Professional Documents
Culture Documents
© 2005
All Rights Reserved 00-1
Printed in Japan 02-05 (01) (4)
GENERAL
CONTENTS
No. of page
01 GENERAL ................................................................................................................................ 01-1
90 OTHERS..................................................................................................................................... 90-1
20-315 (1) 20-401 (1) 20-444 (1) 20-485 (1) 20-527 (1)
20-316 (1) 20-402 (1) 20-445 (1) 20-486 (1) 20-528 (1)
20-317 (1) 20-404 (1) 20-446 (1) 20-487 (1) 20-529 (1)
20-318 (1) 20-405 (1) 20-447 (1) 20-488 (1) 20-530 (1)
20-320 (1) 20-406 (1) 20-448 (1) 20-489 (1) 20-531 (1)
20-321 (1) 20-407 (1) 20-449 (1) 20-490 (1) 20-532 (1)
20-322 (1) 20-408 (1) 20-450 (1) 20-491 (1) 20-533 (1)
20-323 (1) 20-409 (1) 20-451 (1) 20-492 (1) 20-534 (1)
20-324 (1) 20-410 (1) 20-452 (1) 20-493 (1) 20-535 (1)
20-325 (1) 20-411 (1) 20-453 (1) 20-494 (1) 20-536 (1)
20-326 (1) 20-412 (1) 20-454 (1) 20-496 (1) 20-537 (1)
20-327 (1) 20-413 (1) 20-455 (1) 20-497 (1) 20-538 (1)
20-328 (1) 20-414 (1) 20-456 (1) 20-498 (1) 20-539 (1)
20-329 (1) 20-416 (1) 20-457 (1) 20-499 (1) 20-540 (1)
20-330 (1) 20-417 (1) 20-458 (1) 20-500 (1) 20-541 (1)
20-331 (1) 20-418 (1) 20-459 (1) 20-501 (1) 20-542 (1)
20-332 (1) 20-419 (1) 20-460 (1) 20-502 (1) 20-543 (1)
20-333 (1) 20-420 (1) 20-461 (1) 20-503 (1) 20-544 (1)
20-334 (1) 20-421 (1) 20-462 (1) 20-504 (1) 20-545 (1)
20-335 (1) 20-422 (1) 20-463 (1) 20-505 (1) 20-546 (1)
20-336 (1) 20-423 (1) 20-464 (1) 20-506 (1) 20-547 (1)
20-337 (1) 20-424 (1) 20-465 (1) 20-507 (1) 20-548 (1)
20-338 (1) 20-425 (1) 20-466 (1) 20-508 (1) 20-549 (1)
20-339 (1) 20-426 (1) 20-467 (1) 20-510 (1) 20-550 (1)
20-340 (1) 20-427 (1) 20-468 (1) 20-511 (1) 20-551 (1)
20-341 (1) 20-428 (1) 20-469 (1) 20-512 (1) 20-552 (1)
20-342 (1) 20-429 (1) 20-470 (1) 20-513 (1) 20-553 (1)
20-343 (1) 20-430 (1) 20-471 (1) 20-514 (1) 20-554 (1)
20-344 (1) 20-432 (1) 20-472 (1) 20-515 (1) 20-555 (1)
20-345 (1) 20-433 (1) 20-473 (1) 20-516 (1) 20-556 (1)
20-346 (1) 20-434 (1) 20-474 (1) 20-517 (1) 20-557 (1)
20-347 (1) 20-435 (1) 20-475 (1) 20-518 (1) 20-558 (1)
20-348 (1) 20-436 (1) 20-476 (1) 20-519 (1) 20-559 (1)
20-349 (1) 20-437 (1) 20-477 (1) 20-520 (1)
20-350 (1) 20-438 (1) 20-478 (1) 20-521 (1) 20-601 (1)
20-351 (1) 20-439 (1) 20-479 (1) 20-522 (1) 20-602 (1)
20-352 (1) 20-440 (1) 20-480 (1) 20-523 (1) 20-603 (1)
20-353 (1) 20-441 (1) 20-481 (1) 20-524 (1) 20-604 (1)
20-354 (1) 20-442 (1) 20-482 (1) 20-525 (1) 20-605 (1)
20-443 (1) 20-484 (1) 20-526 (1) 20-606 (1)
20-607 (1) 20-650 (1) 20-812 (1) 30-27 (1) 30-68 (1)
20-608 (1) 20-651 (1) 20-813 (1) 30-28 (1) 30-69 (1)
20-609 (1) 20-652 (1) 20-814 (1) 30-29 (1) 30-70 (1)
20-610 (1) 20-653 (1) 20-815 (1) 30-30 (1) 30-71 (1)
20-611 (1) 20-654 (1) 20-816 (1) 30-31 (1) 30-72 (1)
20-612 (1) 20-655 (1) 20-817 (1) 30-32 (1) 30-73 (1)
20-613 (1) 20-656 (1) 20-818 (1) 30-33 (1) 30-74 (1)
20-614 (1) 20-657 (1) 20-819 (1) 30-34 (1) 30-75 (1)
20-615 (1) 20-658 (1) 20-820 (1) 30-35 (1) 30-76 (1)
20-616 (1) 20-659 (1) 20-821 (1) 30-36 (1) 30-77 (1)
20-617 (1) 20-660 (1) 20-822 (1) 30-37 (1) 30-78 (1)
20-618 (1) 20-823 (1) 30-38 (1) 30-79 (1)
20-619 (1) 20-701 (1) 30-39 (1) 30-80 (1)
20-620 (1) 20-702 (3) 30-40 (1) 30-81 (1)
20-621 (1) 20-703 (1) 30-1 (1) 30-41 (1) 30-82 (1)
20-622 (1) 20-704 (1) 30-2 (1) 30-42 (1) 30-83 (1)
20-624 (1) 20-705 (1) 30-3 (1) 30-43 (1) 30-84 (1)
20-625 (1) 20-706 (1) 30-4 (1) 30-44 (1) 30-85 (1)
20-626 (1) 20-707 (1) 30-5 (1) 30-45 (1) 30-86 (1)
20-627 (1) 20-708 (1) 30-6 (1) 30-46 (1)
20-628 (1) 20-709 (1) 30-7 (1) 30-47 (1)
20-629 (1) 20-710 (1) 30-8 (1) 30-48 (1) 90-1
20-630 (1) 20-711 (1) 30-9 (1) 30-49 (1) 90-3
20-631 (1) 20-712 (1) 30-10 (1) 30-50 (1) 90-5
20-632 (1) 20-713 (1) 30-11 (1) 30-51 (1) 90-7
20-633 (1) 20-714 (1) 30-12 (1) 30-52 (1) 90-9
20-634 (1) 20-715 (1) 30-13 (1) 30-53 (1) 90-11
20-635 (1) 20-716 (1) 30-14 (1) 30-54 (1) 90-13
20-636 (1) 30-15 (1) 30-55 (1) 90-15
20-638 (1) 20-801 (1) 30-16 (1) 30-56 (1)
20-639 (1) 20-802 (1) 30-17 (1) 30-57 (1)
20-640 (1) 20-803 (1) 30-18 (1) 30-58 (1)
20-641 (1) 20-804 (1) 30-19 (1) 30-59 (1)
20-642 (1) 20-805 (1) 30-20 (1) 30-60 (1)
20-643 (1) 20-806 (1) 30-21 (1) 30-61 (1)
20-644 (1) 20-807 (1) 30-22 (1) 30-62 (1)
20-646 (1) 20-808 (1) 30-23 (1) 30-63 (1)
20-647 (1) 20-809 (1) 30-24 (1) 30-64 (1)
20-648 (1) 20-810 (1) 30-25 (1) 30-66 (1)
20-649 (1) 20-811 (1) 30-26 (1) 30-67 (1)
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
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 judge-
ments. 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 chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 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
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
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
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
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
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 1352.6 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
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 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 1934 1949 1963 1977
140 1991 2005 2020 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
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn 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.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 10-04
01 GENERAL
SPECIFICATION DRAWING
D31EX-21 D31PX-21
Item Unit 400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
7,650 7,630
Machine weight kg 7,130
(7,630) (7,610)
Engine model — Komatsu SAA4D102E-2-B diesel engine
Engine rated horsepower kW {HP} /rpm 56 {75} /2,000
A Overall length mm 4,015 3,995 3,975
Overall height (not including antenna) 2,700 2,720
B mm
(to tip of exhaust pipe) 2,645 2,665
3,200
C Overall width mm 2,435
(2,875)
FORWARD
km/h 4.3/5.6/8.5
Travel speed (1st/2nd/3rd)
(Quick shift mode) REVERSE
km/h 4.3/6.5/8.5
(1st/2nd/3rd)
D37EX-21 D37PX-21
Item Unit 400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
7,770 7,750
Machine weight kg 7,410
(7,720) (7,700)
Engine model — Komatsu SAA4D102E-2-B diesel engine
Engine rated horsepower kW {HP} /rpm 63 {85} /2,000
A Overall length mm 4,055 4,035 4,015
Overall height (not including antenna) 2,700 2,720
B mm
(to tip of exhaust pipe) 2,645 2,665
3,250
C Overall width mm 2,720
(2,875)
FORWARD
km/h 3.4/5.6/8.5
Travel speed (1st/2nd/3rd)
(Quick shift mode) REVERSE
km/h 4.1/6.5/8.5
(1st/2nd/3rd)
D39EX-21 D39PX-21
Item Unit 460 mm 635 mm 700 mm
Single shoe Single shoe Swamp shoe
9,200 9,180
Machine weight kg 8,820
(9,140) (9,120)
Engine model — Komatsu SAA4D102E-2-B diesel engine
Engine rated horsepower kW {HP} /rpm 71 {95} /2,200
A Overall length mm 4,240 4,220
Overall height (not including antenna) 2,770 2,790
B mm
(to tip of exhaust pipe) 2,720 2,740
3,330
C Overall width mm 2,740
(2,980)
FORWARD
km/h 3.4/5.6/8.5
Travel speed (1st/2nd/3rd)
(Quick shift mode) REVERSE
km/h 4.1/6.5/8.5
(1st/2nd/3rd)
SPECIFICATIONS
D31EX-21 D31PX-21
Machine model 400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
Serial No. 50501 and up 50501 and up
Operating weight
• Bare tractor kg 5,800 6,250 6,230
Weight
Bare tractor
{kg/cm2} {0.36} {0.24} {0.24}
With power angle tiltdozer + kPa 43.1 28.4 28.4
ROPS canopy {kg/cm2} {0.44} {0.29} {0.29}
With power angle tiltdozer + kPa 45.1 29.4 29.4
ROPS cab {kg/cm2} {0.46} {0.30} {0.30}
3,200 3,200
Power angle tiltdozer mm 2,435
(2,875) (2,875)
Dimensions
30 30 30 30 30 30
35 35 35 35 35 35
0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5
0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5 0.8 – 8.5
33.3 23.5 22.6 31.4 23.5 21.6
{0.34} {0.24} {0.23} {0.32} {0.24} {0.22}
40.2 28.4 28.4 38.2 29.4 26.5
{0.41} {0.29} {0.29} {0.39} {0.30} {0.27}
42.2 29.4 29.4 40.2 30.4 27.5
{0.43} {0.30} {0.30} {0.41} {0.31} {0.28}
D31EX-21 D31PX-21
Machine model 400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
Serial No. 50501 and up
Model — SAA4D102E-2-B
4-cycle, water-cooled, in-line vertical type, 4 cylinders,
Type —
direct injection, with turbocharger, air-cooled after cooler
No. of cylinders – bore x stroke mm 4 – 102 x 120
Piston displacement l {cc} 3.92 {3,920}
kW {HP}
Rated horsepower 56 {75}/2,000
/rpm
Nm {kgm}
Performance
/rpm
High idling rpm 2,200
Low idling rpm 800
Min. fuel g/kWh
211 {157}
consumption ratio {g/HPh}
Starting motor — 24 V, 5.5 kW
Alternator — 24 V, 25 A
Battery (*1) — 12 V, 60 Ah x 2
Radiator core type — D-5
Variable displacement swash-plate piston type x 2
Type, number —
Fix displacement internal-gear type x 1
Discharge amount
HST pump
Set pressure
MPa
(variable pump) 42.2 {430}
{kg/cm2}
(charge pump) 3.0 {31}
Variable displacement angled piston type
Type, number —
(3-stage selection, with parking brake) x 2
HST motor
Discharge amount
(Max.) 93
cm3/rev
(Medium) 61
(Min.) 46
Planetary gear, 2-stage reduction type,
Final drive —
splash type lubrication
Suspension — Rigid
Carrier roller — 1 on each side
Track roller — 5 on each side 6 on each side
Track shoe
Undercarriage
63 {85}/2,000 71 {95}/2,200
2,200 2,400
800 825
24 V, 5.5 kW 24 V, 5.5 kW
24 V, 25 A 24 V, 25 A
12 V, 60 Ah x 2 12 V, 60 Ah x 2
D-5 D-7
Variable displacement swash-plate piston type x 2 Variable displacement swash-plate piston type x 2
Fix displacement internal-gear type x 1 Fix displacement internal-gear type x 1
63 63
40 40
93 105
61 68
46 52
Planetary gear, 2-stage reduction type, Planetary gear, 2-stage reduction type,
splash type lubrication splash type lubrication
Rigid Rigid
1 on each side 1 on each side
6 on each side 6 on each side
D31EX-21 D31PX-21
Machine model 400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
Serial No. 50501 and up
Type, number — Fix displacement external-gear type x 1
Hydraulic
MPa
Max. discharge pressure 20.6 {210}
{kg/cm2}
control valve
D31EX-21 D31PX-21
Machine model 400 mm 600 mm 600 mm
Single shoe Single shoe Swamp shoe
Serial No. 50501 and up
Type — Hydraulic type angle tiltdozer
Blade support method — Hydraulic cylinder type
Max. lifting height (from ground) mm 860 855 920
Max. lowering depth
Performance
435 435
Max. tilt mm 330
(395) (395)
3,200 3,200
Blade width mm 2,435
Dimensions
(2,875) (2,875)
750 750
Blade height mm 845
(790) (790)
Blade cutting angle deg 56 56 58
Type Tool bar type
Beam length mm 520
Number of shanks Standard 3 units (Wearing is possible 5 units)
Digging angle (at on the ground/
deg 74/37
Ripper
56 56 58 57 57 59
Tool bar type Tool bar type
520 520
Standard 3 units (Wearing is possible 5 units) Standard 3 units (Wearing is possible 5 units)
74/37 67/37
700/350 700/350
WEIGHT TABLE
a This Weight Table is for reference when handling components or when transporting the machine.
Unit: kg
Unit: kg
58 58 58 58
560 x 2 560 x 2 — —
— — 760 x 2 760 x 2
— 710 x 2 — —
— — — 925 x 2
— 700 x 2 — —
— — — 915 x 2
65 65 65 65
6 6 6 6
16 16 16 16
19 — 19 —
Unit: kg
1,020
Power angle tiltdozer assembly 945
(1,005)
530
• Blade 460
(515)
• Dozer frame 380 380
• Tilt cylinder assembly 20 20
• Angle cylinder assembly 22 x 2 22 x 2
Lift cylinder assembly 23 x 2 23 x 2
Ripper 500 —
Ripper cylinder assembly 30 —
ROPS cab assembly 620 620
ROPS canopy assembly 310 310
Operator's seat 60 60
Floor frame assembly 150 150
Radiator guard assembly (including radiator mask) 175 175
Engine hood assembly 40 40
Engine side cover assembly
55 55
(including left, right, top, bottom)
Front bracket (engine dividing wall) 42 42
Fender (left) 107 107
Fender (right) 113 113
Unit: kg
1,035 1,195
975 1,120
(1,000) (1,140)
550 655
490 580
(505) (600)
380 380 400 400
20 20 20 20
22 x 2 22 x 2 25 x 2 25 x 2
23 x 2 23 x 2 28 x 2 28 x 2
500 — 500 —
30 — 30 —
620 620 620 620
310 310 310 310
60 60 60 60
150 150 150 150
180 180 190 190
40 40 40 40
55 55 55 55
42 42 42 42
107 107 107 107
113 113 113 113
SAE30
SAE10W
Engine oil pan 14 12.5
SAE10W-30
SAE15W-40
D31, 37:
Cooling system 27
Coolant Add antifreeze
(including sub-tank) D39:
32
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to
obtain good fuel consumption and good exhaust gas characteristics. For this reason, it requires high precision
for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a big
drop in durability.
REMARK
• When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual.
• Change oil according to the following table if fuel sulphur content is above 0.5%.
• When staring the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine
oil of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C
(50°F) more or less during the day.
• Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to
half.
• There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature range in the table.
• We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine
and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
COOLING SYSTEM
a The diagram shows D31EX/PX-21, D37EX/PX-21.
Specifications
ENGINE CONTROL
POWER TRAIN
Outline
• The power generated by engine (1) has its tor-
sional vibration reduced by damper (2), and is
then transmitted to the input shaft of the HST
pump.
• HST pump (3) consists of swash plate type pis-
ton 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).
• HST pump (3) changes the discharge direction
and discharge amount continuously in accor-
dance with the movement of the swash plate of
each pump to match the movement of the steer-
ing, 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.
• 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).
• Final drive (6) is a 2-stage planetary gear mech-
anism. It reduces the speed and rotates
sprocket (7) to drive track shoe (8).
DAMPER
Unit: mm
3. Coupling Outline
4. Boss • The damper reduces the torsional vibration
5. HST pump input shaft caused by variations in the engine torque, and
6. Cover acts to protect the engine and downstream drive
7. Flywheel system from the torsional vibration.
• 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.
1. HST pump
2. R.H. HST motor
3. HST charge filter
4. L.H. HST motor
5. 4-spool solenoid valve
6. Towing valve
SOLENOID VALVE
4-spool solenoid valve
Outline
• Block (10) has 4 solenoid valves.
• Parking brake solenoid valve (1) transmits a sig-
nal generated by the potentiometer which oper-
ates 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.
• 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 (2) drains the changeover oil
slowly through the orifice in it to operate the
parking brakes built in the HST motors.
• 3rd travel speed selector solenoid valve (3)
transmits the shift switch signals of the steering/
directional/gear shift lever through the HST con-
troller to output the changeover oil pressure and
change the HST motor capacity for the 3rd
travel speed.
• 2nd travel speed selector solenoid valve (4)
transmits the shift switch signals of the steering/
directional/gear shift lever through the HST con-
troller to output the changeover oil pressure and
change the HST motor capacity for the 2nd
travel speed.
Operation
TOWING VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The towing valve 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 re-
leased by setting lever (1) of this valve in the
"Close" position and applying parking brake re-
lease pressure from outside.
a For the procedure of releasing the parking brake,
see TESTING AND ADJUSTING, Procedure for
releasing parking brake.
FINAL DRIVE
a The diagram shows D31EX/PX-21, D37EX/PX-21.
Outline
• The final drive is a planetary gear, 2-stage reduc-
tion type. It provides splash lubrication when the
gear rotates.
It is also possible to remove or install the final
drive as a single unit.
• A floating seal is installed to the rotating and slid-
ing 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 + 88) / 14) x ((20 + 88) / 20) + 1 = –38.343
Unit: mm
HST PUMP
a HST: Abbreviation for HydoroStatic Transmission
Type: HPV63 + 63
Structure
• This pump consists of a variable displacement
swash plate tandem piston pump, servo valve,
EPC valve, safety valve with suction, charge
safety valve and charge pump.
1. EPC valve
2. Piston pump
3. Servo valve
4. Safety valve with suction
5. Charge safety vavle
6. Charge pump
Outline
• The rotation and torque transmitted to the pump • Rocker cam (3) has flat surface A, and shoe
shaft is converted into hydraulic energy, and (13) is always pressed against this surface while
pressurized oil is discharged according to the sliding in a circular movement. Rocker cam (3)
load. positions cradle bearing (2) between case (4)
• It is possible to change the discharge amount by and cylindrical surface B, and rocks.
changing the swash plate angle (normal io 0 • Piston (11) carries out relative movement in the
io reverse discharge). axial direction inside each cylinder chamber of
cylinder block (7).
Structure • Cylinder block (7) seals the pressure oil to valve
• Cylinder block (7) is supported to shaft (1) by plate (8) and carries out relative rotation. This
spline (12). Shaft (1) is supported by front and surface is designed so that the oil pressure bal-
rear bearings (14) and (10). ance is maintained at a suitable level. The oil
• The tip of piston (11) is a concave ball, and shoe inside each cylinder chamber of cylinder block
(13) is caulked to it to form one unit. Piston (11) (7) is sucked in and discharged through valve
and shoe (13) form a spherical bearing. plate (8).
Operation
1. Operation of pump
SAFETY-SUCTION VALVE
Function
• It restricts the maximum pressure inside the
HST circuit to protect the circuit.
Operation
(valve at piston pump discharge side)
• Port A is connected to the pump circuit and port
B is connected to the charge circuit. The pres-
sure oil passes through drill hole a in piston (3A)
and also fills port C.
• The oil at high-pressure port A passes through
passage groove b in the body and also fills port
D.
• Poppet (3A) is in tight contact with valve seat
(3C).
• If abnormal pressure is generated in the circuit
and the oil pressure at ports A and D reaches
the pressure set by spring (3D), poppet (3A) 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.
Function
• This ensures the oil flow in in the HST closed
circuit. It prevents the charge oil flow from flow-
ing to the pump high-pressure side (discharge
side).
Operation
Operation
• Port PB becomes the suction side, so it is at
low-pressure. Sleeve (3C) 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 (3C) opens.
• 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.
1. Charge pump
2. Charge safety valve
2A. Valve
2B. Spring
2C. Valve seat
2D. Poppet
2E. Spring
2F. Adjustment screw
3. Safety-suction valve
Function
• The charge safety valve is installed to the HST
pump. It limits the maximum pressure in the
charge circuit and protects the charge circuit.
Operation
• Port A is connected to the charge circuit, and
port B is connected through the HST pump case
to the tank drain circuit. The pressure oil passes
through orifice a in valve (2A) and fills chamber
C. Poppet (2D) is in tight contact with valve
seat (2C).
CHARGE PUMP
1. Side plate
2. Coupling
3. Shaft
4. Outer ring
5. Case
6. Inner rotor
7. Outer rotor
Outline
• The HST charge pump is built into the HST
pump and drives at the same time as the HST
pump.
• The HST charge pump supplies pilot-pressure
oil to the low-pressure side of the HST main cir-
cuit, charge safety valve, 4-spool solenoid valve,
and work equipment PPC valve.
• The charge pump sucks in the oil from the
hydraulic tank.
Specifications
Type: Trochoid pump
Theoretical discharge amount: 40 cc/rev
Operation
• The charge pump is connected to the HST
pump shaft by coupling (2) and rotates inner
rotor (6) and outer rotor (7).
• When inner rotor (6) and outer rotor (7) rotate,
the capacity of chamber A increases, oil is
sucked in, the capacity of chamber B
decreases, and the oil is discharged.
TOWING VALVE
Function
• 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).
• If there is a failure on the machine, it is possible
to tow the machine by connecting the HST cir-
cuit.
• However, it is necessary to cancel the shaft
brake of the motor at the same time.
Operation
• To actuate the towing valves, loosen the two
valves a maximum of 4.5 mm (3 turns).
HST MOTOR
a HST: Abbreviation for HydoroStatic Transmission
Model: KMV105
Principle
• Let us assume that the shaft of a disc is sup-
ported 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.
• 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
• 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).
• The angle of cylinder block (3) and pistons (2) is
decided by the ON-OFF signal of the control
pressure to PCMIN and PCMID of 3rd speed
valve (4). The combination is as shown in the
table.
PCMIN PCMID
Motor capacity MAX (1st) OFF OFF
Motor capacity MID (2nd) OFF ON
Motor capacity MIN (3rd) ON OFF
Operation
• 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 pis-
ton (2) and the cylinder block.
Motor capacity MAX (1st) Motor capacity MID (2nd) Motor capacity MIN (3rd)
Chamber A ON ON OFF
Chamber B ON OFF OFF
Chamber C ON ON ON
Function
• As shown in the diagram above, when the main • When the motor capacity is MAX (1st speed),
piston is at the lowest position, the motor capac- high pressure (self pressure) is being supplied
ity is MAX (1st speed). to all of chamber A, chamber B, and chamber C.
• When the main piston is at the highest position, However, the main piston is at the lowest posi-
the motor capacity is MIN (3rd speed). tion because the area on which the high pres-
• When it is at the midpoint position, the motor sure is acting in chamber B is larger than the
capacity is MID (2nd speed). A sub piston is area on which the high pressure is acting in
provided to produce the MID (2nd speed) motor chamber C. As a result, the combined force
capacity. generates a force in the downward direction.
• The area on which the self pressure is acting in
Operation chamber A and chamber B of the sub piston is
• The 3rd speed mechanism includes chamber A, the same. However, the high pressure (self
chamber B, and chamber C. Each of these pressure) acting on chamber A is greater than
chambers has its high pressure (self pressure) the high pressure acting on chamber B (the
turned ON (supplied) and OFF (drained) by the pressure is lower than the self pressure for
3rd speed valve, and the main piston and sub chamber A because the self pressure passes
piston are actuated. through a throttle), so the sub piston is pushed
down.
Function
• The pressure at the high-pressure side is
selected at HST main pressures MA and MB,
and is supplied to the 3rd speed spool.
• A shuttle valve is provided to select the pressure
from the low-pressure side and supply it to the
charge relief valve.
Operation
• With cross section D-D, HST main pressure MA
is taken to the left end face of the shuttle valve;
HST main pressure MB is taken to the right end
face of the shuttle valve.
• The position of the shuttle valve at cross section
D-D is the neutral position when the difference
in pressure between MA and MB is small. Pres-
sures MA and MB are both taken to the 3rd
speed spool.
• Because of the two check valves, a higher pres-
sure than MA and MB is taken to the spool of
the shuttle valve. In this case, the passage to
the charge relief valve is shut off.
• With the position of the shuttle valve at cross
section D-D, when MA>MB, the shuttle valve
moves to the right, MA is selected as the high
pressure, and is taken to the 3rd speed spool.
MB is selected as the low pressure and is taken
to the charge relief valve.
• When MA<MB, the shuttle valve moves to the
left, MB is selected as the high pressure, and is
taken to the 3rd speed spool. MA is selected as
the low pressure and is taken to the charge relief
valve.
a: Check valve
b: Shuttle valve
c: Charge relief valve
Function Operation
• The HST main pressure at the high-pressure • When both PCMIN (3) and PCMID (4) are OFF,
side is selected by the shuttle valve and is taken 3rd speed spool (1) is at neutral, and pressure P
to portion P. is supplied to all of A, B, and C.
• 3rd speed spool (1) is moved by pressures • However, the supply to A passes through the
PCMIN and PCMID, so this pressure is supplied groove on the outside circumference of the
to rounds A, B, and C, which are connected to spool. Compared with this, the supply to B and
chamber A, chamber B, and chamber C of the C passes through flow control valve (2) built into
3rd speed mechanism. 3rd speed spool (1).
• As a result, the pressure at A is the highest and
the pressure at B and C is slightly lower.
[q = MAX (1st speed)]
• When PCMIN (3) is OFF and PCMID (4) is ON,
3rd speed spool (1) moves to the left and pres-
sure P is supplied to A and C, while B is drained
to the tank. [q = MID (2nd speed)]
• When PCMIN (3) is ON and PCMID (4) is OFF,
3rd speed spool (1) moves to the right and pres-
sure P is supplied to C, while A and B are
drained to the tank.
1. Spring
2. Spool
Function Operation
• The high pressure of the HST main pressure is • The oil inside spool (2) of the flow control valve
selected by the shuttle valve and is taken to por- flows W o X o Y. Portion X is a throttle.
tion P. • The position of the spool (area of opening at
• The pressure at this portion P changes from portion W) is determined by the differential pres-
approx. 2.45 MPa {25 kg/cm2} (charge pressure) sure between chamber Y and chamber Z and
to a maximum of 47.1 MPa {480 kg/cm2}. the force of spring (1).
• The flow control valve supplies an almost con-
stant oil flow to B and C, regardless of the (1) When oil does not flow W o X o Y
change in pressure at portion P. • There is no difference in pressure between
• This constant oil flow can be set as desired by chamber Y and chamber Z, so spool (2) is
the diameter of the throttle and spring (1). moved to the right end by the force of spring (1),
and the area of opening at portion W becomes
the maximum.
1. Valve 4. Poppet
2. Spring 5. Spring
3. Valve seat 6. Adjustment screw
Function
• The charge relief valve is installed inside the 3rd
speed valve. 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.
• 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
• Port A connects the pressure at the HST main
low-pressure side (charge circuit) selected by
the shuttle valve.
• In addition, ports B and D are connected to the
tank drain circuit through the HST motor case.
• The pressure oil passes through orifice g in
valve (1) and fills chamber C. Poppet (4) is fit-
ted tightly to valve seat (5).
1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
Function
1. Operating effort characteristics
(1) Operation for forward and reverse travel
• The control lever is held at 3 positions of
Forward, Neutral, and Reverse.
FRAME ASSEMBLY
a The diagram shows the D37PX-21.
1. Engine mount
2. Frame assembly
3. Rear underguard
4. Front underguard
Outline
• A hull frame structure with the main frame, track
frame, and underguard forming one unit is used.
Unit: mm
Outline Specifications
• Recoil spring (9) moves rod (7) to the front or
rear when grease is added or removed from Model D31/D37 D39
lubricator (15), and adjusts the track tension. Grease G2-LI (NLGI No.2)
Recoil spring (9) also acts to absorb any sudden
Amount of grease (cc) 160 270
shock applied to idler (1).
• Track roller
S : Single flange
W : Double flange
The arrangement inside ( ) indicates the arrange-
ment when the double flange roller (If equipped) is
installed.
IDLER
D31EX/PX-21
D37EX/PX-21
Unit: mm
D39EX/PX-21
Unit: mm
TRACK ROLLER
D31EX/PX-21
D37EX/PX-21
Unit: mm
Width of tread
7 34.5 —
(Single-flange type)
Width of tread
8 35.5 —
(Double-flange type)
9 Overall width 151 —
D39EX/PX-21
Unit: mm
Width of tread
7 34.5 —
(Single-flange type)
Width of tread
8 35.5 —
(Double-flange type)
9 Overall width 178 —
CARRIER ROLLER
D31EX/PX-21
D37EX/PX-21
Unit: mm
4 Width of tread 35 42
5 Width of flange 52 42
D39EX/PX-21
Unit: mm
4 Width of tread 39 44
5 Width of flange 15 10
SPROCKET
D31EX/PX-21
D37EX/PX-21
Unit: mm
a Make the dimensions of the scale the actual size and copy on to an OHP sheet.
D39EX/PX-21
Unit: mm
a Make the dimensions of the scale the actual size and copy on to an OHP sheet.
TRACK SHOE
D31EX/PX-21
D37EX/PX-21
Unit: mm
Thickness of link
5 23.5 16.5 Replace
(Bushing fitting part)
D39EX/PX-21
Unit: mm
56 47.5 50
3 Thickness of bushing 11 2.5 5
Standard size Repair limit Repair or
4 Height of link
98 89 replace
Thickness of link
5 27.2 18.2 Replace
(Bushing fitting part)
SINGLE SHOE
Unit:mm
SWAMP SHOE
Unit:mm
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The PPC lock valve is installed between the
HST pump and blade PPC valve. If the work
equipment lock lever is set in the LOCK position,
the lock valve connected to it shuts off the oil in
the PPC circuit, thus the operator cannot oper-
ate the work equipment.
ACCUMULATOR
For PPC circuit (If equipped)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
• The accumulator is installed between the HST
pump and blade PPC valve. Even if the engine
stops with the work equipment raised, the pres-
sure of the compressed nitrogen gas in the
accumulator sends the pilot oil pressure to the
work equipment control valve to operate the
valve so that the work equipment will lower by its
weight.
Specification
Gas used: Nitrogen gas
Quantity of gas: 300 cc
Charged gas pressure:
1.18 MPa {12 kg/cm2} (at 80°C)
Max. using pressure:6.68 MPa {70 kg/cm2}
HYDRAULIC PUMP
SAR(2)040: D31EX/PX-21, D37EX/PX-21
SAR(2)045: D39EX/PX-21
Unit: mm
Lift cylinder
Tilt cylinder
Angle cylinder
D31EX/D37EX-21
Ripper cylinder (If equipped)
Unit: mm
D39EX/PX-21
Lift cylinder
Tilt cylinder
Angle cylinder
D39EX-21
Ripper cylinder (If equipped)
Unit: mm
CONTROL VALVE
Outline
P : Pump port
T : Tank port (to tank)
C : Cooler port (oil cooler)
Unit: mm
Unit: mm
Unit: mm
CLSS
1. Outline of CLSS
Features
CLSS stands for Closed center Load Sensing Sys-
tem, and has the following features.
Structure
• The CLSS consists of a gear pump, control
valve, and the actuators.
2. Basic principle
2. Unload valve
Function
• When the control valve is at HOLD, pump dis-
charge amount Q is all relieved to the tank cir-
cuit. This reduces the pressure loss from the
pump to the tank.
Operation
• At the left end of spool (1), pump pressure PP2
(CPP1) is acting on area S1, and at the right end
of spool (1), pump pressure PP3 and the force
of spring (2) are acting on area S2. In addition,
LS pressure PLS is acting on area S3.
• When the control valve is at HOLD, LS pressure
PLS is not generated. Piston (3) is set at the left
position by spring (4), pressure PP3 is con-
nected to TS, and becomes much lower than
pump pressure PP1.
• Therefore, pump pressure PP2 (CPP1) is set
only by the force of spring (2) to a maximum of
0.53 MPa {5.4 kg/cm2}.
Function
• When the control valve is operated, an amount
of oil corresponding to the opening of the spool
flows to the actuator.
• When the control valve is operated, pump dis-
charge pressure PP1 is set to LS pressure PLS
+ 1.5 MPa {15 kg/cm2}.
Operation
• The operation is the same regardless of whether
the control valve is being fully operated or used
for fine control.
• When more than one actuator is used that the
same time, and the condition becomes pump
discharge < actuator demand, spool (1) moves
further to the left to the end of the stroke.
• As a result, pump circuits PP1 and PP2 and tank
circuit T are shut off, and all the pump discharge
amount flows to the actuators.
• When the control valve is operated fully, LS
pressure PLS is generated and acts on area S1
at the left end of piston (3) and area S3 at the
right end of spool (1).
• When LS pressure PLS reaches 0.07 MPa {0.7
kg/cm2}, piston (3) overcomes the force of spring
(4) and moves fully to the right.
• As a result, the connection between the spring
chamber of spring (2) and port TS is cut off and
the condition becomes PP1 = PP2.
• Spool (1) moves to the left so that the difference
in pressure between pump pressure PP1 and
LS pressure PLS becomes 1.5 MPa {15 kg/
cm2}.
• In addition, when the control valve is at neutral,
the oil being drained to the circuit T all flows to
the actuators.
4. LS bypass plug
PP : Pump circuit
PLS : LS circuit
TS : Seal drain circuit
A : To each valve
Function
• It releases the residual pressure of LS pressure
PLS.
• 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 effective LS differential pressure.
Operation
• The pressurized oil for LS circuit PLS passes
from clearance filter a (formed by the clearance
between LS bypass plug (1) and the valve body)
through orifice b and flows to seal drain circuit
TS.
5. Introduction of LS pressure
Function
• The LS pressure is the actuator load pressure at • Actuator circuit pressure PA (=A) acts on the left
the outlet port end of the control valve. end of pressure reducing valve (3); the reduced
• It actually reduces pump pressure PP at pres- pump discharge pressure PP acts on the other
sure reducing valve (3) of the pressure compen- end.
sation valve to the same pressure as actuation • As a result, pressure reducing valve (3) is bal-
circuit pressure A, and sends it to the LS circuit anced at a position where actuator circuit pres-
PLS. sure PA and the pressure of spring chamber
PLS1 are the same. Pump discharge pressure
Operation PP is reduced at notch C, becomes actuator cir-
• When spool (1) is operated, pump discharge cuit pressure A, and is taken to LS circuit PLS.
pressure PP flows from flow control valve (2)
and notch a in spool (1) through bridge passage
b to actuator circuit A.
• 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.
• 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).
Function
• During compound operations, if the load pres-
sure becomes lower than the other actuator and
the oil flow tries to increase, compensation is
received. (When this happens, the other actua-
tor being used for compound operation (right
side) is at a higher load than the actuator on
this side (left side).)
Operation
• If the load pressure of the other actuator (right • Flow control valve (2) and pressure reducing
side) becomes higher during compound opera- valve (1) are balanced in position where the dif-
tions, the oil flow in actuator circuit A on this side ference in pressure between PLS and PA acting
(left side) tries to increase. on both ends of pressure reducing valve (2) and
• If this happens, the LS pressure PLS of the the pressure loss between PP and PPA on both
other actuator acts on spring chamber PLS1, sides of flow control valve (2) are the same.
and pressure reducing valve (1) and flow control • In this way, the pressure difference between
valve (2) are pushed to the left. upstream pressure PPA and downstream pres-
• Flow control valve (2) throttles the area of open- sure PA of both spools used during compound
ing between pump circuit PP and spool operations is the same, so the pump flow is
upstream PPA, and pressure loss is generated divided in proportion to the area of opening of
between PP and PPA. notch a of each spool.
PPC VALVE
a PPC: Abbreviation for Proportional Pressure Control
Operation
1. At Neutral
FOR RIPPER
Unit: mm
Operation
1. At neutral
• Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D via fine control hole f on spool (1).
4. At full stroke
• 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.
• Thus, pilot pressurized oil from the control pump
passes through fine control hole f and con-
ducted to chamber A via port P1 to push the
control valve spool.
• Return oil from chamber B is conducted from
port P2 to drain chamber D via fine control hole
f’.
WORK EQUIPMENT
a The diagram shows D37PX-21.
D31EX/PX-21
D37EX/PX-21
Unit: mm
D39EX/PX-21
Unit: mm
Unit: mm
RIPPER
D31EX/D37EX/D39EX-21 (If equipped)
a The diagram shows D39EX-21.
Unit: mm
3. Support
4. Ripper cylinder
5. Shank
6. Point
7. Beam
CAB RELATED
AIR CONDITIONER PIPING
ENGINE CONTROL
1. Battery Function
2. Battery relay • A limit switch is installed to the parking brake
3. Starting switch lever linkage and the HST controller controls the
4. Fusible link engine with it so that the engine can start only
5. Fuse box when the parking brake lever is in the LOCK
6. HST controller position and the joystick is in the N (Neutral)
7. Parking brake lever position.
8. Parking brake limit switch 1
9. Joystick (PCCS lever)
10. Electric lever
11. Neutral safety parking brake relay
12. Safety relay
13. Starting motor
14. Engine stop solenoid
Example)
• When the fuel control lever is at the "FULL
SPEED" position and the decelerator pedal is
not pressed:
The deceleration command is 100%, and the
command travel speed is equal to the set travel
speed.
• When the fuel control lever or the decelerator
pedal is set in the "MEDIUM SPEED" position:
The travel speed is limited according to the for-
mula of Command travel speed = Deceleration
command x Set travel speed / 100.
Example)
• When the brake pedal is pressed halfway:
The travel speed is limited according to the for-
mula of Command travel speed = Brake com-
mand x Set travel speed / 100.
When external load increases and engine speed <Command travel speed map>
lowers
• The HST controller lowers the command travel
speed according to command travel speed map
(A).
In addition, the HST controller decides the EPC
valve control signal and gear speed shifting
solenoid valve drive signal to lower the travel
speed according to the HST pump capacity
command map and the HST motor command
map.
Changing travel speed according to change <HST pump capacity command map>
of HST circuit oil pressure
When external load decreases and HST circuit <HST motor capacity command map>
oil pressure lowers
• If the HST controller judges that the HST circuit
oil pressures on both sides are low, it returns the
command travel speed and HST motor capacity
to the original levels.
Function
• The HST controller monitors the operating con-
ditions of each lever and each pedal and con-
stantly 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.
Function
• Parking brake limit switches 1 (12) and 2 (13)
and installed and connected to parking brake
lever (11) so that parking brake (22a) will be
released only when parking brake lever (11) is in
the FREE position.
• Center brake limit switch (10) is installed and
connected to brake pedal (8) so that slow brake
solenoid valve (18) will be de-energized and
parking brake (22a) will be applied when brake
pedal (8) is pressed fully.
1. Potentiometer
2. Connector
Function
• The potentiometer is connected to the decelera-
tor pedal, brake pedal, and fuel control lever and
its shaft is rotated according to the operating
angle of the pedal and lever.
• The movement of the shaft operates the internal
variable resistor, which generates a signal volt-
age by changing the source voltage of 5 V
according to the operating angle.
SAFETY RELAY
1. Relay body
EPC VALVE
a See section on HST pump.
MONITOR PANEL
a See section on monitor system.
MONITOR SYSTEM
• The monitor system notifies the operator of the • The monitor system consists of the monitor
machine condition. It monitors the machine con- panel, controller, sensors, alarm buzzer, and
dition with the sensors installed to the machine power supply.
and processes and displays the obtained infor- • The component parts are connected by wiring
mation on the monitor panel immediately. harnesses and the monitor panel is powered by
The contents displayed on the panel are roughly the battery.
classified as shown below. • If the machine has any trouble (and a sensor
1. Travel direction, gear speed, shift mode detects it), the monitor and alarm lamp flash and
(Display panel A) the alarm buzzer sounds to protect the machine.
2. Coolant temperature, reverse travel speed, The alarm buzzer can be turned OFF tempo-
HST oil temperature, and fuel level (Gauge rarily with the buzzer cancel switch.
section)
3. Machine trouble alarm (Monitor section)
4. Current, voltage, error code, of each sensor
and solenoid (Display panel B)
a For details of the operating method, see TESTING AND ADJUSTING, Special functions of monitor panel
(EMMS).
Other items
a For details of the operating method, see TESTING AND ADJUSTING, Special functions of monitor panel
(EMMS).
MONITOR PANEL
Outline Operation
• The monitor panel consists of the monitor sec-
tion which outputs an alarm when the machine When power is turned ON
has any trouble and the gauge section and dis- (When starting switch is turned to ON position)
play panel which display the machine condition • All the LC segments and lamps of the monitor
constantly. panel light up for 2 seconds and the alarm
The monitor panel has a microcomputer, which buzzer sounds for 2 seconds.
processes and displays the signals from the
sensors, solenoids, and controllers. Check before starting
The items displayed on the monitor section and • After the operation performed when the power is
gauge section are shown in DISPLAY OF MON- turned ON, if there is any abnormal one in the
ITOR PANEL. 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.
Alarm Alarm
Display Display
No. Display item Display range Display method lamp buzzer Remarks
section color
output output
Corresponding segment (1 place)
1a Gauge See figure at left — — Black LCD
lights up
Coolant Below 102°C OFF OFF OFF
temperature
1b Caution 102°C – 108°C Flashing Flashing OFF Red LED
Above 108°C Flashing Flashing ON
Corresponding segment (1 place)
2a Gauge See figure at left — — Black LCD
lights up
HST oil Below 100°C OFF OFF OFF Red LED
temperature
2b Caution 100°C – 110°C Flashing Flashing OFF
Above 110°C Flashing Flashing ON
Reverse travel [*1] Below corresponding segment
3 Gauge — — Black LCD
speed See figure at left All light up
Below corresponding segment
4 Gauge Fuel level See figure at left — —
All light up
P: Parking brake lever in LOCK,
Joystick in NEUTRAL
Travel direction
5a N: Joystick in NEUTRAL
(P, N, F, R)
F: Joystick in FORWARD
Indicator R: Joystick in REVERSE OFF OFF
[*2] 1: Joystick gear shift switch in 1st
Display panel A [*3]
5b 2: Joystick gear shift switch in 2nd
(Travel direction, Gear speed (1, 2, 3)
3: Joystick gear shift switch in 3rd Black LCD
gear speed, shift
[*1], [*4]
mode)
Intermediate gear Below corresponding segment
5c Gauge — —
speed All light up
(See figure at left)
5d Variable shift mode ON — —
Pilot
5e Quick shift mode ON — —
[*2]
Character Time is counted while engine is
6 Display panel B 0 – 99999.9 h — —
display running (alternator is generating)
(Service meter)
When charge is OFF (While engine is stopped) OFF OFF
7 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
8
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
9
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
10
pressure (785 kPa {8.0 kg/cm2}) Flashing (While engine is running) Flashing ON
11 Pilot Preheating In preheating mode ON OFF OFF Green LED
Before 30 h or more OFF
12 Maintenance Before 30 h – Replace- ON for 30 seconds after starting OFF OFF Orange
ment time switch is turned ON
13 Warning lamp See the “warning lamp output” column of this table — — Red
Caution Before 30 h or more OFF
Before 30 h – Replace-
Replacement time ON
14 ment time OFF OFF Yellow
of filter and oil
Passed replacement
Flashing
time
SENSORS
• The signals from the sensors are input directly to the controller or monitor panel.
• There are 4 types of sensors: contact type, resistance type, electromagnetic type, and semiconductor type.
• The contact type sensors always have one side connected to the chassis ground.
Category of display Type of sensor Method of sensor When normal When abnormal
Engine oil pressure Contact (N.C.) OFF (open) ON (closed)
Charge filter clogging Contact (N.O.) OFF (open) ON (closed)
Caution
Brake oil pressure
Contact (N.O.) ON (closed) OFF (open)
(HST charge oil pressure)
Coolant temperature Resistance — —
Gauges HST oil temperature Resistance — —
Fuel level Resistance — —
Engine speed Electromagnetic — —
— HST motor speed Electromagnetic — —
HST circuit oil pressure Semiconductor — —
1. Plug Function
2. Contact ring • The engine oil pressure sensor is installed to the
3. Contact engine cylinder block. Its diaphragm senses oil
4. Diaphragm pressure. If the oil pressure lowers below the
5. Spring set level, the switch is turned ON.
6. Terminal
1. Plug Function
2. Sensor • The brake oil pressure sensor is installed to the
3. Connector parking brake solenoid valve piping. It senses
the brake oil pressure when the brake is
released. If the brake oil pressure lowers below
the set level, the switch is turned ON.
1. Float Function
2. Arm • The fuel level sensor is installed to the side of
3. Connector the fuel tank and its float moves up and down
4. Variable resistor according to the fuel level in the tank. The
5. Contact movement of the float operates the variable
6. Body resistor through the arm, and then signals are
generated according to the change of the resis-
tance.
1. Thermistor Function
2. Plug • The coolant temperature sensor is installed to
3. Connector the engine cylinder block. The HST oil tempera-
ture sensor is installed to the pump suction pip-
ing. They sense the changes of the temperature
as the changes of the resistance of the ther-
mistors in them, and then generate signals
according to the measured temperature.
1. Wire Function
2. Magnet • The engine speed sensor is installed to the ring
3. Terminal gear of the flywheel housing and generates
4. Housing pulse voltages as the gear rotates.
5. Connector
1. Plug Function
2. Sensor • The HST circuit oil pressure sensor is installed
3. Connector to the HST pump. It senses the HST circuit
pressures on the right and left sides as the
changes of the voltage in its semiconductor
parts, and then generates signals according to
the measured pressures.
TROUBLESHOOTING ..........................................................................................................................20-301
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
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.
k 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.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k 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.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
Engine SAA4D102E-2
Standard
Cate- value for Service limit
Item Measurement conditions Unit
gory new value
machine
D37EX-21, D37PX-21
Engine SAA4D102E-2
Standard
Cate- value for Service limit
Item Measurement conditions Unit
gory new value
machine
D39EX, PX-21
Engine SAA4D102E-2
Standard
Cate- value for Service limit
Item Measurement conditions Unit
gory new value
machine
N → Forward/Reverse mm 29 ± 6 29 ± 6
reverse • Center of lever grip
• Engine: Stopped N – Sharp turn to right/
Steering mm 50 ± 10 50 ± 10
• Center of lever knob left
• Engine: Low idling
Brake pedal mm 78 ± 10 78 ± 10
• Center of pedal
Stroke
• Engine: Stopped
Decelerator pedal mm 68 ± 10 68 ± 10
• Center of pedal
Neutral – Raise mm 47 ± 10 47 ± 20
• Engine: Stopped Neutral – Lower mm 47 ± 10 47 ± 20
Work equipment • Center of lever knob Neutral – Float mm 71 ± 10 71 ± 20
control lever • Angle: Twisting angle Neutral – Left/Right tilt mm 52 ± 10 52 ± 20
of lever
Neutral – Left/Right
° 15 ± 3 15 ± 6
angle
N 29.4 ± 19.6 58.8
• Engine: Stopped Low – High
{kg} {3 ± 2} {6}
Fuel control lever • 20 mm from lever
knob end N 68.6 ± 19.6 108
High → Low
{kg} {7 ± 2} {11}
Forward and N 52.9 ± 9.8 52.9 ± 11.8
N – Forward/Reverse
Operating effort
N 26.5 ± 10 39.2
Neutral – Lower
{kg} {2.7 ± 10} {4.0}
Work equipment • Engine: Low idling N 70.6 ± 22 118
Neutral – Float
control lever • Center of lever knob {kg} {7.2 ± 2.2} {12.0}
Neutral – Left/Right N 26.5 ± 10 39.2
tilt {kg} {2.7 ± 1.0} {4.0}
Neutral – Left/Right Nm 2.9 – 5.4 8.3
angle {kgm} {0.3 – 0.55} {0.9}
MPa 40.2 – 44.1 39.2 – 45.1
Left
{kg/cm2} {410 – 450} {400 – 460}
• Engine: High idling Forward
• HST oil temperature MPa 40.2 – 44.1 39.2 – 45.1
Right
Main circuit (hydraulic oil temperature): {kg/cm2} {410 – 450} {400 – 460}
pressure Within operating range MPa 40.2 – 44.1 39.2 – 45.1
HST oil pressure
pressure Within operating range PCCS lever: MPa 2.84 ± 0.29 2.84 ± 0.49
(40 – 60°C) Forward or reverse {kg/cm2} {29 ± 3.0} {29 ± 5.0}
• Stall pressure test mode
2nd gear
Solenoid output pressure
D37EX, PX-21
N → Forward/Reverse mm 29 ± 6 29 ± 6
reverse • Center of lever grip
• Engine: Stopped N – Sharp turn to right/
Steering mm 50 ± 10 50 ± 10
• Center of lever knob left
• Engine: Low idling
Brake pedal mm 78 ± 10 78 ± 10
• Center of pedal
Stroke
• Engine: Stopped
Decelerator pedal mm 68 ± 10 68 ± 10
• Center of pedal
Neutral – Raise mm 47 ± 10 47 ± 20
• Engine: Stopped Neutral – Lower mm 47 ± 10 47 ± 20
Work equipment • Center of lever knob Neutral – Float mm 71 ± 10 71 ± 20
control lever • Angle: Twisting angle Neutral – Left/Right tilt mm 52 ± 10 52 ± 20
of lever
Neutral – Left/Right
° 15 ± 3 15 ± 6
angle
N 29.4 ± 19.6 58.8
• Engine: Stopped Low – High
{kg} {3 ± 2} {6}
Fuel control lever • 20 mm from lever
knob end N 68.6 ± 19.6 108
High → Low
{kg} {7 ± 2} {11}
Forward and N 52.9 ± 9.8 52.9 ± 11.8
N – Forward/Reverse
Operating effort
N 26.5 ± 10 39.2
Neutral – Lower
{kg} {2.7 ± 10} {4.0}
Work equipment • Engine: Low idling N 70.6 ± 22 118
Neutral – Float
control lever • Center of lever knob {kg} {7.2 ± 2.2} {12.0}
Neutral – Left/Right N 26.5 ± 10 39.2
tilt {kg} {2.7 ± 1.0} {4.0}
Neutral – Left/Right Nm 2.9 – 5.4 8.3
angle {kgm} {0.3 – 0.55} {0.9}
MPa 40.2 – 44.1 39.2 – 45.1
Left
{kg/cm2} {410 – 450} {400 – 460}
• Engine: High idling Forward
• HST oil temperature MPa 40.2 – 44.1 39.2 – 45.1
Right
Main circuit (hydraulic oil temperature): {kg/cm2} {410 – 450} {400 – 460}
pressure Within operating range MPa 40.2 – 44.1 39.2 – 45.1
HST oil pressure
pressure Within operating range PCCS lever: MPa 2.84 ± 0.29 2.84 ± 0.49
(40 – 60°C) Forward or reverse {kg/cm2} {29 ± 3.0} {29 ± 5.0}
• Stall pressure test mode
2nd gear
Solenoid output pressure
D39EX, PX-21
N → Forward/Reverse mm 29 ± 6 29 ± 6
reverse • Center of lever grip
• Engine: Stopped N – Sharp turn to right/
Steering mm 50 ± 10 50 ± 10
• Center of lever knob left
• Engine: Low idling
Brake pedal mm 78 ± 10 78 ± 10
• Center of pedal
Stroke
• Engine: Stopped
Decelerator pedal mm 68 ± 10 68 ± 10
• Center of pedal
Neutral – Raise mm 47 ± 10 47 ± 20
• Engine: Stopped Neutral – Lower mm 47 ± 10 47 ± 20
Work equipment • Center of lever knob Neutral – Float mm 71 ± 10 71 ± 20
control lever • Angle: Twisting angle Neutral – Left/Right tilt mm 52 ± 10 52 ± 20
of lever
Neutral – Left/Right
° 15 ± 3 15 ± 6
angle
N 29.4 ± 19.6 58.8
• Engine: Stopped Low – High
{kg} {3 ± 2} {6}
Fuel control lever • 20 mm from lever
knob end N 68.6 ± 19.6 108
High → Low
{kg} {7 ± 2} {11}
Forward and N 52.9 ± 9.8 52.9 ± 11.8
N – Forward/Reverse
Operating effort
N 26.5 ± 10 39.2
Neutral – Lower
{kg} {2.7 ± 10} {4.0}
Work equipment • Engine: Low idling N 70.6 ± 22 118
Neutral – Float
control lever • Center of lever knob {kg} {7.2 ± 2.2} {12.0}
Neutral – Left/Right N 26.5 ± 10 39.2
tilt {kg} {2.7 ± 1.0} {4.0}
Neutral – Left/Right Nm 2.9 – 5.4 8.3
angle {kgm} {0.3 – 0.55} {0.9}
MPa 40.2 – 44.1 39.2 – 45.1
Left
{kg/cm2} {410 – 450} {400 – 460}
• Engine: High idling Forward
• HST oil temperature MPa 40.2 – 44.1 39.2 – 45.1
Right
Main circuit (hydraulic oil temperature): {kg/cm2} {410 – 450} {400 – 460}
pressure Within operating range MPa 40.2 – 44.1 39.2 – 45.1
HST oil pressure
pressure Within operating range PCCS lever: MPa 2.84 ± 0.29 2.84 ± 0.49
(40 – 60°C) Forward or reverse {kg/cm2} {29 ± 3.0} {29 ± 5.0}
• Stall pressure test mode
2nd gear
Solenoid output pressure
Work equipment
Performance measuring posture and measuring Work equipment 2: Blade tilting speed
method
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
Measuring intake air –101 – 200 kPa
A 799-201-2202 Boost gauge kit 1
pressure (boost pressure) {–760 – 1,500 Hg}
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Handy smoke
1 799-201-9001 1
Measuring exhaust checker
C Bosch index: 0 – 9
gas color Commercially
2 Smoke meter 1
available
1 795-799-1131 Gear 1 For 102 Series engine
Adjusting valve clearance D Commercially Air intake side: 0.25 mm,
2 Feeler gauge 1
available Exhaust side: 0.51 mm
Measuring compression 1 795-502-1205 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
E
pressure 2 795-502-1700 Adapter 1 For 102 Series engine
Measuring blow-by 1 799-201-1504 Blow-by checker 1 —
F
pressure 2 795-790-1950 Tool (Nozzle) 1 —
Pressure gauge: 2.5, 5.9, 39.2,
799-101-5002 Hydraulic tester 1 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
G Digital hydraulic Pressure gauge: 58.8 MPa
pressure 790-261-1203 1
tester {600 kg/cm2}
Pressure gauge: 0.98 MPa
2 799-401-2320 Hydraulic tester 1
{10 kg/cm2}
1 795-799-1131 Gear 1
Measuring fuel injection
H 2 795-799-1900 Pin assembly 1 For 102 Series engine
timing
3 795-799-1950 Lock pin 1
799-101-5002 Hydraulic tester 1
1 Digital hydraulic Same as G1
Testing and adjusting HST 790-261-1203 1
J tester
oil pressure
799-101-5220 Nipple 4
2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
799-101-5002 Hydraulic tester 1
1 Digital hydraulic Same as G1
790-261-1203 1
tester
Measuring solenoid valve 799-401-3100 Adapter 1 Size: 02
K
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
Adjusting HST motor
L 791T-265-1110 Wrench 1 a See sketch of special tool
speed sensor
Method of releasing park- 1 790-190-1500 Pump assembly 1 —
ing 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 item Symbol Part No. Part name Q'ty Remarks
799-101-5002 Hydraulic tester 1
1 Digital hydraulic
Testing and adjusting work 790-261-1203 1
N tester Same as J
equipment oil pressure
790-101-5220 Nipple 4
2
07002-11023 O-ring 4
799-101-5002 Hydraulic tester 1
Measuring work 1 Digital hydraulic Same as G1
equipment PPC valve P 790-261-1203 1
tester
output pressure
2 799-401-3100 Adapter 1 Size: 02
Measuring leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
Measuring water tempera-
— 799-101-1502 Digital thermometer 1 Same as B
ture and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Scale 1 —
hydraulic drift available
Measuring work Commercially
— Stopwatch 1 —
equipment speed available
Measuring voltage and Commercially
— Circuit tester 1 —
resistance available
L: Wrench (791T-265-1110)
1. Preparation work
Turn the starting switch ON and set the monitor
panel in the “Real-time monitoring mode” to pre-
pare for measurement of the engine speed.
★ For the operating method, see “Special func-
tions of monitor panel (EMMS)”.
• Monitoring code: 01002-ENG SPEED
• The engine speed is displayed in rpm.
MEASURING INTAKE AIR 3. Turn the starting switch ON, set the monitor
panel in the “Adjustment mode”, and prepare for
PRESSURE (BOOST PRESSURE) stalling the HST.
★ When performing this operation, set the
★ Measuring instruments for intake air pressure parking brake lever in the LOCK position and
(boost pressure) the PCCS lever in the neutral position.
★ For the operating method, see “Special func-
Symbol Part No. Name tions of monitor panel (EMMS)”.
A 799-201-2202 Boost gauge kit • Adjustment code: 3016-STALL CHECK
ADJUSTING VALVE 4. Remove plug (2) of the fuel injection pump and
turn over timing pin (3), then crank the flywheel
CLEARANCE forward with gear D1 until the cut of the pin
meshes with projection (a) in the pump.
★ Adjusting instruments for valve clearance ★ Since you cannot push the timing pin on the
front timing gear side, use the timing pin on
Symbol Part No. Name the fuel injection pump side to set the No. 1
1 795-799-1131 Gear cylinder to the compression top dead center.
★ When the pin meshes, make match marks
D Commercially
2 Feeler gauge on the crank pulley and front timing gear
available case.
3 Locknut:
(7).
3 Nozzle holder:
compound (MOLYCOAT 100)
MEASURING BLOW-BY
PRESSURE
★ Measuring instrument for blow-by pressure
2. Install nozzle tool F2 to blow-by hose (1) and 5. While running the engine at high idle, operate
connect it to gauge [1] of blow-by checker F1. 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.
★ If the PCCS lever is set in the forward or re-
verse position, the HST stalls. If the PCCS
MEASURING ENGINE OIL 3. Run the engine and measure the oil pressure at
low idle and high idle.
PRESSURE
★ Measuring instruments for engine oil pressure
1. Open the left engine side cover and remove 5. Turn over and insert timing pin (4) of the fuel
work equipment pump assembly (1). injection pump and check that its cut is fitted to
6
projection (a) in the pump.
Hydraulic tank: 47 l ★ If you can insert the timing pin smoothly, the
injection timing is correct.
★ If you cannot insert the timing pin, the injec-
tion timing is not correct. In this case, adjust
the injection timing.
★ If it is difficult to check with the timing pin in-
stalled to the fuel injection pump, you may
use metallic pin assembly H3.
Adjusting
★ If the fuel injection timing is not correct, adjust it
according to the following procedure.
1. Using timing pin (2) of the drive gear, check that
the drive gear is fixed.
★ If the timing pin was returned after testing, in-
sert it again according to the testing proce-
dure.
TESTING AND ADJUSTING 2) Start the engine and keep the parking brake
lever in the LOCK position.
HST OIL PRESSURE ★ Stall the HST with the parking brake le-
ver in the LOCK position.
★ Testing and adjusting instruments for HST oil 3) While running the engine at high idle, oper-
pressure ate PCCS lever in the forward or reverse
position to stall the HST and measure the
Symbol Part No. Name HST main circuit pressure.
799-101-5002 Hydraulic tester ★ If the PCCS lever is set in the forward or
1 reverse position, the HST stalls. If the
790-261-1203 Digital hydraulic tester PCCS lever is returned, stalling of the
J
3) Turn the starting switch ON, set the monitor 6) After finishing measurement, remove the
panel in the “Adjustment mode”, and pre- measuring instruments and return the
pare for stalling the HST. removed parts.
★ When performing this operation, set the
parking brake lever in the LOCK position 3. Measuring HST pump EPC valve output pres-
and the PCCS lever in the neutral posi- sure
4 Undercover of HST: 30 kg
4) After finishing adjustment, check that the 4) After finishing adjustment, check that the
HST charge circuit pressure is normal HST charge circuit pressure is normal
according to the measurement procedure according to the measurement procedure
described above. described above.
3. Initializing HST pump EPC valve
2. Adjusting HST charge circuit pressure (on motor The HST pump EPC valve does not need to be
side) adjusted. If it is replaced, however, initialize the
★ If the HST charge circuit pressure (only related items in the adjustment mode of the
when the HST is stalled) is abnormal, adjust monitor panel.
charge relief valve (9) of the HST motor ac- ★ For the operating method, see "Special func-
cording to the following procedure. tions of monitor panel (EMMS)".
★ When adjusting charge relief valve (9) of the • Adjustment code (When adjusting while
HST pump, remove the HST motor covers track shoe is driven idle)
(right and left). 1) 3001-PUMP AJST F
2) 3002-PUMP AJST R
• Adjustment code (When adjusting while ma-
chine is traveling actually)
1) 3003-PU F-UP MAP
2) 3004-PU R-UP MAP
3) 3005-PU F-HF MAP
4) 3006-PU R-HF MAP
799-401-3100 Adapter
K 2
799-401-3200 Adapter
Table 1. Output pressures of 2nd travel speed selection solenoid valve and 3rd travel speed selection
solenoid valve (when normal)
Travel speed and Output pressure of 2nd travel speed Output pressure of 3rd travel speed
Travel mode
travel condition selection solenoid valve selection solenoid valve
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
3.04 ± 0.49 MPa 3.04 ± 0.49 MPa
Both are normal
{31 ± 5 kg/cm2} {31 ± 5 kg/cm2}
3.04 ± 0.49 MPa Parking brake has trouble
FREE Released 0 MPa {0 kg/cm2}
{31 ± 5 kg/cm2} (Sticking, etc.)
Slow brake has trouble
0 MPa {0 kg/cm2} 0 MPa {0 kg/cm2}
(Sticking, etc.)
★ 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)”).
• Monitoring code: 40913-S/T SW4
• From left;
1st: 3rd travel speed selection solenoid valve: ON
2nd: 2nd travel speed selection solenoid valve: ON
3rd: Parking brake solenoid valve: ON
4th: Slow brake solenoid valve: ON
Others: (Unused)
★ Test the travel deviation under the following con- • Monitoring code: 52503-HST L PRES
dition. • Monitoring code: 52501-HST R PRES
• HST oil (Hydraulic oil) temperature: Within
operating range (40 – 60°C)
• Test place: Hard and even ground of con-
crete, etc.
3. Installing and adjusting speed sensor 4) Under the above condition, check match
1) Insert speed sensor (7) in the motor case marks (b) on speed sensor (7) and match
and turn it slowly until it touches the bottom. marks (c) on the mounting plate, and then
★ When inserting the speed sensor in the match the nearer one of match marks (b) to
motor case, take care not to damage its the nearer one of match marks (c) by turning
tip. speed sensor (7).
★ If the speed sensor is tightened too ★ The match marks on the speed sensor
strongly, its tip may be damaged. Ac- are the 2 V-grooves at the hexagonal
cordingly, do not tighten it with a tool but part 27 mm wide across flats. (There
tighten with your hand (Torque: Max. may be 2 white lines on the hexagonal
2.45 Nm {0.25 kgm}). part. Note that those white lines are not
the match marks.)
★ The match marks on the mounting plate
are the 2 punch holes on the seating
face.
★ Since the turning limit for this work is 90 °,
be sure to match the nearer match marks
to each other.
3 Locknut:
sor again, move the O-ring back fully to-
ward the hose according “Preparation
work and precautions”. 84 – 132 Nm {8.5 – 13.5 kgm}
★ The difference limit between the match
marks after this work is 30°. If the differ-
ence exceeds 30°, match the match
marks again.
★ If you look at the match marks diagonal-
ly, you may not able to check them accu-
rately. Accordingly, look them in parallel
with the axis of the speed sensor.
6) After tightening the locknut, measure projec- 8) Start the engine and check that oil does not
tion (a) of the sensor with slide calipers and leak from the speed sensor.
record the result.
★ Standard projection (a) of sensor: 4. Checking operation of speed sensor
24.9 ± 1.9 mm 1) Set the monitor panel in the ”Dual-time dis-
★ If measured projection (a) of the sensor play monitoring mode”.
is out of the standard, move the O-ring ★ For the operating method, see “Special
back fully toward the hose according to functions of monitor panel (EMMS)”.
“Preparation work and precautions”, and • Monitoring code: 40002-R SPEED
then repeat 1) – 5). • Monitoring code: 40003-L SPEED
★ The difference between the projection ★ If you use the “Dual-time display monitor
measured in 2) and the projection meas- mode”, you can check the right and left
ured in this step is the air gap at the speed sensors simultaneously. You
speed sensor tip. may check 1 speed sensor by 1 with the
“Real-time monitoring mode”, however.
ADJUSTING PARKING BRAKE 3. Set the parking brake lever (1) in the LOCK
position and adjust clearance (c) between lever
LEVER (4) and 2 limit switches (5).
★ Clearance (c) between lever and limit switch:
★ If any part related to the parking brake lever has 0 mm
been removed and installed or replaced, adjust ★ When adjusting, do not operate the limit
the parking brake lever according to the following switch.
procedure.
PROCEDURE OF SIMPLE
TEST OF BRAKE
PERFORMANCE
★ Carry out the simple test of the brake perform-
ance under the following condition.
• HST oil (Hydraulic oil) temperature: Within
operating range (40 – 60°C)
• 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.
★ If any part related to the brake pedal has been re- 4. After adjusting the linkage, check that brake limit
moved and installed or replaced, adjust the switch (4) operates as explained below.
brake pedal according to the following proce- 1) When brake pedal (1) is pressed to 2nd
dure. spring operation point (e), limit switch (3)
must not be turned ON.
1. Adjust installed dimension (b) of stopper bolt (2) 2) When brake pedal (1) is pressed to the
so that stroke (a) of brake pedal (1) will be the stroke end, limit switch (3) must be turned
specified value. ON.
★ Adjust the pedal stroke without removing the
spring. 5. After finishing all the adjustment, initialize all the
• Specified pedal stroke (a): 89 ± 1 mm related items in the adjustment mode of the
• Standard installed dimension (b) of stopper monitor panel.
bolt: 35 mm ★ For the operating method, see “Special func-
tions of monitor panel (EMMS)”.
2. Set brake pedal (1) to the 0 position of the • Adjustment code: 0005-BRAKE N-SET
stroke and install brake limit switch (3) so that its • Adjustment code: 3007-BRAKE END
roller end will be in contact with position (c) of
lever (4).
• Contact point (c) of limit switch: 9 – 10 mm
METHOD OF RELEASING
★ After finishing adjustment, open the
PARKING BRAKE valve of the volume pump to release the
(PROCEDURE FOR residual pressure in the pump.
EMERGENCY ESCAPE) ★ After finishing adjustment, remove the
plug (R1/4) and connect the hose and
★ Tools to release parking brake quick coupler [5].
★ If the engine cannot be started and the parking k Fit a block to the track shoe securely.
brake of the HST motor cannot be released, re- 1) Remove the undercover of the HST pump.
1. Testing pump assembly M1 2) Loosen locknuts (3) of towed valve (1) for
the left pump towed valve (2) for the right
k If the following work is performed while the pump, and then loosen plugs (4) by 2 turns.
pressure of the pump assembly is abnor- 3) Tighten locknuts (3) lightly and secure them
mal, the brake piston of the HST motor may so that they will not come off when the
be damaged. Accordingly, be sure to test machine is towed.
the pump assembly.
1) 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
4) Connect the quick coupler at the end of 2) Remove the block of the track shoe and tow
pump assembly M1 to nipple M2. the machine at speed lower than 2 km/h.
4
by the method in 1.
★ If the supply pressure becomes the Undercover of HST pump: 30 kg
specified relief pressure, the parking
brake is released.
TESTING AND ADJUSTING 3. Tighten mounting bolt (3) of guide plate (2).
IDLER CLEARANCE
Testing
★ If the idler vibrates laterally or it slants so much
that the track shoe comes off or is warn uneven-
ly, the guide plate may be worn. In this case,
check according to the following procedure.
Adjusting
★ If the clearance is exceeds the limit, adjust it ac-
cording to the following procedure.
Adjusting
★ If the track shoe tension is abnormal, adjust it ac-
cording to the following procedure.
★ When adjusting the track shoe tension, remove
the outer covers from the track frames. ★ You may supply grease until distance (b) be-
tween the idler guide and frame end is 20
1. When tension is too high mm. If the tension is still low, the pin and
1) Loosen valve (1) slowly to discharge the bushing are worn excessively. In this case,
grease. turn over or replace the pin and bushing.
Measuring
★ Measure the work equipment oil pressure under
the following condition. 3. Run the engine at high idle and relieve the blade
• HST oil (Hydraulic oil) temperature: lift, tilt, and angle cylinders one by one at the
stroke end and measure the work equipment oil
k Loosen the oil filler cap of the hydraulic tank
Within operating range (40 – 60°C)
pressure.
slowly to release the residual pressure in the hy- ★ The relief pressure of the main relief valve of
the control valve is indicated when each of
draulic tank.
the above operation is performed. If only the
1. Open the left engine side cover and remove oil pressure in the angle circuit is low, the
centralized safety valve must be defective,
work equipment oil pressure pickup plug (1)
from the work equipment pump outlet piping. since the bottom side and head side of the
angle cylinder are connected to the central-
ized safety valve.
Adjusting
★ If the oil pressure is abnormal, adjust main relief
valve (2) of the control valve according to the fol-
lowing procedure.
★ When adjusting main relief valve (2) of the con-
trol valve, fold the operator's seat and bracket to-
gether toward the dashboard.
3 Locknut: 39 – 49 Nm {4 – 5 kgm}
3. Fixing adjustment nut (3), tighten locknut (4).
MEASURING WORK
EQUIPMENT PPC VALVE
OUTPUT PRESSURE
★ Testing and adjusting instruments for work
equipment PPC valve output pressure
<Reference>
• Installed length (b) of rod (5): 274.5 mm
MEASURING LEAKAGE IN 4) Run the engine at high idle and move the
blade control lever to the lowering position
WORK EQUIPMENT to relieve the lift cylinder.
CYLINDER
k Do not move the blade control lever to
★ Measuring instruments for leakage in work the raising position.
equipment cylinder 5) Start measuring the oil leakage 30 seconds
after the relief is started and measure the
Symbol Part No. Name leakage in 1 minute.
6) After finishing measurement, remove the
Commercially
Q Measuring cylinder measuring instruments and return the
available
removed parts.
★ Measure the leakage in the work equipment cyl- 2. Measuring leakage in blade tilt cylinder
inder under the following condition. 1) Start the engine and raise the blade to about
• HST oil (Hydraulic oil) temperature: 1 m above the ground.
Within operating range (40 – 60°C) 2) Extend the tilt cylinder to the left tilting stroke
end and stop the engine.
BLEEDING AIR FROM 5) Set the parking brake lever in the FREE
position and set the PCCS lever in the for-
HYDRAULIC CIRCUIT ward and reverse travel positions at least 20
times.
★ If any hydraulic equipment/piping of the HST cir- • Forward o Neutral o Reverse o Neutral
cuit or work equipment circuit was removed/dis- ★ Repeat the operation cycle of setting the
connected and installed/connected, bleed air PCCS lever in the forward and reverse
according to the following procedure after finish- positions at least 20 times.
ing the work.
★ Before and after bleeding air, check that the oil 4. Bleeding air from cylinders
level in the hydraulic tank is normal and no bub- 1) While running the engine at low idle, extend
bles are contained in the oil. and retract each cylinder to before each
stroke end 4 – 5 times.
1. Bleeding air from HST pump ★ Stop the piston rod of each cylinder
1) Remove the inspection cover at the left of about 100 mm before the stroke end to
the floor and the oil filler cap of the hydraulic avoid relieving.
tank under it. 2) Keep running the engine at low idle and
2) Loosen air bleeder (1) at the top of the HST extend and retract each cylinder to each
pump and check that oil oozes out. stroke end 3 – 4 times.
★ If oil oozes out, air has been bled. 3) Keep running the engine at high idle and
3) Tighten air bleeder (1). extend and retract each cylinder to each
stroke end 4 – 5 times.
5. Operating machine
1) After bleeding air, stop the engine and leave
it for 5 minutes.
★ By this operation, the bubbles in the oil in
the hydraulic tank are discharged.
2) Check for oil leakage. If no oil is leaking,
operate the machine.
2. Starting engine
Start the engine and run it at low idle for 10 min-
utes.
2. Pm clinic auxiliary mode (2-PM CLINIC MODE) 3. Fault code display mode
In this mode, the condition of the machine is dis- (3-FAULT CODE DISPLAY MODE)
played on multi-information section (2) as an In this mode, the contents of each fault in the
auxiliary function of the periodic diagnoses such machine are displayed by a 6-character fault
as the Pm clinic, even if any measuring instru- code on the multi-information section (2).
ment is not connected. When the user or the operator needs to be noti-
★ Gear speed/Set travel speed/Shift mode in- fied of the fault code of each fault, this mode is
dicator section (1) keeps displaying ordinari- applied.
ly. ★ Gear speed/Set travel speed/Shift mode in-
dicator section (1) keeps displaying ordinari-
ly.
Adjustment of back
1 01 : LCD BRIGHTNES %
light of LCD gauge
Adjustment of back
2 02 : DSP BRIGHTNES light of multi-informa- %
tion section
Adjustment of LCD
3 03 : DSP CONTRAST contrast of multi- %
information section
<Reference>
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 a fault code in the “Electric system fault
code display mode” and “Mechanical system fault
code display mode” of the service mode.
Operation and display in service mode ★ The following items are displayed in the
service mode.
Method of changing to service mode
★ When using the service mode, change the Gear
screen by the following special operation. speed
No. indica- Item
1) Special operation of switches tor sec-
tion
Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel 5-EXCHG. INTVAL. SET MODE
switch (4). 1 1C
Maintenance interval change mode
★ Keeping the service switch in the ON posi-
tion, hold the buzzer cancel switch in the [U] 6-ELEC. FAULT CODE MODE
2 EE
position for 2.5 seconds. Electric system fault code display mode
★ If the monitor panel is set in the service
mode, [1C] is displayed on the Gear speed/ 7-MACHINE FAULT CODE MODE
3 bE
Set travel speed/Shift mode indicator section Mechanical system fault code display mode
(1).
8-SERVICE ADJUST MODE
★ When the service mode is selected, “Mainte- 4 Cb
nance interval change mode” is displayed Adjustment mode
first. 9-LOAD MEMORY DISPLAY MODE
5 Ld
Load memory display mode
10-REAL TIME MONITORING MODE
6 5R
Real-time monitoring mode
11-DUAL DISPLAY MONITORING MODE
7 dR
Dual display monitoring mode
★ If you do not use the maintenance ★ If the change is not finished normal-
function, set the all times to 0. ly, the information display screen
before the change appears after the
screen shown below. In this case,
execute the above operation again.
★ The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that the
first maintenance has been finished in the maintenance mode of the operator mode, then change the 2nd
and after interval times.
★ The items marked with (*) are displayed but not used for this machine.
6. Electric system fault code display mode 3) Display in the case where 1 or more codes
(6-ELEC. FAULT CODE MODE) are recorded
In this mode, you can check the past electric If any fault code has been output up to now,
system fault codes. the information section displays as shown
below.
(a) Record No. (Up to 20)
(b) Fault code (Code being output currently
is flashing)
(c) Number of past occurrences
(d) Time measured by service meter after
first occurrence
(e) Time measured by service meter after
last occurrence
★ The items shown below are examples.
★ For details of the displayed fault codes,
see the “Fault codes list” in “Trouble-
shooting when fault code is displayed
(Fault code)”.
1) Selecting and executing mode
i) Select “Electric system fault code dis-
play mode” on t he mode selection
screen.
★ If the mode is selected, code [EE] is
displayed on Gear speed/Set travel
speed/Shift mode indicator section
(1) and the title is displayed on multi-
information section (2).
ii) Display the fault code display screen by
operating buzzer cancel switch (4).
• [U]: Execute mode.
4) Operation to perform when multiple codes 7. Mechanical system fault code display mode
are recorded (7-MACHINE FAULT CODE MODE)
When multiple codes are recorded, they can In this mode, you can check the mechanical sys-
be displayed one by one by operating infor- tem fault codes among the codes of the faults
mation switch (5). which occurred in the past or which are occur-
• [>]: Next code ring currently in the machine.
• [<]: Previous code
★ The fault codes are displayed from the
oldest one in order of length of time after
they were output.
3) Display in the case where 1 or more codes 4) Operation to take when multiple codes are
are recorded recorded.
If any fault code has been output up to now, When multiple codes are recorded, they can
the information section displays as shown be displayed one by one by operating infor-
below. mation switch (5).
(a) Record No. • [>]: Next code
(b) Fault code (Code being output currently • [<]: Previous code
is flashing) ★ All the error codes, including the error
(c) Number of past occurrences codes which are not output, are dis-
(d) Service meter reading at first occur- played in the order set internally.
rence.
(e) Service meter reading at last occur- 5) Method of deleting fault code
rence. The mechanical system fault codes cannot
★ The items shown below are examples. be deleted.
★ For details of the displayed fault codes,
see the “Fault codes list” in “Trouble-
shooting when fault code is displayed
(Fault code)”.
[0001]: Phone No. input mode [0002] Model code set (Changed in normal order: A1)
• This code is used to input and change the • This code is used to make the HST controller
phone No. displayed together with the action recognize the machine model and to initialize
code. the set values of the memory in the controller.
• The phone No. and symbols are displayed on • The model code is displayed on the lower line.
the lower line.
• Adjustment method:
• Usable characters: i) Select a correct model code by operating
0, 1, 2, 3, 4, 5, 6, 7, 8, 9, :, ;, <, >, ?, = the shift-up switch (6).
• Using method • Select [D31], [D37], or [D39].
i) Input the phone No. and symbols by operat- ii) Set buzzer cancel switch (4) in the [U] posi-
ing information switch (5), shift-up switch tion and check that the caution buzzer
(6), and shift-down switch (7). sounds.
k If an item is settled with this code, the
• [>]: Move cursor to right.
• [<]: Move cursor to left.
memory in the controller is initialized.
• [UP]: Increase number or select next
Accordingly, use this code only when
character (in the order of usable charac-
required. If any item is settled with this
ters).
code, initialize all the items again.
k If the model name of the machine is dif-
• [DOWN]: Decrease number or select
previous character (in the order of usa-
ble characters). ferent from the setting in the controller,
ii) Set buzzer cancel switch (4) in the [U] posi- the machine may move abnormally or
tion and check that the caution buzzer make an error. Accordingly, be sure to
sounds. set the correct model name in the con-
★ There are 16 places for the phone No. Input troller.
symbols other than digits to empty places to ★ Even if this code is turned OFF, the setting is
prevent confusion. effective.
★ All the 16 places on the lower line are filled
with 0 when the machine is shipped.
★ Even if this code is turned OFF, the setting is
effective.
[0004] Specification code set (Changed in normal [0005]: Brake potentiometer neutral set (Changed in
order: A2) normal order: B6)
• This code is used to make the HST controller • This code is used to adjust the neutral position
recognize the machine specification. of the brake pedal potentiometer.
• The machine specification code is displayed on • The signal output of the brake pedal potentiom-
the lower line. eter is displayed by voltage on the lower line.
(Display range: 0 – 5000)
• Adjustment method:
★ The setting of this code is reset when “Model • Adjustment method:
code set” is executed. Accordingly, adjust i) Check that the brake pedal is in neutral (it is
this code after executing “Model code set”. not pressed).
i) Select a correct specification code by oper- ii) Set buzzer cancel switch (4) in the [U] posi-
ating the shift-up switch (6). tion and check that the caution buzzer
• Select [PX] or [EX]. sounds.
ii) Set buzzer cancel switch (4) in the [U] posi- ★ The display of the lower line does not change
tion and check that the caution buzzer after adjustment.
[1010] Steering lever left counter-rotation set [1011] Steering lever right counter-rotation set
(Operating effort difference) (Changed in normal (Operating effort difference) (Changed in normal
order: B2) order: B4)
• This code is used to adjust the left counter-rota- • This code is used to adjust the right counter-
tion (operating effort difference) position of the rotation (operating effort difference) position of
steering potentiometer of the PCCS lever. the steering potentiometer of the PCCS lever.
• The signal output of the steering potentiometer • The signal output of the steering potentiometer
is displayed by voltage on the lower line (Display is displayed by voltage on the lower line (Display
range: 0 – 5000). range: 0 – 5000).
[1012] Steering lever neutral set (Changed in normal [1013] Steering lever left max. set (Changed in nor-
order: B1) mal order: B3)
• This code is used to adjust the neutral position • This code is used to adjust the left maximum
of the steering potentiometer of the PCCS lever. position of the steering potentiometer of the
• The signal output of the steering potentiometer PCCS lever.
is displayed by voltage on the lower line (Display • The signal output of the steering potentiometer
range: 0 – 5000). is displayed by voltage on the lower line (Display
range: 0 – 5000).
• Adjustment method:
i) Set the PCCS lever in the neutral position. • Adjustment method:
ii) Set buzzer cancel switch (4) in the [U] posi- i) Set the PCCS lever to the left steering
tion and check that the caution buzzer stroke end.
sounds. ii) Set buzzer cancel switch (4) in the [U] posi-
★ The display of the lower line does not change tion and check that the caution buzzer
after adjustment. sounds.
★ Even if this code is turned OFF, the setting is ★ The display of the lower line does not change
effective. after adjustment.
★ This code is not used to adjust the steering ★ Even if this code is turned OFF, the setting is
performance, etc. effective.
★ This code is not used to adjust the steering
performance, etc.
• Adjustment method:
i) Set the PCCS lever to the right steering
stroke end.
ii) Set buzzer cancel switch (4) in the [U] posi-
tion and check that the caution buzzer
sounds.
★ The display of the lower line does not change
after adjustment.
★ Even if this code is turned OFF, the setting is
effective.
★ This code is not used to adjust the steering
performance, etc.
[3001] Forward pump set (For running track shoe idle) v) After adjustment is finished, set the PCCS
(Changed in normal order: A3) lever in the neutral position and set the park-
• This code is used to adjust the command cur- ing brake lever in the LOCK position.
rent of the forward pump while the track shoe is ★ When starting adjustment again after inter-
running idle. rupting it, perform the procedures from ii).
• The command current of the forward pump is ★ Even if this code is turned OFF, the setting is
displayed on the lower line. effective.
★ If adjustment is interrupted and an error is
displayed, check the following devices.
• When the track shoe does not move:
HST pump EPC valve
• When the track shoe moves:
HST motor speed sensor
• 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.
[3002] Reverse pump set (For running track shoe idle) v) After adjustment is finished, set the PCCS
(Changed in normal order: A4) lever in the neutral position and set the park-
• This code is used to adjust the command cur- ing brake lever in the LOCK position.
rent of the reverse pump while the track shoe is ★ When starting adjustment again after inter-
running idle. rupting it, perform the procedures from ii).
• The command current of the reverse pump is ★ Even if this code is turned OFF, the setting is
displayed on the lower line. effective.
★ If adjustment is interrupted and an error is
displayed, check the following devices.
• When the track shoe does not move:
HST pump EPC valve
• When the track shoe moves:
HST motor speed sensor
• 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.
[3003] Forward pump rise/max. delivery set (For travel) ★ When moving the machine after inter-
(Changed in normal order: C1) rupting adjustment, operate it as usually.
• This code is used to adjust the command cur- The travel speed at the time of interrup-
rent of the rise and maximum delivery of the for- tion is kept, however.
ward pump while the machine is traveling. v) After adjustment is finished, set the PCCS
• The command current of the forward pump is lever in the neutral position and set the park-
displayed on the lower line. ing brake lever in the LOCK position.
★ When starting adjustment again after inter-
rupting it, perform the procedures from i).
★ Even if this code is turned OFF, the setting is
effective.
★ If adjustment is interrupted and an error is
displayed, adjust the following parts.
• When machine does not move:
HST pump EPC valve
• When machine moves:
HST motor speed sensor
• Adjustment method:
i) Move the machine to a wide and flat place
where it can travel straight for at least 30 m.
k 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 idling.
iii) Check that the parking brake lever is in the
LOCK position and the PCCS lever is in the
neutral position and [Cb] is flashing in the
gear speed/set travel speed/shift mode indi-
cator section.
iv) Set the parking brake lever in the FREE
position and set the PCCS lever in the for-
ward travel position, and adjustment starts.
k If adjustment starts, the pump command
current increases and the machine starts
traveling forward automatically. (The ma-
chine starts traveling forward, then stops
[3004] Reverse pump rise/max. delivery set (For travel) ★ When moving the machine after inter-
(Changed in normal order: C2) rupting adjustment, operate it as usually.
• This code is used to adjust the command cur- The travel speed at the time of interrup-
rent of the rise and maximum delivery of the tion is kept, however.
reverse pump while the machine is traveling. v) After adjustment is finished, set the PCCS
• The command current of the reverse pump is lever in the neutral position and set the park-
displayed on the lower line. ing brake lever in the LOCK position.
★ When starting adjustment again after inter-
rupting it, perform the procedures from i).
★ Even if this code is turned OFF, the setting is
effective.
★ If adjustment is interrupted and an error is
displayed, adjust the following parts.
• When machine does not move:
HST pump EPC valve
• When machine moves:
HST motor speed sensor
• Adjustment method:
i) Move the machine to a wide and flat place
where it can travel straight for at least 30 m.
k Since the machine will travel straight in
reverse 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 idling.
iii) Check that the parking brake lever is in the
LOCK position and the PCCS lever is in the
neutral position and [Cb] is flashing in the
gear speed/set travel speed/shift mode indi-
cator section.
iv) Set the parking brake lever in the FREE
position and set the PCCS lever in the for-
ward travel position, and adjustment starts.
k If adjustment starts, the pump command
current increases and the machine starts
traveling forward automatically. (The ma-
chine starts traveling forward, then stops
[3005] Forward pump intermediate delivery set (For ★ When moving the machine after inter-
travel) (Changed in normal order: C3) rupting adjustment, operate it as usually.
• This code is used to adjust the command cur- The travel speed at the time of interrup-
rent of the intermediate delivery position of the tion is kept, however.
forward pump while the machine is traveling. v) After adjustment is finished, set the PCCS
• The command current of the forward pump is lever in the neutral position and set the park-
displayed on the lower line. ing brake lever in the LOCK position.
★ When starting adjustment again after inter-
rupting it, perform the procedures from i).
★ Even if this code is turned OFF, the setting is
effective.
★ If adjustment is interrupted and an error is
displayed, adjust the following parts.
• When machine does not move:
HST pump EPC valve
• When machine moves:
HST motor speed sensor
• Adjustment method:
i) Move the machine to a wide and flat place
where it can travel straight for at least 15 m.
k 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 idling.
iii) Check that the parking brake lever is in the
LOCK position and the PCCS lever is in the
neutral position and [Cb] is flashing in the
gear speed/set travel speed/shift mode indi-
cator section.
iv) Set the parking brake lever in the FREE
position and set the PCCS lever in the for-
ward travel position, and adjustment starts.
k If adjustment starts, the pump command
current increases and the machine starts
traveling forward automatically. (The ma-
chine starts traveling forward, then stops
[3006] Reverse pump intermediate delivery set (For v) After adjustment is finished, set the PCCS
travel) (Changed in normal order: C4) lever in the neutral position and set the park-
• This code is used to adjust the command cur- ing brake lever in the LOCK position.
rent of the intermediate delivery position of the ★ When starting adjustment again after inter-
reverse pump while the machine is traveling. rupting it, perform the procedures from i).
• The command current of the reverse pump is ★ Even if this code is turned OFF, the setting is
displayed on the lower line. effective.
★ If adjustment is interrupted and an error is
displayed, adjust the following parts.
• When machine does not move:
HST pump EPC valve
• When machine moves:
HST motor speed sensor
• Adjustment method:
i) Move the machine to a wide and flat place
where it can travel straight for at least 15 m.
k Since the machine will travel straight in
reverse 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 idling.
iii) Check that the parking brake lever is in the
LOCK position and the PCCS lever is in the
neutral position and [Cb] is flashing in the
gear speed/set travel speed/shift mode indi-
cator section.
iv) Set the parking brake lever in the FREE
position and set the PCCS lever in the for-
ward travel position, and adjustment starts.
k If adjustment starts, the pump com-
mand current increases and the ma-
c h in e s t a r t s t r a v e l i ng i n r e v e r s e
[3007] Brake potentiometer max. set (Changed in [3008] Engine high idle set (Changed in normal
normal order: B7) order: B8)
• This code is used to adjust the maximum posi- • This code is used to make the HST controller
tion of the brake pedal potentiometer recognize the high idling positions of the fuel
• The signal output of the brake pedal potentiom- control lever potentiometer and decelerator
eter is displayed by voltage on the lower line. pedal potentiometer.
• The engine speed is displayed on the lower line.
• Adjustment method:
i) Press and hold the brake pedal at the stroke • Adjustment method:
end. ★ Perform the following adjustment after per-
ii) Set buzzer cancel switch (4) in the [U] posi- forming “Adjusting fuel control lever and de-
tion and check that the caution buzzer celerator pedal”.
sounds. i) Start the engine and set the fuel control
★ The display of the lower line does not change lever in the high idle position.
after adjustment. ii) Check that the brake pedal is in neutral (it is
★ Even if this code is turned OFF, the setting is not pressed).
effective. iii) Set buzzer cancel switch (4) in the [U] posi-
★ This code is used to make the HST controller tion and check that the caution buzzer
recognize the maximum position of the brake sounds.
pedal potentiometer. It is not used to adjust ★ Even if this code is turned OFF, the setting is
the brake performance. effective.
[3009] Deceleration set (Changed in normal order: B9) [3010] Fuel control lever set (Changed in normal
• This code is used to make the HST controller order: B10)
recognize each stroke end and low idling posi- • This code is used to make the HST controller
tion of the decelerator pedal potentiometer. recognize each stroke end and low idling posi-
• The engine speed is displayed on the lower line. tion of the fuel control lever potentiometer.
• The engine speed is displayed on the lower line.
• Adjustment method:
★ Perform the following adjustment after per- • Adjustment method:
forming “Adjusting fuel control lever and de- ★ Perform the following adjustment after per-
celerator pedal”. forming “Adjusting fuel control lever and de-
i) Start the engine, set the fuel control lever in celerator pedal”.
the high idle position, and set the decelera- i) Start the engine, set the fuel control lever in
tor pedal in neutral (release it). the high idle position, and set the decelera-
★ If the engine is not running at high idle at tor pedal in neutral (release it).
this time, an error is displayed. If the en- ★ If the engine is not running at high idle at
gine speed is increased to high idle at this time, an error is displayed. If the en-
this time, however, the error is turned gine speed is increased to high idle at
OFF and adjustment can be continued. this time, however, the error is turned
ii) Press the decelerator pedal slowly and keep OFF and adjustment can be continued.
it at the stroke end. ii) Return the fuel control lever slowly and keep
★ Take 5 seconds or more in pressing the it at the low idle position.
decelerator pedal to make the HST con- ★ Take 5 seconds or more in returning the
troller recognize each stroke end of the fuel control lever to make the HST con-
decelerator pedal. troller recognize each stroke end of the
iii) Set buzzer cancel switch (4) in the [U] posi- fuel control lever.
tion and check that the caution buzzer iii) Set buzzer cancel switch (4) in the [U] posi-
sounds. tion and check that the caution buzzer
★ When the buzzer cancel switch is oper- sounds.
ated, if the engine speed is not at low ★ When the buzzer cancel switch is oper-
idling, an error is displayed. In this case, ated, if the engine speed is not at low
perform “Adjusting fuel control lever and idling, an error is displayed. In this case,
decelerator pedal”, then start adjustment perform “Adjusting fuel control lever and
again. decelerator pedal”, then start adjustment
★ Even if this code is turned OFF, the setting is again.
effective. ★ Even if this code is turned OFF, the setting is
effective.
[3016] Stall pressure test mode i) While the engine is running, select an item
• This code is used to test the engine speed, HST to be displayed by operating information
oil temperature (hydraulic oil temperature), and switch (5).
right and left HST main circuit pressures while • [>]: Next code
the HST is stalled. • [<]: Previous code
• The engine speed, HST oil temperature, right ★ The following items can be displayed.
HST main circuit pressure, or left HST main cir-
No. Display Item Unit
cuit pressure is displayed on the lower line.
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
• Using method:
i) Select use of the highest gear speed by
operating shift-up switch (6).
• [3RD]: Permit use of 3rd gear speed.
• [2ND]: Limit use of 3rd gear speed.
ii) Set the buzzer cancel switch (4) in the [U]
position to enter the setting.
★ If the gear speed is limited, it is not shifted to
the 3rd position, even if the shift-up switch is
operated.
★ The setting becomes effective when the
starting switch is turned OFF and ON.
★ The setting is effective in both quick shift
mode and variable shift mode.
10. Real-time monitoring mode ii) After inputting the code, display the
(10-REAL TIME MONITORING MODE) monitoring screen by operating buzzer
In this mode, the speeds, oil pressures, oil tem- cancel switch (4).
peratures, currents, voltages, etc. can be moni- • [U]: Enter input code.
tored by using the signal s f rom sens ors, ★ If the input code is normal, the mon-
switches, and solenoids installed various parts itoring screen shown below ap-
of the machine. pears.
★ This mode is used to monitor only 1 item.
When monitoring 2 items simultaneously,
use the “Dual display monitoring mode”.
Change
No. Code Item Unit Remarks
in order
Right reverse pump EPC output current command
41 52402 RR PUMP mA
value
Left reverse pump EPC output current command
42 52403 LR PUMP mA
value
43 52404 RF PUMP Right forward pump EPC output value cc/rev
44 52405 LF PUMP Left forward pump EPC output value cc/rev
45 52406 RR PUMP Right reverse pump EPC output value cc/rev
46 52407 LR PUMP Left reverse pump EPC output value cc/rev
Right forward pump EPC output current detection
47 52408 RF PUMP mA 14
value
Left forward pump EPC output current detection
48 52409 LF PUMP mA 15
value
Right reverse pump EPC output current detection
49 52410 RR PUMP mA 16
value
Left reverse pump EPC output current detection
50 52411 LR PUMP mA 17
value
51 52500 HST R SENS HST right circuit pressure sensor voltage mV
52 52501 HST R PRES HST right circuit pressure MPa 18
53 52502 HST L SENS HST left circuit pressure sensor voltage mV
54 52503 HST L PRES HST left circuit pressure MPa 19
55 60000 TRACTION Theoretical drawbar pull ton 20
56 60600 BR HOLD Battery relay drive voltage mV 21
57 70401 BACK ALARM Backup alarm drive voltage mV
58 85001 HST TEMP. HST oil temperature °C 22
★ The items having numbers in the “Change in order” column of the above table can be changed in order by
operating the information switch.
★ Unlike other codes, code [00200] displays the model code and specification code set in the adjustment
moved as shown below.
(a): Model code (D31: 31, D37: 37, D39: 39)
(b): Specification code (PX: 01, EX: 02)
[40913]: HTS controller input signal 4 [40918]: HTS controller output signal 1
(a): Shift mode switch: Quick shift mode (Left) (a): (Unused)
(b): (Unused) (b): (Unused)
(c): (Unused) (c): (Unused)
(d): (Unused) (d): Neutral safety relay: ON
(e): (Unused) (e): (Unused)
(f): (Unused) (f): Backup alarm: ON
(g): (Unused) (g): (Unused)
(h): (Unused) (h): Battery relay: ON
[40914]: HTS controller output signal 2 [40921]: Monitor panel input signal 1
(a): 3rd travel speed selection solenoid valve: ON (a): (Unused)
(b): 2nd travel speed selection solenoid valve: ON (b): (Unused)
(c): Parking brake solenoid valve: ON (c): (Unused)
(d): Slow brake solenoid valve: ON (d): (Unused)
(e): (Unused) (e): (Unused)
(f): (Unused) (f): Preheating signal: ON
(g): (Unused) (g): Night light signal: ON
(h): (Unused) (h): Starting switch C signal: ON
11. Dual display monitoring mode ii) After inputting the codes, display the
(11-DUAL DISPLAY MONITORING MODE) monitoring screen by operating buzzer
In this mode, 2 monitored items can be dis- cancel switch (4).
played simultaneously. • [U]: Enter input codes.
★ Note that only codes and monitoring infor- ★ If the input codes are normal, the
mation are displayed in this mode since the monitoring screen shown below ap-
usable display columns are limited. (Item pears.
names and units cannot be displayed.)
1. Monitor panel
1) Remove the 4 mounting bolts of dashboard
(1) and fold dashboard (1) toward the opera-
tor's seat.
PM-CLINIC
6. HST charge circuit pressure: Testing and adjusting HST oil pressure (Page 20-124)
7. Solenoid valve output pressure: Measuring HST solenoid valve output pressure (Page 20-128)
8. Work equipment pump relief pressure: Testing and adjusting work equipment oil pressure (Page 20-141)
9. Work equipment PPC valve output pressure: Measuring work equipment PPC valve output pressure (Page 20-143)
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 47.5
New Turned
d
d RH 56.0 47.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
1.3 10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 50.0
New Turned
d
d RH 56.0 50.0
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 47.5
New Turned
d
d RH 56.0 47.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 50.0
New Turned
d
d RH 56.0 50.0
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
1.3 10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3 h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
1.3 10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 41.6
New Turned
d
d RH 50.0 41.6
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 87.0 80.0
H
RH 87.0 80.0
LINK HEIGHT
New Turned
BUSHING d1
LH 50.0 44.5
New Turned
d
d RH 50.0 44.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 47.0 20.0
H
RH 47.0 20.0
CARRIER LH 142.0 128.0
Front
RH 142.0 128.0
D LH 142.0 128.0
Rear
RH 142.0 128.0
LH 14.0 22.0
IDLER Front
RH 14.0 22.0
H
LH 14.0 22.0
Rear
RH 14.0 22.0
1 LH 170.0 156.0
2 LH 170.0 156.0
3 LH 170.0 156.0
4 LH 170.0 156.0
5 LH 170.0 156.0
6 LH 170.0 156.0
7 LH 170.0 156.0
TRACK ROLLER 8 LH 170.0 156.0
9 LH 170.0 156.0
D 10 LH 170.0 156.0
1 RH 170.0 156.0
h2 h1 2 RH 170.0 156.0
3 RH 170.0 156.0
D=2(h1-h2) 4 RH 170.0 156.0
5 RH 170.0 156.0
6 RH 170.0 156.0
7 RH 170.0 156.0
8 RH 170.0 156.0
9 RH 170.0 156.0
10 RH 170.0 156.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 47.5
New Turned
d
d RH 56.0 47.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 50.0
New Turned
d
d RH 56.0 50.0
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 47.5
New Turned
d
d RH 56.0 47.5
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
LH 98.0 89.0
H
RH 98.0 89.0
LINK HEIGHT
New Turned
BUSHING d1
LH 56.0 50.0
New Turned
d
d RH 56.0 50.0
D is the smallest
of d1, d2 and, d3
GROUSER HIGHT LH 53.0 25.0
H
RH 53.0 25.0
CARRIER LH 150.0 126.0
Front
RH 150.0 126.0
D LH 150.0 126.0
Rear
RH 150.0 126.0
LH 19.0 28.0
IDLER Front
RH 19.0 28.0
H
LH 19.0 28.0
Rear
RH 19.0 28.0
1 LH 175.0 150.0
2 LH 175.0 150.0
3 LH 175.0 150.0
4 LH 175.0 150.0
5 LH 175.0 150.0
6 LH 175.0 150.0
7 LH 175.0 150.0
TRACK ROLLER 8 LH 175.0 150.0
9 LH 175.0 150.0
D 10 LH 175.0 150.0
1 RH 175.0 150.0
h2 h1 2 RH 175.0 150.0
3 RH 175.0 150.0
D=2(h1-h2) 4 RH 175.0 150.0
5 RH 175.0 150.0
6 RH 175.0 150.0
7 RH 175.0 150.0
8 RH 175.0 150.0
9 RH 175.0 150.0
10 RH 175.0 150.0
SPROCKET h1 LH 0.0 6.0
H is the smallest of
h1,h2,h3
h3 h2
RH 0.0 6.0
Remarks:
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
3) Disconnections in wiring
If the wiring is held 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 of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
6) Flushing operations
After disassembling and assembling the equip-
ment, 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c ont r ol v al v e , et c . ) or w he n r un ni ng t h e
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
1. Procedure for troubleshooting to be taken when action code is displayed on monitor panel:
If an action code is displayed on the monitor panel, display the error code in the error code display mode
(for the electrical system and the mechanical system) of the monitor panel (EMMS).
Carry out troubleshooting under the displayed error code.
a Each error code “flashes” when the trouble corresponding to it is detected. Even if an error code “lights
up” when the starting switch is turned ON, the trouble corresponding to that error code may not have
been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If an error code is recorded, be sure to perform the operation for reproducing it to see if the trouble cor-
responding to it has been repaired (For the method of reproducing the error code, see the troubleshoot-
ing under the error code).
2. Procedure for troubleshooting to be taken when error code is recorded:
If an action code is not displayed on the monitor panel, check for an error code in the error code display
mode (for the electrical system and the mechanical system) of the monitor panel (EMMS).
If an error code is recorded, carry out troubleshooting under it.
a Each error code “flashes” when the trouble corresponding to it is detected. Even if an error code “lights
up” when the starting switch is turned ON, the trouble corresponding to that error code may not have
been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If an error code is recorded, be sure to perform the operation for reproducing it to see if the trouble cor-
responding to it has been repaired (For the method of reproducing the error code, see the troubleshoot-
ing under the error code).
3. Procedure of troubleshooting to be taken when action code is not displayed and error code is not
recorded:
If an error code is not recorded in the monitor panel (EMMS), a trouble that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the
table of “Phenomena looking like troubles and troubleshooting Nos.”, and then carry out troubleshooting
related to that phenomenon in the ”E mode“, “H mode”, or “S mode”.
Troubleshooting
No. Phenomenon looking like trouble
Error code E-mode H-mode S-mode
Phenomena related to action code or error code
1 Action codes are displayed on monitor panel. Check error codes.
2 Error codes are displayed in error code display mode. q
Phenomena related to engine
3 Engine does not start easily (It always takes time to start) S-1
4 Engine does not crank E-1(1) S-2 a)
Engine cranks but exhaust smoke
5 E-1(2) S-2 b)
Engine does not start does not come out
Exhaust smoke comes out but engine
6 S-2 c)
does not start
7 Engine speed does not rise sharply (Follow-up performance is low) S-3
8 Engine stops during operation S-4
9 Engine rotation is abnormal (Engine hunts) S-5
10 Output is insufficient (Power is low) S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil is consumed much (or exhaust gas color is bad) S-8
13 Oil becomes dirty quickly S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (or it blows back or reduces) S-11
16 Engine oil pressure caution lamp lights up (Oil pressure lowers) S-12
17 Oil level rises (Water or fuel is mixed in oil) S-13
18 Water temperature rises too high (Overheating) S-14
19 Abnormal sound comes out S-15
20 Vibration is excessive S-16
21 Engine is not preheated normally (Manual preheating mechanism) E-2
22 Engine does not stop E-3
Phenomena related to HST
Right and left travel systems do not operate forward and in reverse
23 H-1
(No travel systems operate)
Right or left travel system does not operate forward and in reverse
24 H-2
(Only right or left travel system does not operate)
Right or left travel system does not operate forward or in reverse
25 H-3
(Only 1 system does not operate)
26 Speed or power of travel is low H-4 S-6
27 Gear is not shifted H-5
28 Large shock is made when machine stops traveling H-6
29 Machine deviates largely during travel H-7
30 Hydraulic drift of travel is large H-8
31 Engine stalls or engine speed lowers extremely during travel H-9 S-4
Troubleshooting
No. Phenomenon looking like trouble
Error code E-mode H-mode S-mode
32 Abnormal sound comes out from around HST pump and motor H-10
33 Work equipment dose not operate at all H-11
34 Speed or power of whole work equipment is low H-12
35 Speed or power of lifting blade is low H-13
36 Speed or power of tilting blade is low H-14
37 Speed or power of angling blade is low H-15
38 Time lag in lifting blade is large H-16
39 Hydraulic drift of lifting blade is large H-17
40 Hydraulic drift of tilting blade is large H-18
Abnormal sound comes out from around work equipment pump and
41 H-19
control valve
42 HST oil temperature (Hydraulic oil temperature) rises too high E-7(3) H-20
Phenomena related to monitor panel (Operator mode: Ordinary screen)
43 When starting switch is turned ON, any item does not light up E-4
When starting switch is turned ON, all items light up and none of
44 E-5
them goes off
45 Charge level caution flashes while engine is running E-6
46 Emergency warning items flash while engine is running E-7
47 Preheating pilot lamp does not light up during preheating operation E-8
48 Engine coolant thermometer is abnormal E-9
49 HST oil thermometer is abnormal E-10
50 Fuel level gauge is abnormal E-11
51 Reverse travel speed indicator is abnormal E-12
52 Gear speed, set travel speed, and shift mode indicator is abnormal E-13
53 Multi-information section is abnormal E-14
54 Caution lamp does not flash or does not go off E-15
55 Caution buzzer does not sound or does not stop E-16
56 Reverse travel speed setting switch does not function E-17
57 Shift mode switch does not function E-18
58 Buzzer cancel switch does not function E-19
59 Information switch does not function E-20
Phenomena related to monitor panel (Service mode: Special function screen)
60 System is not set in service mode or is not set out of service mode E-21
Other phenomena
61 Backup alarm does not sound E-22
62 Headlamp or rear lamp does not light up E-23
63 Canopy heater does not operate [Canopy specification] E-24
64 Air conditioner does not operate [Cab specification] E-25
Windshield wiper and windshield washer do not operate [Cab speci-
65 E-26
fication]
Address
Connector No. of
Type Name of device Stereo-
No. pins M-circuit H-circuit
gram
CN68 M 6 Front wiper circuit breaker [Cab specification] F-8 - -
CN69 KES0 4 Rear wiper motor [Cab specification] I-9 - -
CN70 M 2 Rear speaker (Left) [Cab specification] I-8 - -
CN71 M 2 Rear speaker (Right) [Cab specification] H-9 - -
CN72 KES1 2 Room lamp [Cab specification] H-9 - -
CN73 DT 2 Rear lamp [Cab specification] H-9 K-7 -
CN74 DT 2 Headlamp (Left) [Cab specification] H-9 K-7 -
CN75 DT 2 Headlamp (Right) [Cab specification] E-8 K-6 -
CN76 AMP 12 Air conditioner control panel [Cab specification] J-8 - -
CN77 AMP 16 Air conditioner control panel [Cab specification] J-8 - -
CN78 M 2 Cigarette lighter [Cab specification] K-5 - -
CN80 SWP 16 Air conditioner unit [Cab specification] K-5 - -
CN81 DT 4 Air conditioner unit [Cab specification] K-6 - -
CN82 X 2 Air conditioner condenser [Cab specification] K-6 - -
CN92 DT 4 Intermediate connector K-3 - -
CN-BP1 DT 3 Brake pedal potentiometer Q-1 - E-1
Brake oil pressure switch (HST charge oil pressure
CN-BS DT 2 Q-1 - E-1
switch)
CN-BUZ KES1 3 Buzzer cancel switch Q-7 - J-9
CN-CA DT 3 CAN terminal resistance W-6 K-8 A-1
CN-CA2 DT 3 CAN terminal resistance O-2 A-4 H-9
CN-CB M 2 Caution buzzer P-2 A-4 -
CN-CUR KES1 3 Information switch P-2 - J-9
CN-D3 SWP 2 Diode Y-2 G-9
CN-D4 SWP 8 Assembled-type diode T-1 - B-1
CN-DP1 DT 3 Decelerator pedal potentiometer P-1 - F-1
CN-EL DT 8 PCCS lever (Directional/steering/gear shift lever) V-8 - B-9
CN-EN DT 2 Engine speed sensor AC-2 - L-6
CN-FG Terminal 1 Floor ground P-8 H-5 F-8
CN-EP DT 3 Fuel control lever potentiometer U-2 - E-9
CN-FS X 4 Personal computer connecting terminal W-5 - A-2
CN-FWL KES1 4 Working lamp switch O-7 B-1 -
CN-H1 L 2 Fusible link (Fuse constant power supply) K-6 I-1 L-8
CN-H2 L 2 Fusible link (Fuse switch power supply) K-7 I-1 L-8
CN-H3 L 2 Fusible link (Cab power supply) K-7 - L-8
CN-HS KES1 4 Heater switch [Canopy specification] Q-8 - -
CN-KS Terminal 6 Starting switch N-6 A-3 H-9
CN-LF DT 2 HST pump left forward EPC valve AF-3 - D-9
CN-LP DT 3 HST pump left circuit pressure sensor AD-2 - C-9
CN-LR DT 2 HST pump left reverse EPC valve AE-3 - D-9
CN-LRS DT 4 Left HST motor speed sensor AJ-6 - K-2
CN-MTS KES1 4 Shift mode switch N-7 - I-9
CN-P1 DT 12 Intermediate connector C-5 D-6 H-7
CN-P2 DT 4 Intermediate connector D-5 - J-7
CN-P3 DT 12 Intermediate connector C-4 D-3 H-7
CN-P4 DT 4 Intermediate connector D-5 D-1 I-7
CN-PB DT 3 Brake pedal limit switch Q-1 - D-1
Disconnection detecting resistor (Right motor speed
CN-R1 DT 2 AI-9 - L-2
sensor circuit)
Disconnection detecting resistor (Right motor speed
CN-R2 DT 2 AH-9 - K-2
sensor circuit)
CN-REV KES1 3 Reverse travel speed setting switch N-7 - I-9
Address
Connector No. of
Type Name of device Stereo-
No. pins M-circuit H-circuit
gram
CN-RF DT 2 HST pump right forward EPC valve AF-3 - D-9
CN-RH Terminal 1 Electrical intake air heater Y-6 I-9
CN-RP DT 3 HST pump right circuit pressure sensor AD-9 - E-9
CN-RR DT 2 HST pump right reverse EPC valve AF-4 - E-9
CN-RRS DT 4 Right HST motor speed sensor AG-9 - K-2
CN-S03 070 20 Monitor panel O-2 A-7 G-9
CN-S04 070 12 Monitor panel N-3 A-5 G-9
CN-S1 DT 2 2nd travel speed selection solenoid valve R-1 - C-1
CN-S2 DT 2 3rd travel speed selection solenoid valve R-1 - C-1
CN-S3 DT 2 Slow brake solenoid valve R-1 - C-1
CN-S4 DT 2 Parking brake solenoid valve Q-1 - C-1
CN-S24 Terminal 6 Service switch O-2 A-3 H-9
CN-ST1 DRC26 24 HST controller Q-9 I-8 A-8
CN-ST2 DRC26 40 HST controller R-9 J-8 A-6
CN-ST3 DRC26 40 HST controller S-9 J-8 A-4
CN-T1 Terminal 1 Starting motor (Terminal B) Y-3 C-9 -
CN-T2 Terminal 1 Starting motor (Terminal C) Y-4 D-8 -
CN-T3 Terminal 1 Starting motor safety relay (Terminal B) C-4 B-8 -
CN-T4 Terminal 1 Starting motor safety relay (Terminal C) B-4 B-8 -
CN-T5 Terminal 1 Heater relay (Terminal S) AB-8 H-7 -
CN-T6 Terminal 1 Heater relay (Terminal L) Y-7 I-7 -
CN-T7 Terminal 1 Battery relay (Terminal B) I-2 H-1 J-9
CN-T8 Terminal 1 Battery relay (Terminal M) I-2 H-1 J-9
CN-T9 Terminal 1 Battery relay (Negative (-) terminal) K-3 H-1 J-8
CN-T10 Terminal 1 Fender ground H-1 L-3 J-7
CN-T12 Terminal 1 Heater relay (Terminal B) AB-8 I-7 -
CN-T13 Terminal 1 Battery relay (Position (+) terminal) K-3 H-1 K-8
CN-T15 Terminal 1 Alternator (Terminal B) Y-6 E-8 -
CN-T16 Terminal 1 Alternator (Terminal R) Y-5 E-8 K-7
CN-T17 Terminal 1 Engine stop solenoid (+) Z-2 H-9 -
CN-T18 Terminal 1 Engine stop solenoid (-) AA-1 H-9 -
CN-T19 Terminal 1 Engine oil pressure switch AB-1 F-9 -
CN-T20 Terminal 1 Engine ground AC-1 H-8 -
CN-T34 Terminal 1 HST charge filter clogging switch K-5 - L-4
CN-T35 Terminal 1 Fender ground S-1 J-4 F-7
CN-T36 Terminal 1 Floor ground P-1 H-4 -
CN-T37 Terminal 1 Horn switch P-8 - -
CN-T38 Terminal 1 Horn switch P-8 - -
CN-T39 Terminal 1 Backup alarm K-4 - L-3
CN-T40 Terminal 1 Backup alarm K-4 - L-3
FB-1 - - Fuse box (1) G-1 H-6 G-3
FB-2 - - Fuse box (2) G-1 G-6 G-3
FB-3 - - Fuse box (3) H-9 - -
a This circuit diagram is made by excerpting the monitor panel system, engine preheating/starting/charging/
stopping system, light system, and communication network system from the general electric circuit diagram
(“Connector No. and pin No.” from each branching/merging point indicate the ends of branch or source of
merging within the parts of the same wiring harness).
a This circuit diagram is made by excerpting the HST controller system from the general electric circuit dia-
gram (“Connector No. and pin No.” from each branching/merging point indicate the ends of branch or
source of merging within the parts of the same wiring harness).
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
16 799-601-7320
M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)
13 799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)
17 799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)
21 799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-3460
— —
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
4 —
— —
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
1 —
Part No.: 08192-31200 (Contact size #12) Part No.: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
1 —
Part No.: 08192-31200 (Contact size #12) Part No.: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD30 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DRC 40P
799-601-9360 DRC 24P
799-601-9410 For NE, G sensor 2P
799-601-9420 For fuel, boost
press. 3P
799-601-9430 PVC socket 2P
a “Controller” in the table indicates classification of the controller in charge of system check, monitor panel,
and code.
Monitor: Error code of electric system checked by monitor panel
HST: Error code of electric system checked by HST controller
Mechanical: Error code of mechanical system
<Contents of description>
• Standard value in normal state to judge possible causes
1
• Remarks on judgment
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 refer-
3 Independent wiring harnesses are in contact with each other abnormally.
ence 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 other-
wise specified.
4 • If connector No. has no marks of “male” and “female”, disconnect connector and
insert T-adapters 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 troubleshooting, 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.
Defective battery charge Carry out troubleshooting for E-mode, CAUTION ITEM
2
caution lamp system (BATTERY CHARGE CAUTION LAMP) FLASHES WHILE ENGINE IS RUNNING.
Overheating of engine
A phenomenon seems to have caused overheating of the engine coolant. Find and
1 coolant
stop it and repair the damaged part.
(When system is normal)
Overheating of HST oil A phenomenon seems to have caused overheating of the HST oil. Find and stop it
1
(When system is normal) and repair the damaged part.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Possible causes and
Action code Error Code Monitor controller CAN communication: Defective communication
Trouble
E02 DAFRKR (Abnormality in objective component system) (Monitor panel system)
tContents of
• The monitor panel cannot recognize the HST controller in the CAN communication circuit.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
Action of
• Limits the functions partly.
controller
• If the cause of the failure disappears, the system resets itself.
Problem that
• Once the machine is stopped and started again, its travel speed is limited to 50%.
appears on
• The monitor panel cannot display the information.
machine
Related
• Method of reproducing error code: Turn the starting switch ON.
information
chassis ground in wir- (32) or CN-CA2 (female) (A) or CN-CA (female) (A) or Resistance Min. 1 M z
2
ing harness (Contact CN45 (female) (3) wiring harness and chassis ground
Possible causes and
with ground circuit) Between CN-S04 (female) (3), (4) – CN-ST2 (female)
(22) or CN-CA2 (female) (B) or CN-CA (female) (B) or Resistance Min. 1 M z
CN45 (female) (10) wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Short circuit with Between CN-S04 (female) (1), (2) – CN-ST2 (female)
power source in wiring (32) or CN-CA2 (female) (A) or CN-CA (female) (A) or Voltage Max. 1 V
3
harness (Contact with CN45 (female) (3) wiring harness and chassis ground
24 V circuit) Between CN-S04 (female) (3), (4) – CN-ST2 (female)
(22) or CN-CA2 (female) (B) or CN-CA (female) (B) or Voltage Max. 1 V
CN45 (female) (10) wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Defective CAN termi-
4 CN-CA
nal resistor (male)
Resistance
Action code Error code HST controller: Lowering of source voltage (Input)
Trouble
CALL E04 DAJ0KK (HST controller system)
Contents of
• The source voltage of the HST controller is below 17 V.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
Action of
• Limits the functions partly.
controller
• If the cause of the failure disappears, the system resets itself.
Problem that • Once the machine is stopped, it cannot start again.
appears on • The monitor panel may not display normally.
machine • The relays and solenoids may not be driven and the system may not operate normally.
• The state of the power supply (voltage) of the HST controller can be checked in the monitoring mode.
Related
• (Code: 03200-BATTERY)
information
• Method of reproducing error code: Turn the starting switch ON.
Disconnection in wiring Wiring harness between CN-ST3 (female) (1), (2), (11),
Resistance Max. 1 z
harness (Disconnection (12), (22) and FB1-3 outlet
3 in wiring harness or Wiring harness between FB1-3 inlet and CN-H2 (male)
standard value in normal state
Resistance Max. 1 z
defective contact in con- (2)
Possible causes and
nector) Wiring harness between CN-H2 (male) (1) and CN-T8 Resistance Max. 1 z
Wiring harness between CN-ST3 (female) (21), (31),
Resistance Max. 1 z
(32), (33) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Short circuit with Between CN-ST3 (female) (1), (2), (11), (12), (22) –
Resistance Min. 1 M z
chassis ground in wir- FB1-3 outlet wiring harness and chassis ground
4
ing harness (Contact Between FB1-3 inlet – CN-H2 (male) (2) or other
Resistance Min. 1 M z
with ground circuit) related circuit wiring harness and chassis ground
Between CN-H2 (male) (1) – CN-T8 or other related cir-
Resistance Min. 1 M z
cuit wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Defective HST
5 CN-ST3 Voltage
controller
Between (1), (2), (11), (12), (22) and
20 – 30 V
(21), (31), (32), (33)
User Code Error code Failure HST controller: Internal defect of controller
Trouble
CALL E04 DAJ0KT phenomenon (HST controller system)
Contents of
• The information in the ROM (non-volatile memory) of the HST controller is abnormal.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
Action of • Limits the functions partly (depending on the defective part in the HST controller).
controller • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that • Once the machine is stopped and started again, its travel speed is limited to 50% (regardless of the
appears on defective part in the HST controller).
machine • Some functions do not work normally (depending on the defective part in the HST controller).
Related
• Method of reproducing error code: Turn the starting switch ON.
information
Troubleshooting cannot be carried out since the defect is in the HST controller.
2 Defective HST controller
(If there is not a visible trouble, the controller may be used as it is.)
If error code [D110KB] is displayed or if the monitor is turned OFF just after the start-
Defective holding of
3 ing switch is turned OFF, the battery relay may not be held normally. In this case,
battery relay
carry out troubleshooting for error code [D110KB], too.
Disconnection in wiring
harness (Disconnection
Wiring harness between CN-ST3 (female) (4) and CN-
4 in wiring harness or Resistance Max. 1 z
T13 or CN-KS (260)
defective contact in con-
nector)
Error code [DAJ5KK] (HST controller sensor power supply output: Lowering of source
voltage (Input))
Action code Error Code HST controller sensor power supply output: Lowering of source volt-
Trouble
CALL E04 DAJ5KK age (Input) (HST controller system)
• The voltage of the 5 V power supply circuit of the HST controller is below 4.5 V or above 5.5 V.
Failure content
• An abnormal current flows in the 5 V power supply circuit of the HST controller.
• Flashes the warning lamp and sounds the warning buzzer.
• Turns the output of the 5 V power supply circuit OFF
Action of
• Limits the functions partly.
controller
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Action of • Once the machine is stopped, it cannot start again.
controller • The system may not operate normally.
• If this trouble occurs, the respective error codes of the pressure sensors, potentiometers, and speed
Related
sensors supplied with power from the 5 V power supply are also displayed and recorded.
information
• Method of reproducing error code: Turn the starting switch ON.
Short circuit with Between CN-ST1 (female) (22) – CN-EL (female) (4),
Possible causes and
2 in wiring harness or
defective contact in con- Wiring harness between CN-ST1 (female) (23) and
Resistance Max. 1 z
nector) CN38 (female) (1)
Wiring harness between CN-ST1 (female) (4) and
Resistance Max. 1 z
CN38 (female) (2)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with power starting switch.
source in wiring harness Between CN-ST1 (female) (12) – CN38 (female) (3) wir-
3 Voltage Max. 1 V
(Contact with 24 V cir- ing harness and chassis ground
cuit) Between CN-ST1 (female) (23) – CN38 (female) (1) wir-
Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Shift-up switch
4 Defective HST controller CN-ST1
OFF (Released) ON (Pressed)
Between (12) and (4) Max. 1 V 5 – 11V
Between (23) and (4) 5 – 11V Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with starting switch.
chassis ground in wir- Between CN-ST1 (female) (12) – CN38 (female) (3) wir-
2 Resistance Min. 1 Mz
ing harness (Contact ing harness and chassis ground
with ground circuit) Between CN-ST1 (female) (23) – CN38 (female) (1) wir-
Resistance Min. 1 Mz
ing harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
2 nection in wiring
Wiring harness between CN-ST1 (female) (18) and
harness or defective Resistance Max. 1 z
CN39 (male) (1)
contact in connector)
Wiring harness between CN-ST1 (female) (4) and
Resistance Max. 1 z
CN39 (male) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with troubleshooting.
power source in wiring Between CN-ST1 (female) (24) – CN39 (male) (3) wir-
3 Voltage Max. 1 V
harness (Contact with ing harness and chassis ground
24 V circuit) Between CN-ST1 (female) (18) – CN39 (male) (1) wir-
Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with starting switch.
chassis ground in wir- Between CN-ST1 (female) (24) – CN39 (male) (3) wir-
2 Resistance Min. 1 Mz
ing harness (Contact ing harness and chassis ground
with ground circuit) Between CN-ST1 (female) (18) – CN39 (male) (1) wir-
Resistance Min. 1 Mz
ing harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with starting switch.
chassis ground in wir- Between CN-ST2 (female) (5) – CN26 (female) (B) wir-
2 Resistance Min. 1 Mz
ing harness (Contact ing harness and chassis ground
with ground circuit) Between CN-ST2 (female) (15) – CN26 (female) (C)
Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Parking brake lever
CN-ST1, CN-ST2
Defective HST con- FREE (Upper) LOCK (Lower)
3
troller Between CN-ST2 (5) and
Max. 1 V 5 – 11 V
CN-ST1 (10)
Between CN-ST2 (15) and
5 – 11 V Max. 1 V
CN-ST1 (10)
Center
Between (1) and (3)
Decrease speed (Left) Max. 1 z
Possible causes and
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch.
ground in wiring harness Between CN-ST2 (female) (25) – CN-REV (female) (2)
2 Resistance Min. 1 Mz
(Contact with ground cir- wiring harness and chassis ground
cuit) Between CN-ST2 (female) (35) – CN-REV (female) (3)
Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Reverse travel speed
CN-ST1, CN-ST2 Voltage
setting switch
Defective HST
3 Center 5 – 11 V
controller Between CN-ST2 (25) and
CN-ST1 (10) Increase speed (Right) Max. 1 V
Between CN-ST2 (35) and Center 5 – 11 V
CN-ST1 (10) Decrease speed (Left) Max. 1 V
Disconnection in wir-
Wiring harness between CN-ST2 (female) (5) and
Resistance Max. 1 z
Possible causes and
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Possible causes and
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
1 CN26B (male)
switch 2 (Internal defect) FREE (Upper) LOCK (Lower)
Possible causes and
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
1
switch 2 (Internal defect) Between (A) and (B) Max. 1 z Min. 1 Mz
Between (A) and (C) Min. 1 Mz Max. 1 z
Between (A), (B), (C) and
Min. 1 Mz Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch.
ground in wiring harness Between CN-ST3 (female) (37) – CN26B (female) (A)
2 Resistance Min. 1 Mz
(Contact with ground cir- wiring harness and chassis ground
cuit) Between CN-ST3 (female) (9) – CN26B (female) (C)
Resistance Min. 1 Mz
wiring harness and chassis ground
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
Error code [DDU1KY] (Parking brake ON-OFF switch: Short circuit with power supply line)
Action code Error code Parking brake ON-OFF switch: Short circuit with power supply line
Trouble
CALL E03 DDU1KY (HST controller system)
• The output circuit to the slow brake solenoid valve is outputting normally.
Contents of
• When the signal of travel lock switch 1 is in the FREE position, the slow brake output monitor signal
trouble
(signal of travel lock switch 2) is turned ON (closed).
• Flashes the warning lamp and sounds the warning buzzer.
Action of • Operates the HST brake, limiting the functions partly.
controller • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
appears on • Once the machine is stopped and started again, its travel speed is limited to 50%.
machine
The output state (ON/OFF) to the slow brake solenoid valve can be checked in the monitoring mode.
(Code: 40914-SOL ON/OFF, 4th from left)
Related The input state (ON/OFF) of the slow brake output monitor signal (travel lock switch 2) can be checked in
information the monitoring mode. (Code: 40911-S/T SW2, 5th from left: NO)
Method of reproducing error code: Turn the starting switch ON and set the parking brake lever in the
FREE position.
starting switch.
Possible causes and
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
Error code [DDU1L4] (Parking brake ON-OFF switch: Disagreement of ON and OFF
signals)
User Code Error code Parking brake ON-OFF switch: Disagreement of ON and OFF signals
Trouble
CALL E03 DDU1L4 (HST controller system)
• The output circuit to the slow brake solenoid valve is outputting normally and the signal of travel lock
switch 1 is in the LOCK position.
Contents of • When the pressing ratio of the brake pedal is below 60%, the slow brake output monitor signal (signal
trouble of travel lock switch 2) is turned ON (closed).
• When the pressing ratio of the brake pedal is above 60%, the slow brake output monitor signal (signal
of travel lock switch 2) is turned OFF (opened).
• Limits the functions partly.
Action of
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller
turned OFF.
Problem that
appears on • Once the machine is stopped and started again, its travel speed is limited to 50%.
machine
• The output state (ON/OFF) to the slow brake solenoid valve can be checked in the monitoring mode.
(Code: 40914-SOL ON/OFF, 4th from left)
Related infor- • The input state (ON/OFF) of the slow brake output monitor signal (travel lock switch 2) can be checked
mation in the monitoring mode. (Code: 40912-S/T SW2, 5th from left: NO)
• Method of reproducing error code: Turn the starting switch ON, set the parking brake lever in the LOCK
position, and release the brake pedal or press it fully.
1
switch 2 (Internal defect) Between (A) and (B) Max. 1 z Min. 1 Mz
Between (A) and (C) Min. 1 Mz Max. 1 z
Between (A), (B), (C) and
Min. 1 Mz Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chas- starting switch.
sis ground in wiring har- Between CN-ST3 (female) (9) – CN26B (female) (C)
2 Resistance Min. 1 Mz
ness (Contact with wiring harness and chassis ground
ground circuit) Between CN-ST3 (female) (37) – CN26B (female) (A)
Resistance Min. 1 Mz
wiring harness and chassis ground
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
Error code [DGS1KX] (Hydraulic tank oil temperature sensor: Out of input signal range)
Action code Error code Failure Hydraulic tank oil temperature sensor: Out of input
Trouble
— DGS1KX phenomenon signal range (HST controller system)
Contents of
• The input voltage from the HST oil temperature sensor is below 0.3 V.
trouble
• None in particular.
Action of
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller
turned OFF.
Problem that
• If this trouble occurs, the HST oil thermometer of the monitor panel indicates the maximum level, the
appears on
HST oil overheating caution lamp flashes, and the warning buzzer sounds.
machine
• The input state (voltage, oil temperature) from the HST oil temperature sensor can be checked in the
Related
monitoring mode. (Code: 004402-HST TEMP, Code: 85001-HST TEMP)
information
• ¥ Method of reproducing error code: Turn the starting switch ON.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Disconnection in wiring Wiring harness between CN-ST1 (female) (22) and CN-
harness (Disconnection Resistance Max. 1 z
LP (female) (B)
3 in wiring harness or
defective contact in con- Wiring harness between CN-ST1 (female) (21) and CN-
Resistance Max. 1 z
nector) LP (female) (A)
Wiring harness between CN-ST1 (female) (14) and CN-
Resistance Max. 1 z
LP (female) (C)
Short circuit with chas- a Prepare with starting switch OFF, then carry out troubleshooting without turning
sis ground in wiring har- starting switch.
4
ness (Contact with Between CN-ST1 (female) (14) – CN-LP (female) (C)
ground circuit) Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
5 Defective HST controller CN-ST1 Voltage
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (14) and (21) Signal 0.4 – 0.6 V
Action code Error code Failure LH pump pressure sensor: Short circuit
Trouble
E01 DHH5KB phenomenon (HST controller system)
Contents of
• The input voltage from the LH pump pressure sensor is above 4.5 V.
trouble
• Controls the machine with the pressure signal received just before the trouble occurs until the machine
is stopped.
Action of • Controls the machine, assuming the pump pressure to be 9.81 MPa {100 kg/cm2}, once the machine is
controller stopped.
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
• The auto shift-down/up function may not work.
appears on
• The LH pump oil pressure may not be monitored in the monitoring mode.
machine
a If the 5 V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure
sensor will be broken. Accordingly, take extreme care when checking.
Related
• The input state (voltage) from the LH pump pressure sensor can be checked in the monitoring mode.
information
(Code: 52502-HST L SENS)
• Method of reproducing error code: Turn the starting switch ON or start the engine.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Disconnection in wiring Wiring harness between CN-ST1 (female) (22) and CN-
harness (Disconnection Resistance Max. 1 z
RP (female) (B)
3 in wiring harness or
defective contact in con- Wiring harness between CN-ST1 (female) (21) and CN-
Resistance Max. 1 z
nector) RP (female) (A)
Wiring harness between CN-ST1 (female) (20) and CN-
Resistance Max. 1 z
RP (female) (C)
Short circuit with chas- a Prepare with starting switch OFF, then carry out troubleshooting without turning
sis ground in wiring har- starting switch.
4
ness (Contact with Between CN-ST1 (female) (20) – CN-RP (female) (C)
ground circuit) Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
5 Defective HST controller CN-ST1 Voltage
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (20) and (21) Signal 0.4 – 0.6 V
Defective RH pump
Between (B) and (A) Power supply 4.5 – 5.5 V
2 pressure sensor (Internal
Possible causes and
0.5 – 4.5 kz
Between (B) and (C)
Possible causes and
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
4 source in wiring harness
(Contact with 24 V circuit) Between CN-ST1 (female) (8) – CN-FP (female) (B) wir- Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
5 Defective HST controller CN-ST1 Voltage
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (8) and (21) Signal 0.3 – 4.5 V
0.5 – 4.5 kz
Between (B) and (C)
Possible causes and
0.5 – 4.5 kz
Presumed cause and
6 – 1 kz
Between (7) and (8)
Possible causes and
6 – 1 kz
Between (7) and (8)
(Between right and left ends)
Disconnection in wiring
harness (Disconnec-
Wiring harness between CN-ST1 (female) (22) and CN-
3 tion in wiring harness Resistance Max. 1 z
EL (female) (5)
or defective contact in
connector)
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
4
(Contact with ground cir- Between CN-ST1 (female) (19) – CN-EL (female) (7)
cuit) Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
5 Defective HST controller CN-ST1 Voltage
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (19) and (21) Signal 0.3 – 4.5 V
Error code [DK30KX] (Steering angle sensor: Out of input signal range)
Action code Error code Steering angle sensor: Out of input signal range
Trouble
CALL 04 DK30KX (HST controller system)
Contents of • In steering potentiometer systems 1 and 2, either of error codes [DK30KA] and [DK30KB] and either of
trouble error codes [DK31KA] and [DK31KB] are turned ON simultaneously.
• Flashes the warning lamp and sounds the warning buzzer.
• Limits the functions partly.
Action of • Controls the machine with the position signal received just before the trouble occurs until the machine
controller is stopped.
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
appears on • Once the machine is stopped, it cannot start again.
machine
• The input state (voltage) from the steering potentiometers 1 and 2 can be checked in the monitoring
Related mode. (Code: 50300-S/T LEVER 1, Code: 50301-S/T LEVER 2)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the
steering direction).
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Action code Error code Failure Steering angle sensor: Disconnection or short circuit
Trouble
CALL E04 DK30KZ phenomenon (HST controller system)
• When the starting switch is turned ON, either of steering potentiometer systems 1 and 2 is abnormal,
Contents of
and then either of error codes [DK30KA] and [DK30KB] and either of error codes [DK31KA] and
trouble
[DK31KB] are turned ON simultaneously in those systems.
• Flashes the warning lamp and sounds the warning buzzer.
• Limits the functions partly.
Action of • Controls the machine with the position signal received just before the trouble occurs until the machine
controller is stopped.
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
appears on • Once the machine is stopped, it cannot start again.
machine
• The input state (voltage) from the steering potentiometers 1 and 2 can be checked in the monitoring
Related mode. (Code: 50300-S/T LEVER 1, Code: 50301-S/T LEVER 2)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the
steering direction).
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Action code Error code Steering angle sensor: Disagreement of analog signals
Trouble
CALL E03 DK30L8 (HST controller system)
Contents of • The total of both signal voltages of steeing potentiometer systems 1 and 2 is below 4.41 V or above
trouble 5.59 V.
• Flashes the warning lamp and sounds the warning buzzer.
• Limits the functions partly.
Action of
• Controls the machine with the potentiometer which is outputting normal signals.
controller
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
appears on • Once the machine is stopped and started again, its travel speed is limited to 50%.
machine
• The input state (voltage) from the steering potentiometers 1 and 2 can be checked in the monitoring
Related mode. (Code: 50300-S/T LEVER 1, Code: 50301-S/T LEVER 2)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the
steering direction).
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
1 – 6 kz
Between (6) and (8)
(Between right and left ends)
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning
harness (Disconnection starting switch.
3 in wiring harness or
defective contact in con- Wiring harness between CN-ST1 (female) (21) and CN-
Resistance Max. 1 z
nector) EL (female) (8)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
4 source in wiring harness
(Contact with 24 V circuit) Between CN-ST1 (female) (7) – CN-EL (female) (6) wir-
Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
5 Defective HST controller CN-ST1 Voltage
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (7) and (21) Signal 0.3 – 4.5 V
1 – 6 kz
Between (6) and (8)
value in normal state
0.5 – 4.5 kz
Between (B) and (C)
Possible causes and
Action code Error code Directional potentiometer: Out of input signal range
Trouble
CALL E04 DK55KX (HST controller system)
Contents of • In directional potentiometer systems 1 and 2, either of error codes [DK56KA] and [DK56KB] and either
trouble of error codes [DK57KA] and [DK57KB] are turned ON simultaneously.
• Flashes the warning lamp and sounds the warning buzzer.
• Limits the functions partly.
Action of • Controls the machine with the position signal received just before the trouble occurs until the machine
controller is stopped.
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that
appears on • Once the machine is stopped, it cannot start again.
machine
• The input state (voltage) from the directional potentiometers 1 and 2 can be checked in the monitoring
Related mode. (Code: 50202-FR LEVER 1, Code: 50203-FR LEVER 2)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the F/R
direction).
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
1.5 – 5.5 kz
Between (3) and (1)
Possible causes and
1.5 – 5.5 kz
Between (2) and (1)
(Between forward and reverse ends)
Possible causes and
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning
harness (Disconnection starting switch.
3 in wiring harness or
defective contact in con- Wiring harness between CN-ST1 (female) (21) and CN-
Resistance Max. 1 z
nector) EL (female) (1)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Short circuit with power
Between CN-ST1 (female) (22) – CN-EL (female) (4) or
4 source in wiring harness Voltage Max. 1 V
other related circuit wiring harness and chassis ground
(Contact with 24 V circuit)
Between CN-ST1 (female) (1) – CN-EL (female) (2) wir-
Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
5 Defective HST controller CN-ST1 Voltage
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (1) and (21) Signal 0.3 – 4.5 V
1.5 – 5.5 kz
Between (2) and (1)
Possible causes and
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness (Disconnec-
Wiring harness between CN-ST2 (female) (40) and CN-
2 tion in wiring harness Resistance Max. 1 z
EN (female) (1)
or defective contact in
connector) Wiring harness between CN-ST2 (female) (29) and CN-
Resistance Max. 1 z
EN (female) (2)
Short circuit with a Prepare with starting switch OFF, then turn starting switch ON and carry out
power source in wiring troubleshooting.
3
harness (Contact with Between CN-ST2 (female) (40) – CN-EN (female) (1)
Voltage Max. 1 V
24 V circuit) wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Defective HST control- CN-ST2 (female) Resistance
4
ler
Between (40) and (29) 400 – 1,000 z
Between (40) and chassis ground Min. 1 Mz
Defective adjustment of
2 See TESTING AND ADJUSTING, Adjusting engine speed sensor.
engine speed sensor
Possible causes and
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
3
(Contact with ground cir- Between CN-ST2 (female) (40) – CN-EN (female) (1)
cuit) Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller CN-ST2 (female) Resistance
Between (40) and (29) 400 – 1000 z
Between (40) and chassis ground Min. 1 Mz
Short circuit with power a Prepare with starting switch OFF, then turn starting switch ON and carry out
source in alternator R troubleshooting.
5
signal system (Contact Between CN-ST1 (15) – CN-T16 wiring harness and
with 24 V circuit) Voltage Max. 10 V
chassis ground
Error code [DLM0KX] (Motor speed sensor: Out of input signal range)
Carry out troubleshooting for error codes [DLM1KA], [DLM1KB], [DLM2KA], and [DLM2KB].
starting switch.
Defective resistor for
3 detecting disconnection CN-R1 (male) Resistance
(Internal short circuit) Between (1) and (2) Resistance
Between (1) and (2) 610 – 630 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Disconnection in wiring Wiring harness between CN-ST1 (female) (22) and CN-
harness (Disconnection Resistance Max. 1 z
LRS (female) (1) or CN-R1 (female) (2)
4 in wiring harness or
defective contact in con- Wiring harness between CN-ST2 (female) (39) and CN-
Resistance Max. 1 z
nector) LRS (female) (2)
Wiring harness between CN-ST2 (female) (20) and CN-
Resistance Max. 1 z
LRS (female) (3) or CN-R1 (female) (1)
5 Defective HST controller Between CN-ST1 (22) and Power supply (When
4.5 – 5.5 V
CN-ST2 (39) machine is stopped)
Between CN-ST2 (20) and Signal (When machine 0 V i o 4.5 – 5.0 V
CN-ST2 (39) travels at constant speed) (Constant period)
Error code [DLM1KB] (Left HST motor speed sensor: Short circuit)
Action code Error code Left HST motor speed sensor: Short circuit
Trouble
E01 DLM1KB (HST controller system)
Contents of
• The travel command is output, but no signals are input from the left HST motor speed sensor.
trouble
• Stops the straight travel correction control.
Action of
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller
turned OFF.
Problem that
appears on • The machine deviates during travel.
machine
• The input state (speed, frequency) from the left HST motor speed sensor can be checked in the moni-
toring mode. (Code: 40003-L SPEED, Code: 40005-L SPEED)
• Method of reproducing error code: Start the engine and operate the PCCS lever (in the forward or
Related
reverse direction).
information
• If the error cannot be reproduced, the cause is not a sensor trouble but defective air bleeding after
assembly/modification or wrong detection during start at low temperature. In this case, the sensor
does not need to be replaced.
The left HST motor speed sensor may be adjusted defectively. Check it directly (See
3 left HST motor speed
TESTING AND ADJUSTING).
Possible causes and
sensor
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
4
(Contact with ground cir- Between CN-ST2 (female) (20) – CN-LRS (female) (3)
cuit) Resistance Max. 1 z
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Short circuit with power Between CN-ST1 (female) (22) – CN-LRS (female) (1)
5 source in wiring harness or other related circuit wiring harness and chassis Voltage Max. 1 V
(Contact with 24 V circuit) ground
Between CN-ST2 (female) (20) – CN-LRS (female) (3)
Voltage Max. 1 V
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
CN-ST1, CN-ST2 Voltage
6 Defective HST controller Between CN-ST1 (22) and Power supply (When
4.5 – 5.5 V
CN-ST2 (39) machine is stopped)
Between CN-ST2 (20) and Signal (When machine 0 V i o 4.5 – 5.0 V
CN-ST2 (39) travels at constant speed) (Constant period)
When the current flows in the HST pump EPC valve, if the motor does not rotate
7 Defective HST parts
because of internal fixing, etc., this error code may be turned ON.
troubleshooting.
CN-LRS Voltage
Possible causes and
Action code Error code Right HST motor speed sensor: Disconnection
Trouble
E01 DLM2KA (HST controller system)
Contents of
• Disconnection is detected in the right HST motor speed sensor circuit.
trouble
• Stops the straight travel correction control.
Action of
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller
turned OFF.
Problem that
appears on • The machine deviates during travel.
machine
• The input state (speed, frequency) from the right HST motor speed sensor can be checked in the mon-
Related itoring mode. (Code: 40002-R SPEED, Code: 40004-R SPEED)
information • Method of reproducing error code: Start the engine and operate the PCCS lever (in the forward or
reverse direction).
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective resistor for starting switch.
3 detecting disconnection
CN-R2 (male) Resistance
(Internal short circuit)
Between (1) and (2) 610 – 630 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Disconnection in wiring Wiring harness between CN-ST1 (female) (22) and CN-
harness (Disconnection Resistance Max. 1 z
RRS (female) (1) or CN-R2 (female) (2)
4 in wiring harness or
defective contact in con- Wiring harness between CN-ST2 (female) (39) and CN-
Resistance Max. 1 z
nector) RRS (female) (2)
Wiring harness between CN-ST2 (female) (30) and CN-
Resistance Max. 1 z
RRS (female) (3) or CN-R2 (female) (1)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
CN-ST1, CN-ST2 Voltage
5 Defective HST controller Between CN-ST1 (22) and Power supply (When
4.5 – 5.5 V
CN-ST2 (39) machine is stopped)
Between CN-ST2 (20) and Signal (When machine 0 V i o 4.5 – 5.0 V
CN-ST2 (39) travels at constant speed) (Constant period)
Error code [DLM2KB] (Right HST motor speed sensor: Short circuit)
Defective adjustment of
The right HST motor speed sensor may be adjusted defectively. Check it directly
3 right HST motor speed
Possible causes and
troubleshooting.
CN-RRS Voltage
Possible causes and
starting switch.
Possible causes and
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
1
(Internal short circuit) CN-CB (male) Resistance
Possible causes and
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness (Disconnection
Wiring harness between CN-ST3 (female) (17) and CN-
2 in wiring harness or Resistance Max. 1 z
S1 (female) (1)
defective contact in con-
nector) Wiring harness between CN-ST3 (female) (3) and CN-
Resistance Max. 1 z
S1 (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
3 source in wiring harness
(Contact with 24 V circuit) Between CN-ST3 (female) (17) – CN-S1 (female) (1) Voltage Max. 1 V
wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller
CN-ST3 (female) Resistance
Between (17) and (3) 40 – 60 z
Error code [DW28KB] (2nd gear speed solenoid valve: Short circuit)
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
3
(Contact with ground cir- Between CN-ST3 (female) (17) – CN-S1 (female) (1)
cuit) Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller CN-ST3 (female) Resistance
Between (17) and (3) 40 – 60 z
Between (17) and chassis ground Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness
Wiring harness between CN-ST3 (female) (7) and CN-
2 (Disconnection in wiring Resistance Max. 1 z
S2 (female) (1)
harness or defective con-
tact in connector) Wiring harness between CN-ST3 (female) (3) and CN-
Resistance Max. 1 z
S2 (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
3 source in wiring harness
(Contact with 24 V circuit) Between CN-ST3 (female) (7) – CN-S2 (female) (1) wir- Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller
CN-ST3 (female) Resistance
Between (7) and (3) 40 – 60 z
Error code [DW29KB] (3rd gear speed solenoid valve: Short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness
Wiring harness between CN-ST3 (female) (27) and CN-
2 (Disconnection in wiring Resistance Max. 1 z
S4 (female) (1)
harness or defective con-
tact in connector) Wiring harness between CN-ST3 (female) (3) and CN-
Resistance Max. 1 z
S4 (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
3 source in wiring harness
(Contact with 24 V circuit) Between CN-ST3 (female) (27) – CN-S4 (female) (1) Voltage Max. 1 V
wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller
CN-ST3 (female) Resistance
Between (27) and (3) 40 – 60 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Possible causes and
starting switch.
Wiring harness between CN-ST3 (female) (37) and
Disconnection in wiring Resistance Max. 1 z
CN26B (female) (A)
harness (Disconnection
Wiring harness between CN26B (female) (B) and CN-
4 in wiring harness or Resistance Max. 1 z
PB (female) (A)
defective contact in con-
nector) Wiring harness between CN-PB (female) (B) and CN-S3
Resistance Max. 1 z
(female) (1)
Wiring harness between CN-ST3 (female) (3) and CN-
Resistance Max. 1 z
S3 (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Between CN-ST3 (female) (37) – CN26B (female) (A)
Short circuit with power Voltage Max. 1 V
wiring harness and chassis ground
5 source in wiring harness
(Contact with 24 V circuit) Between CN26B (female) (B) – CN-PB (female) (A) wir- Voltage Max. 1 V
ing harness and chassis ground
Between CN-PB (female) (B) – CN-S3 (female) (1) wir-
Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
6 Defective HST controller
CN-ST3 (female) Resistance
Between (37) and (3) 40 – 60 z
standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting
Possible causes and
Defective installation of
Travel lock switches 1 and 2 may be installed defectively. Check them directly (See
7 travel lock switches 1 and
TESTING AND ADJUSTING).
2
Defective installation of
The brake potentiometer or brake limit switch may be installed defectively. Check
8 brake pedal potentiome-
them directly (See TESTING AND ADJUSTING).
ter or brake limit switch
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
starting switch.
3 switch 2
CN26B (male) Resistance
Possible causes and
Circuit diagram related to travel lock switch 2, brake pedal limit switch, and slow brake solenoid valve
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness (Disconnection
Wiring harness between CN-ST3 (female) (5) and CN-
2 in wiring harness or Resistance Max. 1 z
LF (female) (1)
defective contact in con-
nector) Wiring harness between CN-ST3 (female) (13) and CN-
Resistance Max. 1 z
LF (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
3 source in wiring harness
(Contact with 24 V circuit) Between CN-ST3 (female) (5) – CN-LF (female) (1) wir- Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller
CN-ST3 (female) Resistance
Between (3) and (13) 5 – 15 z
Error code [DXA4KB] (LH pump F-EPC solenoid valve: Short circuit)
Action code Error code LH pump F-EPC solenoid valve: Short circuit
Trouble
CALL E03 DXA4KB (HST controller system)
Contents of
• When the signal is output to the LH pump F-EPC solenoid valve circuit, an abnormal current flows.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting to the LH pump F-EPC solenoid valve circuit.
Action of
• Stops outputting to the RH pump F-EPC solenoid valve circuit, too.
controller
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that • If the machine has been traveling forward, it stops.
appears on • If the machine has been stopped, it cannot start forward.
machine • Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the LH pump F-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52401-LF PUMP, Code: 52409-LF PUMP)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the for-
ward direction).
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness (Disconnection
Wiring harness between CN-ST3 (female) (6) and CN-
2 in wiring harness or Resistance Max. 1 z
LR (female) (1)
defective contact in con-
nector) Wiring harness between CN-ST3 (female) (13) and CN-
Resistance Max. 1 z
LR (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
3 source in wiring harness
(Contact with 24 V circuit) Between CN-ST3 (female) (6) – CN-LR (female) (1) wir- Voltage Max. 1 V
ing harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller
CN-ST3 (female) Resistance
Between (6) and (13) 5 – 15 z
Error code [DXA5KB] (LH pump R-EPC solenoid valve: Short circuit)
Action code Error code LH pump R-EPC solenoid valve: Short circuit
Trouble
CALL E03 DXA5KB (HST controller system)
Contents of
• When the signal is output to the LH pump R-EPC solenoid valve circuit, an abnormal current flows.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting to the LH pump R-EPC solenoid valve circuit.
Action of
• Stops outputting to the RH pump F-EPC solenoid valve circuit, too.
controller
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that • If the machine has been traveling in reverse, it stops.
appears on • If the machine has been stopped, it cannot start in reverse.
machine • Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the LH pump R-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52403-LR PUMP, Code: 52411-LR PUMP)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the
reverse direction).
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness (Disconnection
Wiring harness between CN-ST3 (female) (15) and CN-
2 in wiring harness or Resistance Max. 1 z
RF (female) (1)
defective contact in con-
nector) Wiring harness between CN-ST3 (female) (23) and CN-
Resistance Max. 1 z
RF (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
3 source in wiring harness
(Contact with 24 V circuit) Between CN-ST3 (female) (15) – CN-RF (female) (1) Voltage Max. 1 V
wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller
CN-ST3 (female) Resistance
Between (15) and (23) 5 – 15 z
Error code [DXA6KB] (RH pump F-EPC solenoid valve: Short circuit)
Action code Error code RH pump F-EPC solenoid valve: Short circuit
Trouble
CALL E03 DXA6KB (HST controller system)
Contents of
• When the signal is output to the RH pump F-EPC solenoid valve circuit, an abnormal current flows.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting to the RH pump F-EPC solenoid valve circuit.
Action of
• Stops outputting to the LH pump F-EPC solenoid valve circuit, too.
controller
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that • If the machine has been traveling forward, it stops.
appears on • If the machine has been stopped, it cannot start forward.
machine • Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the RH pump F-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52400-RF PUMP, Code: 52408-RF PUMP)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the for-
ward direction).
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness (Disconnection
Wiring harness between CN-ST3 (female) (16) and CN-
2 in wiring harness or Resistance Max. 1 z
RR (female) (1)
defective contact in con-
nector) Wiring harness between CN-ST3 (female) (23) and CN-
Resistance Max. 1 z
RR (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
3 source in wiring harness
(Contact with 24 V circuit) Between CN-ST3 (female) (16) – CN-RR (female) (1) Voltage Max. 1 V
wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Defective HST controller
CN-ST3 (female) Resistance
Between (16) and (23) 5 – 15 z
Error code [DXA7KB] (RH pump R-EPC solenoid valve: Short circuit)
Action code Error code RH pump R-EPC solenoid valve: Short circuit
Trouble
CALL E03 DXA7KB (HST controller system)
Contents of
• When the signal is output to the RH pump R-EPC solenoid valve circuit, an abnormal current flows.
trouble
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting to the RH pump R-EPC solenoid valve circuit.
Action of
• Stops outputting to the LH pump R-EPC solenoid valve circuit, too.
controller
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Problem that • If the machine has been traveling in reverse, it stops.
appears on • If the machine has been stopped, it cannot start in reverse.
machine • Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the RH pump R-EPC solenoid valve can be
Related checked in the monitoring mode. (Code: 52402-RR PUMP, Code: 52410-RR PUMP)
information • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the
reverse direction).
Fuse
Type of power supply Fuse No. Destination of power
capacity
1 Lamp relay
20A
(Between terminals 1 and 6) Headlamp and rear lamp
2 Monitor panel (Switch power supply)
10A
Switch power supply (Between terminals 2 and 7) Caution buzzer
(Fusible link CN-H2) 3
10A HST controller
(Between terminals 3 and 8)
4
10A Horn
(Between terminals 4 and 9)
Switch 5
15A Engine stop solenoid
(Starting switch ACC) (Between terminals 5 and 10)
Fuse
Type of power supply Fuse No. Destination of power
capacity
Monitor panel (Constant power supply)
Constant power supply 1 Service switch
10A
(Fusible link CN-H1) (Between terminals 1 and 6) Constant power supply for fuse box (FB3)
[Cab specification]
2
10A Spare fuse (No destination)
(Between terminals 2 and 7)
Switch power supply 3
15A Canopy heater [Canopy specification]
(Fusible link CN-H2) (Between terminals 3 and 8)
4
20A Spare power supply (Connector CN17)
(Between terminals 4 and 9)
Constant power supply 5
30A Starting switch (Terminal B)
(Fusible link CN-H1) (Between terminals 5 and 10)
Fuse
Type of power supply Fuse No. Destination of power
capacity
Radio (Constant power supply) [Specification for Japan]
Constant power supply 1
10A Radio with cassette player (Constant power supply)
(Fuse box FB1-6) (Between terminals 1 and F)
[Specification for North America and EU]
Radio (Switch power supply) [Specification for Japan]
Radio with cassette player (Switch power supply)
2
20A [Specification for North America and EU]
(Between terminals 2 and B)
Cigarette lighter
Room lamp
3
Switch power supply 10A Rear wiper and washer
(Between terminals 3 and B)
(Fusible link CN-H3)
4
30A Air conditioner
(Between terminals 4 and B)
5
10A Front wiper and washer
(Between terminals 5 and B)
6 (–) (Unused)
<Contents of description)
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Grounding fault
Wiring harness which is not connected to chassis ground circuit is in contact with
standard value in normal state
2 Wiring harness which is not connected to power source (24 V) circuit is in contact
Possible causes of with power source (24 V) circuit.
trouble • Short circuit
(Given numbers are Independent wiring harnesses are in contact with each other abnormally.
reference numbers,
which do not indicate <Precautions for troubleshooting>
priority) 1) Method of indicating connector No. and handling of T-adapter
3 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 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.
1) Entry order of pin Nos. and handling of circuit tester leads
Connect positive (+) lead and negative (–) lead of circuit tester as explained below
4
for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or harness entered on front side.
• Connect negative (–) lead to pin No. or harness entered on rear side.
Trouble (1) When starting switch is turned to START position, starting motor does not rotate.
• Since the engine starting circuit has the neutral safety function, the engine does not start unless the
parking brake lever is in the LOCK position and the travel lever is in the neutral position. (When the
Related engine can start, [P] is lighted up on the monitor panel.)
information • Since the HST controller controls the neutral safety and parking brake relay with the travel lock switch
signal, check that a related error code is not displayed before carrying out troubleshooting. (If error
code [D130KA], [D130KB], [DD14KB], or [DDQ2KA] is displayed, carry out troubleshooting for it first.)
starting switch.
Between CN-KS (280) – CN11 (female) (3) or CN-S03
(female) (7) or another related circuit wiring harness Resistance Min. 1 Mz
and chassis ground
Short circuit with chassis Between CN11 (female) (5) – CN4 (female) (1) or
ground in wiring harness Resistance Min. 1 Mz
8 CN15 (female) (1) wiring harness and chassis ground
(Contact with ground
circuit) Between CN-T4 – CNT2 wiring harness and chassis
Resistance Min. 1 Mz
ground
Between CN-T8 – CNT1 wiring harness and chassis
Resistance Min. 1 Mz
ground
Between CN-T1 – CN-T3 wiring harness and chassis
Resistance Min. 1 Mz
ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
source in wiring harness
9 Between CN-4 (female) (2) – CN-T16 or CN-S04
(Contact with 24 V
circuit) (female) (9) or CN-ST1 (female) (15) or another related Voltage Max. 1 V
circuit wiring harness and chassis ground
Circuit diagram related to engine preheating, starting, charging, and stopping functions
Trouble (2) Starting motor rotates but engine does not start.
Related • Since the engine stop solenoid is installed, fuel injection is not started until the solenoid pulls the
information governor lever of the fuel injection pump to the RUN position.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective diode starting switch.
3
(Internal short circuit) CN-D3 (male) Resistance (Continuity)
Between (1) and (2) Min. 1 Mz (No continuity)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
harness Wiring harness between CN-KS (270) and FB1 (5) Resistance Max. 1 z
4 (Disconnection in wiring
harness or defective Wiring harness between FB1 (10) and CN-T17 Resistance Max. 1 z
contact in connector) Wiring harness between CN-T18 and chassis ground
Resistance Max. 1 z
(CN-T20)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Short circuit with chassis
Between CN-KS (270) – FB1 (5) or CN11 (female) (1)
ground in wiring harness
5 or CN-ST3 (14), (24) wiring harness and chassis Resistance Min. 1 Mz
(Contact with ground
ground
circuit)
Between FB1 (10) – CN-T17 or CN-D3 (female) (1)
Resistance Min. 1 Mz
and chassis ground
Circuit diagram related to engine preheating, starting, charging, and stopping functions
chassis ground
If the power supply input and preheating input are normal and the preheating output
is not normal, the heater relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective intake air starting switch.
3 heater
Intake air heater Continuity
(Internal disconnection)
Between terminals There is continuity
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring
starting switch.
harness
4 (Disconnection in wiring Wiring harness between CN-KS (255) and CN-T5 Resistance Max. 1 z
harness or defective Wiring harness between CN-T1 and CN-T12 Resistance Max. 1 z
contact in connector)
Wiring harness between CN-T6 and CN-RH Resistance Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Short circuit with chassis Between CN-KS (255) – CN-T5 wiring harness and
Resistance Min. 1 Mz
ground in wiring harness chassis ground
5
(Contact with ground Between CN-T1 – CN-T12 wiring harness and chassis
circuit) Resistance Min. 1 Mz
ground
Between CN-T6 – CN-RH or CN-S03 (female) (9)
Resistance Min. 1 Mz
wiring harness and chassis ground
Circuit diagram related to engine preheating, starting, charging, and stopping functions
Defective engine stop When terminal CN-T17 of the solenoid is disconnected while the engine is running,
1
Possible causes and
solenoid (Internal defect) if the engine does not stop, the engine stop solenoid is defective.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Short circuit with power
Between CN-KS (270) – FB1 (5) or CN11 (female) (11)
source in wiring harness
2 or CN-ST3 (14), (24) wiring harness and chassis Voltage Max. 1 V
(Contact with 24 V
ground
circuit)
Between FB1 (10) – CN-T17 or CN-D3 (female) (1)
Voltage Max. 1 V
and chassis ground
Circuit diagram related to engine preheating, starting, charging, and stopping functions
E-4 When starting switch is turned ON, any item does not light up
Trouble • When starting switch is turned ON, any item does not light up.
Related • When the starting switch is turned ON, the gear speed/Set travel speed/Shift mode indicator section,
information multi-information section, gauge section, and lamp section light up for 2 seconds.
E-5 When starting switch is turned ON, all items light up and none of them goes off
Trouble • When starting switch is turned ON, all items light up and none of them goes off
Related • When the starting switch is turned ON, the gear speed/Set travel speed/Shift mode indicator section,
information multi-information section, gauge section, and lamp section light up for 2 seconds.
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting without turning
Possible causes and
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch.
ground in wiring harness
3 Between CN-S04 (female) (9) – CN-T16 or CN4
(Contact with ground
circuit) (female) (2) or CN-ST1 (female) (15) or another related Resistance Min. 1 Mz
circuit wiring harness and chassis ground
a Prepare with starting switch OFF, then start engine and carry out troubleshooting.
CN-ST1 Engine speed Voltage
4 HST controller
Between (15) and chassis Above medium (half)
20 – 30 V
ground speed
Circuit diagram related to engine preheating, starting, charging, and stopping functions
1 coolant temperature is above 102 °C: Lamp flashes, above 108 °C: Lamp flashes and
Possible causes and
Overheating of HST oil Since overheating of HST oil is detected, check it. (When oil temperature is above
1
(When system is normal) 100 °C: Lamp flashes, above 110 °C: Lamp flashes and buzzer sounds)
Possible causes and
If indication of the HST oil thermometer is abnormal, carry out troubleshooting for
“HST oil thermometer is abnormal”.
Defective HST oil
2 temperature system Oil thermometer See the figure below.
(monitor panel system) White range Red range
Oil temperature lamp
OFF Flashing
If neither of causes 1 and 2 is the cause of the trouble, the monitor panel may be
3 Defective monitor panel defective (Troubleshooting cannot be carried out since the defect is in the monitor
panel).
Indication of HST oil thermometer (a Oil temperature is rough standard for changing indication)
Max. 1 z
{Min. 2 kg/cm2}
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
3
(Contact with ground Between CN-ST1 (female) (5) - CN-T34 wiring harness
circuit) Resistance Min. 1 Mz
and chassis ground
a Prepare with starting switch OFF, then hold starting switch ON and start engine
and carry out troubleshooting.
Difference between inlet
CN-ST1 and outlet pressures of Voltage
4 Defective HST controller HST filter
Max. 0.2 MPa
5 – 11 V
Between (5) and chassis {Max. 2 kg/cm2}
ground Min. 0.2 MPa
Max. 1 V
{Min. 2 kg/cm2}
If none of causes 1 – 4 is the cause of the trouble, the monitor panel may be
5 Defective monitor panel defective (Troubleshooting cannot be carried out since the defect is in the monitor
panel).
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
harness
Wiring harness between CN-ST1 (female) (11) and
3 (Disconnection in wiring Resistance Max. 1 z
CN-BS (female) (2)
harness or defective
contact in connector) Wiring harness between CN-ST1 (female) (4) and CN-
Resistance Max. 1 z
BS (female) (1)
a Prepare with starting switch OFF, then hold starting switch ON and start engine
and carry out troubleshooting. (When checking while engine is operated, set
parking brake lever in FREE position and release brake pedal.)
4 Defective HST controller CN-ST1 Engine Voltage
Stopped
5 – 11 V
Between (11) and (4) (Starting switch: ON)
Operated Max. 1 V
If none of causes 1 – 4 is the cause of the trouble, the monitor panel may be
5 Defective monitor panel defective (Troubleshooting cannot be carried out since the defect is in the monitor
panel).
E-8 Preheating pilot lamp does not light up during preheating operation
Trouble • Preheating pilot lamp does not light up during preheating operation.
• This troubleshooting is for the case when the preheating pilot lamp does not light up during the
preheating operation. (When the intake air heater is not heated, carry out troubleshooting for “Engine
Related
is not preheated”.)
information
• The input state (ON/OFF) from the heater relay can be checked in the monitoring mode. (Monitoring
code: 40921-Mon SW1, 6th from left)
1 (Disconnection in wiring
harness or defective Wiring harness between CN-S03 (female) (9) and CN-
Resistance Max. 1 z
Possible causes and
contact in connector) T6
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
2
(Contact with ground Between CN-S03 (female) (9) – CN-T6 wiring harness
circuit) Resistance Min. 1 Mz
and chassis ground
a Prepare with starting switch OFF, then hold starting switch in OFF and START
position and carry out troubleshooting.
3 Defective monitor panel CN-S03 Starting switch Voltage
Between (9) and chassis OFF Max. 1 V
ground HEAT 20 – 30 V
Circuit diagram related to engine preheating, starting, charging, and stopping functions
harness
Wiring harness between CN-S04 (female) (11) and
2 (Disconnection in wiring Resistance Max. 1 z
Possible causes and
contact in connector) Wiring harness between CN13 (female) (2) and CN-
Resistance Max. 1 z
S03 (female) (3)
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
3
(Contact with ground Between CN-S04 (female) (10) – CN13 (female) (1)
circuit) Resistance Min. 1 Mz
wiring harness and chassis ground
Short circuit with power a Prepare with starting switch OFF, then turn starting switch ON and carry out
source in wiring harness troubleshooting.
4
(Contact with 24 V Between CN-S04 (female) (10) – CN13 (female) (1)
circuit) Voltage Max. 1 V
wiring harness and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
CN-S03 (female)
5 Defective monitor panel Fuel tank Resistance
CN-S04 (female)
Between CN-S04 (10) and Full Max. 12 z
CN-S03 (3) Empty Min. 68 z
E-13 Gear speed, set travel speed, and shift mode indicator is abnormal
Trouble • Gear speed, set travel speed, and shift mode indicator is abnormal.
• Display information of the gear speed, set travel speed, and shift mode indicator is received from the
Related HST controller through the communication system.
information • Display of the gear speed, set travel speed, and shift mode indicator in the quick shift mode is different
from that in the variable shift mode.
Trouble (1) Service meter does not move forward while engine is running.
Related • The service meter counts the time by the signals from the engine speed sensor.
information • While the service meter is moving forward, the hourglass mark is displayed.
harness
Wiring harness between FB1 (7) and CN-CB (female)
3 (Disconnection in wiring Resistance Max. 1 z
(1)
harness or defective
contact in connector) Wiring harness between CN-CB (female) (2) and CN-
Resistance Max. 1 z
S03 (female) (18)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch.
ground in wiring harness Between FB1 (7) – CN-CB (female) (1) or CN-S03
4 Resistance Min. 1 Mz
(Contact with ground (female) (1) or (2) wiring harness and chassis ground
circuit) Between CN-CB (female) (2) – CN-S03 (female) (18)
Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
5 Defective monitor panel CN-S03 Caution buzzer Voltage
Between (18) and chassis Stopped 20 – 30 V
ground Operated (Sounded) Max. 3 V
2 (Disconnection in wiring
harness or defective Wiring harness between CN-ST2 (female) (35) and
Resistance Max. 1 z
contact in connector) CN-REV (female) (3)
Wiring harness between CN-ST1 (female) (10) and
Resistance Max. 1 z
CN-REV (female) (1)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch.
ground in wiring harness Between CN-ST2 (female) (25) – CN-REV (female) (2)
3 Resistance Min. 1 Mz
(Contact with ground wiring harness and chassis ground
circuit) Between CN-ST2 (female) (35) – CN-REV (female) (3)
Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Reverse travel speed
CN-ST1, CN-ST2 Voltage
setting switch
4 Defective HST controller Neutral 5 – 11 V
Between CN-ST2 (25) and
CN-ST1 (10) Higher speed (Right) Max. 1 V
Between CN-ST2 (35) and Neutral 5 – 11 V
CN-ST1 (10) Lower speed (Left) Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch.
Possible causes and
harness
Wiring harness between CN-ST2 (female) (37) and
2 (Disconnection in wiring Resistance Max. 1 z
CN-MTS (female) (2)
harness or defective
contact in connector) Wiring harness between CN-ST1 (female) (10) and
Resistance Max. 1 z
CN-MTS (female) (3)
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch.
3
(Contact with ground Between CN-ST2 (female) (37) – CN-MTS (female) (2)
circuit) Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
4 Defective HST controller CN-ST1, CN-ST2 Shift mode switch Voltage
Between CN-ST2 (37) and Variable shift mode (Left) 5 – 11 V
CN-ST1 (10) Quick shift mode (Right) Max. 1 V
2 (Disconnection in wiring
harness or defective Wiring harness between CN-ST2 (female) (26) and
Resistance Max. 1 z
contact in connector) CN-BUZ (female) (3)
Wiring harness between CN-ST1 (female) (10) and
Resistance Max. 1 z
CN-BUZ (female) (1)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch.
ground in wiring harness Between CN-ST2 (female) (36) – CN-BUZ (female) (2)
3 Resistance Min. 1 Mz
(Contact with ground wiring harness and chassis ground
circuit) Between CN-ST2 (female) (26) – CN-BUZ (female) (3)
Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
CN-ST1, CN-ST2 Buzzer cancel switch Voltage
4 Defective HST controller Between CN-ST2 (36) and Neutral 5 – 11 V
CN-ST1 (10) t (Right) Max. 1 V
Between CN-ST2 (26) and Neutral 5 – 11 V
CN-ST1 (10) U (Left) Max. 1 V
2 (Disconnection in wiring
harness or defective Wiring harness between CN-ST2 (female) (6) and CN-
Resistance Max. 1 z
contact in connector) CUR (female) (3)
Wiring harness between CN-ST1 (female) (10) and
Resistance Max. 1 z
CN-CUR (female) (1)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch.
ground in wiring harness Between CN-ST2 (female) (16) – CN-CUR (female) (2)
3 Resistance Min. 1 Mz
(Contact with ground wiring harness and chassis ground
circuit) Between CN-ST2 (female) (6) – CN-CUR (female) (3)
Resistance Min. 1 Mz
wiring harness and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
CN-ST1, CN-ST2 Information switch Voltage
4 Defective HST controller Between CN-ST2 (16) and Neutral 5 – 11 V
CN-ST1 (10) > (Right) Max. 1 V
Between CN-ST2 (6) and Neutral 5 – 11 V
CN-ST1 (10) < (Left) Max. 1 V
E-21 System is not set in service mode or is not set out of service mode
Trouble • System is not set in service mode or is not set out of service mode.
Related
information
Disconnection in wiring Wiring harness between FB2 (6) and CN-S24 (1) Resistance Max. 1 z
standard value in normal state
harness
Wiring harness between CN-ST3 (female) (18) and
1 (Disconnection in wiring Resistance Max. 1 z
Possible causes and
CN-T39
harness or defective
contact in connector) Wiring harness between CN-T40 and chassis ground
Resistance Max. 1 z
(CN-T10)
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
2 Defective HST controller CN-ST3 PCCS lever Voltage
Between (18) and chassis Neutral Max. 1 V
ground Reverse travel position 20 – 30 V
If neither of causes 1 and 2 is the cause of the trouble, judge the backup alarm
3 Defective backup alarm
defective.
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Possible causes and
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Possible causes and
starting switch.
Wiring harness between FB2 (8) and CN-HS (female)
Disconnection in wiring Resistance Max. 1 z
(4)
harness
Wiring harness between CN-HS (female) (3) and CN92
3 (Disconnection in wiring Resistance Max. 1 z
(female) (3)
harness or defective
contact in connector) Wiring harness between CN-HS (female) (2) and CN92
Resistance Max. 1 z
(female) (1)
Wiring harness between CN92 (female) (4) and
Resistance Max. 1 z
chassis ground (CNT10)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Short circuit with chassis Between FB2 (8) – CN-HS (female) (4) wiring harness
Resistance Min. 1 Mz
ground in wiring harness and chassis ground
4
(Contact with ground Between CN-HS (female) (3) – CN92 (female) (3)
circuit) Resistance Min. 1 Mz
wiring harness and chassis ground
Between CN-HS (female) (2) – CN92 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
Defective heater unit
5 If none of causes 1 – 5 is the cause of the trouble, the heater unit may be defective.
(Internal defect)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective blower Mid starting switch.
6
relay (Coil side) CN-R3 (male) Resistance
Between (1) and (2) 240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Defective blower Mid troubleshooting.
7
relay (Contact side) When the air flow selector switch is set in the “t” position, if the blower motor
rotates, the blower “Mid” relay is normal.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
8 Defective resistor CN-R (male) Resistance
Between (2) and (4) 2.0 z ± 7%
Between (3) and (4) 0.8 z ± 7%
a Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
9 Defective blower motor
When the air flow selector switch is set in the “Lo” position, if the blower motor
rotates, the blower motor is normal.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Disconnection in wiring Wiring harness between FB3 (4) and CN80 (female)
harness Resistance Max. 1 z
(13C)
10 (Disconnection in wiring
harness or defective Wiring harness between FB3 (4) and CN-R1 (female)
Resistance Max. 1 z
contact in connector) (13B)
Wiring harness between FB3 (4) and CN-R2 (female)
Resistance Max. 1 z
(13E)
harness
Wiring harness between CN-R2 (female) (0H) and
10 (Disconnection in wiring Resistance Max. 1 z
CN81 (male) (0A)
harness or defective
contact in connector) Wiring harness between CN-R3 (female) (17A) and
Resistance Max. 1 z
CN80 (female) (17B)
Wiring harness between CN-R3 (female) (0B) and
Resistance Max. 1 z
CN81 (male) (0A)
Wiring harness between CN-R (female) (0E) and CN81
Resistance Max. 1 z
(male) (0A)
Wiring harness between CN-R (female) (12A) and CN-
Resistance Max. 1 z
R3 (female) (12B)
Wiring harness between CN-B (female) (10A) and CN-
Resistance Max. 1 z
R (female) (10C)
Wiring harness between CN-B (female) (10A) and CN-
Resistance Max. 1 z
R2 (female) (10B)
If none of causes 1 – 10 is the cause of the trouble, the control panel may be
11 Defective control panel
defective.
Mistake in checking If the cause is not found out, a mistake may be made in check the trouble. In this
12
trouble case, carry out troubleshooting for “Air is not cooled”.
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective condenser starting switch.
5
relay (Coil side) CN-R5 (male) Resistance
Between (1) and (2) 240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch and air conditioner
switch ON and carry out troubleshooting.
Defective condenser
6 CN-R5 Air flow selector switch Voltage
relay (Contact side)
Between (3) and chassis
Any position 20 – 30 V
ground
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
7 Defective thermistor
CN-T (male) Resistance
Between (1) and (2) Max. 3,500 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective condenser Hi starting switch.
8
relay (Coil side) CN-R6 (male) Resistance
Between (1) and (2) 240 ± 40 z
a Prepare with starting switch OFF, then turn starting switch and air conditioner
Defective condenser Hi switch ON and carry out troubleshooting.
9
relay (Contact side) When the medium pressure switch of the pressure switch operates, if the
condenser motor rotates, the condenser Hi relay is normal.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective condenser starting switch.
10
resistor Condenser resistor Resistance
Between (1) and (2) 2.8 z ± 5%
t (female) (16B)
Wiring harness between CN-P (female) (26B) and
Resistance Max. 1 z
CN80 (female) (26A)
Wiring harness between CN-P (female) (29A) and CN-
Disconnection in wiring Resistance Max. 1 z
R6 (female) (29B)
harness (Disconnection
Wiring harness between CN-R4 (female) (27C) and
14 in wiring harness or Resistance Max. 1 z
CN-R5 (female) (27B)
defective contact in
connector) Wiring harness between CN-R4 (female) (27C), CN-R5
Resistance Max. 1 z
(female) (27)) and CN-P (female) (27A)
Wiring harness between CN-R4 (female) (9B) and
Resistance Max. 1 z
CN81 (male) (9A)
Wiring harness between CN-R5 (female) (28C) and
Resistance Max. 1 z
condenser motor (female) (C361)
Wiring harness between CN-R5 (female) (28C) and
Resistance Max. 1 z
CN-P (female) (28A)
Wiring harness between CN-R6 (female) (0K) and
Resistance Max. 1 z
chassis ground (CN-T35)
Wiring harness between CN-R6 (female) (30B) and
Resistance Max. 1 z
condenser resistor (female) (C381)
Wiring harness between CN-R6 (female) (0I) and
Resistance Max. 1 z
chassis ground (CN-T35)
Wiring harness between condenser resistor (female)
Resistance Max. 1 z
(C04) and chassis ground (CN-T35)
Wiring harness between condenser motor (female)
Resistance Max. 1 z
(C38) and condenser resistor (C381)
If none of causes 1 – 10 is the cause of the trouble, the control panel may be
15 Defective control panel
defective.
E-26 Windshield wiper and windshield washer do not operate [Cab specification]
ON 20 – 30 V
ground
Possible causes and
If the voltage and resistance are normal but the front wiper does not operate, the
front wiper motor is defective.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Wiring harness between FB3 (5) and CN65 (female)
Resistance Max. 1 z
(3)
Wiring harness between FB3 (5) and CN68 (female)
(6) (Note: If only this wiring harness is disconnected,
Disconnection in wiring Resistance Max. 1 z
the wiper operates but does not return to regular
harness position when it stops.)
4 (Disconnection in wiring
harness or defective Wiring harness between CN65 (female) (4) and CN68
Resistance Max. 1 z
contact in connector) (female) (2)
Wiring harness between CN68 (female) (3) and
Resistance Max. 1 z
chassis ground (CN-T35)
Wiring harness between CN65 (female) (5) and CN68
(female) (5) (Note: If only this wiring harness is
Resistance Max. 1 z
disconnected, the wiper operates but does not return to
regular position when it stops.)
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Between FB3 (5) – CN65 (female) (2) or (3) wiring
Resistance Min. 1 Mz
Short circuit with chassis harness and chassis ground
ground in wiring harness Between FB3 (5) – CN68 (female) (6) wiring harness
5 Resistance Min. 1 Mz
(Contact with ground and chassis ground
circuit) Between CN65 (female) (4) – CN68 (female) wiring
Resistance Min. 1 Mz
harness and chassis ground
Between CN65 (female) (5) – CN68 (female) (5) wiring
Resistance Min. 1 Mz
harness and chassis ground
OFF
Between (2) and chassis
Defective rear wiper Max. 1 z
Possible causes and
4 ground
motor (Internal defect)
Between (3) and chassis
ON 20 – 30 V
ground
Between (4) and chassis
OFF Max. 1 z
ground
If the voltage and resistance are normal but the rear wiper does not operate, the
rear wiper motor is defective.
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Wiring harness between FB3 (3) and CN64 (female)
Resistance Max. 1 z
(3)
Wiring harness between FB3 (3) and CN69 (female)
(3) (Note: If only this wiring harness is disconnected,
Resistance Max. 1 z
the wiper operates but does not return to regular
Disconnection in wiring position when it stops.)
harness
Wiring harness between CN64 (female) (4) and CN66
5 (Disconnection in wiring Resistance Max. 1 z
(female) (1)
harness or defective
contact in connector) Wiring harness between CN66 (female) (2) and CN69
Resistance Max. 1 z
(female) (1)
Wiring harness between CN69 (female) (2) and
Resistance Max. 1 z
chassis ground (CN-T35)
Wiring harness between CN64 (female) (5) and CN69
(female) (4) (Note: If only this wiring harness is
Resistance Max. 1 z
disconnected, the wiper operates but does not return to
regular position when it stops.)
starting switch.
Between FB3 (3) - CN64 (female) (2) or (3) wiring
Possible causes and
Resistance Min. 1 Mz
harness and chassis ground
Short circuit with chassis Between FB (3) - CN69 (female) (3) wiring harness
Resistance Min. 1 Mz
ground in wiring harness and chassis ground
6
(Contact with ground Between CN64 (female) (4) – CN66 (female) (1) wiring
circuit) Resistance Min. 1 Mz
harness and chassis ground
Between CN66 (female) (2) – CN69 (female) (1) wiring
Resistance Min. 1 Mz
harness and chassis ground
Between CN64 (female) (5) – CN69 (female) (4) wiring
Resistance Min. 1 Mz
harness and chassis ground
1
Possible causes and
Possible causes of
2 trouble
<Contents of description>
(Given numbers are
• Standard value in normal state to judge possible causes
reference numbers,
• Remarks on judgment
3 which do not indicate
priority)
H-1 Right and left travel systems do not operate forward and in reverse
(No travel systems operate)
Trouble • Right and left travel systems do not operate forward and in reverse (No travel systems operate).
Related
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
information
a Prepare with engine stopped, then run engine at high idling and carry out
Possible causes and
troubleshooting.
Monitor panel HST charge
PCCS lever
(Adjustment mode) circuit pressure
Defective adjustment or
3.04 ± 0.29 MPa
malfunction of HST Neutral
5 3016-STALL CHECK {31 ± 3 kg/cm2}
motor
(charge relief valve) (Stall pressure test mode) 2.84 ± 0.49 MPa
Forward or reverse
{29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge relief
valve of the HST motor may have malfunction or defect in it. Check the charge
relief valve directly.
a Prepare with engine stopped, then run engine at high idling and carry out
troubleshooting.
Malfunction of parking Parking brake lever and Parking brake solenoid Slow brake solenoid valve
brake solenoid valve or brake pedal valve output pressure output pressure
6
slow brake solenoid Lever: Free position 30.4 ± 0.49 MPa 30.4 ± 0.49 MPa
valve Pedal: Released {31 ± 5 kg/cm2} {31 ± 5 kg/cm2}
Lever: Lock position 0 MPa 0 MPa
Pedal: Pressed fully {0 kg/cm2} {0 kg/cm2}
Wrong operation of park-
The parking brake bypass valve (tow valve) may be operated (changed over)
7 ing brake bypass valve
wrongly. Check it directly.
(tow valve)
Defect in HST pump
8 The pump unit of the HST pump may have a defect in it. Check it directly.
(pump unit)
H-2 Right or left travel system does not operate forward and in reverse
(Only right or left travel system does not operate)
• Right or left travel system does not operate forward and in reverse
Trouble
(Only right or left travel system does not operate).
Related
information
1
pump (servo valve) Check it directly.
Possible causes and
Wrong operation of HST The towed valve of the HST pump (on 1 side) may be operated (opened) wrongly.
2
pump (towed valve) Check it directly.
Defect in HST pump The pump unit of the HST pump (on 1 side) may have a defect in it.
3
(pump unit) Check it directly.
Defect in HST pump The parking brake of the HST motor (on 1 side) may have a defect in it.
4
(parking brake) Check it directly.
Defect in HST motor The motor unit of the HST motor (on 1 side) may have a defect in it.
5
(motor unit) Check it directly.
6 Defect in final drive The final drive (on 1 side) may have a defect in it. Check it directly.
H-3 Right or left travel system does not operate forward or in reverse
(Only 1 system does not operate)
Trouble • Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).
• If this trouble occurs just after the initial adjustment of the pump, the pump may be adjusted wrongly. In
this case, perform the initial adjustment of the pump again.
Related
(During idle travel: 3001-PUMP ADJST F, 3002-PUMP ADJST R)
information
(During actual travel: 3003-PU F-UP MPA, 3004-PU R-UP MAP, 3005-PU FHF MAP, 3006-PU R-HF
MAP)
If the oil pressure does not become normal after the adjustment, the charge safety
valve of the HST pump may have malfunction or defect in it. Check the charge
Possible causes and
a Prepare with engine stopped, then run engine at high idling and carry out
troubleshooting.
Possible causes and
a Prepare with engine stopped, then run engine at high idling and carry out
troubleshooting.
Possible causes and
1 Air may be left in the servo valve of the HST pump. Bleed air again.
from HST pump
Warm up the engine (to the green range of the HST oil thermometer).
2 Low HST oil temperature
HST oil thermometer Green range
Defective initial
3 The initial adjustment of the pump may be defective. Adjust the pump again.
adjustment of pump
Defect in HST pump The pump unit of the HST pump (on 1 side) may have a defect in it.
3
Possible causes and
troubleshooting.
Possible causes and
H-10 Abnormal sound comes out from around HST pump and motor
Trouble • Abnormal sound comes out from around HST pump and motor.
Related
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
information
(charge safety valve) (Stall pressure test mode) 2.84 ± 0.49 MPa
Forward or reverse
Possible causes and
{29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge safety
valve of the HST pump may have malfunction or defect in it. Check the charge
safety valve directly.
a Prepare with engine stopped, then run engine at high idling and carry out
troubleshooting.
Monitor panel HST charge
PCCS lever
(Adjustment mode) circuit pressure
Defective adjustment or
3.04 ± 0.29 MPa
malfunction of HST Neutral
7 3016-STALL CHECK {31 ± 3 kg/cm2}
motor
(charge relief valve) (Stall pressure test mode) 2.84 ± 0.49 MPa
Forward or reverse
{29 ± 5 kg/cm2}
If the oil pressure does not become normal after the adjustment, the charge relief
valve of the HST motor may have malfunction or defect in it. Check the charge
relief valve directly.
Defect in HST pump
8 The pump unit of the HST pump may have a defect in it. Check it directly.
(pump unit)
Loosening of piping
The piping between the HST pump and HST motor may be loosened.
9 between HST pump and
Check it directly.
HST motor
Defect in HST motor The motor unit of the HST motor may have a defect in it. Check it directly.
10
(motor unit) Troubleshooting cannot be carried out since the defect is in the motor unit.
Defective air bleeding
11 Air may be left in the servo valve of the HST pump. Bleed air again.
from HST pump
(charge relief valve) If the oil pressure does not become normal after adjustment, the HST charge relief
valve may have a malfunction or a defect in it. Check the HST charge relief valve
Possible causes and
directly.
Malfunction of work
5 equipment PPC lock The work equipment PPC lock valve may be malfunctioning. Check it directly.
valve
6 Defect in front PTO The front PTO may have a defect in it. Check it directly.
Defect in work
7 The work equipment pump may have a defect in it. Check it directly.
equipment pump
Malfunction of control
8 The unload valve of the control valve may be malfunctioning. Check it directly.
valve (unload valve)
a Prepare with engine stopped, then run engine at high idling and carry out
troubleshooting.
Defective adjustment or Blade control lever Work equipment pump relief pressure
9 malfunction of control Relieve blade circuit
valve (main relief valve) 17.6 MPa {180 kg/cm2}
(by lifting, tilting, or angling).
If the oil pressure does not become normal after adjustment, the main relief valve
may have a malfunction or a defect in it. Check the main relief valve directly.
(charge relief valve) If the oil pressure does not become normal after adjustment, the HST charge relief
valve may have a malfunction or a defect in it. Check the HST charge relief valve
directly.
Defect in work
4 The work equipment pump may have a defect in it. Check it directly.
equipment pump
Malfunction of control
5 The unload valve of the control valve may be malfunctioning. Check it directly.
valve (unload valve)
a Prepare with engine stopped, then run engine at high idling and carry out
troubleshooting.
Defective adjustment or Blade control lever Work equipment pump relief pressure
6 malfunction of control Relief of blade circuit
valve (main relief valve) 17.6 MPa {180 kg/cm2}
(by lifting, tilting, or angling)
If the oil pressure does not become normal after adjustment, the main relief valve
may have a malfunction or a defect in it. Check the main relief valve directly.
Right tilting stroke end Min. 1.72 MPa {Min. 17.5 kg/cm2}
Malfunction of blade lift
2 The spool of the blade lift control valve may be malfunctioning. Check it directly.
control valve (spool)
Malfunction of blade tilt
The pressure compensation valve of the blade tilt control valve may be
3 control valve (pressure
malfunctioning. Check it directly.
compensation valve)
a Prepare with engine stopped, then run engine at high idling and carry out
Defect in blade tilt troubleshooting.
4
cylinder Blade tilt cylinder Leakage from cylinder
Relief by tilting left 6.5 cc/min
2 angle control valve The spool of the blade angle control valve may be malfunctioning. Check it directly.
Possible causes and
(spool)
Malfunction of blade
angle control valve The pressure compensation valve of the blade angle control valve may be
3
(pressure compensation malfunctioning. Check it directly.
valve)
Malfunction of blade
The safety valve of the blade angle control valve may be malfunctioning.
4 angle control valve
Check it directly.
(safety valve)
Malfunction of blade
The suction valve of the blade angle control valve may be malfunctioning.
5 angle control valve
Check it directly.
(suction valve)
a Prepare with engine stopped, then run engine at high idling and carry out
Defect in blade angle troubleshooting.
6
cylinder Blade angle cylinder Leakage from cylinder
Relief by right or left angling 6.0 cc/min
H-19 Abnormal sound comes out from around work equipment pump and
control valve
Trouble • Abnormal sound comes out from around work equipment pump and control valve.
Related
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
information
suction strainer
Looseness of work
Possible causes and
H-20 HST oil temperature (Hydraulic oil temperature) rises too high
Trouble • HST oil temperature (Hydraulic oil temperature) rises too high
Related
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
information
troubleshooting.
Possible causes and
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in (B) are items that can be
obtained from the user, depending on the user's Causes
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under (C) in the
chart on the right correspond to this.
The serviceman narrows down the causes from
(b) (2) (3)
information (A) that he has obtained from the user
and the results of (C) that he has obtained from his
own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability form infor-
(a)
mation gained from [Questions] and [Check
Questions
(A) (b)
items].
(c)
(d)
(B) (e)
Check items
(C)
i
shooting
Trouble-
ii
iii
tion)
2. Use the E in the Cause column as refer-
njec
ence for [Degree of use (Operated for long
i
period)] in the [Questions] section as refer-
sive
nce
ence.
zzle
xces
r
fere
r line
As a rule, do not use it when calculating be
n no
nt
p (e
leme
inter
included if necessary to determine the order
inde
g
o
pum
timin
t i
injec
for troubleshooting.
er e
ger,
, cyl
tion
ction
lean
char
ized
ring
injec
air c
r inje
, se
urbo
ton
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
1 Confirm recent repair history
2 Degree of use Operated for long period
d)
ead
tion)
eize
nd h
injec
er s
er a
eat
lung
sive
harg
lve s
nce
ck, p
timin ozzle
xces
rboc
fere
e, va
nt
p (ra
p (e
nn
leme
n tu
inter
ance
er
f valv
g
uffle
r inje injectio
pum
pum
ylind
twee
er e
ger,
lear
dm
act o
c
tion
tion
ction
lean
ir be
char
lve c
gge
ring
ed
injec
injec
Legend
cont
, seiz
air c
of a
, clo
urbo
r va
ton
: Possible causes (judging from Questions and check items)
ctive
ctive
ctive
: Most probable causes (judging from Questions and Check items)
n pis
kage
hed
ged
rope
ged
rope
ed t
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Crus
Clog
Clog
Seiz
Wor
Lea
Imp
Imp
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Remedy
Clean
Five causes
Step 1
Three symptoms
Step 2
Step 3
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel
(At ambient temperature of –10°C or below, ASTM
D975 No. 2 diesel fuel is used)
a Battery charging rate
Causes
Charging rate
Ambient 100% 90% 80% 75% 70%
k)
temperature
stuc
20°C 1.28 1.26 1.24 1.23 1.22
nger
0°C 1.29 1.27 1.25 1.24 1.23
, plu
eat
tank
el
–10°C 1.30 1.28 1.26 1.25 1.24
ing
canc
lve s
(rack
el pip
ry
fuel
batte
• The specific gravity should exceed the value
le
e, va
ator
g
t
nozz
le in
ump
r
men
in fu
aine
timin
er
r
for the charging rate of 70% in the above table.
e
der
pens
rated
f valv
heat
in
er ho
p
er ele
p str
tion
, stra
cylin
g, air
• In cold areas the specific gravity must exceed
tion
tion
p
t com
terio
r
pum
e air
act o
injec
tor
nato
reath
pum
injec
injec
filter
lean
the value for the charging rate of 75% in the
ggin
ing,
egula
or de
boos
intak
alter
feed
cont
fuel
air b
ton r
feed
air c
above table.
lo
fuel
fuel
fuel
c
r
ctive
ctive
ctive
ctive
ctive
ctive
ctive
ctive
age,
n pis
ged
tive
tive
ged
ged
ged
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Wor
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
n
• Hydraulic pump system error
ectio
• Defective electrical system
it
ttery
circu
conn
d ba
ting
inal
ch
otor
e
star
lay
t
term
swit
iora
lay
ng m
r y re
ty re
g of
eter
ting
ery
ear
atte
tarti
wirin
safe
or d
star
batt
ing g
b
s
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Confirm recent repair history
Questions
When starting switch is turned to START, pinion does not move out
Troubleshooting of defective wiring in starting circuit
Remedy
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
General causes why engine turns but not exhaust smoke Causes
comes out
• Supply of fuel impossible
• Supply of fuel extremely small
d)
eize
• Improper selection of fuel (particularly in winter)
er s
Selection of fuel according to
nk
lung
t, ke
ambient temperature
el ta
Type of fuel
n
ck, p
shaf
pisto
–22 –4 –14 32 50 68 86 104°F
n fu
–30 –20 –10 0 10 20 30 140°C
p (ra
er
g
drive
ole i
pipin
r
ump
train
n e
ASTM D975 No.2
pum
er h
a
tank
ump
s
, str
fuel
Diesel oil
eed
d
h
m
tion
on p
ASTM D975A
l use
filter
reat
el in
king
u
No.1
en f
p
injec
air b
jecti
feed
nt fu
r fue
, lea
fuel
brok
ctive
en in
fficie
ged
ged
ged
ged
rope
ed,
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
Confirm recent repair history
Questions
return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found to be
clogged
When feed pump strainer is inspected directly, it is found to be
clogged
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
c.)
• Lack of rotating force due to defective electrical
r, et
system
leve
• Insufficient supply of fuel
uck)
cker
y
• Insufficient intake of air
spra
t
cap
e, ro
• Improper selection of fuel and oil
er s
tive
lung
tank
em
(valv
efec
syst
ck, p
ery
fuel
le, d
stem
er
batt
fuel
n
nt
p (ra
iner
le in
i
nozz
l
r
leme
er
e sy
e
der
ted
ir in
t
rain
stra
r ho
hea
pum
valv
iora
tion
er e
g, a
i
r, st
, cyl
e
mp
e air
d
h
tion
eter
injec
l use
lean
ken
reat
ggin
e
u
ring
t
p
ntak
l
injec
or d
f
, bro
feed
air b
air c
, clo
r fue
fuel
fuel
ton
i
ctive
ctive
ctive
ctive
n pis
kage
ged
ged
ged
ged
ged
rope
Defe
Defe
Defe
Clog
Defe
Clog
Clog
Clog
Clog
Wor
Lea
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly failed to start
Questions
1) Little fuel comes out even when injection pump piping sleeve nut is
loosened
2) No fuel comes out even when fuel filter air bleed plug is loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
y
spra
• Improper fuel used
ap
seat
tive
nk c
alve
efec
ger
el ta
nce
nd v
plun
le, d
in fu
r
fere
r line
nt
g
iner
ve a
nozz
pipin
mp
leme
iner
inter
nce
hole
inde
st ra
n pu
f val
st ra
a
tion
er e
fuel
ger,
lear
her
, cyl
ump
act o
jectio
ilter,
injec
lean
char
reat
king
lve c
ring
ed p
cont
uel f
uel in
air c
air b
, lea
urbo
fuel
r va
ton
e
f
f
ctive
n pis
ged
ged
rope
ged
ged
ged
ed f
ed t
ged
Clog
Defe
Clog
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Questions
Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Engine pick-up suddenly became poor
Rust and water are found when fuel tank is drained
Air cleaner clogging monitor lights up
Noise of interference is heard from around turbocharger
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Mud is stuck to fuel tank cap
Check items
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
c. )
• Insufficient supply of fuel
r, et
)
• Overheating
tuck
leve
a If the engine is overheating and
er s
cker
the engine stops, carry out trou-
lung
e, ro
bleshooting for overheating.
od
nk
ck, p
valv
ing r
el ta
(See S-14 Water temperature
key
t
stem
ton
arin
p (ra
m (
ipme
becomes too high)
nect
in fu
p pis
,
t be
f t
p sy
r
g
yst e
m
a
aine
• Failure in hydraulic pump
equ
pipin
r
e sh
, con
n pu
aine
hole
shaf
pum
in
pum
s
a If the machine stops because of
r t ra
p str
tank
ary
v
e
o
iston
, st r
fuel
rank
her
valv
i
eed
d
t
the failure in hydraulic pump, carry
gea
uxili
injec
aulic
pum
mp
filter
el in
reat
king
ed c
ed p
ed f
c
out troubleshooting for H-mode.
a
i
ized
u
ynam
hydr
fuel
air b
feed
uel p
ump
nt fu
, lea
fuel
seiz
seiz
seiz
ctive
s
re in
en p
fficie
en d
en f
ged
ged
ged
ged
en,
en,
en,
en,
Failu
Defe
Brok
Brok
Clog
Clog
Clog
Clog
Brok
Brok
Brok
Brok
Brok
Insu
Confirm recent repair history
Degree of use of machine Operated for long period
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
Questions
stopped
Engine stopped slowly
There was hunting and engine stopped
Replacement of filters has not been carried out according to
Operation Manual
Non-specified fuel is being used
Fuel level lamp lights up
Fuel tank is found to be empty
When feed pump is operated, operation is too light or too heavy
Mud is stuck to fuel tank cap
Engine rotates, but stops when work equipment and travel
Check items
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
Add
p
pum
• Defective governor mechanism
zzle
• Defective electronical governor mechanism
d no
feed
a If hunting stops when governor spring is dis-
p an
and
connected, carry out troubleshooting for the
pum
tank
troubleshooting for E-mode.
nk
feed
el ta
fuel
ck
or
a
rnor
vern
rol r
in fu
een
een
r
gove
aine
f go
w
cont
betw
betw
iner
hole
oo lo
p st r
nt o
st ra
tank
n of
n of
rcuit
cuit
her
t
stme
pum
lter,
ratio
ratio
r
el in
reat
in ci
in ci
eed
i
adju
uel f
ope
ope
feed
air b
nt fu
g sp
, air
, air
f
ctive
ctive
ctive
fficie
idlin
ged
ged
ged
ged
ged
Clog
Defe
Clog
Clog
Clog
Clog
Defe
Defe
Insu
Low
Confirm recent repair history
Degree of use of machine Operated for long period
Occurs at a certain speed range
Questions
Clean
Clean
Clean
Remedy
Add
y
spra
• Improper fuel used
t
men
eat
ragm
(if non-specified fuel is used, output drops)
tive
t
lve s
djus
nk
• Lack of output due to overheating
efec
iaph
el ta
er
ce
ve a
d va
a If there is overheating and lack of output,
g
e, d
or d
eren
in fu
p plu
fecti
e an
carry out troubleshooting for S-14 over-
nt
iping
r
ozzl
nsat
aine
f
iner
leme
inter
hole
ance
r
pum
heating.
e
inde
valv
g, d
on n
uel p
mpe
p st r
st ra
er e
ger,
her
lear
, cyl
tion
prin
t of
jecti
st co
pum
ing f
ter,
reat
lean
char
ntac
lve c
njec
ring
or s
el in
il
boo
f
air b
feed
air c
, lea
urbo
fuel
o
vern
uel i
r va
ton
c
f u
ctive
ctive
n pis
ged
ged
ged
ged
rope
ged
ged
ed f
ed t
t go
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Seiz
Seiz
Ben
Wor
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly
Power was lost
Questions
Gradually
Engine oil must be added more frequently
Replacement of filters has not been carried out according to
Operation Manual
Non-specified fuel is being used
Air cleaner clogging monitor lights up
Black
Color of exhaust gas
Blue under light load
Noise of interference is heard from around turbocharger
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
Check items
clogged
Speed does not change when operation of certain cylinders is
stopped
When control rack is pushed, it is found to be heavy, or does not
return
When valve clearance is checked directly, it is found to be outside
standard value
When fuel dial is placed at FULL position, lever does not contact
stopper
When feed pump is operated, operation is too light or too heavy
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
ld
• Improper condition of fuel injection
anifo
on)
• Excessive injection of fuel
d)
jecti
em
eize
ve in
intak
at
er s
e se
essi
lung
ger
timin ozzle
valv
(exc
char
nce
ck, p
on n
d
liner
fere
urbo
e an
ump
g
nt
p (ra
jecti
leme
inter
ance
der
ffler
t
valv
on p
pum
el in
twee
ction
cylin
u
er e
ger,
lear
dm
jecti
t of
u
tion
lean
ir be
l inje
f
char
ntac
lve c
gge
ring
n
zed
injec
fuel
air c
of a
r fue
, clo
o
urbo
, sei
r va
ton
c
ctive
ctive
ctive
n pis
kage
hed
ged
rope
ged
rope
ed t
Defe
Defe
Defe
Crus
Clog
Clog
Seiz
Wor
Lea
Imp
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Remedy
Clean
rger
General causes why oil consumption is excessive
ocha
• Abnormal combustion of oil
Turb
• External leakage of oil
seal
d
• Wear of lubrication system
hea
c e
stem
hose
a
er
ken
r f
der
cool
al su
r
, bro
r line
e sy
r
cylin
e
plug
r oil
h
l, se
t
intak
ide)
brea
nde
d
nd
r
n
er o
iping
an o
a
rain
ine e
er e
, gu
e
, cyli
ar s
om
r or
il filt
oil d
oil p
oil p
blow
ring
stem
turb
in fr
oler
e
ring
n re
o
t h
from
rom
from
m
iston
brea
il co
al at
lve (
al at
ked
roke
ton
r o
f
f
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Lea
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Oil consumption suddenly increased
Questions
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
end
• Operation under excessive load
bine
be
r tur
n tu
se
r ho
r
r line
e
drai
harg
athe
r oil
inde
ide
k
rboc
blac
, bre
arge
e gu
, cyl
at tu
r
ke is
ther
oole
boch
valv
ring
lter
seal
brea
smo
oil c
oil fi
ton
r
lve,
t u
ctive
n pis
ged
ged
ged
n va
ged
aust
Defe
Clog
Clog
Clog
Clog
Wor
Wor
Exh
Confirm recent repair history
Operated for long period
Questions
None
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
tion)
• Excessive injection of fuel
injec
on)
y
r
l filte
spra
sive
g
(pist
prin
, fue
r
lder
nge
xces
ump
or s
r
cove
le ho
iping
u
p (e
vern
p
ed p
g
ump
uel p
nozz
imin
pum
ead
f go
e fe
p
ide h
on t
nt o
tion
n
tion
nsid
from
ectio
jecti
stme
injec
l ins
injec
eal i
age
n j
el in
f fue
i
adju
oil s
fuel
fuel
fuel
leak
f u
o
ctive
ctive
ctive
ctive
ctive
ctive
kage
rnal
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Lea
Confirm recent repair history
Operated for long period
Questions
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
S-11 Oil is in cooling water, or water spurts back, or water level goes down
sket
k
d ga
bloc
ring
oler
hea
, O-
der
itting
il co
cylin
core
ad,
lic o
r he
by p
ks in
oler
linde
drau
used
il co
crac
y
y
en o
en h
en c
s ca
rnal
Brok
Brok
Hole
Brok
Inte
Confirm recent repair history
Operated for long period
Questions
Remedy
g
pipin
–30 –20 –10 0 10 20 30 140°C
pan
or
il pa
g
SAE30CD
sens
aulic
azin
e oil
r
e
uctio nside o
enso
valv
Engine SAE10WCD
e br
hydr
ure
insid
l
urna
e
an
v
oil
vel s
lator
ump
SAE10W-30CD
ress
n pip
f val
shed
oil p
ipe i
g, jo
iner
n oil
lter
oil le
regu
relie
oil p
oil p
SAE15W-40CD
oil p
oil fi
stra
il in
, cru
arin
uel i
ctive
ctive
ctive
ctive
ctive
of o
en s
n be
ged
ged
ged
king
er, f
Defe
Defe
Defe
Defe
Defe
Lack
Brok
Clog
Clog
Clog
Wor
Wat
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
over
General causes why oil level rises
ad c
seal
• Water in oil (milky white)
m p
e he
u
• Fuel in oil (diluted, and smells of diesel fuel)
ent
p
et
tion
e
gask
insid
uipm
• Entry of oil from other component
rfac
eve
njec
ring
k
y eq
d
iping
s
r sle
bloc
hea
uel i
, O-
seal
r
e
a
mp
ad,
der
core
itting
f
ld
li
rear
stat
e
auxi
le ho
insid
l f ro
r he
cylin
by p
rmo
oler
ged
p
f fue
nozz
linde
pum
part
side
e
il co
ama
e
h
d
o
t
y
s ma
ctive
ctive
ctive
ks in
ctive
en o
en c
kage
n, d
Defe
Defe
Defe
Hole
Brok
Defe
Crac
Brok
Wor
Lea
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
h
o hig
en)
a Carry out troubleshooting for H-mode.
ge
sket
t op
re to
y
gau
pulle
d ga
s no
ins
ratu
ture
tor f
hea
fan
ler
(doe
mpe
lve
pera
o
radia
worn
il co
,
e va
core
g
ead
r
oil te
stat
wate
pittin
r tem
p
pum
o
shed
er h
ssur
o
ing,
ator
ken
m
mp
ling
e by
wate
ther
ylind
ater
slipp
e
, bro
radi
, cru
ic pu
r
o
d
of co
en w
s ma
ctive
ctive
ctive
en c
ged
ged
ged
belt
raul
Lack
Defe
Brok
Brok
Defe
Clog
Defe
Hole
Clog
Clog
Hyd
Fan
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
is excessive
Temperature difference between top and bottom radiator tanks
is slight
When water filler port is inspected, core is found to be clogged
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
ifold
e)
c.)
General causes why abnormal noise is made
ngin
r, et
man
n)
d)
• Abnormality due to defective parts
tion)
ss e
sitio
eize
leve
take
• Abnormal combustion
f po
c
erle
er s
ker
• Air sucked in from intake system
nd in
ve in
ut o
r (lin
ung
, roc
ance
er a
rd o
essi
k, pl
inde
alve
zzle
lear
e
g
boa
c
renc
nce
(rac
r
, cyl
m (v
a
n no
p (e
lve c
boch
fere
ding
erfe
ring
ash
ump
yste
ectio
pum
of va
r
inter
u
(divi
lt int
ackl
iston
on p
t
lve s
g
j
een
tion
n
n
i
ushi
ain b
n be
ent
ger,
fler
fuel
jecti
of p
betw
ic va
injec
justm
muf
ed b
char
n, fa
ar tr
ized
el in
ear
ynam
of air
fuel
side
seiz
urbo
d
d fa
r ge
ve w
e
u
a
s
f
ctive
ctive
ctive
en d
ct in
,
rme
age
rope
ged
ed t
ing,
essi
Defe
Leak
Defe
Defe
Defo
Defe
Brok
Clog
Miss
Seiz
Imp
Exc
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
k)
“S-15 Abnormal noise is made”.
stuc
etc.
tion)
General causes why vibration is excessive
ver,
injec
• Defective parts (abnormal wear, breakage)
er le
ligne
ion
• Improper alignment
fuel
rock
cush
misa
• Abnormal combustion
sive
lve,
ken
mp
xces
ng
va
ic pu
, bro
(
eari
p (e
e m
raul
ain b
bolts
ash
syst
pum
r
mpe
d
ackl
y
d, m
e
ting
valv
tion
e da
ain b
and
oun
g ro
injec
g
mic
ushin
nsid
e
ar tr
em
ectin
dyna
i
fuel
g
art i
f en
ngin
r ge
mb
conn
ctive
ctive
en p
ter o
n ca
rope
se e
n
Defe
Defe
Brok
Wor
Wor
Cen
Loo
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Vibration occurs at mid-range speed
Check items
Replace
Correct
Correct
Adjust
Remedy
k
available, can be substituted with com-
mercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly
developed for this model. a This mark gives guidance or precau-
R: Tools with upgraded part numbers, tions when doing the procedure.
remodeled from already available tools 2 This mark stands for a specific coating
for other models. agent to be used.
3 This mark
Blank: Tools already available for other mod-
els, used without any modification. indicates the specified
torque.
5
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the This mark indicates an amount of oil or
special tool is presented in the section of water to be added.
Sketches for Special Tools.
a Part No. of special tools starting with 79*T means
that they are locally made parts and as such not SKETCHES OF SPECIAL TOOLS
interchangeable with those made by Komatsu in • Various special tools are illustrated for the con-
Japan e.g. 79*T - xxx - xxxx. venience of local manufacture.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
k
1) Necessity
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com- a This mark gives guidance or precau-
mercially available tools. tions when doing the procedure.
2) Distinction of new and existing special tools 2 This mark stands for a specific coating
N: Tools with new part numbers, newly agent to be used.
3 This mark
developed for this model.
R: Tools with upgraded part numbers, indicates the specified
remodeled from already available tools torque.
for other models. 5 This mark indicates an amount of oil or
Blank: Tools already available for other mod- water to be added.
els, used without any modification.
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the SKETCHES OF SPECIAL TOOLS
special tool is presented in the section of • Various special tools are illustrated for the con-
Sketches for Special Tools. venience of local manufacture.
a Part No. of special tools starting with 79*T means
that they are locally made parts and as such not
interchangeable with those made by Komatsu in
Japan e.g. 79*T - xxx - xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
L1 Push tool
L3 Push tool
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 795-799-1131 Gear t 1
A
2 795-799-1390 Remover t 1
REMOVAL
1. Open up both engine hoods (1).
8. Disconnect fuel inlet hoses (7) and (8) and
return hose (9).
2. Remove left engine side cover (2).
12. Using tool A1, rotate the crankshaft forward to 17. Remove 4 mounting bolts (18) and fuel injection
match the timing gear to the fuel injection timing. pump assembly (19).
a See TESTING AND ADJUSTING, Testing
and adjusting fuel injection timing.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1] [*2]
a Adjust the fuel control linkage and decelera-
tor pedal linkage. For details, see TESTING
15. Using tool A2, disconnect the shaft and drive AND ADJUSTING, Adjusting fuel control le-
gear of the fuel injection pump. ver linkage and decelerator pedal linkage.
[*3]
a Adjust the engine stop solenoid linkage. For
details, see TESTING AND ADJUSTING,
Adjusting engine stop solenoid linkage.
[*4]
a Tighten the cap by turning it by 180 degrees.
[*5]
a Install the fuel injection pump assembly ac-
cording to the following procedure.
1) Using tool A1, crank the engine forward
slowly and push No. 1 cylinder compression
16. Remove brackets (16) and (17). top dead center positioning pin (20) into the
gear.
a Referring to the following, push positioning 4) Install fuel injection pump assembly (19)
3 Nut:
tremely not to drop it in the case.
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
fuel circuit.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
3 795-799-1170 Puller q 1
A
4 790-331-1110 Wrench t 1
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k If the water temperature in the radiator is high,
you may get scalded. Accordingly, wait until the
5. Using eyebolts, lift off engine hood (4).
water temperature lowers, then drain.
4 Engine hood: 45 kg
1. Remove the mounting bolts and cover (1).
6 Radiator: Approx. 20 l
7. Disconnect charge air cooler hose (6). [*1] 12. Disconnect 3 wiring connectors (13) and remove
the heater relay. [*5]
• Secured with bolt (CNT5)
• Secured with nut (CNT6), (CNT12)
18. Disconnect charge air cooler hose (20). [*7] 29. Remove 2 mounting bolts (32) and alternator
assembly (33).
19. Disconnect oil filler tube (21) and oil filler hose
(22).
4 Muffler assembly: 33. Remove the mounting bolt and bracket (37).
40 kg (Including bracket) [*15]
a Remover the bracket and the fuel filter to-
gether.
37. Remove water drain tube (43). 43. Remove the intake air heater ground wire, con-
a Remove the 2 mounting bolts, and the tube nector (52), intake air heater (53), and cover
is removed and divided into 2 pieces. (54). [*20]
[*1]
a When connecting the hose, apply spray
[*7]
a When connecting the hose, apply spray
47. Lift off cylinder head assembly (58). 5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
[*9]
a Pass the reservoir tank drain hose through
the guide pipe of the shroud.
[*13]
a Adjust the engine stop solenoid linkage. For
details, see TESTING AND ADJUSTING,
Adjusting engine stop solenoid linkage.
[*16]
a When connecting the hose, apply spray
[*20]
a Secure clearance of at least 10 mm between
the ground wire and fuel tube.
[*21]
• Install the rocker arm assembly and cylinder
head assembly according to the following
procedure.
a Check that there is not dirt or foreign
matter on the mating face of the cylinder
head and in the cylinders.
1) Set cylinder head gasket (59) to the cylinder
block.
a Check that the gasket is matched to the ii) When not using tool A4
holes of the block. • Make marks on the bolts and
2) Sling cylinder head assembly (58) and set it head with a marker pen, then
to the cylinder block. tighten each bolt by 90 ± 5°.
3) Install push rod (57).
4) Install rocker arm assembly (56) and tighten
the bolt with your fingers.
a Check that the adjustment screw ball is
fitted to the socket of the push rod.
5) Tighten the cylinder head mounting bolts in
• Bleeding air
a Bleed air from the fuel circuit. For details,
see TESTING AND ADJUSTING, Bleeding
air from fuel circuit.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
1 795-799-2610 Installer t 1
B
2 795-799-2620 Installer t 1
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
7. Remove dust seal (8).
1. Remove the radiator guard assembly. For
details, see REMOVAL OF RADIATOR GUARD
ASSEMBLY.
3 Mounting bolt:
• Carry out installation in the reverse order to lowing order.
removal.
24 ± 4 Nm {2.45 ± 0.41 kgm}
vibration damper:
125 ± 5 Nm {12.75 ± 0.51 kgm}
a Install the crankshaft pulley/vibration damper
lightly, then install the fan belt and tighten the
mounting bolts to the specified torque.
[*2]
a Install the front cover according to the follow-
ing procedure.
1) Apply ThreeBond 1207D or equivalent
in the form of a string 1 – 2 mm thick to
the gasket fitting face of the front cover.
a Limit the projection of the gasket
from the oil pan fitting face to 0.25
mm.
2) Install the gasket to the front cover, and
then install them to the engine.
3) Tighten the 7 mounting bolts in the fol-
3 Mounting bolt:
lowing order.
[*3] [*4]
a Install the dust seal to the crankshaft accord- a Install the engine front seal to the front cover
ing to the following procedure. according to the following procedure.
a Even if a dust seal has not been installed, in- 1) Set engine front seal (7) to tool B1.
stall the dust seal contained in the front seal a Since plastic part [2] on the inside of the
kit. engine front seal is used to guide the
1) Install dust seal (8) to the end of the front cover to the crankshaft, do not re-
crankshaft. move it from the engine front seal.
2) Using tool B2, press fit dust seal (8). 2) Press fit engine front seal (7) to front cover
a Press fit the dust seal until the inside (6).
end of tool B2 touches the end of the a Press fit the engine front seal until the
crankshaft. shoulder of tool B1 touches the inside
end of the front cover.
REMOVAL AND 2) Screw the tip of seal puller C into the drilled
hole and slide the hammer to remove
INSTALLATION OF ENGINE engine rear seal (2).
REAR SEAL
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
REMOVAL
1. Remove the coupling. For details, see REMOVAL
AND INSTALLATION OF DAMPER.
a Method of removing with screwdriver
2. Remove the mounting bolts, set guide bolts [1], • Break the seal carrier of engine rear seal
and lift off flywheel assembly (1). [*1] (2) with a screwdriver to remove the en-
gine rear seal.
4 Flywheel assembly: 35 kg a Take care not to damage the seal fitting
part of the flywheel housing and the seal
contact surface of the crankshaft.
1. Remove the mounting bolts and cover (1). 5. Remove both engine covers (5).
6 Radiator: Approx. 15 l
3. Remove clip of heater hose (2) and disconnect 8. Disconnect radiator inlet hose (9).
dust indicator hose (3).
a Disconnect the dust indicator hose end on 9. Disconnect horn wiring connector (CN22) (10).
the air cleaner side.
10. Remove both fan guards (11).
11. Disconnect oil cooler outlet hose (12). 15. Sling radiator guard assembly (17) temporarily
a Prepare a blind plug before disconnecting and remove 8 mounting bolts (16) from both
the hose. sides and 2 from the underside. [*2]
12. Disconnect radiator outlet hose (13). 16. Lift off radiator guard assembly (17).
13. Disconnect charge air cooler inlet hose (14). 4 Radiator guard assembly: 370 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a Pass the reservoir tank drain hose through
the guide pipe of the shroud.
a When connecting the hose, apply spray
[*2]
a When installing the radiator guard assembly,
peep through hole "a" to check that there is
not clearance between the stopper and
frame on each side.
k Never insert your finger in hole "a".
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
a Install the radiator guard assembly so that
distance "b" between back side of the shroud
and the compressor bracket of the air condi-
tioner will be 142 mm.
3) Lift off oil cooler assembly (12). 2) Remove right cleaning and inspection cover
4
(15).
Oil cooler: 35 kg a If the mounting bolt of the cleaning and
inspection cover is loosened with an im-
pact wrench, it is loosened too much and
the bolt pin is broken. Accordingly, loos-
en it with a wrench by hand.
a If the oil cooler assembly is removed
without removing the cleaning and in-
spection cover, the pin may touch and
break the core. Accordingly, remove the
cleaning and inspection cover first.
3. Radiator assembly
1) Remove 4 upper mounting bolts (13) and 2
lower mounting bolts (14).
4 Radiator: 80 kg
4 Radiator: 80 kg
4 Oil cooler: 35 kg
2) Install left cleaning and inspection cover 3. Charge air cooler assembly
(11). 1) Install charge air cooler assembly (8).
a If the mounting bolt of the cleaning and
inspection cover is tightened with an im-
pact wrench, it is tightened too much and
the bolt pin is broken. Accordingly, tight-
en it with a wrench by hand.
4. Disconnect work equipment valve hoses (7) and 7. Remove 2 fuse boxes (19) and disconnect 3 wir-
(8). ing harness clamps (20).
• (7): To oil cooler (Hose color band: Blue) a There is 1 wiring harness clamp inside.
• (8): To work equipment pump
(Hose color band: Red)
8. Disconnect 4 wiring harness clamps (21). 14. Disconnect the 4 wiring connectors.
a There are 1 wiring harness clamp inside and • (32): CN1
1 installed together with other parts. • (33): CN2
• (34): CN3
9. Disconnect starting motor wiring harness (22).
a Disconnect only the positive (+) side.
• (35): CN-EN
4 Front bracket: 65 kg
3 Hose clamp:
[*3]
[*4]
a Install the engine ground terminal straight
down.
[*2]
a Install the coupling with the inside projection
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-630-3200 Remover t 1
Cylinder
R 790-101-1300 t 1
(980 kN {100 tons})
790-101-1102 Hydraulic pump t 1
SPREADING
1. Position the master link properly.
a Start the engine and position each master
link in front of the idler.
4. Remove the track shoe of master link (3). [*2]
a Set a block, jack, etc. under the track shoe in
a Pull both sides of the master link with wires
front of each idler.
and chain blocks and remove the master link
bolts to disconnect the master link.
2. Remove mounting bolts and cover (1).
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a Adjust the tension of the track shoe. For de-
tails, see TESTING AND ADJUSTING, Test-
ing adjusting tension of track shoe.
a Tension of track shoe: 20 – 30 mm
[*2]
a When winding the track shoe, use a bar, etc. to
prevent the link from parting from the sprocket.
a Take proper measures so that the mating faces
and threads of the master link will not be rusted,
bruised, or deformed. In addition, check that the
mating faces and threads are free from dirt.
a Tighten the master link bolts in the order of [1] –
Initial torque:
147.1 ± 19.6 Nm {15 ± 2 kgm}
Retightening angle: 180 ± 10°
REMOVAL
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
k Disconnect the cable from the negative (–) ter-
minal of the battery.
3 Mounting bolt:
[*1]
4
ASSEMBLY.
HST motor and final drive assembly
(Each side): 300 kg
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
791-830-1320 Rod t 1
01580-01613 Nut t 1
01643-31645 Washer t 1
1 790-101-2540 Washer t 1
J 790-101-2102 Puller assembly t 1 3. Ring gear
790-201-2830 Spacer t 1 1) Remove 18 mounting bolts (3).
790-101-1102 Hydraulic pump t 1
2 791-427-1410 Wrench t 1 N
3 791-545-1510 Installer t 1
DISASSEMBLY
1. Draining oil
Remove the drain plug to drain the oil from the
final drive case.
2) Using the push tool, press fit 2 inner race 6) Using tool J2, tighten nut (23) to 245 Nm {25
5) Using push tool [4], press the inner race on a Rotating force: 127 – 206 N {13 – 21 kg}
the bearing on the nut side with a press.
a Pressing force on inner race:
8.8 – 12.7 kN {0.9 – 1.3 tons}
a After installing hub assembly (24), re-
volve the hub by 2 – 3 turns against the
HST motor case.
a When tightening the nut to the above 3. No. 2 planetary carrier assembly
torque, check by the match marks that 1) Install thrust washer (21).
the nut rotates by 0.5 – 1 notch.
a If the lock plate is turned over, it deviates 3) Install 2 inner race bearings (19) to gear
by 1/2 notch. Accordingly, install it so (18).
that its claw will be fitted to a notch of the a 3 sets
3 Mounting bolt:
Adhesive (LT-2) a 3 sets
5) Install shaft (16) and ball (17) to No. 2 plane-
58.8 – 73.5 Nm {6 – 7.5 kgm} tary carrier assembly.
a Install the shaft by expansion fit.
a Match the hole of the shaft to that of the
carrier and install the shaft by hitting it
lightly with a plastic hammer, etc.
a 3 sets
3 Mounting bolt:
6) Tighten mounting bolt (15). 6. No. 1 planetary carrier assembly
1) Assemble No. 1 planetary carrier assembly
98 – 122.5 Nm {10 – 12.5 kgm} according to the following procedure.
a After assembling No. 2 planetary carrier a Replace the thrust washers and pin with
assembly, check that gear (18) rotates new ones.
smoothly. i) Install bearing (11) to gear (10) and fit
a 3 sets upper and lower thrust washers (9),
then set gear (10) to No. 1 planetary
carrier assembly.
ii) Match the pin hole of shaft (8) to that of
the carrier and install shaft (8) by hitting
it lightly with a plastic hammer, etc.
a Take care not to damage the thrust
washers.
iii) Insert pin (7).
3 Mounting bolt:
Gasket sealant (1207B)
7. Ring gear
1) Fit the O-ring to the hub side. Using eye-
bolts [2] and matching the bolt holes of ring
gear (4) to those of the hub, install ring gear
(4).
a Degrease the mating faces of the ring
gear and hub. 9. Refilling with oil
Tighten the plug and add engine oil through the
3 Mounting bolt:
(3).
4 Idler: 100 kg
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
ASSEMBLY
1. Assembly of rod assembly 3) Using push tool [3], install spacer (12) and
1) Install U-packing (18) to rod assembly (5) secure it with snap ring (11).
and secure it with snap ring (17).
2) Install wear ring (16).
DISASSEMBLY AND
ASSEMBLY OF IDLER
ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
ASSEMBLY 4. Using tool L2, install floating seal (9) to idler (7).
5. Using tool L2, install floating seal (9) to support 8. Using tool L2, install floating seal (6) to support
(10). (5).
a For precautions for installing the floating a For precautions for installing the floating
seal, see a in step 4 above. seal, see ain step 4 above.
6. Install idler (7) to the shaft and support assem- 9. Fit the O-ring to shaft (8).
bly.
10. Supply oil through the hole of shaft (8) and
7. Using tool L2, install floating seal (6) to idler (7). tighten the plug.
5
3 Plug: 98 – 137 Nm {10 – 14 kgm}
l (SAE30-CD)
Oil: Approx. 160 ml
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
DISASSEMBLY 6. Remove floating seals (7) and (8) from roller (6).
1. Remove plug (1) and drain oil.
6
7. Remove bushing (9) and (10) from roller (6).
l
Track roller: Approx. 150 ml
9. Remove floating seal (14) from collar (12). a Precautions when assembling floating seal.
1) When assembling the floating seal,
10. Remove O-rings (15) from shaft (13). degrease and dry the parts indicated
with thick line A (O-ring and mating face
of the O-ring).
2) After assembling the floating seal,
check that the angle of the seal is less
than 1 mm.
3) After assembling, check that protrusion
[a] of the floating seal is within a range
of 7 – 11 mm.
ASSEMBLY
1. Fit O-rings (15) to shaft (13) and assemble collar
(12), then install ring (11).
a After assembling, tighten plug (1) temporari-
ly.
4. Install floating seal (8) to roller (6). 7. Install floating seal (8).
a For details of the precautions when installing a For details of the precautions when installing
the floating seals, see Step 2, a Precautions the floating seals, see Step 2, a Precautions
when assembling floating seal. when assembling floating seal.
5. Set shaft (13) and collar (12) assembly on block 8. Install floating seal (5) to collar (3).
[2], then assemble roller (6). a For details of the precautions when installing
a Coat the sliding surface of the floating seal the floating seals, see Step 2, a Precaution
with engine oil, and make sure that no dirt or when assembling floating seal.
dust sticks to the surface. a Coat the sliding surface of the floating seal
a When assembling the roller, coat the shaft or with engine oil, and make sure that no dirt or
bushing with engine oil. dust sticks to the surface.
6. Refilling with oil 9. Fit roller (2) to collar (3), then install ring (4).
Pour oil through clearance between shaft (13)
and roller (6).
10. Using tool L5, apply basic pressure to roller oil 12. Checking oil level
filler port, and check for leakage of air from seal. Stand the track roller as shown in the diagram
a Basic pressure: 0.1 MPa {1 kg/cm2} below and leave it for a short time, then insert a
a Method of checking wire from the oil filler port and check height L to
The basic pressure shall be maintained for the oil surface.
10 seconds and the indicator of the gauge a Distance L from end face of shaft to oil sur-
shall not go down. face: 106 mm
11. If oil was not added in Step 6, use tool L5, to fill
track roller assembly with oil.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
L 6 791-430-3230 Installer t 1
DISASSEMBLY
1. Remove cap (1) from carrier roller assembly.
3 Mounting bolt:
4. Assemble plate (3), and tighten with bolt (2).
2) Install floating seals (8) and (5).
a When installing the floating seal, de- 176.5 ± 19.6 Nm {18 ± 2 kgm}
grease and dry the parts indicated with
thick line A (O-ring and mating face of
the O-ring).
a After installing the floating seal, check
that its slant is within 1 mm and its pro-
jection [a] is 4 – 8 mm.
5 l
Carrier roller: Approx. 200 – 220 ml
(Engine oil EO30-CD)
4
3 Mounting bolts of flanges of hoses (15)
HST pump assembly: 140 kg [*1]
• Bleeding air
a Bleed air from the HST circuit. For details,
see TESTING AND ADJUSTING, Bleeding
air from HST circuit.
DISASSEMBLY AND
ASSEMBLY OF MAIN
CONTROL VALVE ASSEMBLY
DISASSEMBLY
Disassembly of main control valve assem-
bly 1/2
a Since the safety valve assembly cannot be set to
proper pressure while it is mounted on the ma-
chine, do not disassemble it.
a Do not remove the upper and lower covers and
each block.
2. Unload valve
1) Remove unload valve assembly (4).
2) Remove the O-ring and ring (6) from sleeve
(5).
3) Remove plug (7) and spring (8) from sleeve
(5).
4) Remove plug (9) and spring (10).
a Do not remove the spool, seal, and LS
selector valve.
8. Plugs
Remove 2 plugs (23), plug (24), plug (25), and 2
plugs (26).
3 Bolt:
has any defect, replace the assembly. ing bolts.
a Degrease the plug and female screw of the spool
with DRYSOL, etc. and dry them completely be- 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
fore tightening. Do not apply pressure on them
for at least 2 hours after they are tightened.
3 Bolt:
the mounting bolts.
3 Plug:
7) Tighten plug (43).
3 Bolt:
the mounting bolts.
3 Bolt:
ing bolts.
3 Bolt:
ing bolts.
3 Bolt:
ing bolts.
3 Plug:
1) Fit the O-ring and tighten plug (26). into the block
3 Plug:
a 2 sets
147 – 186.2 Nm {15 – 19 kgm}
147 – 186.2 Nm {15 – 19 kgm} 3) Fit the O-ring to plug (7).
3 Plug:
5) Screw plug (7) into sleeve (5).
3 Plug:
3) Fit the O-ring and tighten plug (24).
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
147 – 186.2 Nm {15 – 19 kgm} 6) Fit the O-ring and ring (6) to sleeve (5).
3 Plug:
4) Fit the O-ring and tighten plug (23). 7) Screw unload valve assembly (4) into the
3 Plug:
with plug (20). to plug (1).
2) Screw pressure releasing plug (1) into the
3 Plug:
147 – 186.2 Nm {15 – 19 kgm} block.
3 Plug:
a 2 sets
5. Suction valve
Fit the O-ring and screw suction valve (14) into
the block.
3 Suction valve:
a 3 sets
39.2 – 49 Nm {4 – 5 kgm}
4
• Carry out installation in the reverse order to
Work equipment assembly: removal.
950 kg (D31EX-21)
1,050 kg (D31PX-21) [*1]
1,000 kg (D37EX-21) k When aligning the pin holes, use a bar.
1,100 kg (D37PX-21) Never insert your fingers in the pin holes.
1,150 kg (D39EX-21)
1,200 kg (D39PX-21) [*2]
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes.
• Greasing
a After assembling the blade assembly, apply
grease to the removed pins securely.
New/remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part Name
DISASSEMBLY
1. Piston rod assembly
1) Set cylinder assembly (1) to tool U1.
2) Using a hydraulic pump or a power wrench
and tool U2, disconnect head assembly (2).
3
1) Set the piston rod to tool U1. and tool U2, tighten head assembly (2).
2) Install head assembly (6) and piston assem-
bly (5).
Cylinder name Tightening torque of head
3
3) Using tool U3, tighten nut (4).
637 ± 63.7 Nm
Blade lift
{65 ± 6.5 kgm}
Cylinder Width Tightening 569 ± 56.9 Nm
name across flats torque of nut Blade angle
{58 ± 5.8 kgm}
785 ± 78.5 Nm 677 ± 67.5 Nm
Blade lift 46 mm Blade tilt
{80 ± 8 kgm} {69 ± 6.9 kgm}
785 ± 78.5 Nm
Blade angle 46 mm
{80 ± 8 kgm}
1,080 ± 108 Nm
Blade tilt 50 mm
{110 ± 11 kgm}
2 Threads of rod:
threads of the piston rod thoroughly.
INSTALLATION OF
OPERATOR’S SEAT FRAME
ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
k Loosen the heater hose valve (If the machine is
equipped with the heater or air conditioner).
k Close the fuel stop valve. 6. Disconnect rear lamp wiring connector (CN33)
(6).
1. Drain the hydraulic oil.
6 Hydraulic tank: 47 l
6 Radiator: Approx. 15 l
8. Remove the 2 mounting bolts and seat belt (8). 11. Remove the mounting bolts and cover (11).
15. Disconnect the 4 wiring connectors of the 4- 17. Disconnect the 4 floor wiring harness connec-
spool solenoid valve. tors and floor ground wire.
• (20): Parking brake solenoid valve connec- • (36): CN7
tor S4 (Color band: Brown) • (37): CN6
• (21): Slow brake solenoid valve connector • (38): CN8
S3 (Color band: Blue) • (46): CN5
• (22): 3rd gear speed solenoid valve connec- • (47): Floor ground wire
tor S2 (Color band: Green)
• (23): 2nd gear speed solenoid valve con-
nector S1 (Color band: Yellow)
22. Remove the mounting bolts and lift off operator's INSTALLATION
seat frame assembly (45). • Carry out installation in the reverse order to
4
removal.
Operator's seat frame assembly: 170 kg
3 Mounting bolt:
[*1]
[*2]
a Adjust the fuel control linkage and decelera-
tor pedal linkage. For details, see TESTING
AND ADJUSTING, Adjusting fuel control le-
ver linkage and decelerator pedal linkage.
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
INSTALLATION OF
HYDRAULIC TANK
ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
INSTALLATION
• Carry out installation in the reverse order to
removal.
a Take extreme care that each hose will not be
twisted when connected.