . . . . . . . . . . . . . 19.6 - 27.4 Nm (14.4 - 20.2 lbf ft)


6. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 34 Nm (19.9 - 25.0 lbf ft)
7. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 58.8 Nm (36.1 - 43.3 lbf ft)
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 123 Nm (72.2 - 90.7 lbf ft)

D51EX/PX-22 10-47
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12

1. Front shaft 7. Cylinder block 13. Piston

2. Cradle bearing 8. Valve plate 14. Spline

3. Rocker cam 9. End cap 15. Shoe

4. Front case 10. Rear case 16. Bearing

5. Servo piston 11. Rear Shaft

6. Slider 12. Bearing

10-48 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12

Outline

l The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged
according to the load.
l It is possible to change the delivery by changing the swash plate angle (normal 0 reverse discharge).

Structure

l Cylinder block (7) is supported to front shaft (1) by spline (15). Front shaft (1) is supported by front and rear bearings (12)
and (16).
l The tip of piston (13) is a concave ball, and shoe (14) is caulked to it to form one unit. Piston (13) and shoe (14) form a
spherical bearing.
l Rocker cam (3) has flat surface (A), and shoe (14) is always pressed against this surface while sliding in a circular
movement. Rocker cam (3) positions cradle bearing (2) between front case (4) and cylindrical surface (B), and rocks.
l Piston (13) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
l Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that
the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is
sucked in and discharged through valve plate (8).

D51EX/PX-22 10-49
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
Operation

1. Operation of pump
l Cylinder block (7) rotates together with shaft (1), and shoe (5)
slides on flat surface (A).
l When this happens, rocker cam (4) moves along cylindrical
surface (B), so angle (a) between center line (X) of rocker cam (4)
and the axial direction of cylinder block (7) changes.
l (a) is named the swash plate angle.

l With center line (X) of rocker cam (4) at a swash plate angle (a) in
relation to the axial direction of cylinder block (7), flat surface
(A) acts as a cam in relation to shoe (5).
l In this way, piston (6) slides on the inside of cylinder block (7), so
a difference between volumes (E) and (F) is created inside
cylinder block (7).
l A single piston suctions and discharges the oil by the amount
(F) (E).
l As cylinder block (7) rotates and the volume of chamber (E)
becomes smaller, the pressurized oil is discharged.
l On the other hand, the volume of chamber (F) grows larger and,
in this process, the oil is suctioned.

l As center line (X) of rocker cam (4) matches the axial direction of
cylinder block (7) (swash plate angle (a) = 0), the difference
between volumes (E) and (F) inside cylinder block (7) becomes 0.
l Suction and discharge of pressurized oil is not carried out in this
state. Namely pumping action is not performed. (Actually,
however, the swash plate angle is not set to 0)

10-50 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
2. Control of delivery
l If swash plate angle (a) becomes larger, the difference between
volumes (E) and (F) becomes larger and delivery (Q) increases.
Swash plate angle (a) is changed by servo piston (5).
l Servo spool (7) moves according to the command of the EPC
valve. Servo piston (5) is reciprocated by the command pressure
output from servo spool (7).
l This straight line movement is transmitted through slider (6) to
rocker cam (4). Rocker cam (4), which is supported by the
cylindrical surface to cradle bearing (3), then rocks on the
cylindrical surface.
l For the pump, swash plate angle (a) is a maximum of 16.

D51EX/PX-22 10-51
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
3. Operation of servo valve

10-52 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
A. When lever is operated

i. Operation of servo spool


l The command current from the pump controller flows in the EPC valve solenoids (ESA and ESB).
l This command current works on the EPC valve to output signal pressure. The signal pressure is applied
through port (SA) (SB) to chamber (sa) (sb) and used to change the pressing force on servo spool (1).
l The servo spool (1) stops at a point where the pressing force on servo spool (1) is balanced with the force of
spring (3).
l The strength of the command current is decided by the software of the controller on the basis of the stroke
of the steering lever, pump pressure, etc.

ii. Operation of servo piston


l If servo spool (1) moves to the left, port (CP) is connected to port (A) and pressure is applied to chamber
(a). At the same time, port (B) is connected to port (T) and the oil in chamber (b) is drained. As a result,
servo piston (2) moves to the left.
l If servo piston (2) moves to the left and port (CP) is disconnected from port (A), servo piston (2) stops.
l In short, servo spool (1) and servo piston (2) move by the same distance.
l Similarly, if servo spool (1) moves to the right, port (CP) is connected to port (B) and pressure is applied to
chamber (b). At the same time, port (A) is connected to port (T) and the oil in chamber (a) is drained. As a
result, servo piston (2) moves to the right until port (CP) is disconnected from port (B).

B. When lever is in neutral


l If oil does not flow from the EPC valve, servo spool (1) does not move. Servo piston (2) is kept at the neutral
position by the force of spring (4) and the main pump is kept in neutral.

D51EX/PX-22 10-53
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)

SAFETY-SUCTION VALVE

1. Charge pump 2C. Sleeve

2. Safety-suction valve 2D. Spring

2A. Valve 2E. Spring

2B. Rod 2F. Plug

3. Torque . . . . . . . . . . . . . . . . . . . . . . . . 147 - 186.2 Nm (108 - 137 lbf ft)

10-54 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
1. When it is high-pressure relief valve

Function

It restricts the maximum pressure inside the HST circuit to protect the
circuit.

Operation

(valve at piston pump discharge side)


l Port (A) is connected to the pump circuit and port (B) is connected to
the charge circuit. The pressure oil passes through drill hole (a) in
piston (2A) and also fills port (C).
l The oil at high-pressure port (A) passes through passage groove (b) in
the body and also fills port (D).
l Poppet (2A) is in tight contact with valve seat (2C).
l If abnormal pressure is generated in the circuit and the oil pressure at
ports (A) and (D) reaches the pressure set by spring (2D), poppet (2A)
is pushed to the right, and the oil at port (A) is relieved to port (B), so
the oil pressure at port (A) goes down.

2. When it is safety-suction valve

Function

l This ensures the oil flow in the HST closed circuit. It prevents the
charge oil flow from flowing to the pump high-pressure side
(discharge side).

Operation

A. When HST pump delivery is 0


l The HST closed circuit is sealed, so the charge pressure oil
does not flow into the HST circuit.

D51EX/PX-22 10-55
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
B. When HST pump delivery is being discharged from port (PA)

i. Valve at piston pump discharge side


l If pressure oil is being discharged from port (PA) of
HST pump (3), port (PA) becomes the high-pressure
side.
l This pressure oil at port (PA) passes through passage (b)
in the body and flows into port (D).
l When this happens, sleeve (2C) is pushed fully to the
left because of the relationship of the difference in area
[(A1)>(A2)].
l Therefore, the pressure oil from charge pump (1) is
prevented from flowing in.

3. Valve at piston pump suction side

Operation

l Port (PB) becomes the suction side, so it is at low-pressure. Sleeve


(2C) is pushed to the right by the charge pressure oil from the
relationship of the difference in area [(A1)<(A2)], and the seat of
sleeve (2C) opens.
l As a result, the charge pressure oil at port (B) passes through this gap,
flows to port (PB), and carries out the charge action in the HST circuit.

10-56 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
TOWING VALVE

1. Torque . . . . . . . . . . . . . . . . . . . . . . . . 24.5 - 34.3 Nm (18.0 - 25.2 lbf ft)

Function

l These valves are built into the top surface of the pump. There are two valves: the F valve (for the left track) and the R
valve (for the right track).
l If there is a failure on the machine, it is possible to tow the machine by connecting the HST circuit.
l However, it is necessary to cancel the shaft brake of the motor at the same time.

Operation

l To actuate the towing valves, loosen the two valves a maximum of 4.5 mm (3 turns).

D51EX/PX-22 10-57
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
HST MOTOR
l HST: Abbreviation for HydroStatic Transmission
Type: KMV160

1. Left HST motor


Direction of rotation (as seen facing drive shaft)
Flows in from (MA): Counterclockwise rotation
Flows in from (MB): Clockwise rotation

H Sections C-C and E-E of the illustration are shown in "Shuttle valve".

10-58 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12

1. Drive shaft MA: (High pressure when traveling in reverse) Discharge port
2. Variable bent axis piston motor (L.H.) MB: (High pressure when traveling forward) Discharge port
3. Speed sensor PB: Parking brake cancel signal port
4. Charge relief valve P: Displacement control signal pressure port
T: Drain

5. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 157 - 196 Nm (116 - 144 lbf ft)


6. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 123 Nm (72 - 90.7 lbf ft
7. Torque . . . . . . . . . . . . . . . . . . . . . . . . 78.5 - 76.0 Nm (57.9 - 76.0 lbf ft)
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . 34.3 - 44.1 Nm (25.3 - 32.5 lbf ft)
9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 34 Nm (19.9 - 25.1 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 343 - 427 Nm (253 - 315 lbf ft)
11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 59 Nm (36.1 - 43.5 lbf ft)
12. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 147 - 186 Nm (108 - 137 lbf ft)
13. Torque . . . . . . . . . . . . . . . . . . . . . . . 19.6 - 27.5 Nm (14.5 - 20.3 lbf ft)

D51EX/PX-22 10-59
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
2. Right HST motor
Direction of rotation (as seen facing drive shaft)
Flows in from (MA): Clockwise rotation
Flows in from (MB): Counterclockwise rotation

H Sections C-C and E-E of the illustration are shown in "Shuttle valve".

10-60 D51EX/PX-22
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1. Drive shaft MA: (High pressure when traveling in reverse) Discharge port
2. Variable bent axis piston motor (R.H.) MB: (High pressure when traveling forward) Discharge port
3. Speed sensor PB: Parking brake cancel signal port
4. Charge relief valve P: Displacement control signal pressure port
T: Drain

5. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 157 - 196 Nm (116 - 144 lbf ft)


6. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 123 Nm (72 - 90.7 lbf ft)
7. Torque . . . . . . . . . . . . . . . . . . . . . . . . 78.5 - 76.0 Nm (57.9 - 76.0 lbf ft)
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . 34.3 - 44.1 Nm (25.3 - 32.5 lbf ft)
9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 34 Nm (19.9 - 25.1 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 343 - 427 Nm (253 - 315 lbf ft)
11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 59 Nm (36.1 - 43.5 lbf ft)
12. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 147 - 186 Nm (108 - 137 lbf ft)
13. Torque . . . . . . . . . . . . . . . . . . . . . . . 19.6 - 27.5 Nm (14.5 - 20.3 lbf ft)

D51EX/PX-22 10-61
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12
3. Operation of piston motor
Principle

l Let us assume that the shaft of a disc is supported to allow the disc to
rotate freely. If force (F) is applied to this disc at an angle, this force
(F) can be divided into force (F1) applied at a right angle to the face of
the disc and force (F2) applied in the direction of the circumference of
the disc. Force (F1) pushes the disc in the axial direction, and force
(F2) rotates the disc in a clockwise direction.
l If force (F') is applied to the disc instead of force (F), the force can be
divided in the same way into forces (F'1) and (F'2), and force (F'2) will
rotate the disc in a counterclockwise direction.

Structure

l Seven pistons (2) are installed with a spherical connection to the disc
portion of output shaft (1). Pistons (2) are at a certain angle to drive
shaft (1) and are fitted inside cylinder block (3).
l The angle of cylinder block (3) and piston (2) is determined by the
displacement control signal pressure to port (P). The relationship
between the signal pressure and displacement is shown in the
following figure.

Operation

l The oil sent under pressure from the main piston pump enters from the
piston motor inlet port. Oil pressure is formed at the rear face of piston
(2), and drive shaft (1) is rotated by angle (Q) of piston (2) and the
cylinder block.

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4. Change of displacement of continuous variable displacement motor

1. Chamber (A) (Self pressure) 4. Displacement selector valve spool


2. Displacement control spring 5. Chamber (C) (Displacement control signal pressure)
3. Main piston 6. Chamber (B) (Drain)

Function

l When the main piston is at the bottom, the motor displacement


becomes maximum.
l When the main piston is at the top, the motor displacement becomes
minimum.
l When the main piston is between the top and bottom, the motor
displacement is determined by the displacement control signal
pressure.

Operation

l The servo mechanism section has chambers (A), (B) and (C).
l The self-pressures on the chamber (A) side and chamber (C) side are
applied to their respective pressure receiving areas and the main piston is operated by the load balance on those areas.
l When the EPC pressure is 0 kg/cm2, the main piston is on the maximum side.
l If some EPC pressure is supplied, it is supplied to chamber (C) to push out the displacement selector valve spool. The
displacement selector valve spool supplies the self-pressure to chamber (C) according to the balance between the load
generated by the pressure supplied by the EPC and the load received from the displacement control spring until the set
displacement is obtained.

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12

1. Variable shaft piston motor


2. Angled main piston
3. Shuttle valve
4. Charge relief valve
5. Displacement selector valve
6. Parking brake
7. Speed sensor
8. Tank

Specifications

Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KMV160
Type: . . . . . . . . . . . . . .Variable displacement, bent axis type piston pump
Charge relief valve set pressure: . . . . . . . . . 25 - 26 kg/cm2 (355 - 370 psi)
Parking brake release pressure: . . . . . . . . . .11 18 kg/cm2 (157 - 257 psi)
Theoretical capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 - 160 cm3/rev

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5. Shuttle valve

H For sections C-C and E-E of the illustration, see the general view.
1. Check valve
2. Shuttle valve
3. Main piston
Function

l The pressure at the high-pressure side is selected at HST main pressures (MA) and (MB), and is supplied to main piston
(3).
l A shuttle valve is provided to select the pressure from the low-pressure side and supply it to the charge relief valve.

Operation

l The higher one of pressures (MA) and (MB) is supplied to chamber (A) of the main piston by 2 check valves (1).
l In section E-E, when (MA) > (MB), the shuttle valve leans to the right and (MB) is selected as the low-pressure side and
supplied to the charge relief valve.
l When (MB) > (MA), the shuttle valve leans to the left and (MA) is selected as the low-pressure side and supplied to the
charge relief valve.

D51EX/PX-22 10-65
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12
6. Charge relief valve

1. Valve 4. Poppet
2. Spring 5. Spring
3. Valve seat 6. Adjustment screw
Function

l The charge relief valve is installed inside the motor end cover. It prevents the pressure at the HST main low-pressure side
(charge pressure) selected by the shuttle valve from going above the set pressure. At the same time, it relieves the
determined oil flow inside the motor case and prevents the motor from overheating.
l In addition, it discharges the dirtiest oil inside the HST main circuit to the outside and acts to keep the inside of the HST
main circuit clean.

Operation

l Port (A) connects the pressure at the HST main low-pressure side
(charge circuit) selected by the shuttle valve.
l In addition, ports (B) and (D) are connected to the tank drain circuit
through the HST motor case.
l The pressure oil passes through orifice (g) in valve (1) and fills
chamber (C). Poppet (4) is fitted tightly to valve seat (5).

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l If abnormal pressure is generated inside the circuit, and the oil
pressure in port (A) and chamber (C) rises to the pressure set by spring
(5), poppet (4) is pushed to the right, and the oil in chamber (C) is
relieved to port (D), so the oil pressure in chamber (C) goes down.

l When the oil pressure in chamber (C) goes down, a difference in


pressure between ports (A) and (C) is generated by orifice (g) of valve
(1).
l Valve (1) is pushed to the right by the oil pressure at port (A), and the
oil at port (A) is relieved to port (B).
l As a result, the pressure in the charge circuit is prevented from rising
any further.

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7. Actuation of parking brake

A. When parking brake valve is de-energized


l If the parking brake valve is de-energized, the pressure oil of
the control pump is shut off and port (B) is connected to the
tank.
l As a result, brake piston (2) is pushed down by brake spring
(1), disc (3) and plate (4) are pushed together, and the brake
is applied.

B. When parking brake valve is energized


l If the parking brake valve is energized, the valve is switched,
the pressure oil from the control pump enters port (B), and
flows into brake chamber (A).
l The oil entering chamber (A) overcomes brake spring (1) and
pushes brake piston (2) up. As a result, disc (3) and plate (4)
separate, and the brake is released.

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8. Speed sensor

1. Hall IC (with magnet) 6. Shrinkable tube


2. P.C.B 7. Wire protection hose
3. Housing 8. Rubber cap
4. Wire 9. Connector
5. O-ring

Function

l The speed sensor is installed to the end cover of the motor. It senses revolution pulses from the drive shaft spline in the
motor and transmits electric signals to the HST controller.
l This sensor is of Hall IC type. Unlike a common speed sensor of coil type, the specified gap and angle between this sensor
and spline are maintained.

D51EX/PX-22 10-69
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12
MOTOR CONTROL VALVE
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE

10-70 D51EX/PX-22
STRUCTURE, FUNCTION AND
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P: From HST pump CPA
T: To hydraulic tank
A1: To work equipment PPC valve
A2: To accumulator
A3: To right HST motor P
A4: To left HST motor P
A5: Plug
A6: To right and left HST motor B

1. Work equipment lock solenoid valve Solenoid valve EPC valve

2. Right HST motor gear shift EPC valve 12. Nut 20. Block

3. Left HST motor gear shift EPC valve 13. Plunger 21. Body

4. Slow brake solenoid valve 14. Coil 22. Spool

5. Parking brake solenoid valve 15. Connector 23. Spring

6. Brake pressure sensor 16. Push pin 24. Rod

7. Towing valve 17. Spring 25. Coil

8. Oil pressure pickup plug 18. Spool 26. Plunger

9. Towing plate 19. Block 27. Connector

10. Towing plate fixing bolt

11. Block

Outline

l In block (11), 3 solenoid valves, 2 EPC valves, towing valve and brake
pressure sensor are installed.
l Parking brake solenoid valve (5) transmits a signal generated by the
potentiometer which operates when the brake pedal is pressed or a
signal of the limit switch connected to the parking brake lever through
the HST controller to drain the changeover oil and operate the parking
brakes built in the HST motors.
l Upon receiving a signal generated by the limit switch which operates
when the brake pedal is pressed fully or a signal from the limit switch
connected to the parking brake lever, slow brake solenoid valve (4)
drains the changeover oil slowly through the orifice in it to operate the
parking brakes built in the HST motors.
l Right HST motor gear shift EPC valve (2) and left HST motor gear shift EPC valve (3) transmit the shift switch signals of
the steering/directional/gear shift lever through the HST controller and output the oil pressure according to the signals to
change the HST motor capacity.
l Work equipment lock solenoid valve (1) is installed between HST pump CPA and control valve. If the work equipment
lock lever is set in the "Free" position, the work equipment lock solenoid is linked with the work equipment lock switch
and opens the work equipment control circuit, and then the work equipment can be operated.
l Towing valve (7) is installed between the parking brake solenoid valve and HST motor. When the parking brake cannot be
released because of an engine trouble, etc., the parking brake can be released by removing towing plate (9) and tightening
towing valve (7) to apply parking brake release pressure from outside.
H For the procedure of releasing the parking brake, see Testing and adjusting, Procedure for releasing parking brake.

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12
SOLENOID VALVE

P: From HST pump CPA 1. Nut 5. Push pin

T: To hydraulic tank 2. Plunger 6. Spring

C: To work equipment PPC valve 3. Coil 7. Spool

4. Connector 8. Block

Operation

When solenoid is de-energized

l The signal current does not flow from the controller, so coil (3) is
de-energized.
l For this reason, spool (7) is pushed fully to the left by spring (6).
l As a result, port (A) closes and the flow of pressurized oil from the
pump does not flow to actuator (9).
l At the same time, the oil from actuator (9) flows from port (B) to port
(C) and then, it is drained.

When solenoid is energized

l When the signal current flows to the solenoid valve, coil (3) is
energized, and propulsion force to the right is generated in plunger (2).
l For this reason, spool (7) is pushed to the right by push pin (5).
l As a result, the pressurized oil from the pump flows from port (A)
through port (B), and goes to actuator (9).
l At the same time, port (C) closes, so the oil is not drained.

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MEMORANDUM

D51EX/PX-22 10-73
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12
EPC VALVE

1. Body 4. Coil C: To HST motor


2. Spool 5. Plunger P: From HST pump CPA
3. Push pin 6. Connector T: To hydraulic tank

10-74 D51EX/PX-22
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Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installed Installed Free Installed Replace EPC valve assembly
7 Return spring Outside diameter length load length load if there is damage or deforma-
3.14 N 2.55 N tion
9.0 8.4
{0.32 kg} {0.26 kg}

8. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 - 12.7 Nm (7.3 - 9.3 lbf ft)


9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98 - 1.96 Nm (0.7 - 1.4 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 7.84 - 11.8 Nm (5.8 - 8.7 lbf ft)

Function

l The EPC valve consists of the proportional solenoid section and


hydraulic valve section.
l Upon receiving signal current (i) from the controller, the EPC valve
generates EPC output pressure in proportion to the signal current and
output it to the control valve.

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12
Operation

1. When signal current is 0 (When coil is de-energized)


l While the signal current from the controller is not flowing in coil
(14), coil (14) is de-energized.
l Spool (11) is pushed by spring (12) to the right.
l Port (P) is closed and the oil from the self pressure reducing valve
does not flow in the control valve.
l The oil from the control valve is drained through ports (C) and (T)
to the tank.

2. When signal current is "small" (Coil is energized)


l If a small signal current flows in coil (5), coil (5) is energized and
a thrust to the left is generated in plunger (6).
l Rod (4) pushes spool (2) to the left and the oil from port (P) flows
in port (C).
l The pressure in port (C) rises and the total of the force applied to
face (a) of spool (2) and the load of spring (3) exceeds the thrust
of plunger (6).
l Spool (2) is pushed to the right and ports (P) and (C) are
disconnected from each other.
l Ports (C) and (T) are connected to each other.
l Spool (2) moves until the thrust of plunger (6) is balanced with
the total of the pressure in port (C) and the load of spring (3).
l The pressure in the circuit between the EPC valve and control
valve is controlled in proportion to the signal current.

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3. When signal current is maximum (When coil is energized)
l If the signal current flows in coil (5), coil (5) is energized.
l Since the signal current at this time is maximum, the thrust of
plunger (6) becomes maximum.
l Rod (4) presses spool (2) to the left.
l The maximum oil flows from port (P) to port (C) and the pressure
in the circuit between the EPC valve and control valve becomes
maximum.
l Since port (T) is closed, the oil does not flow to the tank.

D51EX/PX-22 10-77
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12
CHARGE PUMP

1. Front cover 6. Wear plate 11. Inverted shaft seal

2. Stud 7. Rear cover 12. Wear plate

3. Nut 8. Drive gear 13. Square section O-ring

4. Lock washer 9. Inverted shaft seal 14. Center section

5. Seal gland and retainer 10. Snap ring 15. Driven gear

10-78 D51EX/PX-22
STRUCTURE, FUNCTION AND
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Outline
l The HST charge pump is attached to the engine flywheel housing and is driven by the pump drive assembly.
l The HST charge pump supplies pilot pressure oil to the low pressure side of the HST main circuit, charge safety valve,
motor control solenoid valve, and work equipment PPC valve.
l The charge pump sucks in the oil from the hydraulic tank.

Specifications
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Theoretical discharge amount . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 cc/rev

Operation
l The charge pump is connected to the drive assembly by coupling and rotates the drive gear. The drive gear then rotates the
driven gear.

D51EX/PX-22 10-79
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12

MEMORANDUM

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12
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)

CLSS (CLOSED CENTER LOAD SENSING SYSTEM)


Outline of CLSS

Feature
CLSS stands for Closed center Load Sensing System, and has the following features.
l Fine control not influenced by load.
l Control enabling digging even with fine control.
l Ease of compound operation ensured by flow divider function using area of opening of spool during compound
operations.
l Energy saving using variable pump control.

Structure
l The CLSS consists of a variable capacity single piston pump, control valve, and actuator.
l The pump body consists of the main pump, PC valve and LS valve.

D51EX/PX-22 10-81
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12
Basic principle

1. Control of pump swash plate angle


l The pump swash plate angle (pump delivery) is controlled so that
LS differential pressure (PLS) [the difference between pump
discharge pressure (PP) and control valve outlet port LS pressure
(PLS) (load pressure of actuator)] is constant.
(LS pressure (PLS) = Pump discharge pressure (PP) LS
pressure (PLS))

l If LS differential pressure (PLS) becomes lower than the set


pressure of the LS valve (when the actuator load pressure is high),
the pump swash plate moves towards the maximum position; if
the set pressure becomes higher than the set pressure of the LS
valve (when the actuator load pressure is low), the pump swash
plate moves towards the minimum position.

H For details of the operation, see "HST pump".

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12
2. Pressure compensation control
l A pressure compensation valve is installed to the outlet port side of the control valve spool to balance the load.
When two actuators are operated together, this valve acts to make pressure difference (P) between the upstream
(inlet port) and downstream (outlet port) the same, regardless of the size of the load (pressure). In this way, the flow
of oil from the pump is divided (compensated) in proportion to the area of opening (S1) and (S2) of each valve when
it is operated.

D51EX/PX-22 10-83
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12
Hydraulic circuit diagram and the name of valves

1. Unload valve 7. Check valve


2. Safety valve (Set pressure: 310 kg/cm2 [4409 psi]) 8. Fan spool
3. Pressure compensation valve 9. Lift spool
4. Suction valve 10. Tilt spool
5. Main relief valve (Set pressure: 280 kg/cm2 [3982 psi]) 11. Angle spool
6. Fan relief valve (Set pressure: 230 kg/cm2 [3271 psi]) 12. Ripper spool

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12
UNLOAD VALVE

1. When control valve is at neutral

PP : Pump circuit (pressure)


PLS : LS circuit (pressure)
T : Tank circuit (pressure)

1. Spool
2. Spring

Function
l When the control valve is at neutral, pump delivery (Q) discharged by the minimum swash plate angle is released to the
tank circuit. When this happens, pump discharge pressure (PP) is set at 22 kg/cm2 (312 psi) by spring (2) inside the valve:
[LS pressure (PLS): 0 kg/cm2 (0 psi)].

Operation
l Pump discharge pressure (PP) is acting on the left end of spool, and LS pressure (PLS) is acting on the right end.
l When the control valve is at neutral, LS pressure (PLS) is 0, so only pump discharge pressure (PP) has any effect, and
(PP) is set only by the load of spring (2).
l As pump discharge pressure (PP) rises, and reaches the load of spring (2) (22 kg/cm2 [312 psi]), spool (1) is moved to the
right in the direction of the arrow. Pump discharge pressure (PP) then passes through the notch (a) of spool (1) and is
connected to tank circuit (T).
l In this way, pump discharge pressure (PP) is set to 22 kg/cm2 [312 psi]

D51EX/PX-22 10-85
STRUCTURE, FUNCTION AND
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12
2. When control valve is in fine control

PP : Pump circuit (pressure)


PLS : LS circuit (pressure)
T : Tank circuit (pressure)

1. Spool
2. Spring

Function
l When the control valve is in the fine control mode, if the demand flow for actuator is less than the value corresponding to
the minimum swash plate angle of the pump, pump pressure (PP) is set to LS pressure (PLS) + 22 kg/cm2 (312 psi). If the
differential pressure between pump pressure (PP) and LS pressure (PLS) becomes equal to the load of spring (2)
22 kg/cm2 (312 psi), the unload valve opens. Accordingly, LS differential pressure (PLS) is 22 kg/cm2 (312 psi) at this
time.

Operation
When fine control is carried out on the control valve, LS pressure (PLS) is generated and acts on the right end of spool (1).
l When this happens, the area of the opening of the control valve spool is small, so there is a big difference between LS
pressure (PLS) and pump discharge pressure (PP).
l When the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) reaches the load of spring
(2) 22 kg/cm2 (312 psi), spool (1) moves to the right in the direction of the arrow, and pump circuit (PP) and tank circuit
(T) are connected.
l In other words, pump discharge pressure (PP) is set to a pressure equal to the spring force 35 kg/cm2 (497 psi) + LS
pressure (PLS), and LS differential pressure (PLS) becomes 22 kg/cm2 (312 psi).

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12
3. When control valve is being operated (work equipment)

PP : Pump circuit (pressure)


PLS : LS circuit (pressure)
T : Tank circuit (pressure)

1. Spool
2. Spring
3. Actuator circuit

Function
l When the control valve is operated, if the demand flow for actuator exceeds the value corresponding to the minimum
swash plate angle of the pump, the outflow to tank circuit (T) is shut off and all of pump delivery (Q) is sent to the
actuator circuit.

Operation
l When the control valve is operated to a bigger stroke, LS pressure (PLS) is generated and acts on the right end of spool
(1). When this happens, the area of the opening of the control valve spool is large, so the difference between LS pressure
(PLS) and pump discharge pressure (PP) is small.
l For this reason, the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) does not reach the
load of spring (2) 22 kg/cm2 (312 psi), so spool (1) is pushed to the left by spring (2).
l As a result, pump circuit (PP) and tank circuit (T) are shut off, and all the pump delivery (Q) flows to the actuator circuit
(3).

D51EX/PX-22 10-87
STRUCTURE, FUNCTION AND
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12
Work equipment operated

1. When lift is operated to LOWER

l When the lift is operated to LOWER, spool (1) moves to the right from the HOLD position, and the oil from the
pump enters bridge circuit (C), passes through cylinder port (B), and enters the cylinder bottom.
l When this happens, the oil at the cylinder head passes through cylinder port (A) and is drained.

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12
2. When lift is operated to FLOAT

l When the lift is operated to FLOAT, spool (1) moves further to the right. The oil from the pump does not enter bridge
circuit (C).
l The oil at cylinder port (B) is connected to the drain circuit through bridge circuit (C), opening (a), and cylinder port
(A).

D51EX/PX-22 10-89
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12
Introduction of LS pressure

For lift, tilt, angle, ripper valve

Function
l The LS pressure is the actuator load pressure at the outlet port end of the control valve.
l It actually reduces pump pressure (PP) at pressure reducing valve (3) of the pressure compensation valve to the same
pressure as actuation circuit pressure (A), and sends it to the LS circuit (PLS).

Operation
l When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) and notch (a) in spool (1)
through bridge passage (b) to actuator circuit (A).
l At the same time, pressure reducing valve (3) also moves to the right, so pump pressure (PP) has its pressure reduced by
the pressure loss at notch (C). It is introduced to LS circuit (PLS), and then goes to spring chamber (PLS1).
l When this happens, LS circuit (PLS) is connected to tank circuit (TS) from LS bypass plug (4). (See the section on the LS
bypass plug).
l Actuator circuit pressure (PA) [(=(A)] acts on the left end of pressure reducing valve (3); the reduced pump discharge
pressure (PP) acts on the other end.
l As a result, pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure of
spring chamber (PLS1) are the same. Pump discharge pressure (PP) is reduced at notch (C), becomes actuator circuit
pressure (A), and is taken to LS circuit (PLS).

10-90 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
PRESSURE COMPENSATION VALVE

Function
l During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to increase,
compensation is received. [When this happens, the other actuator being used for compound operation (right side) is at a
higher load than the actuator on this side (left side).]

Operation
l If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in actuator
circuit (A) on this side (left side) tries to increase.
l If this happens, the LS pressure (PLS) of the other actuator acts on spring chamber (PLS1), and pressure reducing valve
(1) and flow control valve (2) are pushed to the left.
l Flow control valve (2) throttles the area of opening between pump circuit (PP) and spool upstream (PPA), and pressure
loss is generated between (PP) and (PPA).
l Flow control valve (2) and pressure reducing valve (1) are balanced in position where the difference in pressure between
(PLS) and (PA) acting on both ends of pressure reducing valve (2) and the pressure loss between (PP) and (PPA) on both
sides of flow control valve (2) are the same.
l In this way, the pressure difference between upstream pressure (PPA) and downstream pressure (PA) of both spools used
during compound operations is the same, so the pump flow is divided in proportion to the area of opening of notch (a) of
each spool.

D51EX/PX-22 10-91
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
LS BYPASS VALVE

PLS : LS circuit (pressure)


T : Tank circuit (pressure)

1. LS bypass valve
2. Valve cover

Function
l This releases the residual pressure of LS pressure (PLS).
l It makes the speed of the rise in pressure of LS pressure (PLS) more gentle. In addition, with this discarded throttled flow,
it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the stability by lowering the effec-
tive LS differential pressure.

Operation
l The pressurized oil for LS circuit (PLS) passes from filter (a) of bypass plug (1) through orifice (b) and flows to the tank
circuit (T).

10-92 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM

1. Title cylinder 5. Blade PPC Valve 9. Ripper cylinder (If equipped)

6. Ripper/Winch PPC valve (If


2. Angle cylinder 10. Control valve
equipped)

3. Oil cooler 7. Hydraulic tank 11. Accumulator

4. Lift cylinder 8. Oil filter 12. Work equipment and fan pump

D51EX/PX-22 10-93
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
WORK EQUIPMENT AND FAN PUMP
Type: LPV45

P1: Pump discharge port 1. Pump unit


PS: Pump suction port 2. Servo valve
3. Air breather
4. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 - 9.8 Nm (5.7 - 7.2 lbf ft)
5. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 - 10.8 Nm (8.7 - 10.8 lbf ft)
6. Torque . . . . . . . . . . . . . . . . . . . . . . . . 68.6 - 83.4 Nm (50.5 - 61.5 lbf ft)

10-94 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12

1. Shaft 7. Cylinder block


2. Oil seal 8. Valve plate
3. Case 9. Spring
4. Rocker cam 10. Servo piston
5. Shoe 11. Ball
6. Piston

12. Torque . . . . . . . . . . . . . . . . . . . . . . . 58.8 - 78.4 Nm (43.3 - 57.8 lbf ft)

D51EX/PX-22 10-95
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12

Function
l The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is
discharged according to the load.
l It is possible to change the delivery amount by changing the swash plate angle.

Structure
l Cylinder block (7) is supported to shaft (1) by spline (a), and shaft (1) is supported by the front and rear bearings.
l The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a
spherical bearing.
l Rocker cam (4) has flat surface (A). Shoe (5) is kept pressed against the flat surface (A) and it slides circularly on flat
surface (A). Rocker cam (4) slides around ball (11).
l Piston (6) carries out relative movement in the axial direction inside each cylinder chamber or cylinder block (7).
l Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that
the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is
sucked in and discharged through valve plate (8).
l Hole number of cylinder block (7) is an odd number. So, it is suited to groove of valve plate (8).

10-96 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
Operations
l Shaft (1) and cylinder block (7) rotate together and shoe (5) slides on
the flat surface (A). Since the rocker cam (4) leans around ball (11) at
this time, the angle (a) between the center line (X) of rocker cam (4)
and axis of cylinder block (7) changes. The angle (a) is called the
swash plate angle.
l When the center line (X) of the rocker cam (4) maintains the swash
plate angle (a) in relation to the axial direction of the cylinder block
(7), the flat surface (A) acts as a cam for the shoe (5).
l By this, the piston (6) slides on the inside of the cylinder block (7),
creates a difference between capacities (E) and (F), then suction and
discharge of oil for the amount of this difference (F) (E) will be
carried out.
l In other words, oil is discharged as the capacity of the chamber (E)
decreases when the cylinder block (7) rotates.
l In the mean time, the capacity of the chamber (F) increases, and the oil
is sucked at this process. (The figure shows the state of the pump when
suction of the chamber (F) and discharge of the chamber (E) have
completed.)
l When the center line (X) of the rocker cam (4) becomes in line with
the axial direction of the cylinder block (7) (swash plate angle = 0), the
difference between capacities of (E) and (F) inside the cylinder block
(7) becomes 0, so the pump does not carry out any suction or
discharge action of oil. (In actual fact, the swash plate angle never
becomes 0.)
l In other words, delivery of the pump is directly proportional to the
swash plate angle (a).

D51EX/PX-22 10-97
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
l As the swash plate angle (a) becomes larger, difference between the
capacities (E) and (F) becomes larger, so the pump delivery (Q)
increases.
l The swash plate angle (a) is changed by the servo piston (10).
l Servo piston (10) is reciprocated straight by the signal pressure of the
PC and LS valves. This reciprocation is transferred to rocker cam (4).
Rocker cam (4) supported on ball (11) rocks around ball (11).
l The output pressure (PE) of the LS valve is applied to the pressure
chamber of servo piston (10).
l As output pressure (PE) rises, rocker cam (4) moves to reduce the
swash plate angle (a), so the pump delivery (Q) decreases.

10-98 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
SERVO VALVE

P1L : Pump pressure input port 1. Locknut


PE : Control pressure output port 2. Plug
PH : Pump pressure port 3. Spring
PLS : LS pressure input port 4. Spool
T : Drain port 5. Plug
6. Seat
7. Piston
8. Sleeve
9. Lever
10. Spool
11. PC valve
12. LS valve

13. Torque . . . . . . . . . . . . . . . . . . . . . . . 27.4 - 34.3 Nm (20.2 - 25.2 lbf ft)

D51EX/PX-22 10-99
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
Function

1. LS valve
l The LS valve controls the discharge of the pump according to the
stroke of the control lever, or the demand flow for the actuator.
l The LS valve calculates the demand flow for the actuator from
differential pressure (PLS) between pump discharge pressure
(P1L) and control valve outlet pressure (PLS) and controls pump
delivery (Q).
l [(P1L) is called the pump discharge pressure, (PLS) called the LS
pressure, and (PLS) called the LS differential pressure.]
l That is, the pump discharge is controlled according to the demand
flow for the actuator by the following method; The pressure loss
made when the oil flows through the opening of the control valve
spool [LS differential pressure (PLS)] is sensed and pump
delivery (Q) is so controlled that the pressure loss will be
constant.

2. PC valve
l When pump discharge pressure (P1L) rises, the stroke of the
control valve spool is increased and the opening area is increased
and pump delivery (Q) is increased. At this time, the PC valve
limits pump delivery (Q) according to discharge pressure (P1L) so
that the pump absorption horsepower will not exceed the engine
horsepower. In other words, the PC valve performs approximate
constant-horsepower control.
l That is, if the load on the actuator is increased and pump
discharge pressure (P1L) rises during operation, the PC valve
reduces pump delivery (Q). If the pump discharge pressure
lowers, the PC valve increases pump delivery (Q).
l The relationship between pump discharge pressure (P1L) and
pump delivery (Q) is shown below.

10-100 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12

MEMORANDUM

D51EX/PX-22 10-101
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
CONTROL VALVE
General view

10-102 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
Outline
l This external view diagram shows the ripper valve.
l The standard valve does not have the ripper section.

A1 : To fan pump
A2 : To lift cylinder head
A3 : To tilt cylinder head
A4 : To angle cylinder
A5 : To ripper cylinder bottom
B1 : To fan pump
B2 : To lift cylinder bottom
B3 : To tilt cylinder bottom
B4 : To angle cylinder
B5 : To ripper cylinder head
LS : To LS valve of hydraulic pump
P : From work equipment pump
PA2 : From lift raise PPC valve
PA3 : From tilt left PPC valve
PA4 : From angle left PPC valve
PA5 : From ripper lower PPC valve
PB1 :
PB2 : From lift lower PPC valve
PB3 : From tilt right PPC valve
PB4 : From angle right PPC valve
PB5 : From ripper raise PPC valve
PEPC : From solenoid valve
PP : To LS valve of hydraulic pump
T : To tank
TS : To tank

1. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 - 12.7 Nm (7.2 - 9.3 lbf ft)


2. Torque . . . . . . . . . . . . . . . . . . . . . . . . 29.4 - 34.3 Nm (21.6 - 25.2 lbf ft)

D51EX/PX-22 10-103
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
Sectional view (1/5)

10-104 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12

1. Fan relief valve


2. Suction valve (Lift bottom)
3. Suction valve (Angle)
4. Suction valve (Ripper bottom)
5. Safety valve
6. Suction valve (Ripper head)
7. Suction valve (Angle)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length
8 Suction valve spring Outside diameter length load load If damaged or
2.65 N 2.16 N deformed,
36.3 4.45 33.3
{0.27 kg} {0.22 kg} replace spring.
5.1 N 4.12 N
9 Check valve spring 39.2 4.45 33.5
{0.52 kg} {0.42 kg}

10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 137 - 157 Nm (101 - 115 lbf ft)


11. Torque . . . . . . . . . . . . . . . . . . . . . . . 39.2 - 49.0 Nm (28.9 - 36.1 lbf ft)

D51EX/PX-22 10-105
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
(2/5)

10-106 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
1. Spool (Fan)
2. Spool (Lift)
3. Spool (Tilt)
4. Spool (Angle)
5. Spool (Ripper)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length
6 Spool return spring Outside diameter length load load
180 N 144 N
29 17.5 25
{18.4 kg} {14.7 kg}
50 N 40.0 N
7 Spool return spring 19.92 16.8 18.2
{5.1 kg} {4.08 kg}
39.2 N 31.4 N
8 Spool return spring 14.02 12.1 8.73
{4 kg} {3.2 kg} If damaged or
55.9 N 44.7 N deformed,
9 Spool return spring 31.98 17.4 28.5 replace spring.
{5.7 kg} {4.56 kg}
77.5 N 62.0 N
10 Spool return spring 33.34 17.2 26.8
{7.9 kg} {6.32 kg}
75.4 N 60.0 N
11 Spool return spring 29.27 17.6 26.9
{7.69 kg} {6.12 kg}
45.9 N 36.7 N
12 Spool return spring 17.05 17.2 15.2
{4.68 kg} {3.74 kg}
189 N 151 N
13 Spool return spring 40.73 17.4 28.5
{19.25 kg} {15.4 kg}

14. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 35 - 63 Nm (25.8 - 46.4 lbf ft)

D51EX/PX-22 10-107
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
(3/5)

10-108 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
1. Unload valve 8. Pressure compensation valve R (Angle)
2. Pressure compensation valve F (Fan) 9. Pressure compensation valve R (Tilt)
3. Pressure compensation valve F (Lift) 10. Pressure compensation valve R (Lift)
4. Pressure compensation valve F (Tilt) 11. Pressure compensation valve R (Fan)
5. Pressure compensation valve F (Angle)
6. Pressure compensation valve F (Ripper) F: Flow control valve
7. Pressure compensation valve R (Ripper) R: Pressure reducing valve

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation If damaged or
Free length
12 Unload valve spring Outside diameter length load load deformed,
91.2 N 73.0 N replace spring.
28.64 18.6 18
{9.3 kg} {7.44 kg}

13. Torque . . . . . . . . . . . . . . . . . . . . . . . 14.7 - 19.6 Nm (10.8 - 14.4 lbf ft)


14. Torque . . . . . . . . . . . . . . . . . . . . 117.6 - 161.8 Nm (86.7 - 119.3 lbf ft)

D51EX/PX-22 10-109
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
(4/5)

10-110 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
1. Unload valve 9. Pressure compensation valve R (Lift)
2. Main relief valve 10. Pressure compensation valve F (Lift)
3. Fan relief valve 11. Spool (Tilt)
4. Spool (Fan) 12. Pressure compensation valve R (Tilt)
5. Pressure compensation valve R (Fan) 13. Pressure compensation valve F (Tilt)
6. Pressure compensation valve F (Fan)
7. Suction valve (Lift) F: Flow control valve
8. Spool (Lift) R: Pressure reducing valve

14. Torque . . . . . . . . . . . . . . . . . . . . . . . 137 - 157 Nm (101.0-115.7 lbf ft)


15. Torque . . . . . . . . . . . . . . . . . . . . . . . 49.0 - 58.8 Nm (36.0 - 43.3 lbf ft)
16. Torque . . . . . . . . . . . . . . . . . . . . . . . 29.4 - 39.2 Nm (21.6 - 28.9 lbf ft)

D51EX/PX-22 10-111
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
(5/5)

10-112 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
1. Suction valve 8. Spool (Ripper)
2. Suction valve 9. Pressure compensation valve R (Ripper)
3. Spool (Angle) 10. Pressure compensation valve F (Ripper)
4. Pressure compensation valve R (Angle) 11. Safety valve
5. Pressure compensation valve F (Angle) 12. Pressure bleed plug
6. Suction valve
7. Suction valve F: Flow control valve
R: Pressure reducing valve

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation If damaged or
Free length
13 Check valve spring Outside diameter length load load deformed,
1.98 N 1.57 N replace spring.
21.9 5 15.8
{0.2 kg} {0.16 kg}

14. Torque . . . . . . . . . . . . . . . . . . . . . . . 15.6 - 20.6 Nm (11.5 - 15.1 lbf ft)


15. Torque . . . . . . . . . . . . . . . . . . . . . . 137 - 157 Nm (101.0 - 115.7 lbf ft)
16. Torque . . . . . . . . . . . . . . . . . . . . . . . 19.6 - 24.5 Nm (14.4 - 18.0 lbf ft)
17. Torque . . . . . . . . . . . . . . . . . . . . 117.6 - 161.8 Nm (86.7 - 119.3 lbf ft)

D51EX/PX-22 10-113
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
QUICK DROP VALVE

CB1 : To right lift cylinder bottom 1. Plug


CB2 : To left lift cylinder bottom 2. Piston
CH1 : To right lift cylinder head 3. Retainer
CH2 : To left lift cylinder head 4. Valve
VB : From control valve blade "LOWER" 5. Body
VH : From control valve blade "RAISE" 6. Plug
7. Plug

10-114 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Free Installation
8 Piston spring Outside diameter length load length load
25.5 N 20.4 N If damaged or
27.3 12 20
{2.6 kg} {2.08 kg} deformed, replace
46.1 N 36.9 N spring.
9 Valve spring 53.24 34.8 18
{4.7 kg} {3.76 kg}
52.5 N 42.0 N
10 Valve spring 26.35 23 25
{5.35 kg} {4.28 kg}

11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 98.122.5 Nm 72.2 - 90.3 lbf ft)


12. Torque . . . . . . . . . . . . . . . . . . . . . . . 15.7 - 20.6 Nm (11.5 - 15.1 lbf ft)
13. Torque . . . . . . . . . . . . . . . . . . . 578.2 - 725.2 Nm (426.4 - 534.8 lbf ft)

Outline
l The quick drop valve is installed between the control valve and lift cylinder. When the control lever is operated to
"LOWER" the blade, this device prevents a vacuum in the cylinder bottom and shortens the time lag in starting digging.
l The blade lowering speed is almost decided by the pump discharge. It can be heightened, however, by installing the quick
drop valve.

Operation
Start of lowering blade
l If the blade control lever is set in the "LOWER" position, the oil from
the control valve flows in port (VB), and then flows through ports
(CB1) and (CB2) to the cylinder bottom side and pushes the piston to
the left.
l The oil on the cylinder head side is pushed out by the piston, and then
it enters ports (CH1) and (CH2) and flows through port (VH) and
control valve to the hydraulic tank.

While lowering blade


l The oil pushed out of the cylinder head side flows through ports (CH1)
and (CH2) to port (VH). At this time, the oil flow rate is reduced by
orifice (a) and a pressure difference is made between before and
behind the orifice.
l If the oil pressure in ports (CH1) and (CH2) becomes higher than the
tension of springs (1) and (2), valve (3) and piston (4) move to the
right.
l Since ports (VB), (CH1), and (CH2) are opened, a part of the oil
flowing from ports (CH1) and (CH2) to port (VH) merges with the oil
from the control valve and then flows to the cylinder bottom side.
l Accordingly, 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.

D51EX/PX-22 10-115
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
BLADE PPC VALVE
H PPC: Abbreviation for Proportional Pressure Control

For blade lift, tilt, angle

10-116 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)

P : From control pump 1. Spool


P1 : To blade tilt valve (LEFT tilt) 2. Metering spring
P2 : To blade tilt valve (RIGHT tilt) 3. Centering spring
P3 : To blade lift valve (RAISE) 4. Piston
P4 : To blade lift valve (LOWER) 5. Disc
P5 : To blade angle valve (RIGHT angle) 6. Cap (for connecting lever)
P6 : To blade angle valve (LEFT angle) 7. Joint
T : To hydraulic tank 8. Plate
9. Retainer
10. Body

11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - 49 Nm (28.7 - 36.1 lbf ft)


12. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 127 Nm (72.2 - 93.6 lbf ft)
13. Torque . . . . . . . . . . . . . . . . . . . . . . . . 11.8 - 14.7 Nm (8.7 - 10.8 lbf ft)

D51EX/PX-22 10-117
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
Operation

1. At neutral

A. For blade lift


l Ports (PA) and (PB) of the blade lift 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).

B. For blade tilt


l Ports (PA) and (PB) of the blade tilt control valve and ports
(P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) of spool (1).

10-118 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
C. For blade angle
l Ports (PA) and (PB) of the blade angle control valve and
ports (P5) and (P6) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) of spool (1).

2. During fine control (Neutral fine control)


l When piston (4) is pushed by disc (5), retainer (9) is pushed, and
spool (1) is also pushed through metering spring (2), and moves
down.
l As a result, if fine control hole (f) is shut off from drain chamber
(D), at almost the same time, it is connected with pump pressure
chamber (PP), and the pilot pressure oil from the control pump
passes through fine control hole (f) and flows from port (P4) to
port (PB).
l When the pressure at port (P4) becomes high, if spool (1) is
pushed back and fine control hole (f) is shut off from pump
pressure chamber (PP), at almost the same time, it is connected
with drain chamber (D) and releases the pressure at port (P4).
l As a result, spool (1) moves up and down so that the force of
metering spring (2) is balanced with the pressure at port (P4). 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).
l Therefore, metering spring (2) is compressed an amount
proportional to the movement of the control lever, so the pressure
at port (P4) also rises in proportion to the movement of the control
lever.
l The control valve spool moves to a position where the pressure in
chamber (PB) [same as pressure at port (P4)] is balanced with the force of the return spring.

D51EX/PX-22 10-119
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
3. During fine control
(when control lever is returned)
l When disc (5) starts to be returned, spool (1) is pushed up by the
pressure at port (P4) and the force of centering spring (3).
l As a result, fine control hole (f) is connected to drain chamber
(D), so the pressure oil at port (P4) is relieved.
l If the pressure at port (P4) goes down too far, spool (1) is pushed
down by metering spring (2). Fine control hole (f) is shut off from
drain chamber (D), and at almost the same time, it is connected to
pump pressure chamber (PP). Pump pressure is supplied until the
pressure at port (P4) recovers to a pressure equivalent to the
position of the lever.
l When the control valve spool returns, the oil at drain chamber (D)
flows in from fine control hole (f') in the valve on the side that is
not moving. It passes through port (P3), is taken to chamber (PA),
and the oil fills the chamber.

4. When lever is operated fully


l When disc (5) pushes down piston (4) and retainer (9) pushes
down spool (1), fine control hole (f) is shut off from drain
chamber (D) and is connected to pump pressure chamber (PP).
l Therefore, the pilot pressure oil from the control pump passes
through fine control hole (f), is taken from port (P4) to chamber
(PB), and pushes the control valve spool.
l The return oil from chamber (PA) passes from port (P3) through
fine control hole (f'), and then flows to drain chamber (D).

10-120 D51EX/PX-22
STRUCTURE, FUNCTION AND
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12
5. When blade is operated to FLOAT
l When piston (4) at the port (P4) LOWER side is pushed by disc
(5) and moves down, ball (11) contacts protrusion (a) of the piston
during the stroke. (Detente starts to act.)
l When piston (4) pushed in further, ball (11) pushes up collar (12),
which is being held by detente spring (13). While pushing up col-
lar (12), it escapes to the outside and passes over protrusion (a) of
the piston.
l When this happens, piston (4') on the opposite side is pushed up
by spring (14).
l As a result, the oil inside chamber (F) passes through (b) and (c),
and flows to chamber (E), and piston (4') follows disc (5). Passage
(d) is connected to port (P4), so more or less the same pressure is
applied as is applied to port (P4).
l Chamber (E) is normally connected to drain chamber (D), but if
ball (11) passes over protrusion (a) of the piston, passage (d) and
chamber (E), which were shut off, are connected and the pressure
oil flows.
l At the same time, the control valve also moves to the FLOAT
position and the circuit is set to the FLOAT condition.
l Piston (4') is being pushed up by the oil pressure inside chamber
(E), so even if the lever is released, it is held at the FLOAT
position.

6. When blade is released from FLOAT


l When disc (5) is returned from the FLOAT position, it is pushed down by a force greater than the hydraulic force in
chamber (E).
l As a result, chamber (E) is shut off from passage (d) and is connected to the drain chamber. Therefore, the oil
pressure inside chamber (E) is lost, and the FLOAT position is canceled.

D51EX/PX-22 10-121
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
RIPPER/WINCH PPC VALVE
(If equipped)

10-122 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
P : From charge pump 1. Spool
P1 : To ripper valve 2. Piston
P2 : To ripper valve 3. Lever
T : To tank 4. Plate
5. Retainer
6. Body
7. Filter

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installation Installation Installation
Free length
8 Centering spring Outside diameter length load load If damaged or
125 N 100 N deformed,
33.9 15.3 28.4
{12.7 kg} {10.2 kg} replace spring.
16.7 N 13.3 N
9 Metering spring 22.9 8.10 22.0
{1.70 kg} {1.36 kg}

10. Torque . . . . . . . . . . . . . . . . . . . . . . . 11.76 - 14.7 Nm (8.6 - 10.8 lbf ft)

D51EX/PX-22 10-123
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
Operation

1. At neutral
l Ports (A) and (B) of the control valve and ports (P1) and (P2) of
the PPC valve are connected to drain chamber (D) through fine
control hole (f) on spool (1).

2. During fine control (Neutral fine control)


l As piston (4) is pushed by disc (5), retainer (7) is pushed too. At
the same time, spool (1) is also pushed down through metering
spring (2).
l By this move, connection of fine control hole (f) is switched from
drain chamber (D) to pump pressure chamber (PP), and pilot
pressure oil of control pump is conducted from port (P1) to port
(A).
l As port (P1) pressure increases, spool (1) is pushed back. By this
move, connection of fine control hole (f) is switched from pump
pressure chamber (PP) to drain chamber (D), thereby relieving
port (P1) pressure.
l As the result, spool (1) moves up and down so that force of
metering spring (2) and port (P1) pressure may be balanced.
l Positional relationship between spool (1) and body (8) [fine
control hole (f) is situated at mid point between drain chamber
(D) and pump pressure chamber (PP)] remains unchanged until
retainer (7) is contacted against spool (1).
l Metering spring (2) is, therefore, compressed in proportion to
strokes of the control lever. Thus, port (P1) pressure too, increases
in proportion to strokes of the control lever.
l As the result, the control valve spool moves to the position where
the pressure of chamber (A) [the same as port (P1) pressure] is
balanced against force of the control valve spool return spring.

10-124 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
3. During fine control
(when control lever is returned)
l As lever (5) starts returning, spool (1) is pushed up by force of
centering spring (3) and port (P1) pressure. By this move, fine
control hole (f) is connected to drain chamber (D) and relieves
pressurized oil of port (P1) to it.
l If port (P1) pressure goes excessively low, spool (1) is pushed
down by metering spring (2), and passage between fine control
hole (f) and drain chamber (D) is shut down. And, almost at the
same time, the hole is connected to pump pressure chamber (PP)
and starts supplying pump the pressure. This supply continues
until port (P1) pressure is recovered to the level equivalent to the
lever position.
l When the control valve spool returns, oil in drain chamber (D)
flows in through fine control hole (f') on the not moving side
valve. Oil is then conducted via port (P2) to chamber (B) to fill it
up.

4. At full stroke
l When disc (5) pushes down piston (4) and retainer (7) pushes
down spool (1), connection of fine control hole (f) is switched
from drain chamber (D), to pump pressure chamber (PP).
l Thus, pilot pressurized oil from the control pump passes through
fine control hole (f) and conducted to chamber (A) through port
(P1) to push the control valve spool.
l Return oil from chamber (B) is conducted from port (P2) to drain
chamber (D) through fine control hole (f').

D51EX/PX-22 10-125
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
HYDRAULIC TANK, FILTER

1. Hydraulic tank
2. Hydraulic oil filter
3. Oil filler cap
4. Sight gauge
5. Strainer
6. Drain plug
7. Bypass valve

Specifications

Tank capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.1 L (24.6 gal US)


Quantity of oil in tank . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 L (18 gal US)
Set pressure of bypass valve . . . . . . . . . . 1.5 0.3 kg/cm2 (21.7 4.3 psi)
Cracking pressure of pressure valve . . 0.39 0.15 kg/cm2 (5.54 2.1 psi)
Actuating pressure of vacuum valve . . . . . . 0 - 0.046 kg/cm2 (0 - 0.65 psi)

10-126 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
ACCUMULATOR
(for PPC circuit)

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Specifications
Type of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nitrogen gas
Amount of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 cc
Max. operating pressure . . . . . . . . . . . . . . . . . . . . . .70 kg/cm2 (995.6 psi)
Charge pressure . . . . . . . . . . . . . . . . . . . . . . 12 kg/cm2 (170.6 psi) at 80C

Outline
l A accumulator is installed between the charge valve and the work
equipment valve. In the case the engine is stopped with the work
equipment raised, the compressed nitrogen gas pressure in the
accumulator feeds the pilot oil pressure to the work equipment control
valve so that the work equipment will lower by its weigh.

D51EX/PX-22 10-127
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12

MEMORANDUM

10-128 D51EX/PX-22
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12
WORK EQUIPMENT

WORK EQUIPMENT

a. Title cylinder e. Pitching rod

b. Cutting edge f. Angle cylinder

c. End bit g. U-frame

d. Blade h. Lift cylinder

D51EX/PX-22 10-129
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12

10-130 D51EX/PX-22
STRUCTURE, FUNCTION AND
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12

D51EX/PX-22 10-131
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12

10-132 D51EX/PX-22
STRUCTURE, FUNCTION AND
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12
Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance


Clearance between frame size Shaft Hole clearance limit
1 connecting pin and bushing
+0.207 0.15 ~ 0.283 0.5
+0.120
-0.030
Clearance between frame 75 -0.076 +0.3
2 connecting pin and U-frame 0.13 ~ 0.516 1.0
+0.1
bracket
Clearance between lift cylinder -0.025 +0.046
3 50 0.025 ~ 0.11 1.0
bottom pin and frame bracket -0.064 0
Clearance between lift cylinder -0.025 +0.3
4 50 0.125 ~ 0.364 1.0
head pin and U-frame bracket -0.064 +0.1
Clearance between angle -0.025 +0.3 Replace
5 cylinder bottom pin and 40 0.125 ~ 0.364 1.0
-0.064 +0.1
U-frame bracket
Clearance between angle -0.025 +0.3
6 cylinder head pin and blade 40 0.125 ~ 0.364 1.0
-0.064 +0.1
bracket
Clearance between tilt cylinder -0.025 +0.3
7 40 0.125 ~ 0.364 1.0
bottom pin and U-frame bracket -0.064 +0.1
Clearance between tilt cylinder -0.025 +0.3
8 40 0.125 ~ 0.364 1.0
head pin and blade bracket -0.064 +0.1
Clearance between pitching rod +0.039
9 0.025 ~ 0.103 0.5
pin and bushing -0.025 0
50
Clearance between pitching rod -0.064 +0.164
10 0.145 ~ 0.228 1.0
pin and U-frame bracket +0.120
-0.5
Clearance between blade S 114 ---
0
11 spherical portion and pitching 0.5 - 1.5 3.0
rod cap -0.5
S 115 --- 0
Clearance between blade -0.25 -0.5
12 center spherical portion and S 160 0.25 - 1.25 5.0
-0.75 0 Adjust
U-frame cap shim
Standard shim thickness at
13 main blade spherical portion 8.0
and U-frame cap
Standard shim thickness at
14 blade pitching spherical portion 4.0
end cap

D51EX/PX-22 10-133
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
CUTTING EDGE AND END BIT

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height of cutting edge
204 110
2 Height of end bit 204 110 Replace
D51EX-22 379.6 ---
3 Width of end pit
D51PX-22 379.6 ---

4. Torque . . . . . . . . . . . . . . . . . . . . 225.4 - 294.0 Nm (166.2 - 216.8 lbf ft)

10-134 D51EX/PX-22
STRUCTURE, FUNCTION AND
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12
RIPPER
(If equipped)

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance


Clearance between pin and size Shaft Hole clearance limit
1 bushing
-0.025 +0.142 0.105 -
50 1.0 Replace
-0.064 +0.080 0.206
Standard size Repair limit
2 Wear of point
222 114

3. Support
4. Ripper cylinder
5. Shank
6. Point
7. Beam

D51EX/PX-22 10-135
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
WORK EQUIPMENT CYLINDER
LIFT CYLINDER

TILT CYLINDER

10-136 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
ANGLE CYLINDER

RIPPER CYLINDER
(If equipped)

D51EX/PX-22 10-137
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12

Unit: mm
No. Check item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
0.025 +0.152 0.020
Lift 50 0.516
0.064 0.005 0.216
Clearance between piston rod and 0.030 +0.151 0.024
1 Tilt 55 0.527
bushing 0.076 0.006 0.227
0.025 +0.152 0.020
Angle 50 0.516
0.064 0.005 0.216
0.030 +0.151 0.024
Ripper 60 0.527
0.076 0.006 0.227
0.025 +0.142 0.105
Lift 50 1.0
0.064 +0.080 0.206
0.025 +0.039 0.025 Replace
Tilt 40 1.0 bushing
Clearance between piston rod 0.064 0 0.103
2
support shaft and bushing 0.025 +0.039 0.025
Angle 40 1.0
0.064 0 0.103
0.030 +0.174 0.130
Ripper 70 1.0
0.076 +0.100 0.250
0.025 +0.142 0.105
Lift 50 1.0
0.064 +0.080 0.206
0.025 +0.039 0.025
Tilt 40 1.0
Clearance between cylinder bottom 0.064 0 0.103
3
support shaft and bushing 0.025 +0.025 0.025
Angle 40 1.0
0.064 0 0.089
0.030 +0.174 0.130
Ripper 70 1.0
0.076 +0.100 0.250

4. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 677 67.5 Nm (499 49.7 lbf ft)


5. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 0.14 Nm (1.0 0.10 lbf ft)
6. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 785 78.5 Nm (578 57.8 lbf ft)
7. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 1.67 0.17 Nm (1.2 0.12 lbf ft)
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 1.39 0.14 Nm (1.0 0.10 lbf ft)
9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 923 93.0 Nm (680 68.5 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 0.26 Nm (1.9 0.19 lbf ft)

10-138 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
PISTON VALVE FOR ANGLE CYLINDER
Outline
l The piston valve is installed to the piston section of the angle cylinder.
l When the piston rod is at the stroke end, 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.

Operation

Piston valve is "Open"

The oil from the pump acts on piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right to seal the tapered part of
piston valve seat (4).
As a result, the oil pressure in the cylinder rises to move piston (2) to the
right.

Piston valve is "Closed"

The end of piston valve (3) touches cylinder bottom (a) before piston rod
(1) reaches the stroke end, and then only piston (2) continues moving.
At this time, the oil which has been stopped by piston valve (3) is sent
through piston valve seats (4) and (5) to the bottom side, thus the oil
pressure in the cylinder lowers.

D51EX/PX-22 10-139
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12
CAB AND ITS ATTACHMENTS

ROPS CAB

1. ROPS cab
2. Door
3. Front wiper
4. Rear wiper
5. Door wiper

10-140 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12

MEMORANDUM

D51EX/PX-22 10-141
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12
STEERING AND BRAKE CONTROL
H PCCS: Abbreviation for Palm Command Control System

10-142 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
1. Parking brake lever
2. Joystick (PCCS lever)
3. Electric lever
4. Parking brake limit switch 1
5. Parking brake limit switch 2
6. HST controller
7. Center brake proximity switch
8. Brake pedal potentiometer
9. Brake pedal

Outline
l Electric lever (3) sends electric signals to HST controller (6) according to the stroke of joystick (PCCS lever) (2). Upon
receiving these signals, HST controller (6) sends signals to the EPC valve of HST pump to change the flow in HST pump
and control the HST motor.
l If the joystick (PCCS lever) (2) is leaned to the left a little while it is leaned to the forward position, the machine turns to
the left gradually. If it is leaned to the left stroke end, the machine makes a counter-rotation.
l Brake pedal potentiometer (8) sends electric signals to HST controller (6) according to the stroke of brake pedal (9). Upon
receiving these signals, HST controller (6) sends signals to the EPC valve of HST pump to decelerate the right and left
HST motors simultaneously.
l If brake pedal (9) is pressed fully while parking brake lever (1) is in the FREE position, HST controller (6) receives
electric signals from brake pedal potentiometer (8) and operates the right and left HST brakes simultaneously. After the
machine stops, HST controller (6) stops sending signals to the parking brake solenoid valve. At this time, the signal of
center brake proximity switch (7) operates the relay to stop the signal to the slow brake solenoid valve. If the signal to the
parking brake solenoid valve or slow brake solenoid valve is stopped, the parking brakes built in the right and left HST
motors operate.
l If the parking brake lever (1) is set in the LOCK position, the HST controller receives electric signals from parking brake
limit switch 1 (4) and stops sending signals to the parking brake solenoid valve. At this time, parking brake limit switch 2
(5) stops sending signals to the slow brake solenoid valve. If the signal to the parking brake solenoid valve or slow brake
solenoid valve is stopped, the parking brakes built in the right and left HST motors operate.

D51EX/PX-22 10-143
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12
WORK EQUIPMENT CONTROL

10-144 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12
1. Work equipment lock lever
2. Blade PPC valve
3. Blade control lever
4. Ripper control lever (If equipped)
5. Ripper PPC valve (If equipped)
6. PPC lock limit switch

Outline
l The work equipment control system is a PPC system, 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).
l If work equipment lock lever (1) is set in the LOCK position, the PPC lock limit switch stops the signal to the PPC lock
solenoid valve and the operator can move blade control lever (3) and ripper control lever (4) but cannot operate the work
equipment.
l If blade control lever (3) is set in the FLOAT position, the hydraulic detent of blade PPC valve (2) works so that blade
control lever (3) will hold itself.
l If work equipment lock lever (1) is set in the LOCK position, the hydraulic detent is reset and blade control lever (3)
returns to the HOLD position automatically.
l While the engine is stopped, the hydraulic detent does not work even, if blade control lever (3) is in the FLOAT position,
and blade control lever (3) returns to the HOLD position automatically.

D51EX/PX-22 10-145
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12
CAB DAMPER MOUNT
Cab mount and ROPS stopper

1. Damper mount (Front)


2. Damper mount (Rear)
3. ROPS stopper (Front)
4. ROPS stopper (Rear)

Outline
l The mounts are installed to 2 places on each of the front side and rear side to fix the cab (with the floor frame).
l The oil-filled damper mounts absorb vibrations.
l The ROPS stoppers are installed 2 places on each of the front side and rear side to fix the cab (having the ROPS in it)
when the machine overturns.

10-146 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12
AIR CONDITIONER
AIR CONDITIONER AND FLOOR HEATER

1. Air conditioner unit


2. Heater unit (Floor)
3. Condenser
4. Receiver tank
5. Water valve
6. Refrigerant liquid piping
7. Front window defroster
8. Side window defroster
9. Rear window defroster
10. Face air outlet
11. Foot air outlet

A External air inlet (Bottom of unit)


B Internal air circulation opening

D51EX/PX-22 10-147
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12
AIR CONDITIONER PIPING

1. Compressor
2. Refrigerant discharge piping
3. Refrigerant suction piping
4. Hot water outlet
5. Hot water return piping

10-148 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ELECTRICAL SYSTEM

MONITOR SYSTEM

a. Each sensor f. KOMTRAX


b. Sensor signal g. Battery
c. HST controller h. Power source
d. CAN signal i. Alarm buzzer
e. Engine controller j. Alarm buzzer signal

l The monitor system notifies the operator of the machine condition. It monitors the machine condition with the sensors
installed to the machine and processes and displays the obtained information on the monitor panel immediately.
The contents displayed on the panel are roughly classified as shown below.
l Travel direction, gear speed, shift mode (Display panel A)
l Coolant temperature, HST oil temperature, and fuel level (Gauge section)
l Machine trouble alarm (Monitor section)
l Current, voltage, error code, of each sensor and solenoid (Display panel B)

l The monitor system consists of the monitor panel, controller, sensors, alarm buzzer, and power supply.
l The component parts are connected by wiring harnesses and the monitor panel is powered by the battery.
l If the machine has any trouble (and a sensor detects it), the monitor and alarm lamp flash and the alarm buzzer sounds to
protect the machine. The alarm buzzer can be turned OFF temporarily with the buzzer cancel switch.

D51EX/PX-22 10-149
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
Processing in monitor panel (Common to all specifications)

Display of monitor panel


Contents and conditions of processing Method Flow of signals
1. Display of travel direction and gear speed
l Signals (F1, R3, etc.) are sent to the monitor panel according to the information of the CAN signal
HST controller.
2. Display of coolant temperature, HST oil temperature, and fuel level by gauge
l The controller processes the sensor signals and sends the result to the CAN signal
monitor panel.
3. Display of trouble
l If there is any trouble, its failure code signal is sent to the monitor panel. Each sensor/solenoid

l Information about sounding the buzzer and flashing the caution lamp is sent,
Controller
according to the contents of the trouble.

1) In normal state Monitor panel
An action code and a failure code are displayed.
2) In failure history display mode CAN signal
l A failure code (6-characteristics code) and the following are displayed.
l Elapsed time after first occurrence (When trouble is in electrical system)
l Elapsed time after latest occurrence (When trouble is in electrical
system)
l Number of occurrences

Display of monitor panel


Contents and conditions of processing Method Flow of signals
1. Display of each sensor, each solenoid, communicating state of CAN signal, etc. Each sensor/solenoid
CAN signal
l The signals of condition of each device are sent to the monitor panel.
Controller
2. Selection of each item with buzzer cancel switches (U, t) and cursor switches (>, <).
CAN signal
Monitor panel

H For details of the operating method, see Testing and adjusting, "Special functions of monitor panel (EMMS)".

Other items
Contents and conditions of processing Method Flow of signals
1. Filter and oil maintenance mode (User)
2. Maintenance interval change mode (Service)
3. Electric system failure code display mode
4. Mechanical system failure code display mode
5. Adjustment mode (Service) Each sensor/solenoid
6. Real-time monitoring mode
7. Reduced cylinder mode (Service) CAM signal Controller
8. No-injection cranking mode (Service)
9. Phone No. setting mode (Service) Monitor panel
10. Machine model selection mode (Service)
11. Option selection mode (Service)
12. Initialization mode (Service)
13. Luminance and brightness adjustment mode (User)

H For details of the operating method, see Testing and adjusting, "Special functions of monitor panel (EMMS)".

10-150 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ENGINE CONTROL

1. Battery 5. Monitor panel 9. Limit switch

2. Starting switch 6. HST controller 10. Parking brake lever

3. Engine 7. Neutral safety relay 11. Electric lever

12. Steering/directional/gear shift


4. Starting motor 8. Safety relay
lever (PCCS) lever)

Input and output signals

a. Battery power source

b. Engine start signal

c. Starting switch ACC signal

d. Parking brake signal

e. Neutral signal

Function
l A limit switch is installed to the linkage of the parking brake. HST 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.

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ENGINE CONTROL SYSTEM

1. Battery 6. Fuel control dial 11. Engine oil pressure switch

2. Starting switch 7. Decelerator pedal 12. Injector

3. Engine controller 8. Engine 13. Fuel supply pump valve

4. HST controller 9. Engine speed sensor

5. Monitor panel 10. Coolant temperature

Input and output signals

a. No. 1 throttle signal (fuel control dial signal) f. Engine speed signal

b. No. 2 throttle signal (decelerator pedal signal) g. Coolant temperature signal

c. N0. 3 throttle signal (controller control signal) h. Engine oil pressure signal

d. Starting switch ACC signal i. Sensor signal

e. Controller power source j. Monitor display signal

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ENGINE SPEED CONTROL MECHANISM

l The engine controller receives the No. 1 throttle signal (fuel control dial signal) and No. 2 throttle signal (decelerator
pedal signal) and then selects the lower command signal and controls the fuel supply pump and injector.
l 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.

ENGINE STOP MECHANISM

l If the starting switch is set in the OFF position, the starting switch ACC signal to the engine controller is turned OFF.
l The engine controller stops supplying fuel to the engine to stop the engine.

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COOLING CONTROL SYSTEM

1. Battery 6. Cooling fan motor 11. Fan speed sensor

2. Battery relay 7. Work equipment and cooling fan pump 12. Hydraulic oil temperature sensor

3. HST controller 8. Fan rotation selector switch 13. Engine

4. Engine controller 9. Work equipment valve 14. Engine speed sensor

5. Monitor panel 10. Fan EPC valve 15. Coolant temperature sensor

Input and output signals

a. Controller power source f. Coolant temperature signal

b. Fan rotation selector signal g. CAN signal

c. Fan speed signal h. Fan speed control signal

d. Hydraulic oil temperature signal i. Fan reverse signal

e. Engine speed signal

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Outline

The HST controller monitors the coolant and hydraulic oil temperatures and controls the fan speed according to those
temperatures.

Function

Fan speed control

l The HST controller controls the oil flow to the cooling fan motor to set the fan speed properly according to the informa-
tion from the coolant and hydraulic oil temperature sensors.
l The HST controller selects the maximum target fan speed obtained from the coolant and hydraulic oil temperatures and
output it as the fan speed control signal to the fan EPC valve.
l The fan EPC valve changes the open area of the fan spool in the work equipment valve to control the oil flow to the cool-
ing fan motor.
l The HST controller monitors the actual fan speed with the fan speed sensor and controls it to the target fan speed.

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.
Fan rotation mode includes;

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. 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.
While in the Cleaning mode, the machine does not move for the radiator protection even if the PCCS lever is shifted to
forward or reverse position. The starting switch needs to be turned from off to on to restart the machine under the
forward rotation mode.
According to the selected mode, HST controller operates the reverse solenoid valve of the cooling fan motor to change the
rotation direction of the fan.

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 for 3 seconds.

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HST CONTROL SYSTEM
H HST: Abbreviation for HydroStatic Transmission

1. Battery 9. Fuel control dial potentiometer 17. RH HST pump reverse EPC valve

2. Battery relay 10. Monitor panel 18. LH HST circuit oil pressure sensor

3. Engine controller 11. Reverse travel speed setting switch 19. RH HST circuit oil pressure sensor

4. Fuse box 12. Shift mode switch 20. LH HST motor speed sensor

5. HST controller 13. Engine speed sensor 21. RH HST motor speed sensor

6. Decelerator pedal potentiometer 14. LH HST pump forward EPC valve 22. LH HST motor EPC valve

7. Brake pedal potentiometer 15. RH HST pump forward EPC valve 23. RH HST motor EPC valve

8. Electric lever (for steering) 16. LH HST pump reverse EPC valve

Input and output signals

a. Controller power supply


b. CAN signal
c. Reverse travel speed setting signal
d. Shift mode signal
e. Decelerator pedal stroke signal
f. Brake pedal stroke signal
g. Steering/directional/gear shift signal
h. Fuel control dial stroke signal
j. Engine speed signal
k. HST circuit oil pressure signal
m. HST motor speed signal
n. HST pump EPC valve drive signal
p. HST motor EPC drive signal

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GEAR SHIFT CONTROL SYSTEM
GEAR SHIFTING BY OPERATOR

Function

l Upon receiving the gear shift signal from the shift-up or shift-down switch of the steering/directional/gear shift lever, the
HST controller decides the capacity of the HST pump and HST motor and shift the gear.
l The operator can select the quick shift mode or the variable shift mode with the shift mode switch.
l If the steering/directional/gear shift lever is leaned forward (for forward travel), a set travel speed is decided according to
the gear speed of broken line (B) in the above graph.
l If the steering/directional/gear shift lever is leaned backward (for reverse travel), a set travel speed corresponding to the
gear speed of settings (A) (E) of the reverse travel speed setting switch is decided according to the above graph.
l When the steering/directional/gear shift lever is in the neutral position, the set travel speed is 0 km/h.

The figure to the right shows setting of reverse travel speed (C) in the 1st
gear speed (default).

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SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS

Bar graph gauge No. Set travel speed (km/h)


Gear
F shift R shift gauge Reverse
speed Forward
gauge A B C D E A B C D E
2 2 2 2 2 2 0.8 0.8 0.8 0.8 0.8 0.8
4 3 4 4 5 5 1.0 0.9 1.0 1.1 1.2 1.3
6 5 6 7 8 9 1.5 1.2 1.5 1.7 1.9 2.2
8 7 8 9 11 12 2.0 1.6 2.0 2.3 2.7 3.0
10 8 10 12 14 16 2.4 2.0 2.4 2.9 3.4 3.8
12 10 12 14 17 19 2.9 2.3 2.9 3.5 4.1 4.7
1 14 11 14 17 20 23 3.4 2.7 3.4 4.1 4.8 5.5
16 13 16 19 22 25 3.8 3.0 3.8 4.5 5.2 6.0
18 15 18 21 25 28 4.1 3.4 4.1 4.9 5.7 6.4
20 16 20 24 27 31 4.5 3.7 4.5 5.3 6.1 6.9
22 18 22 26 30 33 4.9 4.0 4.9 5.7 6.5 7.4
24 20 24 28 32 36 5.2 4.4 5.2 6.1 7.0 7.8
2 26 22 26 30 34 38 5.6 4.7 5.6 6.5 7.4 8.3
28 24 28 32 36 40 6.1 5.2 6.1 7.0 7.9 8.8
30 26 30 34 38 40 6.6 5.7 6.6 7.5 8.4 9.0
32 28 32 36 40 40 7.1 6.2 7.1 8.0 8.9 9.0
34 30 34 38 40 40 7.5 6.6 7.5 8.4 9.0 9.0
36 32 36 40 40 40 8.0 7.1 8.0 8.9 9.0 9.0
38 34 38 40 40 40 8.5 7.6 8.5 9.0 9.0 9.0
3 40 36 40 40 40 40 9.0 8.1 9.0 9.9 10.8 11.7

H The values of bold-face type are for the quick shift mode.

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l If the fuel control dial or decelerator pedal is operated, a deceleration command is lowered according to the deceleration
command map.
l The deceleration command of fuel control dial is higher than that of the decelerator pedal. Accordingly, even if the fuel
control dial is returned from the "FULL SPEED" position, higher output is secured.
l The deceleration command means the ratio to the set travel speed.

Example:
l When the fuel control dial is at the "FULL SPEED" position and the decelerator pedal is not pressed:
l The deceleration command is 100%, and the command travel speed is equal to the set travel speed.
l When the fuel control dial or the decelerator pedal is set in the "MEDIUM SPEED" position:
l The travel speed is limited according to the formula of Command travel speed = Deceleration command x Set travel speed
/ 100.

<Deceleration command map>

<Brake command map>


l If the brake pedal is operated, a brake command is lowered according
to the brake command map.
l The brake command means the ratio to the set travel speed.

Example:
l When the brake pedal is pressed halfway:
l The travel speed is limited according to the formula of Command
travel speed = Brake command x Set travel speed / 100.

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CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED

When external load increases and engine speed lowers


The HST controller lowers the command travel speed according to command travel speed map (A).
In addition, the HST controller decides the HST pump EPC valve control signal and HST motor EPC valve control signal to
lower the travel speed according to the HST pump capacity command map and the HST motor capacity command map.

When external load decreases and engine speed rises


The HST controller raises the command travel speed according to command travel speed map (A).
In addition, the HST controller decides the HST pump EPC valve control signal and HST motor EPC valve control signal to
raise the travel speed according to the HST pump capacity command map and the HST motor capacity command map.

<Command travel speed map>

<HST pump capacity command map>

<HST motor capacity command map>

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STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM

Function

l The HST controller monitors the operating conditions of each lever and each pedal and constantly controls the swash plate
angle of the HST pump, or the delivery of the HST pump, so that the output speed of the right and left HST motors will be
the same.
l While the machine is traveling straight forward, if the right HST motor speed is higher than the left HST motor speed, the
HST controller lowers the control signal of the right HST motor forward EPC valve so that the machine will always travel
straight.
l Conditions for resetting straight travel correction control system

A. The steering/directional/gear shift lever is set in the RIGHT or LEFT steering position.

B. The steering/directional/gear shift lever is set in the NEUTRAL travel direction position.

C. A pedal or the fuel control lever is operated and the travel speed sensed by the HST motor speed sensor is 0.15 km/h
or lower.

D. The HST motor speed sensor is judged defective because of disconnection, etc.

Straight travel is secured when none of the above condition is satisfied.

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PARKING BRAKE CONTROL SYSTEM

1. Battery
2. Battery relay
3. Fuse box
4. HST controller
5. Engine
6. HST pump
7. Brake pedal
8. Brake pedal potentiometer
9. Center brake proximity switch
10. Parking brake lever
11. Parking brake limit switch 1
12. Parking brake limit switch 2
13. Center brake relay
14. Slow brake solenoid valve
15. Parking brake solenoid valve
16. Towing valve
17 Brake oil pressure sensor
18. HST motor
18a. Parking brake

Input and output signals

a. Controller power supply


b. Parking brake lever LOCK signal
c. Brake pedal stroke signal
d. Solenoid valve drive signal
e. Brake oil pressure signal

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Function

l Parking brake limit switches 1 (11) and 2 (12) are installed and connected to parking brake lever (10) so that parking brake
(18a) will be released only when parking brake lever (10) is in the FREE position.
l Center brake proximity switch (9) is installed and connected to brake pedal (7) so that slow brake solenoid valve (14) will
be de-energized and parking brake (18a) will be applied when brake pedal (7) is pressed fully.

Conditions for turning parking brake solenoid valve OFF


Operating condition Operation
1. (a) or (b) shown below is satisfied and travel speed is 0.6 km/h or lower.
2. (a) or (b) shown below is satisfied for 1 second continuously.

(a) Parking brake lever is in LOCK position. Parking brake operates.


(Parking brake limit switch 1 is ON.)
(b) Brake pedal is pressed fully.
(Pedal stroke is 90% or more.)

Conditions for turning slow brake solenoid valve OFF


Operating condition Operation
1. (a) or (b) shown below is satisfied.

(a) Parking brake lever is in LOCK position.


Parking brake operates.
(Parking brake limit switch 2 is ON.)
(b) Brake pedal is pressed fully.
(Center brake proximity switch is ON.)

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KOMTRAX SYSTEM
KOMTRAX terminal system

l The KOMTRAX terminal sends various information on the machine by a wireless communication.The KOMTRAX
operator refers to this information in the office, and various services can be provided for the customer.

H To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.

Information that can be sent from the KOMTRAX terminal is as follows:


1. Traveling map
2. Service meter
3. Location information
4. Error history

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MEMORANDUM

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SYSTEM COMPONENTS
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.
The monitor panel has a microcomputer, which processes and displays the signals from the sensors, solenoids, and controllers.
The items displayed on the monitor section and gauge section are shown in DISPLAY OF MONITOR PANEL.

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 (the LC gauges move up and down between MIN
and MAX) and the alarm buzzer sounds for 2 seconds.

Check before starting

After the operation performed when the power is turned ON, if there is any abnormal one in the check-before-starting items,
the lamp of that item flashes or the contents of the abnormality are displayed on display panel B.

Caution items

The caution items are checked constantly while the engine is running.
If any item is abnormal, it and alarm lamp flash synchronously. The alarm buzzer may sound at this time.

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Buzzer cancel switch

l If this switch is operated while the alarm buzzer is sounding, the buzzer is turned OFF temporarily.
While the buzzer is turned OFF, if a new trouble which turns on the buzzer is detected, the buzzer sounds again.
l The lamp lights up and goes off at the intervals of about 0.8 seconds.
l The flashing intervals of the lamp may change a little when the temperature is low (below about 10C). This does not
indicate a trouble.

Input and output signals

AMP070-20P [CN-1] AMP070-12P [CN-2]


Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 ACC terminal Input 1 CAN (0) H Input/Output
2 ACC terminal Input 2 NC Input/Output
3 GND Input 3 CAN (0) L Input/Output
4 GND Input 4 NC Input/Output
5 +24V, unswitched Input 5 NC Input/Output
6 +24V, unswitched Input CAN (0) (Built-in terminal
6 Input
7 Key C Input resistor)
8 Lighting signal Input 7 NC Input
9 Preheating pilot Input 8 NC
10 NC Input 9 Alternator Input
11 NC Input 10 Fuel level Input
12 NC Input 11 NC Input
13 Air cleaner clogging Input 12 NC Input
14 Mode selector switch (<) Input
15 Mode selector switch (>) Input
16 Mode selector switch (U) Input
17 Mode selector switch (t) Input
18 Caution buzzer Output
19 NC Output
20 WAKE UP signal Input/Output

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Monitor panel display
H The following figure shows an example of display in the quick shift mode.

To the right is an example of display panel A in the variable shift mode.

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Alarm Alarm Dis-
Display
No. Display item Display range Display method lamp buzzer play Remarks
section
output output color
Below corresponding segment
1a Gauge See figure at left Black LCD
All light up
Coolant
Below 102C OFF OFF OFF
temperature
1b Caution 102C 105C Flashing Flashing OFF Red LED
Above 105C Flashing Flashing ON
Below corresponding segment
2a Gauge See figure at left Black LCD
All light up
HST oil
Below 100C OFF OFF OFF Red LED
temperature
2b Caution 100C 110C Flashing Flashing OFF
Above 110C Flashing Flashing ON
Below corresponding segment
3 Gauge Fuel level See figure at left
All light up
P: Parking brake lever in LOCK
Travel direction N: Joystick in NEUTRAL
4a
(P, N, F, R) F: Joystick in FORWARD
Indicator R: Joystick in REVERSE OFF OFF
1: Joystick gear shift switch in 1st
[*3]
4b 2: Joystick gear shift switch in 2nd
Display panel A Gear speed (1, 2, 3) 3: Joystick gear shift switch in 3rd
(Travel direction,
[*1]
gear speed, shift
4c Forward gear speed Black LCD
mode)
(See figure at left) Below corresponding segment
Gauge
[*1] All light up
4d Reverse gear speed
(See figure at left)
4e Variable shift mode ON
Pilot
4f Quick shift mode ON
[*2]
Character Display panel B 0 99999.9 h/ Time is counted while engine is running
5
display (Service meter/ 0 9999 rpm (alternator is generating)
Engine speed)
When charge is OFF (While engine is stopped) OFF OFF
6 Charge level
defective (Below 12 V) Flashing (While engine is running) Flashing OFF
Engine oil Below specified value OFF (While engine is stopped) OFF OFF
7
pressure (49 kPa {0.5 kg/cm2}) Flashing (While engine is running) Flashing ON
Caution Red
Charge filter Above specified value OFF (While engine is stopped) OFF OFF
8
clogging (200 kPa {2.0 kg/cm2}) Flashing (While engine is running) Flashing ON
HST charge oil Below specified value OFF (While engine is stopped) OFF OFF
9
pressure (785 kPa {8.0 kg/cm2}) Flashing (While engine is running) Flashing ON
10 Pilot Preheating In preheating mode ON OFF OFF Green
Before 30 h or more OFF
11 Maintenance Before 30 h Replace- ON for 30 seconds after starting switch is OFF OFF Red
ment time turned ON LED
12 Warning lamp See the warning lamp output column of this table Red
Air cleaner Below specified value
13 Flashing OFF OFF Red
clogging (7.47 kPa)
When fan speed selec-
Caution
tor switch is operated Flashing (several times)
Fan operation while engine is running
14 OFF OFF Orange
check In fan cleaning
ON
(reverse) mode
In fan forward mode OFF
Coolant level in When coolant level in
15 Flashing OFF OFF Red
fuel filter water separator rises

*1: For details, see "Hst control system".


*2: For details in the service mode, see Testing and adjusting, "Special functions of monitor panel (EMMS)".
*3: Displayed only in the quick shift mode.

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ENGINE CONTROLLER

CN-CE01 CN-CE01
Input/
Pin No. Signal name Pin No. Signal name Title panel
output
1 Electric power supply for lift pump 18 NC(*)
2 Electric power supply for IMA 19 NC(*)
3 Atmosphere sensor 20 NC(*)
4 NC(*) 21 NC(*)
5 NC(*) 22 Engine brake drive D
6 CAN() 23 Boost temperature sensor B
7 NC(*) 24 NC(*)
8 CAN(+) 25 Common rail pressure sensor B
9 NC(*) 26 G sensor (+) B
10 NC(*) 27 NE sensor (+) B
11 Lift pump return 28 Engine brake return
12 NC(*) 29 NC(*)
13 NC(*) 30 NC(*)
14 NC(*) 31 NC(*) D
15 Coolant temperature sensor 32 IMA return C
16 5V electric power supply for sensor 33 5V electric power supply for sensor
17 Oil pressure switch 34 NC(*)
*: Never connect to NC or malfunctions or failures will occur. *: Never connect to NC or malfunctions or failures will occur.

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CN-CE01 CN-CE02
Pin No. Signal name Title panel Pin No. Signal name Input/output
35 NC(*) A 20 NC(*)
36 NC(*) 21 NC(*)
37 5V electric power supply for sensor A 22 Fuel control dial (+5V)
38 GND C 23 Fuel control dial ()
39 NC(*) 24 NC(*)
40 NC(*) 25 NC(*)
41 NC(*) 26 NC(*)
42 NC(*) C 27 NC(*)
43 NC(*) 28 NC(*)
44 Boost pressure sensor B 29 NC(*)
45 Injector #1 (+) D 30 NC(*)
46 Injector #5 (+) D 31 NC(*)
47 G sensor () C 32 NC(*)
48 Ne sensor () C 33 GND
49 NC(*) 34 NC(*)
50 NC(*) 35 NC(*)
51 Injector #2 () C 36 NC(*)
52 Injector #3 () C 37 NC(*)
53 Injector #1 () C 38 NC(*)
54 Injector #2 (+) D 39 Key switch (ACC)
55 Injector #3 (+) D 40 Electrical intake air heater relay drive
56 Injector #4 (+) D 41 NC(*)
57 Injector #6 (+) D 42 Electrical intake air heater relay return
58 Injector #4 () C 43 NC(*)
59 Injector #6 () C 44 NC(*)
60 Injector #5 () C 45 NC(*)
*: Never connect to NC or malfunctions or failures will occur. 46 CAN(+)
47 CAN()
CN-CE02 48 NC(*)
Pin No. Signal name Input/output 49 PWM OUTPUT
1 NC(*) 50 NC(*)
2 NC(*) *: Never connect to NC or malfunctions or failures will occur.
3 NC(*)
4 NC(*) CN-CE03
5 NC(*) Pin No. Signal name Input/output
6 NC(*) 1 GND
7 NC(*) 2 NC(*)
8 NC(*) 3 Electric power supply (+24V constantly)
9 Fuel control dial (+) 4 NC(*)
10 NC(*) *: Never connect to NC or malfunctions or failures will occur.
11 NC(*)
12 NC(*)
13 NC(*)
14 NC(*)
15 NC(*)
16 NC(*)
17 NC(*)
18 NC(*)
19 NC(*)
*: Never connect to NC or malfunctions or failures will occur.

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HST CONTROLLER

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Input and output signals
DEUTSCH-24P [CN-ST1] DEUTSCH-40P (1) [CN-ST2] DEUTSCH-40P (2) [CN-ST3]
Pin Input/Output Pin Input/Output Pin Input/Output
Signal name Signal name Signal name
No. signal No. signal No. signal
1 Joystick position FR4 Input 1 NC Power source
1 Input
Fuel control dial 2 NC (Controller)
2 Input
potentiometer 3 NC 2 Power source (Solenoid) Input
Brake pedal 4 NC GND
3 Input 3
potentiometer Parking brake limit (Solenoid, common)
5 Input
4 GND (Signal) switch 1 (NC) 4 For driving battery relay Output
Charge filter clogging 6 NC Left HST pump forward
5 Input 5 Output
sensor 7 Fan forward switch Input EPC valve
6 NC 8 Neutral safety relay Output Left HST pump reverse
6 Output
7 Joystick position ST2 Input 9 NC EPC valve
Brake oil pressure 10 Fan speed sensor Input 7 Fan reverse solenoid Output
8 Input
sensor 11 NC 8 NC
HST oil temperature 12 NC Parking brake limit
9 Input 9 Input
sensor 13 Immobilize signal Input switch 2 (NO)
10 GND (Signal) 14 NC 10 Key cylinder C signal Input
11 NC Parking brake limit Power source
15 Input 11 Input
12 Shift-up switch (NC) Input switch 1 (NO) (Controller)
13 Joystick position FR3 Input 16 NC 12 Power source (Solenoid) Input
L.H. HST circuit oil Fan cleaning reverse GND
14 Input 17 Input 13
pressure sensor switch (Solenoid, common)
15 Alternator (R) Input 18 NC 14 Starting switch (ACC) Input
16 NC 19 NC Right HST motor
15 Output
17 NC L.H. HST motor speed forward EPC valve
20 Input
18 Shift-down switch (NO) Input sensor Right HST motor
16 Output
19 Joystick position ST1 Input 21 NC reverse EPC valve
R.H. HST circuit oil 22 CAN0 (L) Input/Output 17 NC
20 Input
pressure sensor 23 NC 18 Back-up alarm Output
21 GND (Analog) Flash ROM write 19 NC
24 Input
Sensor power source permission signal 20 NC
22 Output
(+5 V) Reverse travel speed 21 GND (Power source)
25 Input
23 Shift-up switch (NO) Input setting switch (Up) 22 Power source (Solenoid) Input
24 Shift-down switch (NC) Input 26 NC GND
23
Mode selector switch (Solenoid, common)
27 Input
(VARIABLE) 24 Starting switch (ACC) Input
28 NC 25 Fan control EPC Output
29 GND (Pulse) Left HST motor EPC
26 Output
R.H. HST motor speed valve
30 Input
sensor Parking brake solenoid
27 Output
31 GND (Communication) valve
32 CAN0 (H) Input/Output 28 NC
33 NC 29 NC
34 GND (Communication) 30 NC
Reverse travel speed 31 GND (Power source)
35 Input
setting switch (Down) 32 GND (Power source)
36 NC 33 GND (Power source)
Mode selector switch Sensor power source 1
37 Input 34 Output
(QUICK) (+5V)
38 NC 35 NC
39 GND (Pulse) Right HST motor EPC
36 Output
40 NC valve
Slow brake solenoid
37 Output
valve
38 NC
39 NC
40 NC

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ELECTRIC LEVER (FOR TRAVEL)
H Do not disassemble the electric lever. If it is disassembled, the output voltage characteristics and operating effort
characteristics will need to be adjusted.

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1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt

8. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 - 9.8 Nm (5.1 - 7.2 lbf ft)


9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 11.8 - 14.7 Nm (8.7 - 10.8 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 - 10.8 Nm (6.5 - 7.9 lbf ft)
11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 - 4.4 Nm (2.6 - 3.2 lbf ft)

D51EX/PX-22 10-175
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
KOMTRAX TERMINAL

1. Communication antenna connector


2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

Input and output signals


DEUTSCH-40P [CN-G01]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC 21 Operation mode selection 1 Input
2 NC 22 Operation mode selection 2 Input
3 NC 23 NC
4 NC 24 NC
5 NC 25 NC
6 CAN shield GND 26 NC
7 CAN signal (L) Input/Output 27 Starting switch (C) Input
8 CAN signal (H) Input/Output 28 Alternator (R) Input
9 NC 29 NC
10 NC 30 NC
11 NC 31 NC
12 NC 32 NC
13 NC 33 NC
14 NC 34 NC
15 NC 35 NC
16 NC 36 Starting switch (ACC) Input
17 NC 37 Power source GND
18 NC 38 Power source GND
19 NC 39 Constant power source (24V) Input
20 Immobilizing signal Output 40 Constant power source (24V) Input

Outline

l The KOMTRAX controller can send information via wireless communication antenna, acquiring various information of
the machine from the network signal in the machine and the input signal. Also, the controller incorporates CPU (Central
Processing Unit) and provide the wireless communication function and the GPS function.
l There are the LED lamp and the 7-segment indicator lamp in the display area, and these lamps are used for the testing and
the troubleshooting.
l The information of the LED lamp and the 7-segment indicator lamp can be checked on the monitor panel by EMMS.

10-176 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
SENSORS
The signals from the sensors are input through the controllers to the monitor panel.

Category of When
Sensor method When normal
display abnormal

Caution Brake oil pressure sensor Resistance --- ---

Gauge Hydraulic oil temperature sensor Resistance --- ---

--- HST circuit oil pressure sensor Semiconductor --- ---

Caution Air cleaner clogging sensor Contact Closed Open

--- Decelerator and brake pedal potentiometer Resistance --- ---

--- Fuel control dial Resistance --- ---

Gauge Fuel level sensor Resistance --- ---

Caution Charge filter clogging sensor Contact Open Closed

Gauge Coolant temperature sensor Resistance --- ---

Caution Engine oil pressure switch Contact Closed Open

--- Engine rotation sensor Electromagnetic --- ---

--- boost pressure and temperature sensor Resistance --- ---

Caution WIF sensor

--- HST motor speed sensor HaII IC --- ---

D51EX/PX-22 10-177
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
BRAKE OIL PRESSURE SENSOR
(HST charge oil pressure sensor)

A. Sensor
B. Connector

Function
This sensor is installed to the parking brake solenoid valve piping. It senses
the changes of the brake circuit pressure as the changes of voltage with the
semiconductor in it, and then generates signals according to the measured
pressure.

Operation
l The oil pressure is applied to the diaphragm of the oil pressure sensor
from the pressure intake part, the diaphragm is deformed.
l The deformation in the diaphragm causes the resistance of the gauge
to change. This causes a change in the output voltage, which is
transmitted to the amplifier (voltage amplifier).

l The relationship between the pressure applied to sensors (P) and


output voltage (E) is shown at right.
l The amplifier magnifies output voltage (E) and transmits it to HST
controller.

10-178 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
HYDRAULIC OIL TEMPERATURE SENSOR

1. Thermistor
2. Plug
3. Connector

Function
This sensor is installed to the pump suction piping. It senses the changes of the temperature as the changes of the resistance of
thermistor in it, and then generates signals according to the measured temperature.

D51EX/PX-22 10-179
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
HST CIRCUIT OIL PRESSURE SENSOR

1. Sensor
2. Connector

Function
This sensor is installed to the HST pump. It senses the changes of the right and left HST circuit pressures as the changes of
voltage with the semiconductor in it, and then generates signals according to the measured pressure.

Operation
The relationship between the pressure applied to sensor (P) and output
voltage (E).

10-180 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
AIR CLEANER CLOGGING SENSOR

1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector

D51EX/PX-22 10-181
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
DECELERATOR PEDAL POTENTIOMETER
BRAKE PEDAL POTENTIOMETER

1. Potentiometer
2. Connector

Function
l The potentiometer is connected to the decelerator pedal, brake pedal,
and fuel control lever and its shaft is rotated according to the operating
angle of the pedal and lever.
l The movement of the shaft operates the internal variable resistor,
which generates a signal voltage by changing the source voltage of 5
V according to the operating angle.

10-182 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
FUEL CONTROL DIAL

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

Function
l The fuel control dial is installed to the left side of the operator's seat.
l If knob (1) is turned, the shaft of potentiometer (5) is turned to change
the resistance of the variable resistor and send a throttle signal to the
engine controller.
l The hatched areas in the following graph is the abnormality detection
areas. In those areas, the engine speed is reduced to a half.

D51EX/PX-22 10-183
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
FUEL LEVEL SENSOR

1. Connector 5. Spring

2. Float 6. Contact

3. Arm 7. Spacer

4. Body

Function
The fuel level sensor is installed to the side of the fuel tank. Its float moves up and down according to the fuel level.
The movement of the float operates the variable resistor through the arm. As a result, signals of change in resistance are
generated.

10-184 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
CHARGE FILTER CLOGGING SENSOR

Function
The charge filter clogging sensor is installed to the charge filter and its contact senses the pressures before and after the filter.
If the difference between those pressures exceeds the set level, the switch is turned ON.

COOLANT TEMPERATURE SENSOR

1. Sensor

2. O-ring

3. Connector

D51EX/PX-22 10-185
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ENGINE OIL PRESSURE SWITCH

1. Connector

2. Sensor

3. O-ring

ENGINE ROTATION SENSOR

1. Connector

2. Sensor

3. O-ring

10-186 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
BOOST PRESSURE AND TEMPERATURE SENSOR

1. Connector

2. Sensor

3. O-ring

WIF SENSOR
(WATER-IN-FUEL)

1. Connector

2. Tube

3. Sensor

4. O-ring

D51EX/PX-22 10-187
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
HST MOTOR SPEED SENSOR
See HST motor, this section page 10-70.

10-188 D51EX/PX-22
20 STANDARD VALUE TABLES

STANDARD VALUE TABLE FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2


STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
PERFORMANCE MEASURING POSTURE AND METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8

H Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.

1. 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. It is used as a guideline for judging the progress of wear after the machine has
been operated, and as a reference value when carrying out repairs.

2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of
various tests. It is used for reference together with the state of repair and the history of operation to judge if there
is a failure.

3. These standard values are not the standards used in dealing with claims.

WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on
level ground, insert the safety pins, and use blocks to prevent the machine from
moving.
WARNING! When carrying out work together with other workers, always use signals and do
not let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.

D51EX/PX-22 20-1
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR ENGINE
12
STANDARD VALUE TABLE FOR ENGINE

Machine model D51EX-22, D51PX-22


Serial No. B10001 and up
Engine SAA6D107E-1
Standard
Cate- Service limit
gory Item Measurement conditions Unit value for new value
machine
l Engine coolant High idling 2270 50 2270 50
temperature: Within
operating range
Engine speed l HST oil temperature rpm
(hydraulic oil temperature): Low idling 850 25 850 25
Within operating range (40
- 60C)
l Engine coolant temperature: Within operating
range
l HST oil temperature (hydraulic oil
Intake air pressure kPa Min. 131 106
temperature): Within operating range (40 -
(Boost pressure) (mmHg) (Min. 983) (795)
60C)
l Stall pressure test mode + Work equipment
relief
l Engine coolant temperature: Within operating
range
l HST oil temperature (hydraulic oil
Exhaust temperature temperature): Within operating range (40 - C Max. 650 700
60C)
l All speed range (Outside temperature: 20C)
l Stall pressure test mode
l Engine coolant At sharp Max. 25 35
Exhaust gas color temperature: Within acceleration %
Engine

operating range At high idling Max. 120 22


Intake valve 0.25 0.152 ~ 0.381
Valve clearance l Normal temperature mm
Exhaust valve 0.51 0.381 ` 0.762
l SAE30 or SAE15W-40 oil Compression MPa Min. 2.41 1.69
Compression pressure (kg/cm2) (Min. 24.6) (17.2)
pressure l Engine oil
temperature: 40 - 60C Engine speed rpm 250 ~ 280 250 ~ 280
l Engine coolant temperature: Within operating
range
l HST oil temperature (hydraulic oil Pa Max. 490 980
Blow-by pressure (mmH O)
temperature): Within operating range 2 (Max. 50) (100)
l Stall pressure test mode + Work
equipment relief
Min. 0.29 0.25
Oil pressure l SAE30 or SAE15W-40 oil At high idling (Min. 3.0) (2.5)
MPa
l Engine coolant temperature:
(kg/cm2) Min. 0.10 0.07
Within operating range At low idling
(Min. 1.0) (0.7)
Oil temperature l All speed range (In oil pan) C 80 - 110 120
Oil consumption ratio l At continuous rated (ratio to fuel consumption) % Max. 0.15 0.3
Fan speed l At rated engine speed rpm Hydraulic driven fan
Air compressor belt l Deflection under pressing force of about 98 N (10
tension mm 15 - 18 15 - 18
kg)

20-2 D51EX/PX-22
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS

Machine model D51EX-22, D51PX-22


Serial No. B10001 and up

Cate- Standard value Service limit


Item Measurement conditions Unit for new
gory machine value

Forward and l Engine: Stopped


PCCS lever

N Forward/Reverse 29 6 29 6
reverse l Center of lever grip
l Engine: Stopped
Steering N - Sharp turn to right/left 50 10 50 10
l Center of lever knob
l Engine: stopped 1st stage 52 10 52 10
Brake pedal
l Center of pedal 2nd stage 75 10 75 10
mm
Stroke

l Engine: Stopped
Decelerator pedal 50 10 50 10
l Center of pedal
Neutral - Raise 47 10 47 20
l Engine: Stopped Neutral - Lower 46 10 46 20
Work equipment l Center of lever knob
Neutral - Float 71 10 71 20
control lever l Angle: Twisting angle of
lever Neutral - Left/Right tilt 52 10 52 20
Neutral - Left/Right angle 15 3 15 6
Forward and 55.9 9.8 55.9 11.8
N - Forward/Reverse
reverse (5.7 1.0) (5.7 1.2)
44.1 8.8 44.1 9.8
PCCS lever

Steering l Engine: Stopped N - Sharp turn to right/left (4.5 6.8) (4.5 1.0)
Center of lever knob
Operating effort

l
l Button switch Shift-up 6.9 - 12.7 147.7
Shift-up/down N (0.7 - 1.3) (1.5)
switch (kg) 6.9 - 12.7 147.7
Shift-down
(0.7 - 1.3) (1.5)
142 28 199
1st stage (14.5 2.9) (20)
l Engine: stopped
Brake pedal
l Center of pedal 230 46 322
2nd stage
(23.5 4.7) (33)

D51EX/PX-22 20-3
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
Machine model D51EX-22, D51PX-22
Serial No. B10001 and up

Cate- Standard
Item Measurement conditions Unit value for new Service limit value
gory machine
l Engine: Stopped 70 14 9.8
Decelerator pedal
l Center of pedal (7.1 1.4 (10)
22.5 10 39.2
Neutral - Raise
(2.3 1.0) (4.0)
Operating effort

N 25.5 10 39.2
Neutral - Lower (kg) (2.6 1.0) (4.0)
Work equipment l Engine: Low idling 70 22 118
Neutral - Float
control lever l Center of lever knob (7.1 2.2) (12.0)
25.5 10 39.2
Neutral - Left/Right tilt
(2.6 1.0) (4.0)
Neutral - Left/Right Nm 2.9 - 5.4 8.3
angle (kgm) (0.3 - 0.55) (0.9)
l Engine: High idling Forward - Left 40.2 - 44.1 39.2 - 45.1
(410 - 450) (400 - 460)
l HST oil temperature
(hydraulic oil 40.2 - 44.1 39.2 - 45.1
Forward - Right
Main circuit temperature): Within (410 - 450) (400 - 460)
pressure operating range (40 - 40.2 - 44.1 39.2 - 45.1
60C) Reverse - Left (410 - 450) (400 - 460)
HST oil pressure

l Stall pressure test 40.2 - 44.1 39.2 - 45.1


mode Reverse - Right (410 - 450) (400 - 460)
MPa
HST

l Engine: High idling (kg/cm2) 3.23 0.29 3.23 0.29


PCCS lever: Neutral
l HST oil temperature (33 3.0) (33 3.0)
(hydraulic oil
Charge circuit temperature): Within
pressure operating range (40 - PCCS lever: Forward or 3.04 0.29 3.04 0.49
60C) reverse (31 3.0) (31 5.0)
l Stall pressure test
mode

20-4 D51EX/PX-22
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
Machine model D51EX-22, D51PX-22
Serial No. B10001 and up

Cate- Standard
Item Measurement conditions Unit value for new Service limit value
gory machine
l Engine: High idling 1st 3.4 0.2 3.4 0.4
l Quick shift mode Forward 2nd 5.6 0.3 5.6 0.6
l Reverse travel speed: Set to
3rd 9.0 0.5 9.0 0.8
center
l HST oil temperature 1st 4.1 0.2 4.1 0.4
(hydraulic oil temperature): 2nd 6.5 0.3 6.5 0.6
Within operating range (40 - Reverse
60C)
3rd 9.0 0.5 9.0 0.8
l Measure on flat place.
Travel speed km/h
l Engine: High idling MIN 0.8 0.2 0.8 0.3
l Variable shift mode Forward
MAX 8.5 0.5 8.5 0.8
l Reverse travel speed: Set to
center MIN 0.8 0.2 0.8 0.3
l HST oil temperature
(hydraulic oil temperature): Reverse
Within operating range (40 - MAX 9.0 0.5 9.0 0.8
60C)
l Measure on flat place.
HST

l Engine: High idling


l HST oil temperature
(hydraulic oil temperature): Within operating range
(40 - 60C)
l Flat place (Hard and level place such as concrete
Travel deviation mm Max. 120 Max. 150
floor)
l After approach run of at least 10 m, measure
deviation in travel of 20 m.
l Measure deviation (x).
l For measuring posture, see "Travel 1".
l Engine: High idling
l HST oil temperature (hydraulic oil temperature):
Within operating range (40 - 60C)
l Travel lever: N (Neutral)
Hydraulic drift of travel l Travel lock lever: Free m Max. 3.6 Max. 4.0
l Stop machine on slope of 20
l Posture of machine: With front side up and down
l Hydraulic drift (Hydraulic travel distance) in 1 minute
l For measuring posture, see "Travel 2".
l Engine: High idling
Work equipment relief 27.44 0.98 24.5
pressure l HST oil temperature (hydraulic oil temperature): (280 10) (250)
Within operating range (40 - 60C)
Min. 1.65 Min. 1.65
Neutral - Raise
Work equipment

(Min. 16.8) (Min. 16.8)

Neutral - Lower MPa Min. 1.37 Min. 1.37


l Engine: High idling (Min. 14.0) (Min. 14.0)
(kg/cm2)
Work equipment PPC l HST oil temperature (hydrau- Min. 2.01 Min. 2.01
Neutral - Float
valve output pressure lic oil temperature): Within (Min. 21.0) (Min. 21.0)
operating range (40 - 60C) Min. 1.72 Min. 1.72
Neutral - Left/Right tilt (Min. 17.5) (Min. 17.5)
Neutral - Left/Right Min. 1.96 Min. 1.96
angle (Min. 20.0) (Min. 20.0)

D51EX/PX-22 20-5
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
Machine model D51EX-22, D51PX-22
Serial No. B10001 and up

Cate- Standard
Item Measurement conditions Unit value for new Service limit value
gory machine
l HST oil temperature
l (hydraulic oil temperature):
Raise 2.5 0.2 3.0
l Within operating range(40 -
Blade lifting 60C)
speed l Between max. lifting height
l and ground
Lower 1.9 0.2 2.3
l For measuring posture, see
"Work equipment 1".
l Engine: High idling
Work equipment speed

l HST oil temperature


Left tilt 1.7 0.2 2.1
(hydraulic oil temperature):
Within operating range(40 -
Blade tilting 60C)
speed
l Between max. left and right
tilting positions
Right tilt 1.7 0.2 2.1
l For measuring posture, see
"Work equipment 2". sec.
l Engine: High idling
l HST oil temperature
Left angle 4.5 0.2 5.2
(hydraulic oil temperature):
Within operating range(40 -
Blade angling 60C)
speed
l Between max. left and right
angling positions Right angle 4.5 0.2 5.2
l For measuring posture, see
"Work equipment 3".
Work equipment

l Engine: High idling


l HST oil temperature (hydraulic oil
temperature): Within operating range (40 -
Time lag

Blade lifting time 60C) 1.0 Max. 1.5


lag
l Lower blade from max. lifting height and
measure time after blade comes in contact
with ground until starts rising.
l Measure on level and flat place.
l Engine: Stopped
l Lever: Neutral
l HST oil temperature (hydraulic oil
temperature): Within operating range (40 -
Hydraulic drift of
lifted blade 60C) Max. 50 Max. 50
Hydraulic drift of work equipment

l Start measurement just after setting.


l Measure lowering distance (h) after 15
minutes.
l For measuring posture, see "Work equipment
4". mm/15
l Measure on level and flat place. min.
l Engine: Stopped
l Lever: Neutral
l HST oil temperature (hydraulic oil
temperature): Within operating range (40 -
Hydraulic drift
of tilted blade 60C) Max. 100 Max. 100
l Start measurement just after setting.
l Measure lowering distance (h) after 15
minutes.
l For measuring posture, see "Work equipment
5".

20-6 D51EX/PX-22
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS

Machine model D51EX-22, D51PX-22


Serial No. B10001 and up
Standard
Cate-
gory Item Measurement conditions Unit value for new Service limit value
machine
l Engine: High idling
Leakage from cylinder

Blade lift cylinder 1.6 6.5


l HST oil temperature (
Work equipment

hydraulic oil temperature): Within operating


range (40 - 60C)
Blade tilt cylinder cc/min 1.6 6.5
l Fully extend piston rod of cylinder to be
measured and disconnect hose on head side.
Blade angle l Relieve circuit and measure leakage for 1
cylinder 1.6 6.5
minute. (Lift and tilt only)
Fan speed l Fan 100% mode rpm 1485 - 1515 1450 - 1550
Cooling

l Engine: High idle


fan

Work equipment pump MPa 18.6 - 20.6 17.6 - 21.6


l HST oil temperature (Hydraulic oil tempera- 2)
pressure (kg/cm (190 - 210) (180 - 220)
ture): 50 - 60C

= Angle cylinder should be measured on a test stand.

D51EX/PX-22 20-7
STANDARD VALUE TABLES PERFORMANCE MEASURING POSTURE AND METHOD
12
PERFORMANCE MEASURING POSTURE AND METHOD
Travel 1: Travel deviation

Travel 2: Hydraulic drift travel

Work equipment 1: Blade lifting speed

Work equipment 2: Blade tilting speed

20-8 D51EX/PX-22
STANDARD VALUE TABLES PERFORMANCE MEASURING POSTURE AND METHOD
12
Work equipment 3: Blade angling speed

Work equipment 4: Hydraulic drift of lifted blade

Work equipment 5: Hydraulic drift of tilted blade

D51EX/PX-22 20-9
STANDARD VALUE TABLES PERFORMANCE MEASURING POSTURE AND METHOD
12

MEMORANDUM

20-10 D51EX/PX-22
30 TESTING AND ADJUSTING

LIST OF TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3


ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
AIR INTAKE BOOST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
HANDLING FUEL SYSTEM PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
BLEEDING AIR FROM FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
FUEL RETURN RATE AND LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
FUEL CIRCUIT FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
FAN (WORK EQUIPMENT) PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
FAN SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
FAN SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
DECELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
HST OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
MOTOR CONTROL VALVE OUTLET PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
TRAVEL DEVIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
BRAKE PEDAL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
EMERGENCY RELEASE OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
IDLER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
TRACK SHOE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
PPC VALVE OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
PPC VALVE ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
LOCK LEVER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
CYLINDER LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
RELEASING RESIDUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
BLADE CENTER BALL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
BLADE PITCH BALL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
PROCEDURE FOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . 30-126
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128

D51EX/PX-22 30-1
TESTING AND ADJUSTING
ITEMS TO BE ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
PM-CLINIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
PM-CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
PM-CLINC INSPECTION SHEET (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
PM-CLINC INSPECTION SHEET (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
PM-CLINC UNDERCARRIAGE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
UNDERCARRIAGE TROUBLESHOOTINF REPORT (IMPACT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140

30-2 D51EX/PX-22
TESTING AND ADJUSTING LIST OF TOOLS
12
LIST OF TOOLS
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
-101 - 200 kPa
Measuring intake air pressure 799-201-2202 Boost gauge kit 1
A (-760 - 1,500 Hg)
(boost pressure)
799-401-2220 Hose 1 I-coupler type (if necessary)
Measuring exhaust
B 799-101-1502 Digital thermometer 1 -99.9 - 1,299C
temperature
Handy smoke
1 799-201-9001 1
checker
Measuring exhaust gas color C Bosch index: 0 - 9
Commercially
2 Smoke meter 1
available
1 795-799-1131 Gear 1 For 107 Series engine
Adjusting valve clearance D Commercially
2 Feeler gauge 1
available
1 795-502-1590 Compression gauge 1

Measuring compression 2 795-799-6700 Puller 1


pressure E
795-502-4410 Adapter 1 For 107 Series engine
3
6754-11-3130 Gasket 1
1 799-201-1504 Blow-by checker 1 0 - 5 kPa (0 - 500 mmH2O)
Measuring blow-by pressure F
2 799-201-1411 Adapter 1
Pressure gauge: 2.5, 6.0, 40,
1 799-101-5002 Hydraulic tester 1
58.8 MPa (25, 60, 400, 600 kg/cm2)
2 790-301-1220 Nipple 1
Measuring engine oil pressure G
3 799-101-5160 Nipple 1
Pressure gage:
4 799-401-2320 Gauge 1
1.0 MPa (10 kg/cm2)
Pressure gauge: 6.0, 40, 60 MPa
799-101-5002 Hydraulic tester 1
(25, 60, 400, 600 kg/cm2)
1
Pressure gage:
790-261-1204 Digital hydraulic tester 1
60 MPa (600 kg/cm2)
Measuring fuel pressure H
6732-81-3170 Adapter 1 10 x 1.0 mm PT1/8
2
6215-81-9710 O-ring 1

3 795 - 790 - 1470 Pressure gauge 1 Pressure gauge:


0 ~ 254 kPa (0 ~ 75 in/Hg)
1 795-790-4700 Tester kit 1
2 799-401-3200 Adapter 1
6754-71-5340 Connector 1
3
Measuring fuel return rate and 6754-71-5350 Washer 1
I
leakage
Commercially
4 Measuring cylinder 1
available
Commercially
5 Stopwatch 1
available
799-101-5002 Hydraulic tester 1 h Same as G1
1 Pressure gage:
Testing and adjusting HST oil 790-261-1204 Digital hydraulic tester 1
J 60 MPa (600 kg/cm2)
pressure
799-101-5220 Nipple 4 Size: 10 x 1.25 mm
2
07002-11023 O-ring 4

D51EX/PX-22 30-3
TESTING AND ADJUSTING LIST OF TOOLS

Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
799-101-5002 Hydraulic tester 1
1 Digital hydraulic h Same as G1
790-261-1203 1
tester
Measuring motor control 799-401-3100 Adapter 1 Size: 02
K
valve output pressure for HST 2
799-401-3200 Adapter 1 Size: 03
799-101-5230 Nipple 1
3 Size: 14 x 1.5 mm
07002-11423 O-ring 1
1 790-190-1500 Pump assembly 1 ---
Method of releasing parking
brake (Procedure for M 799-101-5220 Nipple 4
emergency escape) 2 Size: 10 x 1.25 mm
07002-11023 O-ring 4

Testing and adjusting work 799-101-5002 Hydraulic tester 1


N 1 h Same as J
equipment oil pressure 790-261-1203 Digital hydraulic tester 1
799-101-5002 Hydraulic tester 1
Measuring work equipment 1 h Same as G1
P 790-261-1203 Digital hydraulic tester 1
PPC valve output pressure
2 799-401-3100 Adapter 1 Size: 02
Measuring leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
Measuring water temperature --- 799-101-1502 Digital thermometer 1 h Same as B
and oil temperature
Adjusting decelerator pedal & --- 79A-264-0091 Push-pull scale 1 0 - 490 N {0 - 50 kg}
brake pedal
Measuring stroke and Commercially
--- Scale 1 ---
hydraulic drift available
Measuring work equipment Commercially
--- Stopwatch 1 ---
speed available
Measuring voltage and Commercially
--- Circuit tester 1 ---
resistance available

30-4 D51EX/PX-22
TESTING AND ADJUSTING LIST OF TOOLS
12

MEMORANDUM

D51EX/PX-22 30-5
TESTING AND ADJUSTING ENGINE
12
ENGINE

ENGINE SPEED
H Measure the engine speed under the following condition.
Engine coolant temperature: Within operating range
HST oil (Hydraulic oil) temperature: Within operating range (40 60C)

1. Preparation work
Turn the starting switch ON and set the monitor panel in the "Real-time monitoring mode" to prepare for measurement of
the engine speed.
H For the operating method, see "Special functions of monitor panel
(EMMS)".
Controller: ENGINE
Monitoring code: 01002-ENG SPEED
The engine speed is displayed in rpm.

2. Measuring low idle speed


A. Start the engine and set the fuel control dial in the low idle
position.
B. Set the PCCS lever and blade control lever in neutral and measure
the engine speed.

3. Measuring high idle speed


A. Start the engine and set the fuel control dial in the high idle position.
B. Set the PCCS lever and blade control lever in neutral and measure the engine speed.

4. Measuring decelerator pedal speed


A. Start the engine and set the fuel control dial in the high idle position.
B. Set the PCCS lever and work equipment control lever in neutral and press the decelerator pedal and measure the
engine speed.
H The engine speed when the decelerator pedal is pressed to the stroke end is the same as the low idle speed.

30-6 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
AIR INTAKE BOOST PRESSURE

H Testing air boost pressure

WARNING! Be careful not to touch any hot part when


removing or installing the testing tools.

1. Remove air boost pressure pickup plug (1).

2. Install nipple (1) of boost gauge kit A and connect it to gauge [2].

3. Run the engine at the rated output and test the air boost pressure.
When testing with the engine mounted on the machine, test on the
condition described in the shop manual for the machine.

4. After finishing testing, remove the measuring tools and return the
removed parts.

D51EX/PX-22 30-7
TESTING AND ADJUSTING ENGINE
12
EXHAUST TEMPERATURE

WARNING! Install and remove the measuring


instrument after the exhaust manifold is
cooled.

H Measure the exhaust temperature under the following condition.


Engine coolant temperature: Within operating range
HST oil (Hydraulic oil) temperature: Within operating range (40 - 60C)

1. Open the right engine side cover and remove exhaust temperature pickup plug (1) from the exhaust pipe.

2. Install sensor [1] of digital thermometer B and connect them to meter


[2].
H Clamp the wiring harness of the digital thermometer so that it will
not touch a hot part during measurement.
Remark
(1)is exhaust port measurement point.

3. When measuring the maximum exhaust temperature for


troubleshooting, observe the following procedure.
Operate the machine actually and measure the maximum exhaust
temperature.
H Set the digital thermometer in the PEAK mode.
H The exhaust temperature largely depends on the ambient
temperature (intake air temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it by the following
calculation.
Corrected value [C] = Measured value + 2 x (20 - Ambient
temperature)

4. When measuring the exhaust temperature periodically for preventive


maintenance (Pm Clinic), observe the following procedure.
A. Turn the starting switch ON, set the monitor panel in the
"Adjustment mode", and prepare for stalling the HST.
H When performing this operation, set the parking brake lever
in the LOCK position and the PCCS lever in the neutral
position.
H For the operating method, see "Special functions of monitor
panel (EMMS)".
Adjustment code: 3016-STALL CHECK
B. Start the engine and keep the parking brake lever in the LOCK
position.
H Stall the HST with the parking brake lever in the LOCK posi-
tion.

30-8 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
C. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and measure the
exhaust temperature.
H If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST
stops.

WARNING! While the HST is stalled, the oil


temperature rises sharply and locally.
Accordingly, do not stall the HST
continuously for more than 30 seconds.

5. After finishing measurement, remove the measuring instruments and


return the removed parts.

D51EX/PX-22 30-9
TESTING AND ADJUSTING ENGINE
12
EXHAUST GAS COLOR

WARNING! When installing and removing the


measuring instruments, take care not to
touch a hot part.

H If an air source and an electric power source are not available in the field, use handy smoke checker C1. When recording
official data, use smoke meter C2.
H Measure the exhaust gas color under the following condition.
Engine coolant temperature: Within operating range

1. Measuring with handy smoke checker C1.


A. Stick a sheet of filter paper to smoke checker C1.
B. Insert the exhaust gas intake pipe in exhaust pipe (1).
C. Run the engine.
D. 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.
E. Remove the filter paper and compare it with the attached scale.
F. After finishing measurement, remove the measuring instrument
and return the removed parts.

2. Measuring with smoke meter C2.


A. Insert probe [1] of smoke meter C2 in the outlet of exhaust pipe
(1) and fix it to the exhaust pipe with a clip.
B. Connect the probe hose, receptacle of the accelerator switch, and
air hose to smoke meter C2.
H Limit the supplied air pressure to 1.5 MPa {15 kg/cm2} (213
psi).
C. Connect the power cable to a receptacle of AC socket.
H Before connecting the cable, check that the power switch of
the smoke meter is turned OFF.
D. Loosen the cap nut of the suction pump and fit the filter paper.
H Fit the filter paper securely so that the exhaust gas will not
leak.
E. Turn on the power switch of smoke meter C2.
F. Start the engine.
G. 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.
H. Place the contaminated filter paper on the clean filter paper (at
least 10 sheets) in the filter paper holder and read the indicated
value.
I. After finishing measurement, remove the measuring instrument
and return the removed parts.

30-10 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
VALVE CLEARANCE
1. Remove cylinder head cover (1).

2. Remove cap (2) from flywheel housing and install barring tool D1.

3. Rotate the crankshaft forward using barring tool D1 until the stamped
1.6TOP line (a) of the crankshaft pulley faces upward and set the
No. 1 cylinder to the compression top dead center.
H When the No. 1 cylinder is at the compression top dead center, the
rocker arm of the No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm cannot be moved, rotate
the crankshaft one more turn. (Alternatively, adjust the valve
clearance indicated by m of the valve layout plan in the next
section without rotating the crankshaft.)

D51EX/PX-22 30-11
TESTING AND ADJUSTING ENGINE
12
4. Adjust the valve clearance of No. 1 cylinder according to the
following procedure.
H When the No. 1 cylinder is at the compression top dead center, the
valve clearance indicated by l of the valve layout plan can be
adjusted.
Valve layout plan
A. Insert clearance gauge D2 into the clearance between rocker arm
(3) and crosshead (4).
B. Loosen locknut (5) and adjust valve clearance using adjustment
screw (6).
H With the filler gauge inserted, turn the adjustment screw to a
degree that you can move the filler gauge lightly.
C. Fix adjustment screw (6) and tighten locknut (5). 3Locknut:

Locknut: 24 4 Nm (17.7 2.9 lbf ft)

H After tightening the locknut, check the valve clearance again.

5. In the same manner as step 3, rotate the crankshaft forward using


barring tool D1 until the stamped "1.6TOP" line (a) of the crankshaft
pulley faces upward.

6. Adjust the valve clearance of No. 6 cylinder.


H The adjustment method is the same as step 4.
H When the No. 6 cylinder is at the compression top dead center, the
valve clearance indicated by m of the valve layout plan can be
adjusted.

7. After finishing adjustment, return the removed parts.

Cylinder head cover mounting bolt:


24 4 Nm (17.7 2.9 lbf ft)

8. Remove barring tool before operating engine.

30-12 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12

MEMORANDUM

D51EX/PX-22 30-13
TESTING AND ADJUSTING ENGINE
12
COMPRESSION PRESSURE

WARNING! Stop the machine on a level ground and


lower the work equipment to the ground.

H Measure the compression pressure under the following condition.


Engine oil temperature: 40 60C

1. Remove the engine hood and remove cylinder head cover (1).
H Since the breather connector on the rear side of the cylinder head
cover is connected to the flywheel housing through the O-ring,
pull it together with the cylinder head cover.

2. Remove the mounting bolts of rocker arm assembly (2) on the exhaust
side, and then remove rocker arm assembly (2).
H When removing the injector, you do not need to remove the
rocker arm assembly on the intake side.

3. Remove fuel tube (3), and then remove inlet connector (7) in the
cylinder head.
H The inlet connector is connecting the fuel tube to the injector.

4. Disconnect injector wiring harness. Using tool E2, remove injector


(4).

5. Install adapter E3 to the injector mounting part with the injector clamp
and connect compression gauge E1.
H Install the gasket to the adapter end without fail.

Injector clamp mounting bolt:


1st time: 3.5 0.35 Nm (2.5 0.25 lbf ft)
2nd time: 75 5 (Angle tightening)

H If a little quantity of engine oil is applied the joint of the adapter


and gauge, air does not leak easily.

6. Install rocker arm assembly (2) on the exhaust side and adjust the
valve clearance.
H See Adjusting valve clearance.

30-14 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
7. Disconnect CN-117 connector (5) of the engine controller.

WARNING! If the connector is not disconnected, the


engine will start during measurement
which will be dangerous.

WARNING! Since the CN-117 connector is a part of


the power supply circuit of the engine
controller, cover the connector on the
machine side with electrical tape, etc. to
prevent sparking and a ground fault.

8. Rotate the engine with the starting motor and measure the
compression pressure.
H Read the gauge when the pointer is stabilized.

9. After finishing measurement, remove the measuring tools and return


the removed parts.
H Install the injector and inlet connector according to the following
procedure.
A. Apply new engine oil (SAE15W-40) to the O-ring of injector (4)
and cylinder head.
B. Install injector (4) with the fuel inlet hole directed to the air intake
manifold.
C. Install injector clamp (6) and tighten the mounting bolt by 3 4
threads.
D. Install inlet connector (7) and tighten inlet connector retainer
temporarily.
E. Tighten the mounting bolt of injector clamp (6) securely.

Injector clamp mounting bolt:


8 0.8 Nm (5.9 0.59 lbf ft)

F. Tighten inlet connector retainer (8) securely.

Inlet connector retainer: 50 5 Nm (36.8 3.6 lbf ft)

H Tighten the bolts and nuts other than the injector and inlet connector to the following torque.

Injector wiring harness nut:


1.5 0.25 Nm (1.1 0.18 lbf ft)

Fuel tube sleeve nut: 35 3.5 Nm 25.8 2.58 lbf ft)

Rocker arm assembly mounting bolt:


36 6 Nm (26.5 4.4 lbf ft)

H Adjust the valve clearance. For details, see Adjusting valve clearance.

Cylinder head cover mounting nut:


24 4 Nm 17.7 2.9 lbf ft)

D51EX/PX-22 30-15
TESTING AND ADJUSTING ENGINE
12
BLOW-BY PRESSURE
H Measure the blow-by pressure under the following condition.
Engine coolant temperature: Within operating range
HST oil (Hydraulic oil) temperature: Within operating range (40 -
60C)

1. Open the left engine side cover and pull out blow-by hose (1).

2. Install nozzle tool F2 to blow-by hose (1) and connect it to gauge [1]
of blow-by checker F1.

3. Turn the starting switch ON, set the monitor panel in the "Adjustment
mode", and prepare for stalling the HST.
H When performing this operation, set the parking brake lever in the
LOCK position and the PCCS lever in the neutral position.
H For the operating method, see "Special functions of monitor panel
(EMMS)".
H Adjustment code: 3016-STALL CHECK

4. While keeping the parking brake lever in the LOCK position, set the
work equipment lock lever in the FREE position and raise the blade to
the stroke end.
H Stall the HST with the parking brake lever in the LOCK position.

5. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and relieve the blade
circuit by raising the blade, and then measure the blow-by pressure.
H If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST
stops.

WARNING! While the HST is stalled, the oil


temperature rises sharply and locally.
Accordingly, do not stall the HST
continuously for more than 30 seconds.

6. After finishing measurement, remove the measuring instruments and


return the removed parts.

30-16 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
ENGINE OIL PRESSURE
1. Remove right engine side covers.

2. Remove oil pressure pickup plug (1).

3. Install the nipples to the plug mount in order of G2 and G3.


Test the engine at standard operating conditions.

4. Connect the hose of the hydraulic tester G1 to the nipples and gauge
G4.

5. Run the engine at the rated output and low idle and test the oil
pressure.
H When testing with the engine mounted on the machine, test on the
condition described in the shop manual for the machine.

6. After finishing testing, remove the measuring tools and return the
removed parts.

D51EX/PX-22 30-17
TESTING AND ADJUSTING HANDLING CONTROLLER HIGH-VOLTAGE
12
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT

WARNING! The engine controller uses a high-voltage


circuit to drive the fuel injector.
Accordingly, the high-voltage circuit is
connected to the wiring harnesses and
connectors between the engine controller
and injector.

H Normally, the engine controller keeps outputting the high voltage to


the injector only while the engine is running and quits outputting when
the engine stops.

WARNING! If you touch the high-voltage circuit


directly, you may get an electric shock. To
avoid this, observe the following
precautions when testing.

1. The following connectors are used in the high voltage circuit.


Engine controller connector: C1
Injector intermediate connector: C3 = INJ CYL 1&2,
C4 = INJ CYL 3&4,
C5 = INJ CYL 5&6
Injector head terminal (in head cover)

2. When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting switch OFF.

3. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start
the engine.
H You may turn the starting switch to the OFF or ON position but must not turn it to the START position.

30-18 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL SYSTEM

HANDLING FUEL SYSTEM PARTS


H Precautions for checking and maintaining fuel system
The common rail fuel injection system (CRIS) consists of more precise parts than the conventional fuel injection pump
and nozzle. If foreign matter enters this system, it can cause trouble. When checking and maintaining the fuel system, take
care more than the past. If dust, etc.sticks to any part, wash that part thoroughly with clean fuel.
H Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
Since the common rail fuel injection system (CRIS) 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


H 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 main filter Supply pump
High-pressure circuit: Supply pump Common rail Injector
H The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after
the engine is stopped.
H Before the fuel circuit is checked and its parts are removed, the residual pressure in the fuel circuit must be released
completely. Accordingly, observe the following.

WARNING! Before checking 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.)

D51EX/PX-22 30-19
TESTING AND ADJUSTING FUEL SYSTEM
12
BLEEDING AIR FROM FUEL CIRCUIT
H If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following
procedure.

WARNING! Stop the machine on a level ground and


lower the work equipment to the ground.

1. Fill the fuel tank with fuel.

2. Open the front cover of the engine hood.

Remark
Item 2 is the water separator.

3. Loosen knob (1) of the feed pump and pull it out, and then operate it
forward and backward.
H Move the knob until it becomes stiff.
H The plug at the top of the fuel main filter does not need to be
removed.

4. After bleeding air, push in and tighten knob (1).

30-20 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
H Air bleeding route of fuel circuit
Fuel tank Pre-filter Feed pump Main filter Metering unit Fuel tank

D51EX/PX-22 30-21
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL PRESSURE

WARNING! Stop the machine on a level ground and lower the work equipment to the ground.

H Measure only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply
pump and the return circuit from the supply pump/common rail/injector to fuel tank.

WARNING! Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it cannot be measured.

1. Measuring pressure in fuel low-pressure circuit.


A. Open the engine hood and remove fuel pressure pickup plug (1)
from the fuel main filter.

B. Install adapter H2 and nipple [1] of hydraulic tester H1 and


connect them to oil pressure gauge [2].
H Use the oil pressure gauge of 2.5 MPa {25 kg/cm2}.
C. Run the engine at low idle and measure the pressure in the fuel
low-pressure circuit.
H If the pressure in the fuel low-pressure circuit is in the
following range, it is normal.

At low idle 0.5 - 1.3 MPa (5.1 - 13.3 kg/cm2)


During cranking 0.3 - 1.1 MPa (3.1 - 11.3 kg/cm2)

WARNING! If the engine cannot be started, you may


measure the fuel pressure while rotating
the engine with the starting motor. Do not
rotate for more than 20 seconds continu-
ously, however, for protection of the start-
ing motor.

D. After finishing measurement, remove the measuring tools and


return the removed parts.

Fuel pressure pickup plug: 10 2 Nm (7.3 1.4 lbf ft)

30-22 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
2. Measuring pressure in fuel return circuit.
A. Disconnect the fuel return elbow (2) from the check valve at the
rear of the head.
B. Install adapter [F4] between fuel return hose and check valve.
C. Install nipple [1] of hydraulic tester F1 and connect to pressure
gauge.
Nipple [3]: . . . . . . . . . . . . . . . . . . . . . . 790-301-1181, 07002-11223

D. Run the engine at low idle and measure the pressure in the fuel
return circuit.
H If the pressure in the fuel return circuit is in the following
range, it is normal.

At low idle Max. 0.02 MPa


During cranking (Max. 0.19 kg/cm2)

WARNING! If the engine cannot be started, you may


measure the fuel pressure while rotating
the engine with the starting motor. Do not
rotate for more than 20 seconds continu-
ously, however, for protection of the start-
ing motor.

E. After finishing measurement, remove the measuring tools and return the removed parts.

Fuel pressure pickup plug: 24 4 Nm (17.7 2.9 lbf ft)

D51EX/PX-22 30-23
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL RETURN RATE AND LEAKAGE
H Since some fuel flows out during check, prepare an oil (receiving) pan of about 20 liters.

WARNING! Stop the machine on a level ground and


lower the work equipment to the ground.

1. Measuring return rate from supply pump.


A. Open the engine hood and disconnect return hose (1) of the
supply pump.
H The return hose is connected by a quick coupler.

B. Install connector I3 and cap nut [1] of tester kit I1 to the return
hose to stop the fuel from flowing out.
C. Connect test hose [2] of tester kit I1 to the supply pump.
H Lay the test hose so that it will not slacken and put its end in
the oil (receiving) pan.

D. Run the engine at low idle and measure the return rate in 1 minute
with measuring cylinder I4.
H If the return rate from the supply pump is in the following
range, it is normal.
At low idle 1,000 cc/min
During cranking 140 cc/min

WARNING! If the engine cannot be started, you may


measure the fuel return rate while rotating
the engine with the starting motor. Do not
rotate for more than 20 seconds
continuously, however, for protection of
the starting motor.

E. After finishing measurement, remove the measuring tools and return the removed parts.
H When measuring the leakage from the pressure limiter or finishing the measurement: Return the removed parts to
their original positions.
H When measuring the leakage from the injector: Leave the removed parts as they are and keep the hose end in the
oil pan.

30-24 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
2. Measuring leakage from pressure limiter.
A. Open the engine hood and disconnect return hose (2) of the
pressure limiter.
H Install the seal washer to the connector bolt.
B. Install removed connector bolt -3 and cap nut [I1] of tester kit I1
to the return hose to stop the fuel from flowing out.

C. Install connector I3 to the common rail and connect test hose [2]
of tester kit I1.
H Lay the test hose so that it will not slacken and put its end in
the oil (receiving) pan.

D. Run the engine at low idle and measure the return rate in 1 minute
with measuring cylinder I4.
H If the leakage from the pressure limiter is in the following
range, it is normal.

At low idle 0 cc (No leakage)

E. After finishing measurement, remove the measuring tools and


return the removed parts.

Joint bolt: 24 4 Nm (17.7 2.9 lbf ft)

3. Measuring return rate from injector.


H The leakage from the injector is measured while the return hose of
the pressure limiter is connected. Accordingly, before measuring the leakage from the injector, check that the leakage
from the pressure limiter is normal.
A. Referring to Measuring return rate from supply pump, set the supply pump for testing.

WARNING! The fuel returning from the supply pump flows out during measurement of the return rate
from the injector. Accordingly, keep the test hose end in the oil pan.

D51EX/PX-22 30-25
TESTING AND ADJUSTING FUEL SYSTEM
B. Disconnect return hose (4) of the return block.
H Install the seal washer to the return hose.

C. Install connector bolt [3] of adapter I2 instead of the removed


connector bolt, and connect test hose [4].
H Lay the test hose so that it will not slacken and put its end in
the oil (receiving) pan.

D. Run the engine at low idle and measure the return rate in 1 minute
with measuring cylinder I4.
H If the return rate from the injector is in the following range, it
is normal.
At low idle 180 cc/min
During cranking 90 cc/min

WARNING! If the engine cannot be started, you may


measure the fuel return rate while rotating
the engine with the starting motor. Do not
rotate for more than 20 seconds
continuously, however, for protection of
the starting motor.

E. After finishing measurement, remove the measuring tools and return the removed parts.

Joint bolt: 24 4 Nm (17.7 2.9 lbf ft)

30-26 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL CIRCUIT FOR LEAKAGE

WARNING! 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 checking the fuel system or removing its parts, check it for fuel leakage according to
the following procedure.

WARNING! Stop the machine on a level ground and lower the work equipment to the ground.

H Clean and degrease the engine and the parts around it in advance so that you can check 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. Check the fuel piping and devices for fuel leakage.


H Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage.
H If any fuel leakage is detected, repair it and check again from step 2.

4. Run the engine at low idle.

5. Check the fuel piping and devices for fuel leakage.


H Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage.
H If any fuel leakage is detected, repair it and check again from step 2.

6. Run the engine at high idle.

7. Check the fuel piping and devices for fuel leakage.


H Check around the high-pressure circuit parts coated with the color checker for fuel leakage.
H If any fuel leakage is detected, repair it and check again from step 2.

8. Run the engine at high idle and load it.


H Relieve the blade lift circuit at the IN stroke end.

9. Check the fuel piping and devices for fuel leakage.


H Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage.
H If any fuel leakage is detected, repair it and check again from step 2.
H If no fuel leakage is detected, check is completed.

D51EX/PX-22 30-27
TESTING AND ADJUSTING FAN (WORK EQUIPMENT) PUMP PRES-
12
FAN (WORK EQUIPMENT) PUMP PRESSURE
Remark
If the HST oil temperature is below 45C and the engine coolant temperature is below 60C, the fan EPC
command current is set to 1,000 mA and the fan speed lowers below 200 rpm even in the fan 100% mode.
In this case, increase the oil temperature to above 55C and the coolant temperature to above 65C and
then check again.
HST oil (Hydraulic oil) temperature: 50 - 60C.

1. Measuring fan motor pressure.


A. The fan motor is common with the work equipment pump.
B. Measure the oil pressure at the same port as for the work equipment pump.
See "Testing and adjusting work equipment oil pressure".

FAN SPEED
MEASURING FAN SPEED

Remark
If the HST oil temperature is below 45C and the engine coolant temperature is below 60C, the fan EPC
command current is set to 1,000 mA and the fan speed lowers below 200 rpm even in the fan 100% mode.
In this case, increase the oil temperature to above 55C and the coolant temperature to above 65C and
then check again.
H Measure the fan speed under the following conditions.
HST oil (Hydraulic oil) temperature: 50 - 60C.

1. Preparation work
H Measure the fan speed in the "Fan 100% mode".
A. Turn the starting switch ON and set monitor panel in the "Tuning mode" and select the "Fan 100% mode".
H For operation method, see "Special functions of monitor panel (EMMS)".
Tuning code: 3022 FAN MODE
B. Set monitor panel in the: Real time monitoring mode" to prepare
for measurement of the fan speed.
H For operation method, see "Special functions of monitor
panel (EMMS)".
Controller: HST
Monitor code: 10007 FAN SPEED
The fan speed is displayed in rpm.

2. Measuring fan speed


A. Start the engine and set the fuel control dial in the high idle posi-
tion.
B. Set the PCCS lever and blade control lever in neutral and measure
the fan speed.

30-28 D51EX/PX-22
TESTING AND ADJUSTING FAN SPEED
12
FAN SPEED SENSOR
ADJUSTING

H If the fan speed sensor has been removed and installed or its signal
contains an error, adjust it according to the following procedure.
H Remove fan speed sensor (1) before adjusting it and check that its tip
is free from steel chips.
The fan speed sensor is installed to the left top of the fan motor.

To install sensor:

1. Position indicator (2) on fan assembly in order to have a bar in front of


the threaded indicator hole.

2. Install sensor (1) by threading in until stopped by the indicator plate


(2).

3. Rotate out two full turns.

4. If sensor wire lies in "Zone A" after adjustment, rotate sensor counterclockwise until wire is in the "Required position
range".

5. If sensor wire lies in "Zone B" after adjustment, rotate sensor clockwise until wire is in the "Required position range".

D51EX/PX-22 30-29
TESTING AND ADJUSTING FAN SPEED

6. If sensor wire lies in "Zone C" after adjustment, no further rotation is required.

Jam nut: 49 ~ 68.7 Nm (36.1 ~ 50.6 lbf ft)

7. After finishing adjustment, check that the monitor panel displays the fan speed normally in the "Real-time monitoring
mode".
H For the operating method, see "Special functions of the monitor panel (EMMS)".
Controller: HST
Monitoring code: 10007-FAN SPEED

30-30 D51EX/PX-22
TESTING AND ADJUSTING DECELERATOR PEDAL
12
DECELERATOR PEDAL
ADJUSTING

H When adjusting the decelerator pedal, remove the dashboard cover, dashboard undercover and pedal assembly.
Place the removed pedal assembly on the floor and connect the wiring harness connector between floor and pedal.

1. Adjusting decelerator pedal potentiometer


A. Turn the starting switch ON and change the monitor for display of the decelerator pedal potentiometer voltage in the
"real-time monitoring mode".
Controller: ENGINE
Monitoring code: 31702-DECEL PEDAL
For the operating method, see "Special functions of monitor panel (EMMS)".
B. Adjust installed dimension (b) of stopper (2) so that pedal height (a) will be 209 mm when decelerator pedal (1) is in
neutral.
Dimension (b) = 33.1 mm (Reference value)
C. Adjust (Rotate) the installed position of the potentiometer so that the decelerator pedal potentiometer voltage will be
the specified voltage when decelerator pedal (1) is in neutral.
DECEL PEDAL VOLTAGE: . . . . . . . . . . . . . . . . . . . . 1.23 0.10 V
D. Adjust stopper (3) temporarily so that pedal height (c) will be 159 mm when decelerator pedal (1) is pressed to the
stroke end.
E. Adjust installed dimension (d) of stopper (3) so that decelerator pedal potentiometer voltage will be the specified
voltage when decelerator pedal (1) is pressed to the stroke end.
DECEL PEDAL VOLTAGE: . . . . . . . . . . . . . . . . . . . . 2.59 0.10 V
Dimension (d) = 22.3 mm (Reference value)

D51EX/PX-22 30-31
TESTING AND ADJUSTING DECELERATOR PEDAL
12
2. Measuring decelerator pedal pressing effort
A. Press the decelerator pedal with the foot to check that it operates smoothly.
B. If the decelerator pedal does not operate smoothly, supply grease through grease fitting (4) and apply grease to spring
(5).
Grease fitting (4): . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease (G2-LI)
Spring (5): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease (G2-LI)
C. Using push-pull scale, measure the full-stroke pressing effort of the decelerator pedal.
Full-stroke pressing effort: . . . . . . . . . . . . . . . . . . . . . 71 N {7.3 kg}

3. Work after finishing measurement


After finishing all adjustment, return the removed parts.

4. Testing decelerator pedal potentiometer


A. Turn the starting switch ON and change the monitor for display of the decelerator pedal operating degree in the
"real-time monitoring mode".
Controller: ENGINE
Monitoring code: 31701-DECEL PEDAL
For the operating method, see "Special functions of monitor panel (EMMS)".
B. The relationship between the position and operating degree of the decelerator pedal is shown below.

Decelerator pedal
Decelerator pedal
operating degree

Released 100%

Pressed (Fully) 0%

30-32 D51EX/PX-22
TESTING AND ADJUSTING HST OIL PRESSURE
12
HST OIL PRESSURE
MEASURING

H Measure the HST oil pressure under the following condition.


HST oil (Hydraulic oil) temperature: Within operating range (40 60C)

1. Measuring HST main circuit pressure.


H Measure the HST main circuit pressure in the "Tuning mode" of the monitor panel.

WARNING! If the HST is stalled while the bypass valve (tow valve) of the parking brake circuit is
closed, the HST equipment may be damaged or it may move beyond your expectations.
Accordingly, do not stall the HST out of the "Tuning mode".

A. Turn the starting switch ON, set the monitor panel in the "Tuning mode", and prepare for stalling the HST.
When performing this operation, set the parking brake lever in the LOCK position and the PCCS lever in the
neutral position.
For the operating method, see "Special functions of monitor panel (EMMS)".
Tuning code: 3016-STALL CHECK
If the HST main circuit pressure is selected in the tuning
mode, it is displayed in 0.1 MPa.
(The figure shows the item displayed first (engine speed)
when the mode is selected.)
B. Start the engine and keep the parking brake lever in the LOCK
position.
Stall the HST with the parking brake lever in the LOCK
position.
C. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and measure the HST
main circuit pressure.
If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST stops.

WARNING! While the HST is stalled, the oil temperature rises sharply and locally. Accordingly, do not
stall the HST continuously for more than 30 seconds.

2. Measuring HST charge circuit pressure


A. Measure the HST charge circuit pressure with the "Real-time monitoring mode" of the monitor panel.
If the parking brake is released (the parking brake lever is in the FREE position and the brake pedal is released),
the HST charge circuit pressure and the brake pressure are the same. Measure the brake pressure in this case.

WARNING! The HST charge circuit pressure needs to be measured while the machine is stopped
and while the machine is actually traveling. Accordingly, measure it on a level ground
where there are no obstacles.

i. Turn the starting switch ON and display the "Real-time monitoring mode" on the monitor panel to prepare for
measuring the brake pressure.
For the operating method, see "Special functions of monitor panel (EMMS)".
Controller: HST
Monitoring code: 91902-BRAKE PRESS

D51EX/PX-22 30-33
TESTING AND ADJUSTING HST OIL PRESSURE
12 The brake pressure is displayed in 0.01 MPa.

ii. Start the engine and set the parking brake lever in the FREE
position.

iii. While running the engine at high idle, measure the brake
pressure with the PCCS lever in the neutral position and in
the forward or reverse position.
While the machine is stopped, only the charge safety valve
on the oil cooler bypass valve side operates. While the
machine is traveling, the charge relief valve on the HST
motor side operates, also.
B. When measuring the HST charge circuit pressure directly for troubleshooting of the brake pressure sensor, parking
brake solenoid or slow brake solenoid, apply the following method.

WARNING! The HST charge circuit pressure needs to be measured while the machine is stopped
and while the machine is traveling actually. Accordingly, measure it on a level ground
where there are no obstacles.

WARNING! Loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the
tank.

WARNING! Turn the starting switch ON, set the work equipment lock lever in the FREE position, and
lower the blade to the ground. Move the work equipment control lever until it is not held in
the FLOAT position to release the residual pressure in the accumulator. After the residual
pressure is released, set the work equipment lock lever in the LOCK position and turn
starting switch OFF.

i. Remove the inspection cover of the floor and remove HST


charge circuit pressure pickup plug (1) on the 5-spool
solenoid valve.

30-34 D51EX/PX-22
TESTING AND ADJUSTING HST OIL PRESSURE
ii. Install nipple [1] of hydraulic tester J1 and connect it to oil
pressure gauge [2].
Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}.

iii. Start the engine and set the parking brake lever in the FREE
position.

iv. While running the engine at high idle, measure the HST
charge circuit pressure with the PCCS lever in the neutral
position and in the forward or reverse position.

v. After finishing measurement, remove the measuring


instruments and return the removed parts.

3. Measuring HST pump EPC valve output pressure

WARNING! Since the machine will be stopped and driven actually to measure the EPC valve output
pressure, work on a flat place where there is not an obstacle.

WARNING! Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure in the
hydraulic tank.

A. Remove the cover at the floor, and then remove EPC valve output
pressure pickup plugs (2) (5) at the top of the HST pump.
Plug (2): For left forward EPC valve
Plug (3): For left reverse EPC valve
Plug (4): For right forward EPC valve
Plug (5): For right reverse EPC valve

B. Install nipple J2 and connect it to oil pressure gauge [2].


Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}.
C. Start the engine and set the parking brake lever in the FREE
position.
D. Select the quick shift mode and set the gear speed to the 1st.
E. While the engine is running at high idle, set the PCCS lever in the
neutral position and forward or reverse position and measure the
EPC valve output pressure.
If the EPC valve output pressure is as follows, it is normal.

EPC valve output


During travel
pressure
Neutral 0 MPa {0 kg/cm2}
Travel in F1 Min. 1.0 MPa
Travel in R1 {Min. 10 kg/cm2}

D51EX/PX-22 30-35
TESTING AND ADJUSTING HST OIL PRESSURE

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

ADJUSTING

H The HST main circuit pressure and the HST pump EPC valve output
pressure cannot be adjusted.

1. Adjusting HST charge circuit pressure (on oil cooler bypass valve
side)
H If the HST charge circuit pressure (only when the HST is in
neutral) is abnormal, adjust charge safety valve (6) of the oil
cooler bypass valve according to the following procedure.
H When adjusting charge safety valve (6) of the oil cooler bypass
valve, remove the cooling core undercover.

Undercover of cooling core: 15 kg (33 lb)

A. Fixing tuning screw (7), loosen locknut (8).


B. Turn tuning screw (7) to adjust the pressure.
H If the adjustment screw is
turned to the right, the pressure rises.
turned to the left, the pressure lowers.
H Quantity of tuning per turn of adjustment screw:
Approximately 1.55 MPa {15.38 kg/cm2}
C. Fixing adjustment screw (7), tighten locknut (8).

Locknut: 58.8 78.5 Nm {6 8 kgm} (43.3 - 57.8 lbf ft)

D. After finishing adjustment, check that the HST charge circuit


pressure is normal according to the measurement procedure
described above.

30-36 D51EX/PX-22
TESTING AND ADJUSTING HST OIL PRESSURE
12
2. Adjusting HST charge circuit pressure (on motor side)
H If the HST charge circuit pressure (only when traveling) is
abnormal, adjust charge relief valve (9) of the HST motor
according to the following procedure.
H When adjusting charge relief valve (9) of the HST pump, remove
the HST motor covers (right and left).

A. Fixing adjustment screw (10), loosen locknut (11).


B. Turn adjustment screw (10) to adjust the pressure.
H If the adjustment screw is
turned to the right, the pressure rises.
turned to the left, the pressure lowers.
H Quantity of adjustment per turn of adjustment screw:
Approximately 1.02 MPa {10.4 kg/cm2}
C. Fixing adjustment screw (10), tighten locknut (11).

Locknut: 58.8 78.5 Nm {6 8 kgm} (43.3 - 57.8 lbf ft)

D. After finishing adjustment, check that the HST charge circuit


pressure is normal according to the measurement procedure
described above.

3. Initializing HST pump EPC valve


The HST pump EPC valve does not need to be adjusted. If it is replaced, however, initialize the related items in the tuning
mode of the monitor panel.
H For the operating method, see "Special functions of monitor panel (EMMS)".
Tuning code (When adjusting while track shoe is driven idle)

i. 3001: F-PUMP LINE

ii. 3002: R-PUMP LINE


Tuning code (When adjusting while machine is actually traveling )

i. 3003: F-PUMP RUN1

ii. 3004: R-PUMP RUN1

iii. 3005: F-PUMP RUN2

iv. 3006: R-PUMP RUN2

D51EX/PX-22 30-37
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-
12
MOTOR CONTROL VALVE OUTLET PRESSURE
H Measure the solenoid valve outlet pressure under the following
condition.
HST oil (Hydraulic oil) temperature: Within operating range (40
60C)

1. Preparation work
H If the pressures in the parking brake solenoid valve and slow
brake solenoid valve are not measured simultaneously, the
operation cannot be checked.

WARNING! Loosen the oil filler cap of the hydraulic


tank slowly to release the residual
pressure in the hydraulic tank.

WARNING! Turn the starting switch ON, set the work


equipment lock lever in the FREE
position, and lower the blade to the
ground. Move the work equipment control
lever until it is not held in the FLOAT
position to release the residual pressure
in the accumulator. After the residual
pressure is released, set the work
equipment lock lever in the LOCK position
and turn starting switch OFF.

A. Remove the inspection cover at the floor.


B. Disconnect solenoid valve outlet hoses (2), (3), (4) and (5) of the
circuit to be measured or remove oil pressure pickup plug (6)
from the valve block (1).
Hose (2): Right HST motor EPC valve
Hose (3): Left HST motor EPC valve
Hose (4): Parking brake solenoid valve
Hose (5): Work equipment lock solenoid valve
Plug (6): Slow brake solenoid valve
H The output pressure of the parking brake solenoid valve can
be measured with the "Real-time monitoring mode" of the
monitor panel.

30-38 D51EX/PX-22
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-
H For the operating method, see "Special functions of monitor
panel (EMMS)".
Controller: HST
Monitoring code: 91902-BRAKE PRESS

C. If the hoses are disconnected, insert adapters K2 and connect the


hoses again.
D. Install nipple [1] or nipple M2 of hydraulic tester K1 to the plug
hole and connect it to oil pressure gauge [2].
Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}.
The figure shows the measuring instruments installed to the
outlet hose of the solenoid valve.

2. Measuring Right HST motor EPC valve and Left HST motor EPC
valve

WARNING! Since the machine will be stopped and driven actually to measure the right HST motor
EPC valve and left HST motor EPC valves, work on a flat place where there is no
obstacles.

A. Start the engine and set the travel mode in the quick shift mode, then set the reverse speed setting "B".
B. While running the engine at high idle, change the travel speed and measure the solenoid valve output pressure.
H If the output pressure is as shown in Table 1, the solenoid valve is normal.
C. After finishing measurement, remove the measuring instruments and return the removed parts.
D. Initialization of HST motor EPC valve
If the EPC valve is replaced, initialize the items related to it in the tuning mode of the monitor panel. The EPC valve
does not need to be adjusted, however, in this case.
H For the operating method, see "Special functions of monitor panel (EMMS)".
Tuning code: 3024-MOTOR LINE

3. Measuring parking brake solenoid and slow brake solenoid


A. Start the engine.
B. While running the engine at high idle, operate the parking brake lever and brake pedal and measure the solenoid valve
output pressure.
H The relationship between the output pressure and operating states of the solenoids is shown in Table 2.
C. After finishing measurement, remove the measuring instruments and return the removed parts.

D51EX/PX-22 30-39
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-

Table 1. Output pressures of right HST motor EPC valve and left HST motor EPC valve (when normal)
Travel speed and Output pressure of right HST motor EPC valve
Travel mode
travel condition and left HST motor EPC valve

Stopped or traveling 1st 0 MPa {0 kg/cm2}

Quick shift mode Traveling in 2nd 1.47 0.49 MPa {15 5 kg/cm2}

Traveling in 3rd 2.16 0.49 MPa {22 5 kg/cm2}

Table 2. Output pressures of parking brake solenoid valve and slow brake solenoid valve
(when normal and abnormal)
Parking brake Output pressure of parking Output pressure of slow
Brake pedal Condition of each solenoid
lever brake solenoid valve brake solenoid valve
3.23 0.49 MPa 3.23 0.49 MPa
Both are normal
{33 5 kg/cm2} {33 5 kg/cm2}
0 MPa 3.23 0.49 MPa Parking brake has trouble
{0 kg/cm2} {33 5 kg/cm2} (Sticking, etc.)
FREE Released
Slow brake has trouble
0 MPa 0 MPa (Sticking, etc.).
{0 kg/cm2} {0 kg/cm2} or charge pressure is
abnormal
0 MPa 0 MPa
Both are normal
{0 kg/cm2} {0 kg/cm2}
LOCK Pressed (fully)
0 MPa 3.23 0.49 MPa Slow brake has trouble
{0 kg/cm2} {33 5 kg/cm2} (Sticking, etc.)

H The operation state (ON/OFF) of the solenoid valve can be checked in the monitoring mode of the monitor panel (For the
operating method, see Special functions of monitor panel (EMMS)).
Controller: HST
Monitoring code: 40914 D-OUT
[10]: Parking brake solenoid valve
[11]: Slow brake solenoid valve
Remark
Output from HST controller to the slow brake solenoid is always "ON".

4. Measuring work equipment lock solenoid


1) Start the engine.
2) While running the engine at high idle, operate the work equipment lock lever and measure the output pressure of the
solenoid valve.
a) The relationship between the output pressure and operation of the solenoid valve is shown in Table 3.
3) After finishing measurement, remove the measuring instruments and return the removed parts.

Table 3. Output pressure of work equipment lock solenoid valve (Normal values)
Work equipment lock lever Output pressure of work equipment lock solenoid valve
Lock 0 MPa {0 kg/cm2}
Free 3.23 0.49 MPa {33 5 kg/cm2}
Stop engine with lever in free position and
turn starting switch ON immediately Decreases gradually from 3.23 MPa {33 kg/cm2}.

30-40 D51EX/PX-22
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-
12
TRAVEL DEVIATION

H Test the travel deviation under the following condition.


HST oil (Hydraulic oil) temperature: Within operating range (40 60C)
Test place: Hard and even ground.

1. Start the engine and raise the blade to about 300 mm above the ground
and set the machine in the measuring posture.

2. Set the travel speed to the 1st in the quick shift mode.

3. After running up for 10 m with the engine speed at high idle, measure
the deviation in the travel of 20 m.
H While measuring the travel deviation, check the HST main circuit
pressures on the right and left sides.
Controller: HST
Monitoring code: 52503-HST L PRESS
Monitoring code: 52501-HST R PRESS

D51EX/PX-22 30-41
TESTING AND ADJUSTING PARKING BRAKE LEVER
12
PARKING BRAKE LEVER

H If any part related to the parking brake lever was removed and installed or replaced, adjust the parking brake lever
according to the following procedure.

1. Set parking brake lever (1) in free position (A) and adjust installed height (b) of stopper bolt (2) so that dimension (a) of
lever (1) will be 30.7 mm.
Standard installed height (b) of stopper bolt = 4 mm

2. Set parking brake lever (1) in lock position (B) and adjust installed height (c) of stopper bolt (3).
Standard installed height (c) of stopper bolt: 4 mm

3. Set parking brake lever (1) in free position (A) and adjust clearance (d) between lever (4) and 2 limit switches (5).
Clearance (d) between lever and limit switch = 0 mm
When adjusting, do not operate the limit switch.

4.Check that limit switch (5) operates 2.5 3 mm when parking brake lever (1) is operated.
When lever is lock position (B): Switch is ON
When lever is free position (A): Switch is OFF
H The operating condition (ON/OFF) of limit switch (5) can be checked in the "real-time monitoring mode" of the monitor.
H For the operating method, see "Special functions of monitor panel (EMMS)".
H Controller: HST
H Real-time monitoring code:
40911-D-IN--8-----15
40912-D-IN-16-----22

30-42 D51EX/PX-22
TESTING AND ADJUSTING PARKING BRAKE LEVER
12
If the parking brake lever is adjusted normally, the following is displayed.

D51EX/PX-22 30-43
TESTING AND ADJUSTING BRAKE PERFORMANCE
12
BRAKE PERFORMANCE
H Carry out the simple test of the brake performance under the following condition.
HST oil (Hydraulic oil) temperature: Within operating range (40 - 60C)
Check point:
Since the test will be carried out while the machine is traveling, work on a sufficiently wide place so that you can
avoid an accident even if there is a trouble.

1. Start the engine and raise the blade to about 300 mm above the ground
and set the machine in the measuring posture.

2. Set the parking brake lever in the FREE position and set the gear speed
to the 1st.

3. Run the engine at high idle and set the PCCS lever in the forward
travel position to drive the machine forward straight.

4. While the machine is traveling, press the brake pedal and check the
stopping condition of the machine.
H If the machine stops securely, the brake is normal.

30-44 D51EX/PX-22
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
12
BRAKE PEDAL LINKAGE

H When adjusting the brake pedal, remove the dashboard cover, dashboard undercover and pedal assembly.
Place the removed pedal assembly on the floor and connect the wiring harness connector between floor and pedal.

1. Adjusting brake pedal potentiometer


A. Turn the starting switch ON and change the monitor for display of the brake pedal potentiometer voltage in the
"real-time monitoring mode".
Controller: HST
Monitoring code: 50400-BRAKE PEDAL
For the operating method, see "Special functions of monitor panel (EMMS)".
B. Adjust stopper (2) temporarily so that pedal height (a) will be 258 mm when brake pedal (1) is in neutral.
C. Adjust (Rotate) the installed position of the potentiometer so that the brake pedal potentiometer voltage will be the
specified voltage when brake pedal (1) is pressed to the stroke end.
BRAKE PEDAL VOLTAGE: 3.87 0.10 V
D. Adjust installed dimension (b) of stopper (2) so that brake pedal potentiometer voltage will be the specified voltage
when brake pedal (1) is in neutral
BRAKE PEDAL VOLTAGE: 2.08 0.10 V
Dimension (b) = 37.0 mm (Reference value)
E. Check that the brake pedal potentiometer voltage is the specified voltage when brake pedal (1) is at 2-stage spring
operating point (d). If not, return to adjustment step B).
H 2-stage spring operating point (3) is the position where effort of a brake pedal increases (148N{15.1kg} 211N
{21.5kg} [Reference value]) at the time of operation greatly.
BRAKE PEDAL VOLTAGE: 3.42 0.18 V

D51EX/PX-22 30-45
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
12
2. Adjusting proximity switch
A. Adjust clearance (c) between proximity switch (3) and brake pedal (1).
Clearance (c) = 2 0.5 mm
B. Check that the lamp in proximity switch (3) lights up when brake pedal (1) is between the neutral position and 2-stage
spring operating point (d).
C. Check that the lamp in proximity switch (3) does not light up when brake pedal (1) is pressed to the stroke end.

3. Measuring brake pedal pressing effort


A. Press the brake pedal with the foot to check that it operates smoothly.
B. If the brake pedal does not operate smoothly, supply grease through grease fitting (4) and apply grease to large spring
(5) and small spring (6).

Grease fitting (4): Grease (G2-LI)

Large spring (5) and small spring (6): Grease (G2-LI)

C. Using push-pull scale, measure the pressing effort of the brake pedal at 2-stage spring operating point (d).
Pressing effort at 2-stage spring operating point (d): 148 N {15.1 kg}
D. Using push-pull scale, measure the full-stroke pressing effort of the brake pedal.
Full-stroke pressing effort: 234 N {23.8 kg}

4. Work after finishing measurement


After finishing all adjustment, return the removed parts and perform the related initial tuning in the "Tuning mode" of the
monitor panel.
For the operating method, see "Special functions of monitor panel (EMMS)".
Tuning code: 0005-BRAKE N-SET
Tuning code: 3007-BRAKE END

5. Testing brake pedal potentiometer


(If the initial adjustment was performed, turn the starting switch OFF before starting the measurement.)
A. Turn the starting switch ON and change the monitor for display of the brake pedal stroke in the "real-time monitoring
mode".
Controller: HST
Monitoring code: 50401-BRAKE PEDAL
B. The relationship between the position and stroke of the brake pedal is shown in the table.

Brake pedal Brake pedal stroke


Released 0 10%
2-stage spring operating point (d) 60 90%
Pressed (Fully) 90 100%

30-46 D51EX/PX-22
TESTING AND ADJUSTING EMERGENCY RELEASE OF PARKING
12
EMERGENCY RELEASE OF PARKING BRAKE
H If the engine cannot be started and the parking brake of the HST motor cannot be released, release it according to the
following procedure.

1. Testing pump assembly M1

WARNING! If the following work is performed while the pressure of the pump assembly is abnormal,
the brake piston of the HST motor may be damaged. Accordingly, be sure to test the
pump assembly.

A. Check that pump assembly M1 is connected in the following


order.
[1] Volume pump
[2] Relief valve
[3] T-piece
[4]Oil pressure gauge (5.9 MPa {60 kg/cm2})
[5] Hose and quick coupler
B. Remove the hose and quick coupler [5] and block the volume
pump [1] side with a plug (R1/4).
C. Close the valve of volume pump [1] and operate the handle to
adjust relief valve [2] so that it will relieve at the specified
pressure.
Specified relief pressure: . . . . . . . . 2.7 3.1 MPa {28 32 kg/cm2}
H After finishing adjustment, open the valve of the volume pump to release the residual pressure in the pump.
H After finishing adjustment, remove the plug (R1/4) and connect the hose and quick coupler [5].

2. Opening HST pump


H If the machine is towed after the parking brake is released, the HST motor works as a pump to make the oil flow.
Accordingly, open the forward travel circuit and reverse travel circuit of the HST pump.

WARNING! Fit a block to the track shoe securely.

A. Remove the inspection cover of the floor.


B. Loosen locknuts (6) of towed valve (5) for the left pump towed
valve (2) for the right pump, and then loosen plugs (4) by 2 turns.
C. Tighten locknuts lightly and secure them so that they will not
come off when the machine is towed.

D51EX/PX-22 30-47
TESTING AND ADJUSTING EMERGENCY RELEASE OF PARKING
3. Connecting pump assembly M1

WARNING! Loosen the oil filler cap of the hydraulic


tank slowly to release the residual
pressure in the hydraulic tank.

A. Install pump assembly M1 onto the floor frame.


B. Loosen plug (5) and bolt (6) of the 5-spool valve and remove lock
plate (7) and then tighten plug (5) to the end. Tighten bolt (6)
lightly so that it will not come off when the machine is towed.
C. Remove plug (8) and install nipple M2.

D. Connect the quick coupler at the end of pump assembly M1 to


nipple M2.

4. Releasing parking brake and towing machine


A. Close the valve of volume pump [1] and operate the handle to
supply oil to the parking brake circuit.
H Increase the supply pressure until relief valve [2] relieves
once.
H Check that the supply pressure is lower than the specified
relief pressure with oil pressure gauge [4].
Specified relief pressure: . . . . . . . . 2.7 3.1 MPa {28 32 kg/cm2}

WARNING! If the supply pressure rises above the


specified relief pressure, the brake piston
of the HST motor may be damaged.
Accordingly, if the supply pressure
exceeds the specified relief pressure,
open the valve of the volume pump
immediately and adjust the relief pressure
by the method in 1.

H If the supply pressure becomes the specified relief pressure, the parking brake is released.
B. Remove the block of the track shoe and tow the machine at speed lower than 2 km/h.

WARNING! If the supply pressure lowers below 1.5 MPa {15 kg/cm2}, the parking brake is not
released completely (it works partially). Accordingly, keep checking oil pressure gauge [4]
while towing the machine. If the oil pressure lowers, operate the handle to maintain the oil
pressure in the range of 1.5 3.1 MPa {15 32 kg/cm2}.

C. After towing the machine to a safe place, open the valve of volume pump [1] to release the pressure supplied to the
parking brake circuit.

30-48 D51EX/PX-22
TESTING AND ADJUSTING EMERGENCY RELEASE OF PARKING
12
5. Remedy to take after towing machine
H After towing the machine to a safe place, take the following remedy without fail to return the machine to the
condition before towing.
A. Remove pump assembly M1 and nipple M2 and install plug (8).
B. Loosen plug (5) of the 5-spool valve and return lock plate (7) and
then tighten plug (5) and bolt (6) to fix lock plate (7).
C. Install the inspection cover to the right of the floor.
D. Return plugs (4) of towed valves (1) and (2) of the HST pump and
secure them with locknuts (3).

Plug and locknut: 24.5 34.3 Nm {2.5 3.5 kgm}

D51EX/PX-22 30-49
TESTING AND ADJUSTING IDLER CLEARANCE
12
IDLER CLEARANCE
TESTING

H If the lateral guide and vertical 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.

1. Lateral adjustment
A. Drive the machine forward slowly by 1 - 2 m onto flat ground, and then stop it.
B. Measure clearance (a) between track frame (1) and guide plate (2).
H Measure clearance (a) on inside and outside of the right and left idlers.
Clearance limit (a): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. 4 mm
ADJUSTING

H If the clearance exceeds the limit, adjust it according to the following procedure.
A. Loosen mounting bolt (3) of guide plate (2).
H Since 2-piece shims are used, the guide plate does not need to be removed.
B. Remove the shims between guide plate (2) and support (4) and
adjust clearance (a).
Adjusted clearance (a): . . . . . . . . . . . . . . . . . . . . . . . 0.5 - 1.0 mm
Thickness shim x quantity for new machine: . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm x 4 pieces (for each place)

C. Tighten mount bolt (3) of guide plate (2).

Bolts: 245 - 309 Nm [25 - 31.5 kgm] (180.7 - 227.9 lbf ft)

30-50 D51EX/PX-22
TESTING AND ADJUSTING IDLER CLEARANCE
12
2. Vertical adjustment

A. Measure clearance b, subtract 2 mm from it, and record the result (quantity of adjustment).
Example: When clearance b is 5 mm. The quantity of adjustment is 5 -2 = 3 mm.
B. Loosen bolts (5) (4 pieces on inside and outside) until the reaction force of the spring is lost.
C. Loosen bolt (6). Do not loosen more than 3 turns.
D. Pull up vertical guide (7) with a bar and pull out shim (8) by quantity of adjustment obtained in step A.
E. Add shim (8) pulled out onto shim (9).
Remark
8 pieces in total on both sides, inside and outside.
Remark
The total number of shims (5) and (6) before adjustment must be the same as that after adjustment.
Shim thickness: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm
F. Tighten bolts (5) of spring set.

Bolts: 245 - 309 Nm [25 - 31.5 kgm] (180.7 - 227.9 lbf ft)

G. Tighten bolts (6) of guide plate.

Bolts: 245 - 309 Nm [25 - 31.5 kgm] (180.7 - 227.9 lbf ft)

D51EX/PX-22 30-51
TESTING AND ADJUSTING TRACK SHOE TENSION
12
TRACK SHOE TENSION
TESTING

1. Drive the machine forward slowly on a level place, and then stop it.
H Do not apply the brake when stopping.

2. Place straight steel bar (1) between the idler and carrier roller and
measure clearance (a) between the bottom of the steel bar and shoe
grouser.
H As the steel bar, use an L-shape steel, etc. which will be deflected
less.
Standard clearance (a): . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 30 mm
ADJUSTING

H If the track shoe tension is abnormal, adjust it according to the


following procedure.
H When adjusting the track shoe tension, remove the outer covers from
the track frames.

1. When tension is too high.


A. Loosen valve (1) slowly to discharge the grease.

WARNING! Since the valve may jump out because of


the high-pressure grease, do not loosen it
more than 1 turn.

B. If the grease does not come out, move the machine forward and in
reverse slowly.
C. Tighten valve (1).

Valve: 58.8 - 88.2 Nm {6 - 9 kgm} (43.3 - 65.0 lbf ft)

D. After adjusting, check the tension again according to the


procedure described above.

2. When tension is low.


A. Using a grease pump, add grease through grease fitting (2).
B. After adjusting, check the tension again according to the
procedure described above.
H You may supply grease until distance (b) between the idler
guide and frame end is 20 mm. If the tension is still low, the
pins and bushings are worn excessively. In this case, turn
over or replace the pin and bushing.

30-52 D51EX/PX-22
TESTING AND ADJUSTING WORK EQUIPMENT
12
WORK EQUIPMENT

OIL PRESSURE
MEASURING

H Measure the work equipment oil pressure under the following


condition.
HST oil (Hydraulic oil) temperature: Within operating range
(40 - 60C)

WARNING! Loosen the oil filler cap of the hydraulic


tank slowly to release the residual
pressure in the hydraulic tank.

1. A pressure check fitting (1) is standard in the work equipment circuit.


The fitting (1) is located at the top section of the control valve.

2. Connect the oil pressure gauge [1] of hydraulic tester N1 to pressure


check fitting.
H Use the oil pressure gauge of 39.2 MPa {400 kg/cm2}.

3. Run the engine at high idle and relieve the blade lift and tilt cylinders
one by one at the stroke end and measure the work equipment oil
pressure.
H The relief pressure of the main relief valve of the control valve is
indicated when each of the above operation is performed. The oil
pressure in the angle circuit is low at the stroke end, because it has
piston valves.

4. After finishing measurement, remove the measuring instruments.

D51EX/PX-22 30-53
TESTING AND ADJUSTING WORK EQUIPMENT
12
ADJUSTING

H If the oil pressure is abnormal, adjust main relief valve (2) of the
control valve according to the following procedure.
H Remove the panel on the right hand side of the operators seat.

1. Fixing adjustment nut (3), loosen locknut (4).

2. Turn adjustment nut (3) to adjust the pressure.

WARNING! Do not remove the adjustment nut. If it is


removed, the internal parts may fall.

H If the adjustment nut is:


turned to the right, the pressure rises.
turned to the left, the pressure lowers.
Quantity of adjustment per turn of adjustment nut: . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . Approximately 19.6 MPa {200 kg/cm2}

3. Fixing adjustment nut (3), tighten locknut (4).

Locknut: 39 - 49 Nm {4 - 5 kgm} (28.7 - 36.1 lbf ft)

4. After finishing adjustment, check the oil pressure again according to


the measurement procedure described above.

30-54 D51EX/PX-22
TESTING AND ADJUSTING WORK EQUIPMENT
12
LOCK LEVER ADJUSTMENT

H If any part related to the work equipment lock lever was removed and installed or replaced, adjust the work equipment
lock lever according to the following procedure.

1. Adjust rod (1) to standard dimension (a).


Standard dimension (a) between rod pins:195 mm (Reference value)

2. Set work equipment lock lever (2) in lock position (B) and adjust clearance (b) between lever (3) and limit switch (4).
Clearance (b) between lever and limit switch = 0 mm
When adjusting, do not operate the limit switch.

3. Check that limit switch (4) operates 2.5 3 mm when work equipment lock lever (1) is operated.
When lever is lock position (B): Switch is OFF
When lever is free position (A): Switch is ON

D51EX/PX-22 30-55
TESTING AND ADJUSTING WORK EQUIPMENT
12
CYLINDER LEAKAGE
H Measure the leakage in the work equipment cylinder under the following condition.
HST oil (Hydraulic oil) temperature: Within operating range (40 - 60C)

1. Measuring leakage in blade lift cylinder.


A. Start the engine and put the front part of the track shoe (idler side) on a wood block, etc. to raise the front part of the
machine.

WARNING! Raise the front part of the machine to a height where the blade will not touch the ground
when the blade lift cylinder is extended to the lowering stroke end.

WARNING! Set the parking brake lever in the LOCK position and put a block to the rear of the track
shoe.

B. Extend the lift cylinder to the lowering stroke end and stop the engine.

WARNING! Operate the blade control lever in the lifting direction several times within 15 seconds
after stopping the engine, and then loosen the oil filler cap of the hydraulic tank slowly to
release the residual pressure in the cylinder and tank.

C. Remove the cylinder cover on the side to be measured, disconnect


hose (1) on the head side, and block the hose side with a plug.
H Plug used to block hose: 07376-70422 (# 04).
D. Run the engine at high idle and move the blade control lever to
the lowering position to relieve the lift cylinder.

WARNING! Do not move the blade control lever to the


raising position.

E. Start measuring the oil leakage 30 seconds after the relief is


started and measure the leakage in 1 minute.
F. After finishing measurement, remove the measuring instruments
and return the removed parts.

30-56 D51EX/PX-22
TESTING AND ADJUSTING WORK EQUIPMENT
12
2. Measuring leakage in blade tilt cylinder.
A. Remove guard on blade above tilt cylinder and cylinder cover.
B. Start the engine and raise the blade to about 1 m above the ground.
C. Fully extend the tilt cylinder to the stroke end and stop the engine.

WARNING! Operate the blade control lever in the


tilting direction several times within 15
seconds after stopping the engine, and
then loosen the oil filler cap of the
hydraulic tank slowly to release the
residual pressure in the cylinder and tank.

D. Disconnect hose (2) on the head side, and block the hose side with
a plug.
H Plug used to block hose: 07376-70210 (# 02)
E. Run the engine at high idle and move the blade control lever to
the right position and hold the tilt cylinder at relief.

WARNING! Do not move the blade control lever to the


left tilting position.

F. Continuing to hold the blade control lever at relief, wait 30


seconds and then measure amount of fluid coming out of cylinder
for one minute (60 seconds).
G. After finishing measurement, remove the measuring instruments
and return the removed parts.

3. Measuring leakage in blade angle cylinder.


Since the angle cylinder is equipped with piston valves, its internal leakage cannot be measured on the machine.
Send the angle cylinder to a test stand for measuring.

D51EX/PX-22 30-57
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT

RELEASING RESIDUAL PRESSURE


H When removing any hydraulic equipment or disconnecting any piping
from the HST circuit or work equipment circuit, release the residual
pressure according to the following procedure.

1. Stop the machine on a hard and level place.

2. Lower the blade to the ground and stop the engine.

3. Operate the blade control lever in each direction to the stroke end
several times within 15 seconds after stopping the engine to release the
residual pressure in the circuit.

4. Loosen oil filler cap (1) of the hydraulic tank slowly to release the
residual pressure in the tank.

WARNING! Since the oil may spout out, depending on


the condition in the tank, loosen the oil
filler cap slowly.

H Once the residual pressure is released, tighten the oil filler cap to
prevent dirt from entering the tank.

30-58 D51EX/PX-22
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
BLEEDING AIR
H If any hydraulic equipment/piping of the HST circuit or work equipment circuit was removed/disconnected and installed/
connected, bleed air according to the following procedure after finishing the work.
H Before and after bleeding air, check that the oil level in the hydraulic tank is normal and no bubbles are contained in the
oil.

1. Bleeding air from HST pump.


A. Remove the floor mat and floor plate in front of the seat.
B. Loosen air bleeder (1) at the top of the HST pump and check that
oil oozes out.
If oil with out bubbles oozes out, the pump has been bled.
C. Tighten air bleeder (1).
D. Tighten the filler cap of hydraulic oil tank.

2. Starting engine.
Start the engine and run it at low idle for 10 minutes.

3. Bleeding air from HST pump servo section.

WARNING! Since the machine will travel forward and


in reverse during the following work, stop
the machine in a place where it can travel.

A. Warm up the engine until the HST oil temperature (hydraulic oil temperature) reaches 80C.
H Air is bled more effectively when the HST oil temperature (hydraulic oil temperature) is high.
B. Set the shift mode switch in the variable shift mode position.
C. While the 1st gear speed is selected, press the shift-up switch twice.
D. Set the reverse travel speed set switch to the left once to set the reverse travel speed equal -to the forward travel
speed.
E. Set the parking brake lever in the FREE position and set the PCCS lever in the forward and reverse travel positions at
least 20 times.
Forward Neutral Reverse Neutral
H Repeat the operation cycle of setting the PCCS lever in the forward and reverse positions at least 20 times.

4. Bleeding air from cylinders.


A. While running the engine at low idle, extend and retract each cylinder to before each stroke end 4 5 times.
H Stop the piston rod of each cylinder about 100 mm before the stroke end to avoid relieving.
B. Keep running the engine at low idle and extend and retract each cylinder to each stroke end 3 4 times.
C. Keep running the engine at high idle and extend and retract each cylinder to each stroke end 4 5 times.

5. Operating machine.
A. After bleeding air, stop the engine and leave it for 5 minutes.
H By this operation, the bubbles in the oil in the hydraulic tank are discharged.
B. Check for oil leakage. If no oil is leaking, operate the machine.

D51EX/PX-22 30-59
TESTING AND ADJUSTING BLADE CENTER BALL ADJUSTMENT
12
BLADE CENTER BALL ADJUSTMENT
H If the blade was disassembled and assembled or transported, adjust the play of the center ball according to the following
procedure.

1. Tentatively assemble trunnion and cap (1) to bearing attached to the blade using bolts (2) without shims and tighten.

2. Set clearance a equal around the entire rim and measure value a.

3. Install 0.5 mm shim and 1.0 mm shim so that the total thickness of
shims equals the value of a+0.5 mm.
H Include at least one pair of 0.5 mm shims.

4. Tighten bolts to full torque.

Bolt: 608 ~ 726 Nm {62 ~ 74 kgm} (448 ~ 535 lbf ft)

BLADE PITCH BALL ADJUSTMENT


H If the blade was disassembled and assembled or transported, adjust the play of the center ball according to the following
procedure.

1. Tentatively assemble trunnion and cap to bearing attached to the blade


using bolts (2) without shims and tighten.

2. Set clearance b equal around the entire rim and measure value b.

3. Install minimum of one set of shims so that the total thickness of


shims equals the value of b+0.5 mm.

4. Tighten bolts to full torque.

Bolt: 823 ~ 1029 Nm {84 ~ 105 kgm} (607 ~ 758 lbf ft)

30-60 D51EX/PX-22
TESTING AND ADJUSTING DIODES
12
DIODES

PROCEDURE FOR TESTING


H Test the assembled-type diode (8-pin) and the single diode (2-pin) according to the following procedure.
H The conductive directions of the assembled-type diode are shown to
the right.

H The conductive direction of the single diode is indicated on the surface


of the diode.

1. When using digital circuit tester.


A. Set the tester in the diode range and check the indicated value.
H When an ordinary circuit tester is used, the voltage of the
internal battery is indicated.
B. Apply the red (+) lead of the tester to the anode (P) side of the
diode and apply the black (-) lead to the cathode (N) side and
check the indicated value.
C. Judge the condition of the diode by the indicated value.
The indicated value does not change: The diode do not have
conductivity (Defective).
The indicated value changes: The diode has conductivity
(Normal).
Remark
In the case of a silicon diode, a value in the range from 460 to 600 is indicated.

D51EX/PX-22 30-61
TESTING AND ADJUSTING DIODES
12
2. When using analog circuit tester.
A. Set the tester in the resistance range.
B. Apply the leads of the tester as shown below and check the movement of the pointer.

i. Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (-) lead to the cathode
(N) side.

ii. Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (-) lead to the anode
(P) side.
C. Judge the condition of the diode by the movement of the pointer.
The pointer does not move in i) but moves in ii): The diode is normal (The moving range (resistance) depends on
the type and selected range of the tester, however).
The pointer moves in both i) and ii): The diode is defective (Internal short circuit).
The pointer moves in neither of i) and ii): The diode is defective (Internal disconnection).

30-62 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS
H EMMS: Equipment Management Monitoring System

1. Buzzer cancel switch (Used to change, select or confirm modes in this chapter)

2. Information switch (Used to move the cursor or input values in this chapter)

3. Character display (Used to display information in this chapter)

Normal functions and the special functions of monitor panel (EMMS)


The monitor panel is equipped with normal functions and special functions. Various items of data are displayed on the
character display in the middle of the monitor panel. The display items are divided by the internal setting of the monitor panel
(EMMS), into automatic display items and items displayed when the monitor panel switches are operated.
A. Normal functions: Operator mode.
Functions for which the content is normally displayed or which can be displayed and operated by the operator
operating the switches.
B. Special functions: Service mode.
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.

D51EX/PX-22 30-63
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12

Operator mode Service mode


1 Operating mode 6 Electrical system failure history display mode
2 Action code display mode 7 Mechanical system failure history display mode
3 Error code display mode 8 Real-time monitoring mode
4 Oil/Filter maintenance mode 9 Cylinder cut-out mode
5 Brightness adjustment mode 10 No-injection cranking mode
11 Tuning mode
12 Maintenance interval change mode
13 Telephone number input mode
14 Model selection mode
15 Option selection mode
16 Initialize mode (factory use only)

30-64 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12

D51EX/PX-22 30-65
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
Remark
The following Nos. correspond to those in the table on the previous page. Each No. in the table is put in [_]
in the title of each item in the text.
Operator mode

H No. 4 No. 5 is displayed endlessly by following the switch operation.


H When a failure occurs, the screen changes automatically to No. 2 regardless of the displayed screen.
H If the switch is not operated for over 30 seconds regardless of the display screen, the screen automatically;
Changes to No. 1. (If malfunction has not occurred.)
Changes to No. 2. (If malfunction has occurred.)
H After moving from No. 3 to No. 1 by the switch operation, if no switch operation is performed for longer than 10 seconds,
then it automatically moves to No. 2.
Service mode

H No. 6 No. 16 is displayed endlessly by following the switch operation.


H By inputting and determining the ID once, it will be effective until the starting switch is turned off.
Character display portion

16 characters can be displayed on each upper and lower row of the


character display section, and depending on the contents displays the
combination of the next figures, letters, and symbols.
A. Arabic numbers: 1, 2, 3...
B. Small letters: a, b, c...
C. Capital letters: A, B, C...
D. Symbols: @,?, $...
E. Special letters:
Control switch section

All the display operation of the monitor panel is operated by the buzzer
cancel switch (1) and information switch (2).
Each switch of [], [n], [>], [<] is assigned to the following function.
: Determine and execute
n To cancel, release, and determine (only YES and NO screen)
>: To right, to next, to proceed, to increase (only when inputting Arabic
numbers)
<: To left, to previous, to return, to decrease (only when inputting Arabic
numbers)

30-66 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
n Operator mode (Outline)

[1] Operating mode (Default)


When turning the starting switch ON, the service meter is displayed in
the upper row.
If this function is selected, the engine speed is displayed in the lower
row.
Turn ON and OFF the display with the [>] and [<] switches.
For details, see Operation and maintenance manual.

[2] Action code display mode


When abnormal situations occur, the monitor panel automatically
displays the action code depending on the extent of the abnormality in
order to remind the operator of proper remedy.
H When action code [E03] or [E04] is displayed, it and "CALL +
phone No." are displayed alternately.
H When action code [E01] or [E02] is displayed, "CALL + phone
No." is not displayed.
H The phone No. is displayed only when it is set.
Remark
An action code is displayed only when a serious fault occurs.
Even if an action code is not displayed, a fault may have
occurred. If you feel any abnormality, be sure to check for an
failure history in the Electrical system failure history
display mode and Mechanical system error code display mode of the service mode.

Action codes table


Action code Indication method of fault Contents of fault Remedy notified to operator
Only action code is displayed. Backup alarm does not sound. Functions are defective or they stop
Fan speed is kept at maximum. partially, but operator can work
E01 safely.
After finishing work, however, call
your Komatsu distributor for repair.
Action code is displayed. Gear is not shifted up or down. Important functions are defective or
Caution lamp flashes. Engine rotated irregularly. they stop partially.
Caution buzzer sounds. When continuing work, take care
E02
extremely.
After finishing work, call your
Komatsu distributor for repair.
Action code is displayed. Usable gear speeds are limited. Move machine to safe place and
E03 Caution lamp flashes. Engine speed does not rise fully. stop it immediately.
CALL Caution buzzer sounds. Call your Komatsu distributor for
repair.
Action code is displayed. Engine can not be controlled. Stop machine immediately.
E04
Caution lamp flashes. Machine can not travel. Call your Komatsu distributor for
CALL
Caution buzzer sounds. repair.

D51EX/PX-22 30-67
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3] Error code display mode
By pressing the [>] switch once while the action code is displayed on
the monitor panel, the present error code is displayed.
[>]: To display error code.

H The error codes which have been detected in the past are
separated into electrical and mechanical systems and recorded as
failure history (refer to service mode for a detail).
H If there are several failures, other error codes are displayed by
pressing the [>] switch.
H After displaying all the error codes by pressing the [>] switch,
press [>] switch further to return to the service meter display
screen.
H Press the [>] switch again, and the error code is displayed from
the beginning.
H If there is no switch operation for longer than 10 seconds in the
service meter display screen, it automatically switches to the
action code display screen.
H The following information is displayed in the service code display
function.
A: Error code
B: Controller code
MON:Monitor panel
ENG:Engine controller
HST:HST controller
C: Trouble occurring system
H Refer to "Error code table" for details of displayed error codes.
H Be careful of the partial difference in the displayed information for the error code display mode and the failure history
display mode (service mode).

30-68 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
Error code table
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Mechanical
6091NX HST charge filter element Clogging HST l l
system
Mechanical
AA10NX Air cleaner Clogging MON
system
Mechanical
AB00MA Alternator Malfunction MON l
system
Mechanical
B@BAZG Engine oil Lowering of oil pressure ENG l l
system
Mechanical
B@BCNS Coolant Overheating ENG l l
system
Mechanical
B@CRNS HST oil Overheating HST l l
system
Mechanical
B@CRZG HST oil Lowering of oil pressure HST l l
system
CONTROLLER Electrical
CA111 Engine controller Internal defect ENG E04 l l
R system
Engine Ne/Bkup speed Electrical
CA115 Abnormal ENG E04 ENG SPEED l l
sensor system
Excessively high voltage Electrical
CA122 Charge pressure sensor ENG E03 ENGINE l l
detected system
Electrical
CA123 Charge pressure sensor Excessively low voltage detected ENG E03 ENGINE l l
system
Excessively high voltage Electrical
CA131 Throttle sensor ENG E03 DECEL PEDAL l l
detected system
Electrical
CA132 Throttle sensor Excessively low voltage detected ENG E03 DECEL PEDAL l l
system
Excessively high voltage Electrical
CA144 Coolant temperature sensor ENG E02 WATER TEMP l l
detected system
Electrical
CA145 Coolant temperature sensor Excessively low voltage detected ENG E02 WATER TEMP l l
system
Excessively high voltage Electrical
CA153 Charge temperature sensor ENG E01 ENGINE
detected system
Electrical
CA154 Charge temperature sensor Excessively low voltage detected ENG E01 ENGINE
system
SENSOR Electrical
CA187 Sensor power supply 2 Excessively low voltage detected ENG E03 l l
VOLTAGE system
Atmospheric pressure Excessively high voltage Electrical
CA221 ENG E03 ENGINE l l
sensor detected system
Atmospheric pressure Electrical
CA222 Excessively low voltage detected ENG E03 ENGINE l l
sensor system
Excessively high voltage SENSOR Electrical
CA227 Sensor power supply 2 ENG E03 l l
detected VOLTAGE system
Mechanical
CA234 Engine Excessively high speed ENG l l
system
Ne speed sensor power Electrical
CA238 Excessively low voltage detected ENG E03 ENG SPEED l l
supply system
Electrical
CA271 IMV/PCV1 Short circuit ENG E03 ENGINE l l
system
Electrical
CA272 IMV/PCV1 Disconnection ENG E03 ENGINE l l
system
Electrical
CA322 Injector # 1 Disconnection or short circuit ENG E03 ENGINE l l
system

D51EX/PX-22 30-69
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Electrical
CA323 Injector # 5 Disconnection or short circuit ENG E03 ENGINE l l
system
Electrical
CA324 Injector # 3 Disconnection or short circuit ENG E03 ENGINE l l
system
Electrical
CA325 Injector # 6 Disconnection or short circuit ENG E03 ENGINE l l
system
Electrical
CA331 Injector # 2 Disconnection or short circuit ENG E03 ENGINE l l
system
Electrical
CA332 Injector # 4 Disconnection or short circuit ENG E03 ENGINE l l
system
Electrical
CA342 Engine controller Defective matching of data ENG E04 ENGINE l l
system
Electrical
CA351 Injector system Abnormal circuit ENG E03 ENGINE l l
system
SENSOR Electrical
CA352 Sensor power source 1 Excessively low voltage detected ENG E03 l l
VOLTAGE system
Excessively high voltage SENSOR Electrical
CA386 Sensor power source 1 ENG E03 l l
detected VOLTAGE system
Excessively high voltage Electrical
CA428 Coolant sensor ENG E01 FUEL FILTER
detected system
Electrical
CA429 Coolant sensor Excessively low voltage detected ENG E01 FUEL FILTER
system
ENG OIL Electrical
CA435 Engine oil pressure switch Abnormal signal circuit ENG E02 l l
PRESS SW system
BATTERY Electrical
CA441 Power supply voltage Excessively low voltage detected ENG E04 l l
VOLTAGE system
Excessively high voltage BATTERY Electrical
CA442 Power supply voltage ENG E04 l l
detected VOLTAGE system
Excessively high pressure Electrical
CA449 Common rail pressure 2 ENG E03 ENGINE l l
detected system
Common rail pressure Excessively high voltage Electrical
CA451 ENG E03 ENGINE l l
sensor detected system
Common rail pressure Electrical
CA452 Excessively low voltage detected ENG E03 ENGINE l l
sensor system
Exceeded upper control limit of CAC Electrical
CA488 Charge temperature ENG E03 l l
temperature OVERHEAT system
Excessively high pressure Electrical
CA553 Common rail pressure 1 ENG E02 ENGINE l l
detected system
Electrical
CA559 Supply pump 1 No pressure feeding detected ENG E02 ENGINE l l
system
Electrical
CA689 Engine Ne speed sensor Abnormality in signal ENG E03 ENG SPEED l l
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03 ENG SPEED l l
system
CONTROLLER Electrical
CA757 Engine controller Loss of data ENG E04 l l
R system
Electrical
CA778 Engine Bkup speed sensor Abnormal signal ENG E03 ENG SPEED l l
system
CAN communication
Electrical
CA1633 (Engine controller - HST Abnormal communication ENG E03 DATA LINK l l
system
controller)
Excessively high voltage Electrical
CA2185 Decelerator pedal sensor ENG E03 DECEL PEDAL l l
detected system

30-70 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Electrical
CA2186 Decelerator pedal sensor Excessively low voltage detected ENG E03 DECEL PEDAL l l
system
Electrical
CA2249 Supply pump 2 No pressure feeding detected ENG E03 ENGINE l l
system
Electrical
CA2311 IMV solenoid Abnormal resistance ENG E03 ENGINE l l
system
HEATER Electrical
CA2555 Air intake heater relay Disconnection ENG E01
RELAY system
HEATER Electrical
CA2556 Air intake heater relay Short circuit ENG E01
RELAY system
N SAFETY Electrical
D130KA Neutral safety relay Disconnection HST E02 l l
RELAY system
N SAFETY Electrical
D130KB Neutral safety relay Short circuit HST E02 l l
RELAY system
CAN communication Defective communication
Electrical
DAFRKR (Monitor panel - HST (Abnormality in objective MON E03 DATA LINK l l
system
controller) component system)
CAN communication Defective communication
Electrical
DAFRMC (Monitor panel - Engine (Abnormality in objective MON E03 DATA LINK l l
system
controller) component system)
Electrical
DAJ000 HST controller Memory error HST
system
BATTERY Electrical
DAJ0KK HST controller Lowering of source voltage HST E04 l l
VOLTAGE system
MACHINE Electrical
DAJ0KQ HST controller Machine code error HST E03 l l
CODE system
CONTROLLER Electrical
DAJ0KT HST controller Memory error HST E03 l l
R system
HST controller sensor 5V SENSOR Electrical
DAJ5KK Lowering of source voltage/Input HST E04 l l
power supply No.1 VOLTAGE system
HST controller sensor 5V SENSOR Electrical
DAJ6KK Lowering of source voltage/Input HST E03 l l
power supply No.2 VOLTAGE system
Defective communication
CAN communication (HST Electrical
DAJRKR (Abnormality in objective HST E03 DATA LINK l l
controller - Monitor panel) system
component system)
CAN communication (HST Defective communication
Electrical
DB2RKR controller - Engine (Abnormality in objective HST E03 DATA LINK l l
system
controller) component system)
Electrical
DD12KA Shift up switch Disconnection HST E02 SHIFT UP SW l l
system
Electrical
DD12KB Shift up switch Short circuit HST E02 SHIFT UP SW l l
system
SHIFT DOWN Electrical
DD13KA Shift down switch Disconnection HST E02 l l
SW system
SHIFT DOWN Electrical
DD13KB Shift down switch Short circuit HST E02 l l
SW system
Electrical
DD14KB Travel lock SW 1 Short circuit HST E03 TRAVEL LOCK l l
system
Disagreement of ON/OFF Electrical
DD1NL4 Fan rotation selector switch HST E01 FAN SW
signals system
Reverse travel speed Electrical
DDDCKB Short circuit HST E01 R SPEED SW
switch system
Electrical
DDP6KA Brake oil pressure sensor Disconnection HST E02 BRAKE PRESS l l
system

D51EX/PX-22 30-71
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Electrical
DDP6KB Brake oil pressure sensor Short circuit HST E02 BRAKE PRESS l l
system
Electrical
DDP6MA Brake oil pressure sensor Malfunction HST E02 BRAKE PRESS l l
system
Electrical
DDQ2KA Travel lock SW 1 Disconnection HST E03 TRAVEL LOCK l l
system
Disagreement of ON/OFF SHIFT MODE Electrical
DDT0L4 Shift mode SW HST E01
signals SW system
Travel lock limit switches 1 Electrical
DDU1FS Fixing HST E03 TRAVEL LOCK l l
and 2 system
Electrical
DDU1KA Travel lock limit switch 2 Disconnection HST E03 TRAVEL LOCK l l
system
Short circuit with power supply Electrical
DDU1KY Travel lock limit switch 2 HST E03 TRAVEL LOCK l l
line system
Hydraulic tank oil Electrical
DGS1KA Disconnection HST E01 OIL TEMP
temperature sensor system
Hydraulic tank oil Electrical
DGS1KX Out of input signal range HST E01 OIL TEMP
temperature sensor system
Electrical
DHH5KA LH pump pressure sensor Disconnection HST E02 HST PRESS l l
system
Electrical
DHH5KB LH pump pressure sensor Short circuit HST E02 HST PRESS l l
system
Electrical
DHH6KA RH pump pressure sensor Disconnection HST E02 HST PRESS l l
system
Electrical
DHH6KB RH pump pressure sensor Short circuit HST E02 HST PRESS l l
system
Electrical
DK10KA Fuel dial sensor Disconnection HST E03 FUEL DIAL l l
system
Electrical
DK10KB Fuel dial sensor Short circuit HST E03 FUEL DIAL l l
system
Electrical
DK30KA Steering angle sensor 1 Disconnection HST E03 ST LEVER l l
system
Electrical
DK30KB Steering angle sensor 1 Short circuit HST E03 ST LEVER l l
system
Electrical
DK30KX Steering angle sensor Out of input signal range HST E04 ST LEVER l l
system
Electrical
DK30KZ Steering angle sensor Disconnection or short circuit HST E04 ST LEVER l l
system
Electrical
DK30L8 Steering angle sensor Disagreement of analog signals HST E03 ST LEVER l l
system
Electrical
DK31KA Steering angle sensor 2 Disconnection HST E03 ST LEVER l l
system
Electrical
DK31KB Steering angle sensor 2 Short circuit HST E03 ST LEVER l l
system
Electrical
DK40KA Brake pedal sensor Disconnection HST E03 BRAKE PEDAL l l
system
Electrical
DK40KB Brake pedal sensor Short circuit HST E03 BRAKE PEDAL l l
system
Electrical
DK55KX Directional potentiometer Out of input signal range HST E04 FR LEVER l l
system
Electrical
DK55KZ Directional potentiometer Disconnection or short circuit HST E04 FR LEVER l l
system
Electrical
DK55L8 Directional potentiometer Disagreement of analog signals HST E03 FR LEVER l l
system

30-72 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Electrical
DK56KA Directional potentiometer 1 Disconnection HST E03 FR LEVER l l
system
Electrical
DK56KB Directional potentiometer 1 Short circuit HST E03 FR LEVER l l
system
Electrical
DK57KA Directional potentiometer 2 Disconnection HST E03 FR LEVER l l
system
Electrical
DK57KB Directional potentiometer 2 Short circuit HST E03 FR LEVER l l
system
TRAVEL Electrical
DLM0KX HST motor speed sensor Out of input signal range HST E03 l l
SPEED system
Left HST motor speed TRAVEL Electrical
DLM1KA Disconnection HST E01
sensor SPEED system
Left HST motor speed TRAVEL Electrical
DLM1KB Short circuit HST
sensor SPEED system
Left HST motor speed Electrical
DLM1MA Malfunction HST
sensor system
Right HST motor speed TRAVEL Electrical
DLM2KA Disconnection HST E01
sensor SPEED system
Right HST motor speed TRAVEL Electrical
DLM2KB Short circuit HST
sensor SPEED system
Right HST motor speed Electrical
DLM2MA Malfunction HST
sensor system
Electrical
DLM3KA Fan speed sensor Disconnection HST E01 FAN SPEED
system
Electrical
DLM3KB Fan speed sensor Short circuit HST E02 FAN SPEED l l
system
Brake pedal and proximity Electrical
DN21FS Fixing HST E03 BRAKE PEDAL l l
switch system
Electrical
DV00KB Caution buzzer: Short circuit MOM E01 BUZZER
system
Electrical
DV20KB Back alarm buzzer Short circuit HST E01 BACK ALARM
system
Parking brake solenoid Electrical
DW4BKA Disconnection HST E04 P BRAKE SOL l l
valve system
Parking brake solenoid Electrical
DW4BKB Short circuit HST E04 P BRAKE SOL l l
valve system
Parking brake solenoid Short circuit with power supply Electrical
DW4BKY HST E03 P BRAKE SOL l l
valve line system
Electrical
DW7BKA Fan reverse solenoid valve Disconnection HST E01 FAN CLN SOL
system
Electrical
DW7BKB Fan reverse solenoid valve Short circuit HST E01 FAN CLN SOL
system
Short circuit with power supply Electrical
DW7BKY Fan reverse solenoid valve HST E03 FAN CLN SOL l l
line system
SLOW BRAKE Electrical
DW7EKA Slow brake solenoid valve Disconnection HST E04 l l
SOL system
SLOW BRAKE Electrical
DW7EKB Slow brake solenoid valve Short circuit HST E04 l l
SOL system
Short circuit with power supply SLOW BRAKE Electrical
DW7EKY Slow brake solenoid valve HST E03 l l
line SOL system
Fan pump EPC solenoid Electrical
DWN5KA Disconnection HST E01 FAN EPC
valve system
Fan pump EPC solenoid Electrical
DWN5KB Short circuit HST E01 FAN EPC
valve system

D51EX/PX-22 30-73
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Fan pump EPC solenoid Short circuit with power supply Electrical
DWN5KY HST E02 FAN EPC l l
valve line system
LF HST pump EPC HST PUMP Electrical
DXA4KA Disconnection HST E03 l l
solenoid valve EPC system
LF HST pump EPC HST PUMP Electrical
DXA4KB Short circuit HST E03 l l
solenoid valve EPC system
LF HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA4KY HST E04 l l
solenoid valve line EPC system
LR HST pump EPC HST PUMP Electrical
DXA5KA Disconnection HST E03 l l
solenoid valve EPC system
LR HST pump EPC HST PUMP Electrical
DXA5KB Short circuit HST E03 l l
solenoid valve EPC system
LR HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA5KY HST E04 l l
solenoid valve line EPC system
RF HST pump EPC HST PUMP Electrical
DXA6KA Disconnection HST E03 l l
solenoid valve EPC system
RF HST pump EPC HST PUMP Electrical
DXA6KB Short circuit HST E03 l l
solenoid valve EPC system
RF HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA6KY HST E04 l l
solenoid valve line EPC system
RR HST pump EPC HST PUMP Electrical
DXA7KA Disconnection HST E03 l l
solenoid valve EPC system
RR HST pump EPC HST PUMP Electrical
DXA7KB Short circuit HST E03 l l
solenoid valve EPC system
RR HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA7KY HST E04 l l
solenoid valve line EPC system
Left HST motor EPC HST MOTOR Electrical
DXK1KA Disconnection HST E02 l l
solenoid valve EPC system
Left HST motor EPC HST MOTOR Electrical
DXK1KB Short circuit HST E02 l l
solenoid valve EPC system
Left HST motor EPC Short circuit with power supply HST MOTOR Electrical
DXK1KY HST E04 l l
solenoid valve line EPC system
Right HST motor EPC HST MOTOR Electrical
DXK2KA Disconnection HST E02 l l
solenoid valve EPC system
Right HST motor EPC HST MOTOR Electrical
DXK2KB Short circuit HST E02 l l
solenoid valve EPC system
Right HST motor EPC Short circuit with power supply HST MOTOR Electrical
DXK2KY HST E04 l l
solenoid valve line EPC system

H Error codes:
The error code table is written in alphabetical order and also starting from small number.
The error code in parentheses is not recorded in the failure history for both electrical system and mechanical system.
H Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON: Monitor panel system
ENG: Engine controller system
HST: HST controller system
H Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
H History classification:
History classification indicates in which system, either electrical system or mechanical system in the failure history
display function, a failure has been recorded.

30-74 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[4] Oil/filter maintenance mode (MAINTENANCE MONITOR)

1. If buzzer cancel switch [] is pressed on the normal display screen, the


maintenance mode is selected and the filter/oil maintenance mode
screen is displayed first.

2. Replacement time display of filter and oil (displayed automatically).


When the replacement interval for the various filters or oils
approaches, the monitor panel automatically displays the information
to remind an operator of maintenance.

Table of maintenance items


Code Display Maintenance items
01 01: ENG OIL Engine oil
02 02: ENG FILT Engine oil filter
03 03: FUEL FILT Fuel main filter
41 41: FUEL P FILT Fuel pre filter
04 04: HYD FILT Hydraulic oil filter
06 06: CORR RES Corrosion resistor (*)
18 18: BYPS FILT Bypass filter (*)
07 07: DAMP OIL Damper filter (*)
08 08: FNL OIL Final drive oil
10 10: HYD OIL Hydraulic oil
19 19: POWL OIL Power train oil (*)
20 20: POWL FILT Power train oil filter (*)
21 21: HST FILT HST charge filter

* Unused on D51.

3. Reset of replacement time (selection menu)


The monitor panel can reset the interval time by operating the switch,
if various filters and oils maintenances are finished.
For details, see Operation and Maintenance Manual.
Replacement interval time setting can be operated by the
maintenance interval change mode in the service mode.

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[5] Brightness adjustment mode (BRIGHTNESS)
In this mode, the display condition of the monitor panel can be
adjusted on the character display portion.
The following items are displayed in the brightness adjustment mode.
Order Display Item

1 BRIGHTNESS GAUGE Adjustment of back light of LCD gauge

BRIGHTNESS Adjustment of back light of character display


2
CHARACTER DISP portion.

CONTRAST Adjustment of LCD contrast of character display


3
CHARACTER DISP portion.

Screen during adjustment


[>]: To increase adjustment value
[<]: To decrease adjustment value
[]: To determine and return to previous screen
H The state when [] is pressed is recorded.

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n Service mode

Procedure for switching to service mode and screen display


H When using the service mode, change the screen by the following special operation.

1. Confirming the screen display.


Check that the monitor panel is in operator mode and the screen is displaying either of the "service meter, "action code",
or "error code".

2. Displaying ID input initial screen.


Press the following 2 switches at the same time for longer than 5
seconds to display the ID input screen.
[n] switch and [<] switch
H If the switch is pressed for longer than 5 seconds, the character
display section becomes blank. After confirming this condition,
release the switch.

3. Input and determination of ID.


After displaying ID input screen, operate [>], [<], [], and [n] switch
and input 4 digits ID.
H ID: 6491
[>]: Number at the cursor increases.
[<]: Number at the cursor decreases
[]: Number at the cursor is determined
[n]:Cursor moves to left end or the display returns to operator
mode screen.
H If the ID input screen is left without switch operation for longer
than 60 seconds, it automatically returns to the operator mode
screen.

4. Displaying service menu selection screen.


After confirming all 4 digits of ID, display the service menu selection
screen in the service mode.
H By inputting and determining the ID once, it will be effective until
the starting switch is turned off.

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5. Selection of the service menu.
If the [>] switch or [<] switch is pressed on the service menu selection screen, the service menu is displayed endlessly in
the order of the following table, then select the menu that is used.
[>]: To proceed to next service menu.
[<]: To return to previous service menu.

H Displayed service menu:


Remark
No. 1 - 5 are used in the operator mode.
Order Display Function
6 ELECTRIC FAULT Electrical system failure history display mode
7 MACHINE FAULT Mechanical system failure history display mode
8 REAL-TIME MONITOR Real-time monitoring mode
9 CYLINDER CUT-OUT Cylinder cut-out mode
10 NO INJECTION No injection cranking mode
11 TUNING Tuning mode
12 MAINTENANCE MONITOR Maintenance interval change mode
13 TEL Phone No. input mode
14 MACHINE Model selection mode
15 OPTIONAL SELECT Option selection mode
16 INITIALIZE Initialize mode (exclusive function for factory)

H The service menu is displayed in the places marked with [*].

6. Finishing mode and function.


The current mode and function can be finished by either of the
following method, regardless of the current function and hierarchy.
When continuing operations in another mode or function:
Press the [n] switch and return to the mode screen to be used or menu screen to be used.
H Note that if the [] switch is pressed on the YES/NO screen, the function will be executed.
H If you return to the operator mode screen by mistake, repeat the procedure from step 1 above (however there is
no need to input the ID again).
When completing all operations: Turn the starting switch OFF.

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[6] Electrical system failure history display mode (ELECTRIC FAULT)
The monitor panel retains the data for problems that occurred in the electrical system in the past as failure history. They
can be displayed as follows.

1. Selection of the service menu.


Select electrical system failure history display mode (ELECTRIC
FAULT) in the service menu selection screen.
H The total number of failure history data items recorded in memory
is displayed in the [* *] portion.

2. Failure history data display.


With the service menu selected, press the [] switch and display the
failure history data recorded in memory.
[]: Conduct the service menu.

3. Displayed failure history data.


With the electrical system failure history display mode, the following
data can be displayed.
1: Record number (recorded up to a maximum of 20 items)
A: Error code (4-digits device code + 2-digits symptom code)
2: Number of occurrences (number of occurrences of same code in
the past)
3: Elapsed time 1 (time elapsed on service meter since first
occurrence)
4: Elapsed time 2 (time elapsed on service meter since last
occurrence)
H Error codes for problems that are still existing are shown on a
flashing display.
H Refer to error code table of operator mode for details of displayed
error codes.
H Note that with the electrical system failure history display mode and error code display mode (operator mode), the
displayed data are partially different.
H If the fault history is not recorded, "" is displayed on the display section of 1/A/2/3/4.

4. Switching failure history display.


If the [>] switch or [<] switch is pressed during the display of failure history, the display switches to another failure
history data recorded.
[>]: To proceed to data for next record number
[<]: Go back to data for previous record number

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5. Deleting individual failure history data.
A. With the failure history data to be deleted displayed, press the []
switch and display the individual deletion screen.
[]: Display the deletion screen
B. When the individual deletion screen is displayed, operate each
switch of [<], [>] and [].
[<]: Select YES (move cursor)
[>]: Select NO (move cursor)
[]: Execute YES or NO
An information which is active currently (display is flashing)
cannot be deleted.

6. Deletion of all the failure history information.


A. With the failure history data displayed, press the [>] switch or [<]
switch and display ALL CLEAR menu screen.
The ALL CLEAR menu is displayed at the end of failure
history data.
B. When the ALL CLEAR menu is displayed, press the [] switch
and display the ALL CLEAR execution screen.
[]: Execute ALL CLEAR menu

C. When the ALL CLEAR execution screen is displayed, operate


each switch of [<], [>] and [].
[<]: Select YES (move cursor)
[>]: Select NO (move cursor)
[]: Execute YES or NO
H An information which is active currently (display is flashing)
cannot be deleted.

D. The screen changes to the fault history screen. Check that the
number of records in ** is "0".

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[7] Mechanical system failure history display mode (MACHINE
FAULT)
The monitor panel retains the data for problems that occurred in the
mechanical system in the past as failure history. They can be displayed
as follows.

1. Selection of the service menu.


Select mechanical system failure history display mode (MACHINE
FAULT) in the service menu selection screen.
H The total number of failure history data items recorded in memory
is displayed in the [* *] portion.

2. Failure history data display.


With the service menu selected, press the [] switch and display the
failure history data recorded in memory.
[]: Conduct the service menu.

3. Displayed failure history data.


With the mechanical system failure history display mode, the
following data can be displayed.
1: Record number
A: Error code (4-digits device code + 2-digits symptom code)
2: Number of occurrences (number of occurrences of same code in
the past)
3: Service meter at first occurrence)
4: Service meter at last occurrence)
H Error codes for problems that are still existing are shown on a
flashing display.
H Refer to error code table of operator mode for details of displayed
error codes.
H Note that with the mechanical system failure history display mode
and error code display mode (operator mode), the displayed data are partially different.
H If the fault history is not recorded, "" is displayed on the display section of 1/A/2/3/4.

4. Switching failure history display.


If the [>] switch or [<] switch is pressed during the display of failure history, the display switches to another failure
history data recorded.
[>]: To proceed to data for next record number
[<]: Go back to data for previous record number

5. Deleting failure history data (not permitted).


The failure history data for the mechanical system cannot be deleted.

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[8] Real time monitoring mode (REAL-TIME MONITOR)
The monitor panel can monitor the condition of the machine in real
time through the signals from the sensors installed to various parts of
the machine. In the real time monitoring mode, the following 2 types
of display can be shown.
1 item independent display (for each controller)
2 items simultaneous display (code input)

1. Selection of the service menu.


Select real time monitoring mode (REAL-TIME MONITOR) in the
service menu selection screen.

2. Display and selection of monitoring system and mode.


A. With the service menu selected, press the [] switch to display the
monitoring system and mode selection screen.
[]: Execute the service menu.
B. If the [>] switch or [<] switch is pressed on the monitoring system
and mode selection screen, the monitoring system and device is
displayed endlessly in the following order, then select the system
or mode that is used.
[>]: To proceed to next monitoring system and mode
[<]: Go back to data for previous monitoring system and
mode
H Monitoring system and mode to be displayed:
No. Display System and function
1 MONITOR PANEL Monitor panel system
2 HST HST controller system
3 ENGINE Engine controller system
4 KOMTRAX KOMTRAX controller system
5 2 ITEMS 2 items simultaneous monitoring

H Monitoring system and mode is displayed in the "*" section.

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3. Setting 1 item individual monitoring.
A. In the monitoring system and mode selection screen, select the
monitoring system (example: ENGINE) to be used.
B. With the monitoring system selected, press the [] switch and
display the monitoring display and item selection screen.
[]: Implement 1 system individual monitoring

C. With the monitoring display and item selection screen displayed,


press the [>] switch or [<] switch and select items to monitor.
[>]: To proceed to the next monitoring item
[<]: Return to the previous monitoring item
H The monitored items are scroll-displayed due to internal
setting.
H If the switch is kept pressed, the monitoring items scroll at
high speed.
H In the monitoring display and item selection screen, the
information of the monitored items are displayed on real
time.
D. To hold or cancel monitoring data display: If the [] switch is
pressed during monitoring, the monitoring data display is held
and the [] mark flashes. If the [] switch is pressed again, hold is canceled and it becomes active again.
[]: Hold and release of data display

4. Display data for 1 item individual monitoring.


On the 1 item individual monitoring display screen, the following data
are displayed.
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
H For details, see "Monitoring code table".

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5. Setting 2 items simultaneous monitoring
A. Select 2 items simultaneous monitoring (2 ITEMS) in the
monitoring system and function selection screen.
B. With 2 items simultaneous monitoring selected, press the []
switch to display the monitoring code input screen.
[]: Implement 2 system individual monitoring

C. In the monitoring code input screen, operate the switches [>], [<],
[] and [n], to input two monitoring codes directly.
[>]: Number at the cursor increases.
[<]: Number at the cursor decreases
[]: Number at the cursor is determined
[n]:Cursor moves to the left end / To return to the monitoring
system and function selection screen.

D. When both of the monitoring codes have been confirmed, the


screen switches to the 2 items simultaneous monitoring display
screen.
E. To hold or cancel monitoring data display:
If the [] switch is pressed during monitoring, the monitor data is
held and the [] mark flashes.
If the [] switch is pressed again, hold is canceled and it becomes
active again.
[]: Hold and release of data

6. Display data for 2 items simultaneous monitoring.


On the 2 item simultaneous monitoring display screen, the following
data are displayed.
A : Monitoring code 1
1 : Monitoring data 1 (including unit)
B : Monitoring code 2
2 : Monitoring data 2 (including unit)
H For details, see "Monitoring code table".

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Monitoring code table
MONITOR PANEL [Monitor panel system]
Display Monitoring
Monitoring item Item display Data display range Unit
order code
D51
1 Machine model code MACHINE CODE 00205
(Example of display)
01010101
2 Monitor panel input signal 1 DIN07 40921 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
3 Monitor panel input signal 2 DIN810 40922 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
4 Fuel sensor voltage FUEL SENSOR 04200 0 500 mV
5 Alternator R signal input voltage R SIGNAL 04303 0 500 mV
****
6 Application ver. 1 VERSION (APP) 20221
(8 digits/symbols)
****
7 Application data ver. 1 VERSION (DATA) 20222
(8 digits/symbols)
****
8 Program No. VERSION 20228
(8 digits/symbols)
****
9 Assembly No. PART NUMBER 20227
(8 digits/symbols)
*******
10 Serial No. SERIAL NUMBER 20402
(7 digits)

Display example of bit information

H Bit information is displayed in parts [0] [10] and "OFF" is indicated


with "0" and "ON" with "1".
H In case of no use, displayed "0".
H The state of each item described in this section indicates the condition
for turning on the bit.

Detailed information of 40921 (DIN07)


[0] Staring switch C signal: Start position
[1] Front lamp and rear lamp: ON
[2] Preheater: ON
[3] (Unused)
[4] (Unused)
[5] (Unused)
[6] Air cleaner clogging sensor: ON (Clogged)
[7] Information switch: < (Left)

Detailed information of 40922 (DIN810)


[8] Information switch: > (Right)
[9] Buzzer cancel switch: U (Left)
[10] Buzzer cancel switch: t (Right)

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HST CONTROLLER [HST controller system]
Display Monitoring
Monitoring item Item display Data display range Unit
order code
D51
1 Machine model code MACHINE CODE 00204
(Example of display)
2 HST oil temperature HST TEMP 04401 -99.9 999.9 C
3 HST oil temperature sensor voltage HST TEMP 04402 0 5.00 V
4 Travel speed (Faster one of right and left) VEHICLE SPEED 40010 0 99.9 km/h
5 Right travel speed R SPEED 40002 0 99.9 km/h
6 Left travel speed L SPEED 40003 0 99.9 km/h
7 Right travel speed R SPEED 40963 0 9999 Hz
8 Left travel speed L SPEED 40964 0 9999 Hz
9 HST right circuit pressure HST R PRESS 52501 0 99.9 MPa
10 HST left circuit pressure HST L PRESS 52503 0 99.9 MPa
11 HST right circuit pressure sensor voltage HST R PRESS 52500 0 5.00 V
12 HST left circuit pressure sensor voltage HST L PRESS 52502 0 5.00 V
13 Brake pressure BRAKE PRESS 91902 0.00 9.99 MPa
14 Brake pressure sensor voltage BRAKE PRESS 91903 0 5000 mV
15 FR lever stroke FR LEVER 50204 -100.0 100.0 %
16 FR potentiometer 1 voltage FR LEVER 1 50202 0 5.00 V
17 FR potentiometer 2 voltage FR LEVER 2 50203 0 5.00 V
18 Steering stroke S/T LEVER 50303 -100.0 100.0 %
19 Steering potentiometer 1 voltage S/T LEVER 1 50300 0 5.00 V
20 Steering potentiometer 2 voltage S/T LEVER 2 50301 0 5.00 V
21 Brake pedal stroke BREAK PEDAL 50401 0.0 100.0 %
22 Brake potentiometer voltage BREAK PEDAL 50400 0 5.00 V
23 Throttle dial command speed FUEL DIAL 03003 0 9999 rpm
24 Throttle dial voltage FUEL DIAL 03002 0 5.00 V
25 Right forward pump capacity command value RF PUMP 52404 0.0 95.0 CC/r
26 Left forward pump capacity command value LF PUMP 52405 0.0 95.0 CC/r
27 Right reverse pump capacity command value RR PUMP 52406 0.0 95.0 CC/r
28 Left reverse pump capacity command value LR PUMP 52407 0.0 95.0 CC/r
Right forward pump output current command
29 RF PUMP 52400 0 9999 mA
value
30 Left forward pump output current command value LF PUMP 52401 0 9999 mA
Right reverse pump output current command
31 RR PUMP 52402 0 9999 mA
value
32 Left reverse pump output current command value LR PUMP 52403 0 9999 mA
33 Right forward pump output current sensed value RF PUMP FB 52408 0 9999 mA
34 Left forward pump output current sensed value LF PUMP FB 52409 0 9999 mA
35 Right reverse pump output current sensed value RR PUMP FB 42410 0 9999 mA
36 Left reverse pump output current sensed value LR PUMP FB 52411 0 9999 mA
37 Motor capacity command value MOTOR 52300 0 160 CC/r
38 Right motor output current command value R MOTOR 52301 0 9999 mA
39 Left motor output current command value L MOTOR 52302 0 9999 mA
40 Right motor output current sensed value R MOTOR FB 52303 0 9999 mA
41 Left motor output current sensed value L MOTOR FB 52304 0 9999 mA
42 Theoretical traction force TRACTION 60000 0 99.9 ton
43 Fan speed FAN SPEED 10007 0 9999 rpm

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HST CONTROLLER [HST controller system]


Display Monitoring
Monitoring item Item display Data display range Unit
order code
44 Fan speed FAN SPEED 40965 0 9999 Hz
45 Fan EPC output current command value FAN EPC 31623 0 9999 rpm
46 Fan EPC output current sensed value FAN EPC FB 31624 0 9999 mA
47 R signal input voltage R SIGNAL 04303 0 50.0 V
48 Battery relay drive voltage BR HOLD 60600 0 50.0 V
49 Neutral safety relay drive voltage N-SAFETY 50901 0 50.0 V
50 Backup alarm drive voltage BACK ALARM 70401 0 50.0 V
51 Controller unswitched power supply voltage (VB) PWR IN BATT 03207 0 50.0 V
52 Controller load drive power supply voltage (VIS) PWR IN BRY 03202 0 50.0 V
53 Key ACC input voltage PWR CNT KEY 03201 0 50.0 V
01010101
54 Machine controller switch input 1 DIN07 40910 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
55 Machine controller switch input 2 DIN815 40911 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
56 Machine controller switch input 3 DIN1623 40912 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
57 Machine controller switch input 4 DIN2331 40913 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
58 Machine controller D-OUT output DOUT07 40918 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
59 Machine controller SOL OUT output DOUT815 40914 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
60 Forward odometer FORWARD ODO M 53501 0 9999999 m
61 Reverse odometer BACKWARD ODO M 53502 0 9999999 m
62 1000 rpm service meter 1000rpm SMR 31105 0 9999999 h
********
63 Application ver. 1 VERSION (APP) 20235
(8 digits/symbols)
********
64 Application data ver. 1 VERSION (DATA) 20236
(8 digits/symbols)
********
65 Program No. VERSION 20238
(8 digits/symbols)
********
66 Assembly No. PART NUMBER 20237
(8 digits/symbols)
*******
67 Serial No. SERIAL NUMBER 20406
(7 digits/symbols)

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Detailed information of 40910 (DIN0 7)
[0] Travel lever shift-up switch (NO): ON
[1] (Unused)
[2] (Unused)
[3] HST filter switch: ON (Filter is clogged)
[4] Travel lever shift-down switch (NC): OFF
[5] Travel lever shift-down switch (NO): ON
[6] Travel lever shift-up switch (NC): OFF
[7] (Unused)
Examples of display of bit information

H The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
H In case of no use, displayed "0".

Detailed information of 40911 (DIN8 15)


[8] Starting switch C signal: Start position
[9] (Unused)
[10] (Unused)
[11] (Unused)
[12] Travel lock switch 2 (NO): Lock
[13] (Unused)
[14] (Unused)
[15] (Unused)
Examples of display of bit information

H The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
H In case of no use, displayed "0".

Detailed information of 40912 (DIN16 23)


[16] Reverse travel speed set switch: Deceleration (Left)
[17] Reverse travel speed set switch: Acceleration (Right)
[18] Travel lock switch (NO): Lock
[19] Travel lock switch (NC): Free
[20] (Unused)
[21] (Unused)
[22] (Unused)
[23] (Unused)
Examples of display of bit information

H The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
H In case of no use, displayed "0".

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Detailed information of 40913 (DIN24 31)
[24] Shift mode switch: Quick shift mode (Right)
[25] Shift mode switch: Variable shift mode (Left)
[26] Fan rotation selector switch: Reverse (Right)
[27] Fan rotation selector switch: Forward (Left)
[28] (Unused)
[29] (Unused)
[30] (Unused)
[31] (Unused)
Examples of display of bit information

H The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
H In case of no use, displayed "0".

Detailed information of 40918 (DOUT0 7)


[0] (Unused)
[1] (Unused)
[2] (Unused)
[3] Neutral safety relay: ON
[4] (Unused)
[5] Backup alarm: ON
[6] (Unused)
[7] Battery relay: ON
Examples of display of bit information

H The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
H In case of no use, displayed "0".

Detailed information of 40914 (DOUT8 15)


[8] Fan reverse solenoid valve: ON
[9] (Unused)
[10] Parking brake solenoid valve: ON
[11] Slow brake solenoid valve: ON
[12] (Unused)
[13] (Unused)
[14] (Unused)
[15] (Unused)
Examples of display of bit information

H The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
H In case of no use, displayed "0".

D51EX/PX-22 30-89
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ENGINE [Engine controller system]
Display Monitoring
Monitoring item Item display Data display range Unit
order code
1 Engine speed 1 ENG SPEED 01002 0 4000 rpm
2 Engine coolant temperature COOLANT TEMP 04107 -40 210 C
3 Engine coolant temperature sensor voltage COOLANT TEMP 04105 0.00 5.00 V
4 Decelerator pedal operating degree DECEL PEDAL 31701 0 100 %
5 Decelerator pedal sensor voltage DECEL PEDAL 31702 0.00 5.00 V
6 Selected machine model name MACHINE ID 00201
7 Build version BUILD VER 20216
8 Calibration data version CAL VER 20217
9 Controller internal temperature ECMINT TEMP 18900 -40 210 C
10 Hardware serial No. ECM S/N 20400 0 49999999
11 Converted torque TORQUE RATIO 36700 0 100 %
12 Engine mode selection POWER MODE 17500 04
13 Common rail pressure RAIL PRESS 36400 0 400 MPa
14 Common rail pressure sensor voltage RAIL PRESS 36401 0.00 5.00 V
15 Final common rail pressure command PFIN PRESS COMMAND 36200 0 400 MPa
16 Final injection timing command TFIN INJECT TIMING 36300 -180.0 180.0 CA
17 Ambient pressure AMBIENT PRESS 37400 -99.9 999.9 kPa
18 Ambient pressure sensor voltage AMBIENT PRESS 37401 0.00 5.00 V
19 Boost pressure 1 CHG PRESS-A 36500 -99.9 99.9 kPa
20 Boost pressure sensor voltage 1 CHG PRESS-A 36501 0.00 5.00 V
21 Battery voltage POWER PATE 03203 0.0 480.0 V
22 Momentary fuel consumption FUEL RATE 37300 0.0 999.9 L/h
23 Final accelerator pedal operating degree FINAL THROTTLE 31706 0 100 %
24 Intake air temperature INTAKE TEMP 18400 -50 200 C
25 Intake air temperature sensor voltage INTAKE TEMP 18401 0.00 5.00 V
26 Boost temperature CHG TEMP 18500 -50 200 C
27 Boost temperature sensor voltage CHG TEMP 18501 0.00 5.00 V
28 Idle validation switch 1 IVS 1 18300 0 or 1
29 Idle validation switch 2 IVS 2 18301 0 or 1
30 Final injection command (Weight unit) INJECT COMMAND 18600 0 1000 mg
31 Engine output torque OUTPUT TORQUE 18700 -24000 24000 Nm
32 WIF sensor state WATER IN FUEL 18800 0 or 1

KOMTRAX [KOMTRAX controller system]


Display Monitoring
Monitoring item Item display Data display range Unit
order code
1 LED display LED STATUS 20300 0_00_ 7 (Example)

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[9] Cylinder cut-out mode (CYLINDER CUT-OUT)
As one method of troubleshooting for the engine, the monitor panel
has a reduced cylinder mode that can set the desired cylinder to the no
injection condition.

1. Starting engine.
Use this function while the engine is running, because a defective
cylinder is determined depending on the engine speed in the reduced
cylinder mode.

2. Selection in the service menu.


A. Select the reduced cylinder mode (CYLINDER CUT-OUT) in the
service menu selection screen.
B. With the cylinder cut-out mode selected, press the [] switch and
display the reduced cylinder mode execution screen.
[]: Execute the service menu.
H The cylinder No. and the engine speed are displayed on the
upper line, and the final injection amount command is
displayed on the lower line.
H When being switched to the reduced cylinder mode execution
screen, the cursor of cylinder selection is always displayed
under the No.1 cylinder.

3. Setting cut-out cylinder.


In the reduced cylinder mode execution screen, operate the switches
[>], [<], [] and [n] to select the cut-out cylinder.
[>]: Selector cursor moves to the right.
[<]: Selector cursor moves to the left.
[]: Determine the cylinder.
[n]:To return to the service menu selection screen.
H When the [] switch is used to confirm the cut-out cylinder,
communication is carried out between the monitor panel and
engine controller. During this time, the cylinder No. flashes.
After completion of the communication, the segment under
the cylinder No. becomes black to show that the cylinder has
been cut out.
H A single cylinder or multiple cylinders can be cut out.

4. Canceling cylinder cut-out.


Cancellation of cylinder cut-out is done by the same procedure as
setting cut-out cylinder.
H When the [] switch is used to confirm the cancellation of the
cut-out cylinder, communication is carried out between the
monitor panel and engine controller. During this time, the
cylinder No. flashes.
After completion of the communication, the segment under the
cylinder No. becomes white to show that the cylinder cut-out has
been canceled.

D51EX/PX-22 30-91
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[10] No injection cranking mode
(NO INJECTION)
The monitor panel has the mode of no injection cranking, which is used for cranking after long-term storage, stopping fuel
injection of all the cylinders without starting the engine.
H The mode of no injection cranking must be operated under the condition that the engine is stopped.

1. Selection in the service menu.


In the service menu selection screen, select no injection cranking
mode (NO INJECTION).

2. Establishment of no injection cranking.


With the no injection cranking selected, press the [] switch to display
no injection cranking execution screen.
[]: Execute the service menu.
H If "CRANKING READY" is displayed on the lower line, the
none injection cranking is set.
H If the starting switch is operated to the START position under this
condition, the engine cranks but will not start.

3. Setting is rejected during engine running.


During engine running, if the setting of no injection cranking is
attempted, "STOP ENGINE" is displayed with blinking in the lower
line, and setting is rejected.
H No injection cranking mode cannot be used during engine
running.

4. Canceling no injection cranking.


If the [n] switch is pressed on the no injection cranking execution
screen, the screen returns to the service menu selection screen and the
no injection cranking is cancelled.
[n]:To return to the service menu selection screen.

30-92 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[11] Tuning mode (TUNING)
Various devices can be set and tuned with this mode. The changes of the screen in this mode are outlined below.

1. Selecting service menu.


A. Select the tuning mode (TUNING) on the service menu selection
screen.

D51EX/PX-22 30-93
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
B. While the tuning mode (TUNING) screen is displayed, press the
[] switch to display the ID input (ID INPUT) screen.
[]: Display ID input (ID INPUT) screen.
C. If the [n] switch is pressed on the screen, the screen returns to the
tuning mode (TUNING) screen.
[n]: Return to tuning mode (TUNING) screen.

2. Selecting display pattern.


A. Select a pattern of displaying desired items on the ID input (ID
INPUT) screen by pressing the [], [>] or [<] switch.
[]: Go to tuning item ID input (ID = 0000) screen.
On this screen, all the tuning items can be called up by input-
ting the ID.
H For the selectable tuning items, see "Tuning mode table".
[>]: Go to tuning 1 (TUNING 1) screen.
On this screen, the set tuning items can be called up in order.
[<]: Go to tuning 2 (TUNING 2) screen.
On this screen, the set tuning items can be called up in order.
H For the selectable tuning items, see "Tuning mode table".
H The following figure shows the display of tuning 1 (TUNING
1) as an example.

30-94 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
3. Changing display pattern.
A. When changing the display pattern on the ID input (ID INPUT),
tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen, press the
[>] or [<] switch, and the 3 patterns are selected in order.
H For the switches to be pressed and the changing order, see the
figure.

4. Selecting tuning item.


A. When selecting a tuning item on tuning item ID input (ID = 0000)
screen.

i. Input the tuning item ID to be selected to the position of


"0000" on the following screen with the [>], [<], [] and [n]
switches.
[>]: Increase value.
[<]: Decrease value.
[]: Confirm value. After value is confirmed, cursor
moves to right next position.
[n]: Move cursor to left most position from right most
position.

ii. After inputting tuning item ID, press the [] switch, and the
ID is confirmed and the selected item screen appears.
H The displayed contents of the tuning screen are as
follows.
a: Tuning item ID
b: Tuning item name
c: Value

D51EX/PX-22 30-95
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
H If a tuning item ID which has not been set is input, the
message is displayed. In this case, input another tuning
item ID.

iii. If the [n] switch is pressed on each tuning item screen, the screen returns to the tuning item ID input (ID = 0000)
screen.
[n] Return to tuning item ID input (ID = 0000) screen.
B. When selecting a tuning item on tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen.
H The selecting procedure is the same on the tuning 1 (TUNING 1) and tuning 2 (TUNING 2) screens, but
selectable items on those screens are different.
H An example of display in tuning 1 (TUNING 1) is shown below.

i.Press the [] switch on the tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen, and the top item of the set
tuning items is displayed.
[]: Display top item of set tuning items.
H In tuning 2 (TUNING 2), "ID: 3001 F-PUMP LINE" is
displayed.

ii.
Press the [>] or [<] switch, and the set items are displayed in order.
[>]: Display set items in normal order.
[<]: Display set items in reverse order.
H For the displayable items, see "Tuning mode table".
<Normal display order> (For the symbols, see "Tuning mode table") Tuning 1 (TUNING 1): A1 A2 A3
A4 A5 A6 A7 A1 --- (Repeated continuously).
Tuning 2 (TUNING 2): B1 B2 B3 B1 --- (Repeated continuously).

iii. If the [n] switch is pressed on each tuning screen, the screen returns to the tuning 1 (TUNING 1) or tuning 2
(TUNING 2) screen.
[n]: Return to tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen.

30-96 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
5. Tuning mode table and adjustment procedure
Tuning Automatic selection
No. Display Item Related information
item ID TUNING1 TUNING2
1 0005 BRAKE N-SET Brake potentiometer neutral set Potentiometer voltage A6
Steering lever left counter-rotation set
2 1010 S/T H.L-SET Potentiometer voltage A2
(Operating effort difference)
Steering lever right counter-rotation set
3 1011 S/T H.R-SET Potentiometer voltage A4
(Operating effort difference)
4 1012 S/T N-SET Steering lever neutral set Potentiometer voltage A1
5 1013 S/T M.L-SET Steering lever left max. set Potentiometer voltage A3
6 1014 S/T M.R-SET Steering lever right max. set Potentiometer voltage A5
Forward pump set
7 3001 F-PUMP LINE Command current B1
(For running track shoe idle)
Reverse pump set
8 3002 R-PUMP LINE Command current B2
(For running track shoe idle)
Forward pump start/max. capacity set
9 3003 F-PUMP RUN1 Command current
(For travel)
Reverse pump start/max. capacity set
10 3004 R-PUMP RUN1 Command current
(For travel)
11 3005 F-PUMP RUN2 Forward pump medium capacity set (For travel) Command current
12 3006 R-PUMP RUN2 Reverse pump medium capacity set (For travel) Command current
13 3007 BRAK END Brake potentiometer max. set Potentiometer voltage A7
Engine speed
EST oil temperature
14 3016 STALL CHECK Stall pressure test mode (Hydraulic oil temperature)
Right HST main circuit pressure
Left HST main circuit pressure
15 3019 SHIFT LIMIT Gear speed limit mode Limit gear speed
16 3024 MOTOR LINE Motor set (For running track shoe idle) Command current B3
17 3032 FAN MODE Fan test mode selection Mode name
18 3033 FAN AMP SET Fan set Command current
Forward pump start adjustment value change Adjustment direction
19 3035 F-PUMP MAP1
(For right and left separately) adjustment value
Reverse pump start adjustment value change Adjustment direction
20 3036 R-PUMP MAP1
(For right and left separately) adjustment value
Forward pump start adjustment value change
21 3037 F-PUMP MAP2 Travel speed adjustment value
(For right and left simultaneously)
Reverse pump start adjustment value change
22 3038 R-PUMP MAP2 Travel speed adjustment value
(For right and left simultaneously)
23 -- -- Service meter set (*) Service meter value

*: Refer to Parts and Service News (PSN) AA07024.


<Automatic selection of adjustment item>
H For items having numbers in the "Automatic selection" column of the above table, once TUNING 1 or TUNING 2 is
selected on the ID INPUT/TUNING 1/TUNING 2 selection screen, those items can be selected automatically in the order
within the group by operating the information switch.
<Items to be adjusted after disassembly and assembly>
When HST controller assembly is replaced (Either of the following):
H Perform the following adjustment after selecting the machine model.
A. TUNING 1: [A1] [A2] [A3] [A4] [A5] [A6] [A7] and TUNING 2: [B1] [B2] [B3] and ID INPUT: [3033]
B. TUNING 1: [A1] [A2] [A3] [A4] [A5] [A6] [A7] and ID INPUT: [3003] [3005] [3004] [3006] [3024] [3033]
H When HST pump assembly or HST pump EPC valve is replaced (Either of the following)
A. ID INPUT: [3001] [3002]
B. ID INPUT: [3003] [3005] [3004] [3006]
When HST motor assembly or HST motor EPC valve is replaced: ID INPUT: [3024]

D51EX/PX-22 30-97
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
When hydraulic fan, fan motor, work equipment valve, fan EPC or work equipment pump is replaced: ID INPUT: Items
of [3033]
When PCCS lever assembly is replaced: ID INPUT: [1012] [1010] [1013] [1011] [1014]
When brake linkage is adjusted or brake potentiometer is replaced: ID INPUT [0005] [3007]

n Details of each item

H The 4-digit number in [_] is the adjustment item ID.


[0005]: Brake potentiometer neutral set (Changed in normal order: A6)
This code is used to adjust the neutral position of the brake pedal
potentiometer.
The signal output of the brake pedal potentiometer is displayed by
voltage on the lower line. (Display range: 0 5000)
Adjustment method:

i. Check that the brake pedal is in neutral (it is not pressed).

ii.
Set buzzer cancel switch in the [] position and check that the
caution buzzer sounds.
H The display of the lower line does not change after
adjustment.
H Even if this code is turned OFF, the setting is effective.
H This adjustment is performed to make the HST controller recognize the neutral position of the brake pedal
potentiometer. It is not performed to adjust the effect of the brake.

[1010] Steering lever left counter-rotation set


(Operating effort difference) (Changed in normal order: A2)
This code is used to adjust the left counter-rotation (operating effort
difference) position of the steering potentiometer of the PCCS lever.
The signal output of the steering potentiometer is displayed by voltage
on the lower line (Display range: 0 5000).
Adjustment method:

i. Set the PCCS lever in the left counter-rotation (operating


effort difference) position.

ii. Set buzzer cancel switch in the [] position and check that the
caution buzzer sounds.
H The display of the lower line does not change after
adjustment.
H Even if this code is turned OFF, the setting is effective.
H This code is not used to adjust the steering performance, etc.
H The adjustment value cannot be adjusted higher than 2,000 mV to prevent wrong setting (The caution buzzer
does not sound).

30-98 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[1011] Steering lever right counter-rotation set
(Operating effort difference) (Changed in normal order: A4)
This code is used to adjust the right counter-rotation (operating effort
difference) position of the steering potentiometer of the PCCS lever.
The signal output of the steering potentiometer is displayed by voltage
on the lower line (Display range: 0 5000).
Adjustment method:

i. Set the PCCS lever in the right counter-rotation (operating


effort difference) position.

ii. Set buzzer cancel switch in the [] position and check that the
caution buzzer sounds.
H The display of the lower line does not change after
adjustment.
H Even if this code is turned OFF, the setting is effective.
H This code is not used to adjust the steering performance, etc.
H The adjustment value cannot be adjusted lower than 3,000 mV to prevent wrong setting (The caution buzzer does
not sound).

[1012] Steering lever neutral set


(Changed in normal order: A1)
H This code is used to adjust the neutral position of the steering
potentiometer of the PCCS lever.
H The signal output of the steering potentiometer is displayed by voltage
on the lower line (Display range: 0 5000).
Adjustment method:

i. Set the PCCS lever in the neutral position.

ii. Set buzzer cancel switch in the [] position and check that the
caution buzzer sounds.
H The display of the lower line does not change after adjust-
ment.
H Even if this code is turned OFF, the setting is effective.
H This code is not used to adjust the steering performance, etc.
H The adjustment value cannot be adjusted lower than 2,000 mV or higher than 3,000 mV to prevent wrong setting
(The caution buzzer does not sound).

D51EX/PX-22 30-99
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[1013] Steering lever left max. set
(Changed in normal order: A3)
This code is used to adjust the left maximum position of the steering
potentiometer of the PCCS lever.
The signal output of the steering potentiometer is displayed by voltage
on the lower line (Display range: 0 5000).
Adjustment method:

i. Set the PCCS lever to the left steering stroke end.

ii. Set buzzer cancel switch in the [] position and check that the
caution buzzer sounds.
H The display of the lower line does not change after
adjustment.
H Even if this code is turned OFF, the setting is effective.
H This code is not used to adjust the steering performance, etc.
H The adjustment value cannot be adjusted higher than 2,000 mV to prevent wrong setting (The caution buzzer
does not sound).

[1014] Steering lever right max. set


(Changed in normal order: A5)
This code is used to adjust the right maximum position of the steering
potentiometer of the PCCS lever.
The signal output of the steering potentiometer is displayed by voltage
on the lower line (Display range: 0 5000).
Adjustment method:

i. Set the PCCS lever to the right steering stroke end.

ii. Set buzzer cancel switch in the [] position and check that the
caution buzzer sounds.
H The display of the lower line does not change after
adjustment.
H Even if this code is turned OFF, the setting is effective.
H This code is not used to adjust the steering performance, etc.
H The adjustment value cannot be adjusted lower than 3,000 mV to prevent wrong setting (The caution buzzer does
not sound).

30-100 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3001] Forward pump set
(For running track shoe idle) (Changed in normal order: B1)
This code is used to adjust the command current of the forward pump
while the track shoe is running idle.
The command current of the forward pump is displayed on the lower
line.
Adjustment method:

i. Jack up the rear frame bottom of the machine and brace the
blade in the lowering direction to float the whole track shoe
so that it can run idle.

WARNING! Since the track shoe will run idle during


adjustment, check that it is floated
securely above the ground.

ii. Run the engine at high idle.

iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.

iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.

WARNING! If adjustment starts, the pump command current increases and the track shoe starts
running automatically. (The track shoe starts running idle, then stops and starts again.
Take care.)

WARNING! The caution buzzer keeps sounding during adjustment.

WARNING! The command current of the forward pump increases to 805 mA, then the track shoe
stops.

H When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.

WARNING! When stopping (interrupting) the track shoe during adjustment, return the PCCS lever to
the neutral position. (Operations of steering with the PCCS lever, brake pedal, fuel
control dial, and decelerator pedal are not accepted during adjustment. Take care.)

v. After adjustment is finished, set the PCCS lever in the neutral


position and set the parking brake lever in the LOCK
position.
H When starting adjustment again after interrupting it, perform
the procedures from ii).
H Even if this code is turned OFF, the setting is effective.
H If adjustment is interrupted and an error is displayed, check
the following devices.
When the track shoe does not move: HST pump
When the track shoe moves: HST motor speed sensor
Display example of error
H The arrowed letters indicate the abnormal sides.
R: Right side
L: Left side
LR: Both right and left sides

D51EX/PX-22 30-101
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3002] Reverse pump set (For running track shoe idle) (Changed in normal
order: B2)
This code is used to adjust the command current of the reverse pump
while the track shoe is running idle.
The command current of the reverse pump is displayed on the lower
line.
Adjustment method:

i. Jack up the rear frame bottom of the machine and brace the
blade in the lowering direction to float the whole track shoe
so that it can run idle.

WARNING! Since the track shoe will run idle during


adjustment, check that it is floated
securely above the ground.

ii. Run the engine at high idle.

iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.

iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.

WARNING! If adjustment starts, the pump command current increases and the track shoe starts
running automatically. (The track shoe starts running idle, then stops and starts again.
Take care.)

WARNING! The caution buzzer keeps sounding during adjustment.

WARNING! The command current of the reverse pump increases to 805 mA, then the track shoe
stops.

H When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.

WARNING! When stopping (interrupting) the track shoe during adjustment, return the PCCS lever to
the neutral position. (Operations of steering with the PCCS lever, brake pedal, fuel
control dial, and decelerator pedal are not accepted during adjustment. Take care.)

v. After adjustment is finished, set the PCCS lever in the neutral


position and set the parking brake lever in the LOCK
position.
H When starting adjustment again after interrupting it, perform
the procedures from ii).
H Even if this code is turned OFF, the setting is effective.
H If adjustment is interrupted and an error is displayed, check
the following devices.
When the track shoe does not move: HST pump
When the track shoe moves: HST motor speed sensor
Display example of error
H The arrowed letters indicate the abnormal sides.
R: Right side
L: Left side
LR: Both right and left sides

30-102 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3003] Forward pump start/maximum capacity set (For travel)
This code is used to adjust the command current of the start and
maximum capacity of the forward pump while the machine is
traveling.
The command current of the forward pump is displayed on the lower
line.
Adjustment method:

i. Move the machine to a wide and flat place where it can travel
straight for at least 30 m.

WARNING! Since the machine will travel straight


forward during adjustment, work in a
place where there is not an obstacle
through length of at least 30 m.

ii. Run the engine at high idle.

iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.

iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.

WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)

WARNING! The caution buzzer keeps sounding during adjustment.

WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.

H When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.

WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.

H When moving the machine after interrupting adjustment,


operate it as usually. The travel speed at the time of
interruption is kept, however.

v. After adjustment is finished, set the PCCS lever in the neutral


position and set the parking brake lever in the LOCK
position.
H When starting adjustment again after interrupting it, perform
the procedures from i).
H Even if this code is turned OFF, the setting is effective.
H If adjustment is interrupted and an error is displayed, adjust
the following parts.
When machine does not move: HST pump
When machine moves: HST motor speed sensor
Display example of error
H The arrowed letters indicate the abnormal sides.
R: Right side
L: Left side
LR: Both right and left sides

D51EX/PX-22 30-103
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
[3004] Reverse pump start/maximum capacity set (For travel)
This code is used to adjust the command current of the start and
maximum capacity of the forward pump while the machine is
traveling.
The command current of the forward pump is displayed on the lower
line.
Adjustment method:

i. Move the machine to a wide and flat place where it can travel
straight for at least 30 m.

WARNING! Since the machine will travel straight


forward during adjustment, work in a
place where there is not an obstacle
through length of at least 30 m.

ii. Run the engine at high idle.

iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.

iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.

WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)

WARNING! The caution buzzer keeps sounding during adjustment.

WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.

H When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.

WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.

H When moving the machine after interrupting adjustment,


operate it as usually. The travel speed at the time of
interruption is kept, however.

v. After adjustment is finished, set the PCCS lever in the neutral


position and set the parking brake lever in the LOCK
position.
H When starting adjustment again after interrupting it, perform
the procedures from i).
H Even if this code is turned OFF, the setting is effective.
H If adjustment is interrupted and an error is displayed, adjust
the following parts.
When machine does not move: HST pump
When machine moves: HST motor speed sensor
Display example of error
H The arrowed letters indicate the abnormal sides.
R: Right side
L: Left side
LR: Both right and left sides

30-104 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
[3005] Forward pump medium capacity set (For travel)
This code is used to adjust the command current of the medium
capacity of the forward pump while the machine is traveling.
The command current of the forward pump is displayed on the lower
line.
Adjustment method:

i. Move the machine to a wide and flat place where it can travel
straight for at least 15 m.

WARNING! Since the machine will travel straight


forward during adjustment, work in a
place where there is not an obstacle
through length of at least 15 m.

ii. Run the engine at high idle.

iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.

iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.

WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)

WARNING! The caution buzzer keeps sounding during adjustment.

WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.

H When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.

WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.

H When moving the machine after interrupting adjustment, operate it as usually. The travel speed at the time of
interruption is kept, however.

v.After adjustment is finished, set the PCCS lever in the neutral position and set the parking brake lever in the
LOCK position.
H When starting adjustment again after interrupting it, perform the procedures from i).
H Even if this code is turned OFF, the setting is effective.

D51EX/PX-22 30-105
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3006] Reverse pump medium capacity set (For travel)
This code is used to adjust the command current of the medium
capacity of the forward pump while the machine is traveling.
The command current of the forward pump is displayed on the lower
line.
Adjustment method:

i. Move the machine to a wide and flat place where it can travel
straight for at least 15 m.

WARNING! Since the machine will travel straight


forward during adjustment, work in a
place where there is not an obstacle
through length of at least 15 m.

ii. Run the engine at high idle.

iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.

iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.

WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)

WARNING! The caution buzzer keeps sounding during adjustment.

WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.

H When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.

WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.

H When moving the machine after interrupting adjustment, operate it as usually. The travel speed at the time of
interruption is kept, however.

v.After adjustment is finished, set the PCCS lever in the neutral position and set the parking brake lever in the
LOCK position.
H When starting adjustment again after interrupting it, perform the procedures from i).
H Even if this code is turned OFF, the setting is effective.

30-106 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3007] Brake potentiometer maximum set (Changed in normal order: A7)
This code is used to adjust the maximum position of the brake pedal
potentiometer.
The signal output of the brake pedal potentiometer is displayed by
voltage on the lower line.
(Display range: 0 5000)
Adjustment method:

i. Press and hold the brake pedal at the stroke end.

ii.
Set buzzer cancel switch in the [] position and check that the
caution buzzer sounds.
H The display of the lower line does not change after
adjustment.
H Even if this code is turned OFF, the setting is effective.
H This code is used to make the HST controller recognize the maximum position of the brake pedal potentiometer.
It is not used to adjust the brake performance.

D51EX/PX-22 30-107
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3016] Stall pressure test mode
This code is used to test the engine speed, HST oil temperature
(hydraulic oil temperature), and right and left HST main circuit
pressures while the HST is stalled.
The engine speed, HST oil temperature, right HST main circuit
pressure, or left HST main circuit pressure is displayed on the lower
line.
How to use:

WARNING! Check that the HST oil temperature


(hydraulic oil temperature) is in the range
from 40 to 60C while the HST is stalled.
(Do not stall the HST while the oil
temperature is out of the specified range.)

WARNING! Before selecting this code, check that the parking brake lever is in the LOCK position and
the PCCS lever is in the neutral position.

H If this code is selected, the HST is stalled automatically. (The HST is stalled only when the PCCS lever is set in the
FORWARD or REVERSE position, however.)
Travel speed: 3rd (Min. delivery of HST motor)
Parking brake solenoid valve: OFF
Slow brake solenoid valve: OFF

WARNING! The following errors are set in this code for safety. If one of them is turned ON, the
command current to the HST pump EPC valve is stopped.
No. 1: When the machine is set in this mode, it is moving.
No. 2: The parking brake lever is not in the LOCK position.
No. 3: After the machine is set in this mode, it is moving.
No. 4: The parking brake release pressure is increased.
No. 0: The above errors are reset.

i. While the engine is running, select an item to be displayed by operating information switch (5).
[>]: Next code
[<]: Previous code
H The following items can be displayed.
No. Display Item Unit
1 ENG-REV Engine speed rpm
2 HST TEMP HST oil temperature C
3 R PRESS Right HST main circuit pressure MPa
4 L PRESS Left HST main circuit pressure MPa

ii. Check that the parking brake lever is in the LOCK position.
H Stall the HST while the parking brake lever is in the LOCK position.

iii. Set the PCCS lever in the FORWARD or REVERSE position to stall the HST and test the necessary items.
If the PCCS lever is set in the FORWARD or REVERSE position, the HST stalls. If the PCCS lever is
returned, stalling of the HST stops.
The displayed item can be changed even while the HST is stalled.

WARNING! While the HST is stalled, the oil temperature rises sharply and locally. Accordingly, do not
stall the HST continuously for more than 30 seconds. Accordingly, the following restric-
tion function is installed.

30-108 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
H If stalling of the HST starts, the gauge displays gear speed, set travel speed and the shift indicator section
cycles one cell at a time. If stalling is stopped, the gauges are lit one cell at a time.
If all the gauges are out, stalling of the HST is stopped automatically. When you start the stalling again,
return the PCCS lever to the neutral position once. Then start the stalling again.

[3019] Gear speed limit mode


This code is used to prevent shifting the gear to the 3rd position.
The usable gear speeds are displayed on the lower line.
Using method:

i. Select use of the highest gear speed by operating shift-up


switch.
[3RD]: Permit use of 3rd gear speed.
[2ND]: Limit use of 3rd gear speed.

ii.
Set the buzzer cancel switch in the [] position to enter the
setting.
H If the gear speed is limited, it is not shifted to the 3rd
position, even if the shift-up switch is operated.
H The setting becomes effective when the starting switch is turned OFF and ON.
H The setting is effective in both quick shift mode and variable shift mode.

D51EX/PX-22 30-109
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3024] Motor set (For running track shoe idle) (Changed in normal order:
B3)
This code is used to adjust the command current of the motor while
the track shoe is running idle.
The command current of the motor is displayed on the lower line.
Adjustment method:

i. Jack up the rear frame bottom of the machine and brace the
blade in the lowering direction to float the whole track shoe
so that it can run idle.

WARNING! Since the track shoe will run idle during


adjustment, check that it is floated
securely above the ground.

ii. Run the engine at high idle.

iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.

iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.

WARNING! If adjustment starts, the motor command current increases and the track shoe starts
running automatically. Take care.

WARNING! The caution buzzer keeps sounding during adjustment.

WARNING! The motor command current changes from 248 mA 448 mA 605 mA .... and the
track shoe stops finally.

H If adjustment stops automatically and an error is displayed, check the following items.
When track shoe does not move: HST pump
When track shoe moves:
1) HST motor speed sensor
2) Hose between motor EPC of 5-spool valve and motor
3) Connector between motor EPC of 5-spool valve and wiring harness
4) Is hydraulic oil temperature abnormally low?
Display example of error
H The arrowed letters indicate the abnormal sides.
R: Right side
L: Left side
LR: Both right and left sides

30-110 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3032] Fan test mode selection
This code is used to select the normal control mode, fan 100% mode
or fan 70% mode.
The mode to be selected is displayed on the lower line.
How to select

i. Start the engine, set the fuel control dial to the high idle
position, and set the decelerator pedal in neutral (release it).

ii. Operate the information switch to select a mode.

iii. Set buzzer cancel switch in the [] position to settle the


setting.
The following modes can be selected.
Order Display Item
1 OFF Normal control mode
2 100% Fan 100% operation mode
3 70% Fan 70% operation mode

Use this code while the engine coolant temperature is above 65C and the HST oil temperature is above 55C.
Even if this code is turned OFF, the setting is effective as long as the starting switch is in the ON position.
Accordingly, set the fan in the normal control mode before turning this code OFF.

[3033] Fan set


This code is used to adjust the fan command current while the fan is
running.
The fan command current is displayed on the lower line.
Adjustment method

WARNING! Before selecting this code, adjust the HST


oil temperature (hydraulic oil temperature)
to 50 60C.

WARNING! Keep the work equipment lowered to the


ground and set the work equipment lock
lever in the LOCK position during this
adjustment.

i. Start the engine, set the fuel control dial in the high idle position, and set the decelerator pedal in neutral (release
it).

ii. Set the buzzer cancel switch in the [] position, and adjustment starts.

iii. The fan command current changes from 800 mA to 300 mA and adjustment is finished.
H When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.

D51EX/PX-22 30-111
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3035] Forward pump start adjustment value change (For right and left
separately)
This code is used to adjust the forward pump command value finely
when the right and left track shoes do not start forward simultaneously
(the machine swings in either direction) after performing adjustments
of [B1], or [3003] and [3005].
The correction value of the right or left side to be adjusted is displayed
on the lower line.
Adjustment method

i. Operate the information switch to select the side which starts


earlier (RIGHT/LEFT).
Press the [>] or [<] button to select [RIGHT] or [LEFT].

ii. Set the buzzer cancel switch in the [] position to settle the selected correction direction.
If the selection is settled, [AD:***] is added next to [RIGHT/LEFT] on the lower line.
Once adjustment is completed, it cannot be returned. Accordingly, be sure to record the value on the right side of
[DA:***] before starting iii).

iii. Operate the information switch to decrease the value by 1. (Decrease the value by 1)
[>]: Increase value (Start earlier)
[<]: Decrease value (Start later)

WARNING! If the value is increased, the machine starts sharply. Take care.

WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.

iv. Check that the right and left track shoes start forward simultaneously.

v. Repeat steps iii) and iv) until the right and left track shoes start simultaneously.

vi. Set the buzzer cancel switch in the [] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
H Even if this code is turned OFF, the setting is effective.

30-112 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3036] Reverse pump start adjustment value change (For right and left
separately)
This code is used to adjust the reverse pump command value finely
when the right and left track shoes do not start reverse simultaneously
(the machine swings in either direction) after performing adjustments
of [B2], or [3004] and [3006].
The correction value of the right or left side to be adjusted is displayed
on the lower line.
Adjustment method

i. Operate the information switch to select the side which starts


earlier (RIGHT/LEFT).
Press the [>] or [<] button to select [RIGHT] or [LEFT].

ii.
Set the buzzer cancel switch in the [] position to settle the selected side.
If the selection is settled, [AD:***] is added next to [RIGHT/LEFT] on the lower line.
H Once adjustment is completed, it cannot be returned. Accordingly, be sure to record the value on the right side of
[DA:***] before starting iii).

iii. Operate the information switch to decrease the value by 1.


[>]: Increase value (Start earlier)
[<]: Decrease value (Start later)

WARNING! If the value is changed largely, the track shoe starts sharply. Take care.

WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.

iv. Check that the right and left track shoes start reverse simultaneously.

v. Repeat steps iii) and iv) until the right and left track shoes start simultaneously.

vi. Set the buzzer cancel switch in the [] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
H Even if this code is turned OFF, the setting is effective.

D51EX/PX-22 30-113
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3037] Forward pump start adjustment value change (For right and left
simultaneously)
This code is used to adjust the forward pump command value finely
when remarkably large shocks are made at the starting and stopping
moments of forward travel after performing adjustments of [B1], or
[3003] and [3005].
The travel speed and correction value are displayed on the lower line.
Adjustment method

WARNING! Once adjustment is completed, it cannot


be returned. Accordingly, be sure to
record the value on the right side of
[DA:****] before starting adjustment.

i. Operate the information switch to decrease the value by 1.


[>]: Increase value (Start earlier)
[<]: Decrease value (Start later)

WARNING! If the value is changed largely, the track shoe starts sharply. Take care.

WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.

ii. Check that shocks are not made at the moments when the machine starts and stops forward travel.

iii. Repeat i) and ii) until shocks are not made.

iv. Select the variable gear shift mode, set the gear speed display to the minimum (2 gauge segments), drive the
machine, and check that the travel speed is "0.6 km/h" or higher (the value on the right of [SPD:1] on the lower
line, is 600 or higher).
If the travel speed is below "0.6 km/h", time lag in start and other negative effects are made. Accordingly, return
the adjusted value until the travel speed lowers below "0.6 km/h".

v. Set the buzzer cancel switch in the [] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
H Even if this code is turned OFF, the setting is effective.
H This code is not used to adjust the starting acceleration performance but used to adjust the shocks made at the
moments when the machine starts and stops.
[_-_] Service meter set: Refer to Parts and Service News (PSN) AA07024.

30-114 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3038] Reverse pump start adjustment value change (For right and left
simultaneously)
This code is used to adjust the forward pump command value finely
when remarkably large shocks are made at the starting and stopping
moments of forward travel after performing adjustments of [B2], or
[3004] and [3006].
The travel speed and correction value are displayed on the lower line.
Adjustment method

WARNING! Once adjustment is completed, it cannot


be returned. Accordingly, be sure to
record the value on the right side of
[DA:****] before starting adjustment.

i. Operate the information switch to decrease the value by 1.


[>]: Increase value (Start earlier)
[<]: Decrease value (Start later)

WARNING! If the value is changed largely, the track shoe starts sharply. Take care.

WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.

ii. Check that shocks are not made at the moments when the machine starts and stops forward travel.

iii. Repeat i) and ii) until shocks are not made.

iv. Select the variable gear shift mode, set the gear speed display to the minimum (2 gauge segments), drive the
machine, and check that the travel speed is "0.6 km/h" or higher (the value on the right of [SPD:1] on the lower
line, is 600 or higher).
If the travel speed is below "0.6 km/h", time lag in start and other negative effects are made. Accordingly, return
the adjusted value until the travel speed lowers below "0.6 km/h".

v. Set the buzzer cancel switch in the [] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
H Even if this code is turned OFF, the setting is effective.
H This code is not used to adjust the starting acceleration performance but used to adjust the shocks made at the
moments when the machine starts and stops.
[_-_] Service meter set: Refer to Parts and Service News (PSN) AA07024.

D51EX/PX-22 30-115
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[12] Maintenance interval change mode (MAINTENANCE
MONITOR)
Monitor panel can set the maintenance intervals for various filters and
oil which become the base of replacement time display for filter and
oil. Also the monitor panel can activate or deactivate the display
function.

1. Selection of the service menu.


Select the filter and oil replacement time setting function
(MAINTENANCE MONITOR) in the service menu selection screen.

2. Displaying and selecting the maintenance item and function


A. With the service menu selected, press the [] switch to display the
maintenance item and function selection screen.
[]: Conduct the service menu.
B. If [>] switch or [<] switch is pushed while the maintenance item
and function selection screen is displayed, the maintenance item
and function will be displayed endlessly in the order shown by the
below table. Select the item or the function which will be used.
[>]: To proceed to next maintenance item and function.
[<]: To return to the previous maintenance item and function.
H Displayed maintenance item and function:
Maintenance items
Code Display
and functions
01 01: ENG OIL Engine oil
02 02: ENG FILT Engine oil filter
03 03: FUEL FILT Fuel main filter
41 41: FUEL P FILT Fuel pre-filter
04 04: HYD FILT Hydraulic oil filter
06 06: CORR RES Corrosion resistor (*)
18 18: BYPS FILT Bypass filter (*)
07 07: DAMP OIL Damper filter (*)
08 08: FNL OIL Final drive oil
10 10: HYD OIL Hydraulic oil
19 19: POWL OIL Power train oil (*)
20 20: POWL FILT Power train oil filter (*)
21 21: HST FILT HST charge filter
INITIALIZE Setting default value for all items
Setting validity or invalidity for all
ALL ITEMS
items

* Unused on D51.
H The maintenance items which have their respective codes
are changed separately and the functions which have no
codes are used to change all the items simultaneously.
H The item and function is displayed in the [*] section.

30-116 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
3. Display contents of the maintenance item (Items with code No.)
If the maintenance item for filter or oil is selected, the following
contents are displayed.
1: Code (2 digits)
A: Filter and oil replacement time set item
2: Remaining time to set replacement time
3: Number of times of replacement up to present

4. Changing the interval time by maintenance item (Items with code No.)
A. With the item to change the interval time (ex: P FUEL FILT)
selected on the maintenance item and the function selection
screen, press the [] switch to display the interval change screen.
[]: Execute the function to change maintenance item.
H The current set interval is displayed on the screen.
H With this screen displayed, if the [>] switch or the [<] switch is
operated, the screen switches to the setting screen for enable or
disable the maintenance item.
B. On the interval change screen, operate the switches [>], [<], []
and [n] to input the interval time.
[>]: Number at the cursor increases.
[<]: Number at the cursor decreases.
[]: Number at the cursor is determined.
[n]:To return to the service menu selection screen.
H The time must always be input with 4 digits. For the time
with less than 4 digits, input 0s in place of the vacant number.
C. When the interval time is completely determined, the screen to
confirm the changes is displayed. Then, operate the switches [<],
[>] and [].
[<]: Select YES (move cursor)
[>]: Select NO (move cursor)
[]: Execute YES or NO

5. Set the function activation or deactivation by maintenance item (items


with code No.).
A. With the item (ex: 41: FUEL P FILT) to change the enable or
disable of the function selected on the maintenance item and
function selection screen, press the [] switch to display the
interval input screen.
[]: Execute the function to change maintenance item.

D51EX/PX-22 30-117
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
B. After the screen to input intervals is displayed, press the [>]
switch or the [<] switch to display the activation or deactivation
setting screen.
[>]: Switch the setting screen.
[<]: Switch the setting screen
H If the function is activated, it is displayed like the upper line.
And if it is deactivated, it is displayed like the lower line.
C. After the activate or deactivate setting screen is displayed, check
the present setting status and the contents of change. Then operate
the switches [] or [n].
[]: Switch to the change confirmation screen
[n]:To return to the maintenance item and function selection
screen.
[<]: Switch to the interval change screen.
D. When the change confirmation screen is displayed, operate each
[<], [>] and [] switches.
[<]: Select YES (move cursor)
[>]: Select NO (move cursor)
[]: Execute YES or NO
H If the timer which has been OFF is turned ON, the interval is
set to the value before it was turned OFF and the rest of set
time of the timer is reset. The number of resetting times is set
to the value before it was turned OFF.

6. Setting default values of interval time for all items (INITIALIZE)


A. With all item default value setting (INITIALIZE) selected on the
maintenance item and function selection screen, press the []
switch to display the all item default value setting screen.
[]: Execute the function to set the default values of all the
items.

B. After the all item default value setting screen is displayed operate
[<], [>] and [] switches.
[<]: Select YES (move cursor)
[>]: Select NO (move cursor)
[]: Execute YES or NO
H All the items are set to their respective default values,
regardless of the ON or OFF state of each item.
H The rest of the set time of the timer is set to the [default
value/elapsed time after the previous replacement].
H The number of resetting times is kept at the value before the
default was set.
H Each item is set turned ON.

30-118 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
7. Setting the function activation or deactivation for all the items (ALL
ITEMS).
A. With the activation or deactivation setting for all items selected
(ALL ITEMS) on the maintenance item and function selection
screen, press the [] switch to display the all items activation or
deactivation setting screen.
[]: Implement the function to set activation or deactivation
of all the items.
B. After the all items activation or deactivation setting screen is
displayed, press the [>] switch or the [<] switch to display the
activation setting or deactivation setting screen.
[>]: Switch the setting screen.
[<]: Switch the setting screen
H To deactivate all the items, display the upper line setting screen (OFF), and to activate all the items, display the
lower line setting screen (ON).
C. Confirm the setting screen, press the [] switch or the [n] switch
to display the change confirmation screen.
[]: To switch to the change confirmation screen.
[n]:To return to the maintenance item and function selection
screen.
H If deactivation of all the items (OFF) is set, it will stop the
maintenance function of all the items, regardless of the
setting of each maintenance item.
H If activation of all the items (ON) is set, the maintenance
function of all the items starts to work regardless of the
setting of each maintenance item and the interval is set to the
previous time before the interval has been deactivated.
H The timer is reset simultaneously and it restarts to count from
0 h.
The number of resetting times is set to the value before it was turned OFF.
D. When the change confirmation screen is displayed, operate each
[<], [>] and [] switches.
[<]: Select YES (move cursor)
[>]: Select NO (move cursor)
[]: Execute YES or NO

D51EX/PX-22 30-119
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12

Table of filter and oil replacement time set items


Replacement frequency
Order System and function Code Display Remarks
(Default value)
1 Engine oil 01 ENG OIL 0500h
2 Engine oil filter 02 ENG FILT 0500h
3 Fuel main filter 03 FUEL FILT 1000h
4 Fuel pre filter 41 FUEL P FILT 0500h
5 Hydraulic oil filter 04 HYD FILT 2000h
6 Corrosion resistor 06 CORR RES Unused
7 Bypass filter 18 BYPS FILT Unused
8 Damper filter 07 DAMP OIL Unused
9 Final drive oil 08 FNL OIL 1000h
10 Hydraulic oil 10 HYD OIL 2000h
11 Power train oil 19 POWL OIL Unused
12 Power train oil filter 20 POWL FILT Unused
13 HST charge filter 21 HST FILT 2000h
All item simultaneous
14 Setting default value for all items (None) INITIALIZE
setting function
All item simultaneous
15 Setting enable or disable for all items (None) ALL ITEMS
setting function

30-120 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[13] Telephone number input function (TEL)
The phone No. set in the monitor panel can be input, corrected or reset
with switches.
When action code "E03" or "E04" is displayed, the phone No. is
displayed together with "CALL".

A. Press buzzer cancel switch [] on the above screen to display the


phone No. input screen.
Once the phone No. is input, it is displayed after next time.
Up to 12 digits can be input as the phone No. Input them in
order from the left most one.
B. The cursor is displayed on the position to input the next digit.
Select the next digit with information switches [>] and [<]. To
leave a position blank, select "*".
C. After inputting the digit, press the [] switch to move the cursor to
the next position.
Repeat steps B and C until the right most digit is input.
To change an input digit, press the [n] switch, and the screen
returns to the previous screen.
D. To finish the inputting operation, press the [n] switch twice.
The inputting operation can be also finished by turning the starting switch OFF.

D51EX/PX-22 30-121
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[14] Model selection mode (MACHINE).
This mode is used to make the monitor panel and HST controller recognize a machine model.

WARNING! If an input is settled carelessly in this mode, the memory in the controller is initialized.
Accordingly, use this mode only when it is necessary.

H If a machine model different from the one which the HST controller has recognized is settled, perform all the
initialization work again.

WARNING! If the actual machine model is different from that set in the controller, the machine may
move unexpectedly or an error may be made. Accordingly, be sure to set the correct
machine model in the controller.

H The machine model currently recognized by the monitor panel and HST controller can be checked in the real-time
monitoring mode.
Controller: MONITOR PANEL
Code: 00204 MACHINE CODE
Controller: HST
Code: 00205 MACHINE CODE

1. Selecting and setting of model


A. To enter the machine model selection mode, hold down the [] switch (for 3 seconds).
B. When pressing the [>] switch or [<] switch in the model selection setting screen, the model which can be set is
displayed endlessly in the order shown in the below table, so select the applied model.
[>] switch:To proceed to next model
[<] switch:To return to previous model
H Displayed model:

Display Model
D51 D51 (Default)
D39 D39
D37 D37
D31 D31

C. After selecting the model in the model selecting screen, determine


the model by pressing the [] switch.
[]: Determine the setting.
[n]: To cancel the setting
H The below figure shows the example that D51 has been
selected.

30-122 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
2. Storing data in controller
A. After determining the model selection setting, check that the
display automatically returned to the service menu screen and the
selected model is surely displayed.
B. Turn the starting switch OFF and keep that condition for longer
than 15 seconds.
H Unless the starting switch is turned off for longer than 15
seconds, the new data is not memorized in the controller.
C. Turn the starting switch ON again.
H After this operation, the model setting becomes effective.

[15] Optional selection mode (OPTIONAL SELECT)


H Do not use this mode.

[16] Initializing mode (INITIALIZE)


H This mode is exclusive for the plant, and is not used for field
service.

D51EX/PX-22 30-123
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRI-
CAL SYSTEM
H When carrying out troubleshooting for an electric circuit related to the
monitor panel and HST controller, expose the related connectors
according to the following procedure.

1. Monitor panel
A. Pull out the starting key (1), remove the 4 mounting bolts (3) of
each side of plastic panel (2), and move plastic panel (2) toward
the operator's seat.
B. Remove the 7 connectors of panel switches (4) and remove the
plastic panel (2).
C. Remove 7 panel switches (4) from the plastic panel (2) and insert
them in their respective connectors correctly.
D. Remove 6 mounting bolts (6) of monitor panel mounting bracket
(5) and move the bracket toward the operator's seat.
E. Remove connectors CN-P1, CN-P2 and CN-P3 and remove the
monitor panel mounting bracket (5).

F. Insert the diagnostic T-adapters in connectors CN-S04 and


CN-S03 of monitor panel (7).
G. Insert connectors CN-P1, CN-P2 and CN-P3 and install the
monitor panel mounting bracket (5) with the mounting bolts (6)
temporarily.

30-124 D51EX/PX-22
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
2. HST controller
A. Perform steps A C for the "monitor panel".
B. Insert or connect the diagnostic T-adapters in connectors CN-ST1,
CN-ST2 and CN-ST3 of HST controller (1).
H If it is difficult to remove and install the connectors, remove
the controller for the ease of work.
H Since each connector is fixed with a screw, loosen the screw
before disconnecting it.
H When returning each connector, tighten its screw to the
specified torque to fix it.

Screw: 2.82 Nm {0.288 kgm}

D51EX/PX-22 30-125
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
12
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED

ITEMS TO BE ADJUSTED
H If any of the following electrical/hydraulic devices are adjusted or replaced, perform the following system adjustment.

WARNING! If the system is not adjusted, the machine may not operate normally but may move
unexpectedly. Accordingly, be sure to adjust system.

System adjustment
Device
Tuning item Mode ID No. Display Reference

HST controller See page 30-130

Monitor panel See page 30-132

HST pump Forward HST pump set 3001 F-PUMP LINE page 30-103
TUNING 2
HST pump EPC Reverse HST pump set 3002 R-PUMP LINE page 30-104

HST motor HST motor set TUNING 2 3024 MOTOR LINE page 30-112
5-spool valve
HST motor EPC

Travel lever Steering lever neutral set 1012 S/T N-SET page 30-101
Steering lever left pivot turn 1010 S/T H. L-SET page 30-100
Steering lever left max. set TUNING 1 1013 S/T M.L-SET page 30-102
Steering lever right pivot turn set 1011 S/T H. R-SET page 30-101
Steering laver right max. set 1014 S/T M.R-SET page 30-102

Brake pedal Brake potentiometer neutral set 0005 BRAKE N-SET page 30-100
TUNING 1
Brake potentiometer Brake potentiometer max. set 3007 BRAKE END page 30-107

Fan Fan set ID INPUT 3033 FAN AMP SET page 30-113
Fan motor
Fan EPC
Work equipment valve
Work equipment pump

H For system adjustment, use "Tuning mode" in the service mode of monitor panel (EMMS) special function.
For usage of monitor panel (EMMS) special function , see page 30-65.
For usage of service mode, see page 30-79
For usage of tuning mode, see page 30-95.
For usage of each tuning item, see the corresponding ID number.

30-126 D51EX/PX-22
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
H For system adjustment, use "Model selection mode", "Tuning mode" or "Electrical system failure history display mode" in
the service mode of "Monitor panel (EMMS) special function".
For usage of monitor panel (EMMS) special function , see page 30-65.
For usage of selection mode, see page 30-124
For usage of tuning mode, see page 30-95.
For usage of each tuning item, see the corresponding ID number.
For usage of electrical system failure history display mode, see page 30-81

HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT


H When the machine is assembled or the HST controller is replaced,
adjust the system according to the following procedure.

WARNING! If the system is not adjusted, the machine


may not operate normally but may move
unexpectedly. Accordingly, be sure to
adjust the system.

H Precautions for replacing HST controller:


When replacing the HST controller, stop the machine on a safe place
and turn the starting switch OFF.
H For time till next maintenance, check with using "OIL/filler mainte-
nance mode" in the "Operator mode" of "Monitor panel (EMMS) spe-
cial function".
For usage of monitor panel (EMMS) special function , see page
30-65.
For usage of operator mode, see page 30-69
For usage of oil/filter maintenance mode, see page 30-77.
H For telephone number, check with using "Telephone number input mode" in the "Service mode" of the monitor panel
(EMMS) special function".
For usage of monitor panel (EMMS) special function, see page 30-65.
For usage of service mode, see page 30-79.
For usage of telephone number input mode, see page 30-123.
H For system adjustment, use "Model selection mode", "Tuning mode" or "Electrical system failure history display mode" in
the service mode of "Monitor panel (EMMS) special function".
For usage of monitor panel (EMMS) special function , see page 30-65.
For usage of selection mode, see page 30-124
For usage of tuning mode, see page 30-95.
For usage of each tuning item, see the corresponding ID number.
For usage of electrical system failure history display mode, see page 30-81

D51EX/PX-22 30-127
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
12
1. Selecting machine model.
A. Turn the starting switch ON, set the monitor panel in "Machine
model selection mode" in the service mode, and select the
machine model.
B. Turn the starting switch OFF.

2. Adjusting steering lever and brake potentiometer.


A. Turn the starting switch ON again and set the monitor panel in
"Tuning mode" in the service mode.
B. Select "TUNING1" and initialize the steering lever and brake
potentiometer.
(1012, 1010, 1013, 1011, 1014, 0005, 3007)

C. Turn the starting switch OFF.

3. Adjusting HST pump and HST motor.

A. Jack up the rear part of the machine frame and brace the blade
against the ground to float all the track shoes above the ground so
that the tracks can be rotated with no load.

WARNING! Since the tracks are rotated with no load


during adjustment, check that the tracks
are floated above the ground.

B. Run the engine at high idle.


C. Set the monitor panel in "Tuning mode" in the service mode,
select "TUNING2", and initialize the HST pump and HST motor.
(3001, 3002, 3024)
D. Turn the starting switch OFF.

30-128 D51EX/PX-22
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
4. Initializing fan.
A. Adjust the HST oil temperature (hydraulic oil temperature) to 50
60 C.
B. Run the engine at high idle.
C. Set the monitor panel in "Tuning mode" in the service mode,
select "ID INPUT", select fan initialization (3033), and adjust the
fan.
D. Turn the starting switch OFF.

5. Checking error code.


A. Turn the starting switch ON again and set the monitor panel in
"Electrical system failure history display mode" in the service
mode.
B. Check to see if there is any error code being indicated. If there is not any, delete all the recorded error codes.
H If there is any error code being indicated, remove the cause of the failure by troubleshooting and then perform
steps A and B.

D51EX/PX-22 30-129
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
12
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT
H When the monitor panel is replaced, adjust the system according to the following procedure.

WARNING! If the system is not adjusted, the machine


may not operate normally but may move
unexpectedly. Accordingly, be sure to
adjust the system.

H Precautions before replacement of monitor panel:


If the monitor panel is replaced, the saved values of the service meter, oil and filter maintenance mode and phone No. are
reset. Accordingly, check and record the service meter reading, time before maintenance and phone No. before replacing
the monitor panel.
H For time till next maintenance, check with using "OIL/filler maintenance mode" in the "Operator mode" of "Monitor
panel (EMMS) special function".
For usage of monitor panel (EMMS) special function , see page 30-65.
For usage of operator mode, see page 30-69
For usage of oil/filter maintenance mode, see page 30-77.
H For telephone number, check with using "Telephone number input mode" in the "Service mode" of the monitor panel
(EMMS) special function".
For usage of monitor panel (EMMS) special function, see page 30-65.
For usage of service mode, see page 30-79.
For usage of telephone number input mode, see page 30-123.
H For system adjustment, use "Model selection mode", "Tuning mode" or "Electrical system failure history display mode" in
the service mode of "Monitor panel (EMMS) special function".
For usage of monitor panel (EMMS) special function , see page 30-65.
For usage of selection mode, see page 30-124
For usage of tuning mode, see page 30-95.
For usage of each tuning item, see the corresponding ID number.
For usage of electrical system failure history display mode, see page 30-81
H Precautions for replacing monitor panel:
When replacing the monitor panel, stop the machine on a safe place and turn the starting switch OFF.

1. Selecting machine model.


A. Turn the starting switch ON, set the monitor panel in "Machine
model selection mode" in the service mode, and select the
machine model.
B. Turn the starting switch OFF.

2. Setting service meter.


Referring to "Parts and Service News", set the service meter if
required.

30-130 D51EX/PX-22
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
3. Setting phone No.
Set the monitor panel in "Telephone number input mode" in the
service mode and set the phone No.

4. Checking error code.


A. Set the monitor panel in "Electrical system failure history display
mode" in the service mode.
B. Check to see if there is any error code being indicated. If there is
not any, delete all the recorded error codes.
H If there is any error code being indicated, remove the cause of the fail-
ure by troubleshooting and then perform steps A and B.
H Precautions after replacement of monitor panel:
If the monitor panel is replaced, the service meter for the oil and filter
maintenance function restarts from 0. As a result, the replacement time shown on the monitor panel may be different from
the actual operating time. Accordingly, apply the time before the maintenance recorded before the replacement until the
first maintenance after the replacement.

D51EX/PX-22 30-131
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC

PM-CLINIC SERVICE

30-132 D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
Pm-clinic measuring points for D51EX/PX-22 (1/2)

Reference pages for measurement procedure designated


*1. Engine speed: Testing and adjusting, page 30-6.
*2. Blow-by pressure: Testing and adjusting, page 30-16.
*3. Engine oil pressure: Testing and adjusting, page 30-17.
*4. Boost pressure: Testing and adjusting, page 30-7.
*5. Exhaust temperature: Testing and adjusting, page 30-8.

D51EX/PX-22 30-133
TESTING AND ADJUSTING PM-CLINIC
12
Pm-clinic measuring points for D51EX/PX-22 (2/2)

Reference pages for measurement procedure designated


*6. HST charge circuit pressure: Testing and adjusting HST oil pressure, page 30-33.
*7. Solenoid valve output pressure: Measuring HST solenoid valve output pressure, page 30-38.
*8. Fan speed: Measuring fan speed and fan (work equipment) pump pressure, page 30-28.
*9. Work equipment pump relief pressure: Testing and adjusting work equipment oil pressure, page 30-53
*10.Work equipment PPC valve output pressure: Measuring work equipment PPC valve output pressure, page 30-55

30-134 D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC INSPECTION SHEET (1/2)

D51EX/PX-22 30-135
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC INSPECTION SHEET (2/2)

30-136 D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC UNDERCARRIAGE CHECK SHEET

D51EX/PX-22 30-137
TESTING AND ADJUSTING PM-CLINIC
12
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)

30-138 D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)

D51EX/PX-22 30-139
TESTING AND ADJUSTING PM-CLINIC

30-140 D51EX/PX-22
40 TROUBLESHOOTING (GENERAL)

POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 40-102


SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . 40-105
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT . . . . . . . . . . . . 40-105
HANDLING ELECTRONIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110
POINTS TO REMEMBER WHEN TROUBLESHOOTING
ELECTRICAL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-111
ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
CLASSIFICATION BY THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
CLASSIFICATION BY COLOR AND CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
HOW TO READ ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-113
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . 40-115
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-117
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS . . . . 40-118
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS . . . . . . . . . . . . . . 40-119
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . 40-122
T-ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146
MODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150

D51EX/PX-22 40-101
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING! Stop the machine in a level place, and check to be sure the blocks, and parking brake are
in place.

WARNING! When carrying out operation with two or more workers, strictly agreed to a set of
signals to use, and do not allow any unauthorized person to come near during repairs.

WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, wait for the engine to cool down before starting any troubleshooting.

WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.

WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the error, to carry out repairs swiftly, and to prevent reoccurrence
of the error.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However,
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the
error that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a error occurs:
Parts that have no connection with the error or other unnecessary parts will be disassembled.
It will become impossible to find the cause of the error.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.

2. Points to ask the user or operator.

A. Have any other problems occurred apart from the problem that has been reported?

B. Was there anything strange about the machine before the error occurred?

C. Did the error occur suddenly, or were there problems with the machine condition before this?

D. Under what conditions did the error occur?

E. Had any repairs been carried out before the error? When were these repairs carried out?

F. Has the same kind of error occurred before?

40-102 D51EX/PX-22
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
3. Check before troubleshooting.

A. Check the oil level.

B. Check for any external leakage of oil from the piping or hydraulic equipment.

C. Check the travel of the control levers.

D. Check the stroke of the control valve spool.

E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.

4. Confirming the error.

A. Confirm the extent of the error yourself, and judge whether to handle it as a real error or as a problem with the
method of operation, etc.
H When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.

5. Troubleshooting

A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the error, then use the
troubleshooting flowchart to locate the position of the error exactly.

B. The basic procedure for troubleshooting is as follows.

i. Start from the simple points.

ii. Start from the most likely points.

iii. Investigate other related parts or information.

6. Measures to remove root cause of error.

A. Even if the error is repaired, if the root cause of the error is not repaired, the same error will occur again.

B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

D51EX/PX-22 40-103
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLE-

SEQUENCE OF EVENTS IN TROUBLESHOOTING

40-104 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent errors or other troubles before they occur, cor-
rect operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly
with correct repair procedures for electronics and is aimed at improving the quality of repairs. For this purpose, it gives
sections on 'Handling electric equipment' and 'Handling hydraulic equipment' (particularly hydraulic oil).

PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT


1. Handling High Voltage Circuits

A. If the machine is equipped with an electronically controlled


engine, high voltage is used to control fuel injection,
(110 - 130 V) for the fuel injector drive. Never handle the
engine wiring harness while the engine is running, tamper with
or modify this circuit, sever injury may result due to the high
voltage and amps in the circuit. Always use caution when
working around this circuit.

2. Handling Wiring Harnesses And Connectors

A. Wiring harnesses consist of wiring connecting one component


to another component, connectors used for connecting and
disconnecting one wire from another wire, and protector or
tubes used for protecting the wiring. Compared with other
electrical components fitted in boxes or cases, wiring harnesses
are more likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during inspection and
repair operations they are frequently removed and installed
again, so they are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when
handling wiring harnesses.

3. Main errors Occurring In Wiring Harness

A. Faulty contact of connectors:


(faulty contact between male and female). Problems with
faulty contact are likely to occur because the male connector is
not properly inserted into the female connector, or because one
or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidation of
the contact surfaces.

D51EX/PX-22 40-105
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
B. Defective compression or soldering of connectors:
The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.

C. Disconnections in wiring:
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring
still connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.

D. High pressure water entering a connector:


The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector
depending on the direction of the water jet.
The connector is designed to prevent water from entering, but
if water does enter, it is difficult for it to be drained. Therefore,
if water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropriate action
before passing electricity through it.

E. Oil, grease 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, the oil will not let the electricity pass, and this will cause
a defective contact.If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or blow dry with air, and
spray it with a contact restorer.
H When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
H If there is water or oil present, it will increase the
contamination of the points, so clean with air until all
water and oil has been removed.

40-106 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
4. Removing, Installing, And Drying Connectors And Wiring
Harnesses.

A. Disconnecting connectors:

i. Hold the connectors when disconnecting.


When disconnecting the connectors, hold the connectors
and not the wires. For connectors held by a screw, loosen
the screw fully, then hold the male and female connectors
in each hand and pull apart. For connectors which have a
lock stopper, press down the stopper with your thumb and
pull the connectors apart.
H Never try to pull apart with one hand

ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
H If the connector is twisted to the left and right or up
and down, the housing may break.

iii. When disconnecting male and female connectors, release


the lock and pull in parallel with both hands.
H Never try to pull apart with one hand.

iv. Action to take after removing connectors.


After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.

D51EX/PX-22 40-107
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
B. Connecting connectors:

i. Check the connector visually.


l Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
l Check that there is no deformation, faulty contact,
corrosion, or damage to the connector pins.
l Check that there is no damage or breakage to the
outside of the connector.
H If there is any oil, water, or dirt stuck to the connector,
wipe it off with a dry cloth. If any water has gotten
inside the connector, warm the inside of the wiring
with a dryer, but be careful not to make it too hot as
this will cause short circuits.
H If there is any damage or breakage, replace the
connector.

ii. Assemble the connector securely.


Align the position of the connector correctly, then insert it
securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks into position.

iii. Correct any protrusion of the boot and any misalignment


of the wiring harness.
For connectors fitted with boots, correct any protrusion or
the boot. In addition, if the wiring harness is misaligned,
or the clamp is out of position, adjust it to its correct
position.
H When blowing with dry air, there is danger that the oil
in the air may cause improper contact, so clean with
properly filtered air.

iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.

C. Connecting connectors (DT type connector)


Since the DT 8-pole and 12-pole DT type connectors have two
latches respectively, push them in until they click 2 times.
l Male connector (1), Female connector (2).
l Normal locking state (Horizontal): a, b, d
l Incomplete locking state (Diagonal): c

40-108 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
D. Drying wiring harness:
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:

i. Disconnect the connector and wipe off the water with a


dry cloth.
H If the connector is blown dry with air, there is the risk
that oil in the air may cause a faulty contact, so avoid
blowing with air.

ii. Dry the inside of the connector with a dryer.


If water gets inside the connector, use a dryer to dry the
connector.
H Hot air from the dryer can be used, but be careful not
to make the connector or related parts too hot, as this
will cause deformation or damage to the connector.

iii. Carry out a continuity test on the connector.


After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.
H After completely drying the connector, spray it with
contact restorer and reassemble.

D51EX/PX-22 40-109
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
HANDLING ELECTRONIC CONTROL UNIT
1. The electronic control unit contains a microcomputer and electronic
circuits.
H This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control unit.

2. Do not open the cover of the control box unless necessary.

3. Do not place objects on top of the control unit.

4. Cover the control connectors with tape or a vinyl bag.

5. Do not leave the control unit in a place where it is exposed to rain.

6. Do not place the control unit on oil, water, or soil, or in any hot
place, even for a short time.
H Place it on a suitable dry stand.

7. Precautions when carrying out arc welding.


H When carrying out arc welding on the body, disconnect all
wiring harness connectors connected to the control unit. Attach
the arc welding ground close to the welding point as possible.

40-110 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL
CIRCUITS
1. Always turn power OFF before disconnecting or connecting connectors.

2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
H Disconnect and connect the related connectors several times to check.
H Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.

3. Always connect any disconnected connectors before going on to the next step.
H If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.

4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
H If there is any charge, there is probably defective contact in that circuit.

5. When checking a single diode circuit:


H Isolate the diode from the circuit.
H Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
H Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.

6. When checking a dual diode circuit:


H Isolate the diode from the circuit.
H Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
H Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.

7. Always be aware of what you are measuring. Voltage, Ohms or


Amps. Always use caution when measuring a circuit.
H When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are
measuring.
H When measuring ohms, be sure the circuit is dead and has (no
voltage) in it before you take any readings. Be sure the meter is
set in the proper ohms range.
H When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. error to follow these
procedures may damage your equipment or possibly cause
injury. Always study the operators manuel for the meter you
will be using.

D51EX/PX-22 40-111
TROUBLESHOOTING ELECTRIC WIRE CODE

ELECTRIC WIRE CODE


In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
number (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE


Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
Primary

1
Color White Black Black Red Yellow Green Blue
Code WR BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color
Red White White Red White White
Code WB BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color Red & Black Blue & Red
Black low Black Red
Code WL BR RY YG GY LY
Auxiliary

4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color Black & Red
Blue low Green Yellow low
Code WG RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color
Green Green Blue Black Black
Code RL YW GL
6 Yellow & Green &
Color Red & Blue
White Blue

40-112 D51EX/PX-22
TROUBLESHOOTING ELECTRIC WIRE CODE
12
HOW TO READ ELECTRIC WIRE CODE
H The information about the wires unique to each machine model is described in Troubleshooting section, Relational infor-
mation 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)
Using
Type Symbol Material temperature Example of use
range (C)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for auto- AV appliance
(Nominal No. 5 and above)
mobile Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric 30 to +60
Conductor
low-voltage appliance General wiring
AVS
wire for auto- (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
mobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold dis-
low-voltage appliance
AEX 50 to +110 trict, wiring at high-temperature
wire for auto- Heat-resistant crosslinked poly-
Insulator place
mobile ethylene

D51EX/PX-22 40-113
TROUBLESHOOTING 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 area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(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
Cover D

AV Standard 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
Diameter of
Conductor strand
Sectional area
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cover D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

f of nominal No. denotes flexible.

40-114 D51EX/PX-22
TROUBLESHOOTING ELECTRIC WIRE CODE
12
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of error is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.

1. Be careful of the operating environment.


Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot
of dust.

2. Disassembly and maintenance work in the field.


If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the
equipment. It is also difficult to confirm the performance after
repairs, so it is desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be carried out in a
specially prepared dust proof workshop, and the performance
should be confirmed with special test equipment.

3. Seal or cover all openings of disconnected piping.


After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag,
this could cause particles or dirt to get into the system. Drain all oil
into a container and not unto the ground and be sure to follow the
proper environmental regulation for any disposal of oil.

4. 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. Always keep the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt that has collected
during storage, so this is an even more effective method.

D51EX/PX-22 40-115
TROUBLESHOOTING ELECTRIC WIRE CODE
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.

6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.

7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.

40-116 D51EX/PX-22
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING


Item Judgement Value Action
1. Check fuel level, type of fuel Add fuel
Lubricating oil, coolant

2. Check for impurities in fuel Clean, drain


3. Check engine oil level, type of oil Add oil
4. Check coolant level Add coolant
5. Check air cleaner for clogging Clean or replace
6. Check hydraulic oil level, type of oil Add oil
7. Check hydraulic filter and HST charge filter Replace
8. Check for looseness, corrosion of battery terminals, wiring Tighten or replace
Equipment
Electrical
Before Starting Checking Item

9. Check for looseness, corrosion of alternator terminals, wiring Tighten or replace

10. Check for looseness, corrosion of starting motor terminal, wiring Tighten or replace

11. Check for abnormal noise or smells Repair


Hyd. Mech.

12. Check for leaks Repair

13. Bleed any air from circuit Bleed air

14. Check battery voltage (with engine stopped) 20 - 30V Replace


15 Check battery electrolyte level (if available) Add or replace
16. Check for discolored, burnt, exposed wiring Replace
Electrical equipment

17. Check for missing wiring clamps or loose wires Repair

18. Check for water leaking on wiring terminals or connections Disconnect connector
and dry
19. Check for blown or corroded fuse links or fuses Replace

20. Check alternator voltage (engine running at 1/2 throttle speed or above After running for several minutes: 27.5 - Replace
29.5V
21. Check operating sound of battery relay
Replace
(when switch is turned ON/OFF)

D51EX/PX-22 40-117
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS
1. Categories of troubleshooting codes
H If the machine monitor displays a error code, the name of the controller is also displayed at the same time, so the trou-
bleshooting codes are categorized according to the name of each controller. (This may also includes some error codes
for the electrical system that are not displayed)
H errors of the hydraulic and mechanical system that the machine monitor cannot display are categorized as H mode.
Troubleshooting Code Troubleshooting system
ERROR CODES Troubleshooting when error codes are displayed
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine system

Troubleshooting procedures
When any symptom supposed to be a error appeared on the machine, select a troubleshooting No. according to the procedures
below and proceed to the text of the relevant troubleshooting:

1. Troubleshooting procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display an error code in the error code display mode (electrical
system, mechanical system) on the monitor display (EMMS).
Carry out the troubleshooting of the relevant [error code] in accordance with the displayed error code.
H Since an error code flashes when a error is detected, the error has not always been corrected even if it lights when
the starting switch is set to ON. (For some codes, errors can be detected by only turning the starting switch ON.)
H When an error code has been recorded, be sure to perform the duplication operation corresponding to the error
code and confirm if the error has still remained or has been already corrected. (For the duplication method, refer
to the troubleshooting relevant to the error code.)

2. Troubleshooting procedures when an error code has been recorded:


When no action code is displayed on the monitor panel, display an error code in the error code display mode (electrical
system, mechanical system) on the monitor display (EMMS).
When an error code has been recorded, carry out the troubleshooting of the relevant [error code] in accordance with the
displayed error code.
H Since an error code flashes when a error is detected, the error has not always been corrected even if it lights when
the starting switch is set to ON. (For some codes, errors can be detected by only turning the starting switch ON.)
H When an error code has been recorded, be sure to perform the duplication operation corresponding to the error
code and confirm if the error has still remained or has been already corrected. (For the duplication method, refer
to the troubleshooting relevant to the error code.)

3. Troubleshooting procedures when no action code is displayed and an error code has not been recorded:
When an error code has not been recorded in the monitor panel (EMMS), a error that the machine cannot diagnose by
itself is supposed to have occurred in the electrical system or the hydraulic and mechanical system.
In this case, check again a symptom supposed to be a error and select the relevant symptom out of the table of Symptom
supposed to be error and troubleshooting No. Then, carry out the troubleshooting in the [E-Mode], [H-Mode] or [S-
Mode] related to the symptom.

40-118 D51EX/PX-22
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS
This method is also displayed at the beginning of each electrical system troubleshooting mode. It is important to follow each
step in the troubleshooting chart. Do not skip steps, jump ahead or stop when a problem is found. It is important to complete all
steps due to the fact that there may be several other problems causing the error code. The chart is set-up to start with the most
likely problem first down to the least likely
Action code Error code
Display on Trouble Trouble in machine
Display on panel
panel
Contents of
Condition at the time when the monitor panel or controller detects the trouble
trouble
Action of The action taken by the monitor panel or controller to protect the system or devices when the monitor panel or controller
controller detects the trouble
Problem that
appears on The problem that appears on the machine as a result of the action taken by the monitor panel or controller (shown above)
machine
Related
Information related to the detected trouble or troubleshooting
information

Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
1 Standard value in normal state to judge possible causes
Remarks on judgment

<Troubles in wiring harness>


Disconnection
Connector is connected imperfectly or wiring harness is broken.
Grounding fault
2 Wiring harness which is not connected to chassis ground circuit is in contact with chassis
ground circuit.
Possible causes and standard

Short circuit with power source


value in normal state

Wiring harness which is not connected to power source (24 V) circuit is in contact with power
source (24 V) circuit.
Possible causes of trouble Short circuit
(Given numbers are Independent wiring harnesses are in contact with each other abnormally.
3
reference numbers, which do not
indicate priority) <Precautions for troubleshooting>

1. Method of indicating connector No. and handling of T-adapter


Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
If connector No. has no marks of male and female, disconnect connector and insert T-adapters
4 in both male side and female side.
If connector No. has marks of male and female, disconnect connector and connect T-adapter to
only male side or female side.

2. Entry order of pin Nos. and handling of circuit tester leads


Connect positive (+) lead and negative () lead of circuit tester as explained below for troubleshoot-
ing, unless otherwise specified.
5 Connect positive (+) lead to pin No. or harness entered on front side.
Connect negative () lead to pin No. or harness entered on rear side.

D51EX/PX-22 40-119
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Related circuit diagram

This is the excerpted circuit diagram related to troubleshooting.


Connector No.: Indicates (model number of pins) (color)
Arrow (): Indicates the approximate mounting place on machine

40-120 D51EX/PX-22
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
Chart Use

H Repair Shop Use

When using this chart in a repair shop environment where you have access to a copier it is advised to remove the
pages of the fault codes displayed on the machine monitor and copy these pages. After copping the needed pages,
return the original pages back to the Shop Manual for future use. On the copied pages in the right hand column of the
chart you can record your findings for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.

H Road Service Use

When using this chart while on a road service call where a copier is not available it is advised to use a blank piece of
paper and number it from #1 through the last number listed in conjunction with the Shop Manual. Record your
readings by each number on the paper for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.

Chart Tips

Check all fuses and fuse links first.


If the system has a relay replace the relay with a known good relay, do not test the relay itself.
For diode checking procedures see POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL
CIRCUITS page 111
When checking Ohms in a system or component always isolate the component you are checking, this will ensure
there are no additional circuits adding continuity to the component you are testing.
Never measure Amps unless instructed in the testing procedure. Damage to the meter or injury may result.
Never use a welder or a battery system of a higher voltage than the machine you are troubleshooting to jump or sup-
ply electricity to. Damage to the machines electrical system may result.

D51EX/PX-22 40-121
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS


H The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
H Deuscht connector has marks of pin numbers on the wiring harness side.

X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010

2 799-601-7020

Part number: 08055-00282 Part number: 08055-00292

3 799-601-7030

Part number: 08055-00381 Part number: 08055-00391

4 799-601-7040

Part number: 08055-00481 Part number: 08055-00491


Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
Wire size: 0.85 Wire size: 0.85

Quantity: 20 pieces Quantity: 20 pieces
Grommet: black Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
Wire size: 2.0 Wire size: 2.0

Quantity: 20 pieces Quantity: 20 pieces
Grommet: red Grommet: red

40-122 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

SWP Type Connector


Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

6 799-601-7050

Part number: 08055-10681 Part number: 08055-10691

8 799-601-7060

Part number: 08055-10881 Part number: 08055-10891

12 799-601-7310

Part number: 08055-11281 Part number: 08055-11291

14 799-601-7070

Part number: 08055-11481 Part number: 08055-11491

D51EX/PX-22 40-123
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

SWP Type Connector


Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

16 799-601-7320

Part number: 08055-11681 Part number: 08055-11691


Terminal part number: Terminal part number:
Wire size: 0.85 Wire size: 0.85

Quantity: 20 pieces Quantity: 20 pieces
Grommet: black Grommet: black
Terminal part number: Terminal part number:
Wire size: 1.25 Wire size: 1.25

Quantity: 20 pieces Quantity: 20 pieces
Grommet: red Grommet: red

40-124 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

M Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080

2 799-601-7090

Part number: 08056-00271 Part number: 08056-00281

3 799-601-7110

Part number: 08056-00371 Part number: 08056-00381

4 799-601-7120

Part number: 08056-00471 Part number: 08056-00481

6 799-601-7130

Part number: 08056-00671 Part number: 08056-00681

D51EX/PX-22 40-125
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

8 799-601-7340

Part number: 08056-00871 Part number: 08056-00881

S Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number

8 799-601-7140

Part number: 08056-10871 Part number: 08056-10881

10 (white) 799-601-7150

Part number: 08056-11071 Part number: 08056-11081

12 (white) 799-601-7350

Part number: 08056-11271 Part number: 08056-11281

40-126 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

16 (white) 799-601-7330

Part number: 08056-11671 Part number: 08056-11681

S Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number

10 (blue)

12 (blue) 799-601-7160

Part number: 08056-11272 Part number: 08056-11282

16 (blue) 799-601-7170

Part number: 08056-11672 Part number: 08056-11682

D51EX/PX-22 40-127
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
MIC Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 (Quantity: 5 pieces) (Quantity: 5 pieces)

11 Body part number: 79A-222-2680 Body part number: 79A-222-2670


(Quantity: 5 pieces) (Quantity: 5 pieces)

5 799-601-2710

Body part number: 79A-222-2620 Body part number: 79A-222-2610


(Quantity: 5 pieces) (Quantity: 5 pieces)

9 799-601-2950

Body part number: 79A-222-2660 Body part number: 79A-222-2650


(Quantity: 5 pieces) (Quantity: 5 pieces)

13 799-601-2720

Body part number: 79A-222-2710 Body part number: 79A-222-2690


(Quantity: 2 pieces) (Quantity: 2 pieces)

40-128 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

MIC Type Connector


Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

17 799-601-2730

Body part number: 79A-222-2730 Body part number: 79A-222-2720


(Quantity: 2 pieces) (Quantity: 2 pieces)

21 799-601-2740

Body part number: 79A-222-2750 Body part number: 79A-222-2740


(Quantity: 2 pieces) (Quantity: 2 pieces)
Body part number: 79A-222-2770 Body part number: 79A-222-2760

(Quantity: 50 pieces) (Quantity: 50 pieces)

AMP040 Type Connector


Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

8 799-601-7180

Housing part number: 79A-222-3430



(Quantity: 5 pieces)

D51EX/PX-22 40-129
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

12 799-601-7190

Housing part number: 79A-222-3440


(Quantity: 5 pieces)

16 799-601-7210

Housing part number: 79A-222-3450


(Quantity: 5 pieces)

20 799-601-7220

Housing part number: 79A-222-3460


(Quantity: 5 pieces)

H Terminal part number: 79A-222-3470 (for all numbers of pins).


AMP070 Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number

10 799-601-7510

Part number: 08195-10210

40-130 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

12 799-601-7520

Part number: 08195-12210

14 799-601-7530

Part number: 08195-14210

18 799-601-7540

Part number: 08195-18210

20 799-601-7550

Part number: 08195-20210

L Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number

D51EX/PX-22 40-131
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

PA Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number

40-132 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

BENDIX (MS) Type Connector


Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

10 799-601-3460

D51EX/PX-22 40-133
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

KES1 Automobile Type Connector


Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)

Part number: 08027-10310 Part number: 08027-10360

Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)

Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)

40-134 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

KES1 Automobile Type Connector


Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)

D51EX/PX-22 40-135
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR

Connector for relay (Socket)


Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

5 799-601-7360

6 799-601-7370

Type F Type Connector


(shell size T-adapter Part
code) Pin (Male terminal) Body (Female terminal)
Number

40-136 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
H The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector


(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9210

Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102


18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)

799-601-9210

Part number: 08191-11201, 08191-12202 Part number: 08191-13101, 08191-13102


08191-11205, 08191-12206 08191-13105, 08191-13106
Pin (male terminal) Pin (female terminal)

799-601-9220

Part number: 08191-21201, 08191-12202 Part number: 08191-24101, 08191-24102


18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (female terminal) Pin