[SM Eng] D65EX-15 со 125 ДВС (SEBM029508)

SEBM029508
Machine model
Serial number
D65EX-15
D65PX-15
D65WX-15
67001 and up
67001 and up
67001 and up
•
This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
•
D65-15 mount the SA6D125E-3 engine.
For details of the engine, see the 125-3 Series Engine Shop Manual.
© 2008
All Rights Reserved
Printed in Japan 02-08 (01)
00-1
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CONTENTS
No. of page
01
GENERAL ......................................................................................... 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1
20
TESTING AND ADJUSTING ............................................................ 20-1
30
DISASSEMBLY AND ASSEMBLY .................................................. 30-1
90
OTHERS ........................................................................................... 90-1
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D65EX, PX-15
FOREWORD
SAFETY NOTICE
SAFETY NOTICE
(Rev. 2007/03)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe. Some
of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation
arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
1. General precautions
k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating
the machine.
1) Before carrying out any greasing or repairs,
read all the safety plates stuck to the
machine. For the locations of the safety
plates and detailed explanation of precautions, see the Operation and Maintenance
Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt, water, or oil on the
floor. Smoke only in the areas provided for
smoking. Never smoke while working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
• Always wear safety glasses when hitting
parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always inform
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones of them. Before starting work, thoroughly check the tools, machine, forklift,
service car, etc.
7) If welding repairs are needed, always have
a trained and experienced welder carry out
the work. When carrying out welding work,
always wear welding gloves, apron, shielding goggles, cap and other clothes suited for
welding work.
D65EX, PX-15
8) Before starting work, warm up your body
thoroughly to start work under good condition.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by
unlicensed workers
6 Safety check before starting work
7
Wearing protective goggles
(for cleaning or grinding work)
8
Wearing shielding goggles and protectors
(for welding work)
9 Good physical condition and preparation
10
Precautions against work which you are
not used to or you are used to too much
2. Preparations for work
1) Before adding oil or making any repairs,
park the machine on hard and level ground,
and apply the parking brake and block the
wheels or tracks to prevent the machine
from moving.
2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the lock
pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock
all the control levers and hang warning
signs on them.
3) When disassembling or assembling, support
the machine with blocks, jacks, or stands
before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders
or steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
00-3
(8)
FOREWORD
3. Precautions during work
1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and coolant to cool before carrying out any work on
the oil or water circuits.
3) Before starting work, stop the engine. When
working on or around a rotating part, in particular, stop the engine. When checking the
machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get
rolled or caught in rotating parts or moving
parts.
4) Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (–) terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually and
alternately to release the pressure, and then
remove the cover.
7) When removing components, be careful not
to break or damage the electrical wiring.
Damaged wiring may cause electrical fires.
8) When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip and can
even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10) Be sure to assemble all parts again in their
original places. Replace any damaged parts
and parts which must not be reused with
new parts. When installing hoses and wires,
be sure that they will not be damaged by
contact with other parts when the machine is
operated.
00-4
(8)
SAFETY NOTICE
11) When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely careful when installing tubes for high pressure
circuits. In addition, check that connecting
parts are correctly installed.
12) When assembling or installing parts, always
tighten them to the specified torques. When
installing protective parts such as guards, or
parts which vibrate violently or rotate at high
speed, be particularly careful to check that
they are installed correctly.
13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
14) When measuring hydraulic pressure, check
that the measuring tools are correctly
assembled.
15) Take care when removing or installing the
tracks of track-type machines. When removing the track, the track separates suddenly,
so never let anyone stand at either end of
the track.
16) If the engine is operated for a long time in a
place which is not ventilated well, you may
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.
D65EX, PX-15
FOREWORD
4. Precautions for sling work and making signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well from
the operator's seat and where he can see
the working condition easily. The sign maker
must always stand in front of the load and
guide the operator safely.
• Do not stand under the load.
• Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight of
the load and method of slinging. If too thick
wire ropes are used to sling a light load, the
load may slip and fall.
6) Do not sling a load with 1 wire rope alone. If
it is slung so, it may rotate and may slip out
of the rope. Install 2 or more wire ropes
symmetrically.
k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of
the rope from its original winding position on the load, which can result
in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes forming
a wide hanging angle from the hook.
When hoisting a load with 2 or more ropes,
the force subjected to each rope will
increase with the hanging angle. The table
below shows the variation of allowable load
in kN {kg} when hoisting is made with 2
ropes, each of which is allowed to sling up
to 9.8 kN {1,000 kg} vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 19.6 kN {2,000 kg} of
total weight can be suspended. This weight
is reduced to 9.8 kN {1,000 kg} when the 2
ropes make a hanging angle of 120°. If the 2
ropes sling a 19.6 kN {2,000 kg} load at a
lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000
kg}.
D65EX, PX-15
SAFETY NOTICE
8) When installing wire ropes to an angular
load, apply pads to protect the wire ropes. If
the load is slippery, apply proper material to
prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of the
hook.
• Slinging near the tip of the hook may
cause the rope to slip off the hook during
hoisting. The hook has the maximum
strength at the middle portion.
11) Do not use twisted or kinked wire ropes.
12) When lifting up a load, observe the following.
• Wind in the crane slowly until wire ropes
are stretched. When settling the wire
ropes with the hand, do not grasp them
but press them from above. If you grasp
them, your fingers may be caught.
• After the wire ropes are stretched, stop
the crane and check the condition of the
slung load, wire ropes, and pads.
• If the load is unstable or the wire rope or
chains are twisted, lower the load and lift
it up again.
• Do not lift up the load slantingly.
00-5
(8)
FOREWORD
13) When lifting down a load, observe the following.
• When lifting down a load, stop it temporarily at 30 cm above the floor, and then
lower it slowly.
• Check that the load is stable, and then
remove the sling.
• Remove kinks and dirt from the wire
ropes and chains used for the sling work,
and put them in the specified place.
5. Precautions for using mobile crane
★ Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
6. Precautions for using overhead hoist crane
k When raising a heavy part (heavier than
25 kg), use a hoist, etc. In Disassembly
and assembly, the weight of a part heavier than 25 kg is indicated after the mark
of 4.
1) Before starting work, inspect the wire ropes,
brake, clutch, controller, rails, over wind stop
device, electric shock prevention earth leakage breaker, crane collision prevention
device, and power application warning
lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions of
the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10) Place the control switch on a position where
it will not be an obstacle to work and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immediately in an emergency.
13) If the hoist stops because of a power failure,
turn the power switch OFF. When turning on
a switch which was turned OFF by the electric shock prevention earth leakage breaker,
check that the devices related to that switch
are not in operation state.
14) If you find an obstacle around the hoist, stop
the operation.
00-6
(8)
SAFETY NOTICE
15) After finishing the work, stop the hoist at the
specified position and raise the hook to at
least 2 m above the floor. Do not leave the
sling installed to the hook.
7. Selecting wire ropes
1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to the
table below.
Wire ropes
(Standard “Z” twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
★ The allowable load is one-sixth of the
breaking strength of the rope used
(Safety coefficient: 6).
D65EX, PX-15
FOREWORD
SAFETY NOTICE
8. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
1) Disconnection
k Collect the air conditioner refrigerant
(R134a) from the air conditioner circuit in advance.
★ Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
★ Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on
protective goggles.
2) Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, ZEXEL:
ZXL100PG (equivalent to PAG46)) to
its O-rings.
★ Example of O-ring (Fitted to every joint of hoses
and tubes)
★ For tightening torque, see the precautions for installation in each section of “Disassembly and
assembly”.
D65EX, PX-15
00-7
(8)
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
•
•
•
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. FOREWORD
This section explains the safety and basic information.
01. GENERAL
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and
adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume)
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most upto-date information before you start any work.
00-8
(8)
D65EX, PX-15
FOREWORD
HOW TO READ THE SHOP MANUAL
3. Filing method
• See the page number on the bottom of the page. File the pages in correct order.
• Following examples show how to read the page number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and Function, Maintenance Standard)
Consecutive page number for each item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each item.
•
Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number.
File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
•
Revised edition mark
When a manual is revised, an edition mark ((1) (2) (3)....) is recorded on the bottom of the pages.
•
Revisions
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol
Item
k
Safety
Special safety precautions are necessary when performing work.
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when
selecting hoisting wire, or when working posture is important, etc.
3
Tightening
torque
Places that require special attention for tightening torque during
assembly.
2
Coat
5
Oil, coolant
6
Drain
Remarks
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
D65EX, PX-15
00-9
(8)
FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
The maintenance standard values necessary for judgment of products and parts are described by the following
terms.
1. Standard size and tolerance
• To be accurate, the finishing size of parts is
a little different from one to another.
• To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
• The above size set temporarily is called the
“standard size” and the range of difference
from the standard size is called the “tolerance”.
• The tolerance with the symbols of + or – is indicated on the right side of the standard size.
Example:
Standard size
Tolerance
–0.022
–0.126
120
★ The tolerance may be indicated in the text
and a table as [standard size (upper limit of
tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
•
Usually, the size of a hole and the size of the
shaft to be fitted to that hole are indicated by
the same standard size and different tolerances of the hole and shaft. The tightness of
fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
•
Example:
Standard size
60
00-10
(8)
Tolerance
Shaft
–0.030
–0.076
Hole
+0.046
+0
D65EX, PX-15
FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
2. Standard clearance and standard value
• The clearance made when new parts are assembled is called the “standard clearance“,
which is indicated by the range from the minimum clearance to the maximum clearance.
• When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
• A value of performance and function of new
products or equivalent is called the “standard
value“, which is indicated by a range or a target value.
• When some parts are repaired, the value of
performance/function is set to the standard
value.
3. Standard interference
• When the diameter of a hole of a part shown
in the given standard size and tolerance table is smaller than that of the mating shaft,
the difference between those diameters is
called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the
maximum size of the hole to the difference
(B) between the maximum size of the shaft
and the minimum size of the hole is the
“standard interference”.
• After repairing or replacing some parts,
measure the size of their hole and shaft and
check that the interference is in the standard
range.
5. Clearance limit
• Parts can be used until the clearance between them is increased to a certain limit.
The limit at which those parts cannot be used
is called the “clearance limit”.
• If the clearance between the parts exceeds
the clearance limit, they must be replaced or
repaired.
6. Interference limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the
“interference limit”.
• The interference limit shows the repair limit
of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
4. Repair limit and allowable value
• The size of a part changes because of wear
and deformation while it is used. The limit of
changed size is called the “repair limit”.
• If a part is worn to the repair limit must be replaced or repaired.
• The performance and function of a product
lowers while it is used. A value below which
the product can be used without causing a
problem is called the “allowable value”.
• If a product is worn to the allowable value, it
must be checked or repaired. Since the permissible value is estimated from various
tests or experiences in most cases, however, it must be judged after considering the
operating condition and customer's requirement.
D65EX, PX-15
00-11
(8)
FOREWORD
HOW TO READ ELECTRIC WIRE CODE
HOW TO READ ELECTRIC WIRE CODE
★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material
AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type
Symbol
Low-voltage
wire for
automobile
AV
Thin-cover
low-voltage
wire for
automobile
AVS
Heat-resistant low-voltAEX
age wire for
automobile
00-12
(8)
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance
Soft polyvinyl chloride
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance
Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (°C)
Example of use
General wiring
(Nominal No. 5 and above)
–30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
–50 to +110 cold district, wiring at high-temperature place
D65EX, PX-15
FOREWORD
2.
HOW TO READ ELECTRIC WIRE CODE
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
–
CovAV
Standard
–
–
–
–
–
–
–
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
–
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
108/0.80 127/0.80 169/0.80 217/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
–
5.5
5.3
4.8
–
7.0
7.0
6.0
–
8.2
8.2
8.0
–
10.8
10.8
8.6
–
11.4
11.4
9.8
–
13.0
13.0
10.4
–
13.6
13.6
12.0
–
16.0
16.0
13.6
–
17.6
17.6
“f” of nominal No. denotes flexible”.
D65EX, PX-15
00-13
(8)
FOREWORD
3.
HOW TO READ ELECTRIC WIRE CODE
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the
second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
00-14
(8)
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
WG
–
–
–
–
–
–
–
–
–
–
–
–
–
–
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
–
–
–
–
–
–
–
–
–
–
R
B
R
D
Y
G
L
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW
GL
–
–
–
–
Gr
Br
–
–
D65EX, PX-15
FOREWORD
PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.]
1.
•
•
•
•
Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal.
★ Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06
10
12
2)
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes
Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
D65EX, PX-15
22.5
34
00-15
(8)
FOREWORD
2.
•
•
•
•
•
•
•
•
•
•
•
•
•
PRECAUTIONS WHEN CARRYING OUT OPERATION
Precautions when carrying out installation work
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 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.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation
1) Refilling with coolant, oil and grease
• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run
the engine to circulate the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after
reassembling the parts.
★ For details, see Testing and adjusting, “Bleeding air”.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
• For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant
leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
If any part is loosened or damaged, retighten or repair it.
00-16
(8)
D65EX, PX-15
FOREWORD
PRECAUTIONS WHEN CARRYING OUT OPERATION
4) Checking muffler and exhaust pipe for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and
assembly”.
D65EX, PX-15
00-17
(8)
FOREWORD
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL
TYPE COUPLER
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to re-
lease the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when
the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
★ Since some hydraulic oil flows out, prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose
about 3.5 mm. This does not indicate abnormality, however.
00-18
(8)
D65EX, PX-15
FOREWORD
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)
2. Connection
• Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
D65EX, PX-15
00-19
(8)
FOREWORD
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)
2. Connection
• Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
00-20
(8)
D65EX, PX-15
FOREWORD
STANDARD TIGHTENING TORQUE TABLE
STANDARD TIGHTENING TORQUE TABLE
1. Table of tightening torques for bolts and nuts
★ Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
★ The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt
mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
Width across flats
mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Tightening torque
Nm
11.8 – 14.7
27 – 34
59 – 74
98 – 123
153 – 190
235 – 285
320 – 400
455 – 565
610 – 765
785 – 980
1,150 – 1,440
1,520 – 1,910
1,960 – 2,450
2,450 – 3,040
2,890 – 3,630
kgm
1.2 – 1.5
2.8 – 3.5
6.0 – 7.5
10.0 – 12.5
15.5 – 19.5
23.5 – 29.5
33.0 – 41.0
46.5 – 58.0
62.5 – 78.0
80.0 – 100.0
118 – 147
155 – 195
200 – 250
250 – 310
295 – 370
★ The following table corresponds to the bolts in Fig. B.
Thread diameter of bolt
mm
6
8
10
12
a Fig. A
D65EX, PX-15
Width across flats
mm
10
13
14
27
Tightening torque
Nm
kgm
5.9 – 9.8
0.6 – 1.0
13.7 – 23.5
1.4 – 2.4
34.3 – 46.1
3.5 – 4.7
74.5 – 90.2
7.6 – 9.2
a Fig. B
00-21
(8)
FOREWORD
STANDARD TIGHTENING TORQUE TABLE
2. Table of tightening torques for split flange bolts
★ Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt
mm
10
12
16
Width across flats
mm
14
17
22
Tightening torque
Nm
59 – 74
98 – 123
235 – 285
kgm
6.0 – 7.5
10.0 – 12.5
23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints
★ Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No.
02
03,04
05,06
10,12
14
Thread diameter
mm
14
20
24
33
42
Width across flats
mm
Tightening torque Nm {kgm}
Range
Target
35 – 63 { 3.5 – 6.5}
44 { 4.5}
84
–
132
{
8.5
–
13.5}
103
{10.5}
Varies depending
157 {16.0}
on type of connec- 128 – 186 {13.0 – 19.0}
tor.
363 – 480 {37.0 – 49.0}
422 {43.0}
746 – 1,010 {76.0 – 103}
883 {90.0}
4. Table of tightening torques for O-ring boss plugs
★ Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
00-22
(8)
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
Width across flats
mm
14
17
19
22
24
27
30
32
32
–
36
–
–
Tightening torque Nm {kgm}
Range
Target
5.88 – 8.82 {0.6 – 0.9}
7.35 {0.75}
9.81 – 12.74 {1.0 – 1.3}
11.27 {1.15}
14.7 – 19.6 {1.5 – 2.0}
17.64 {1.8}
19.6 – 24.5 {2.0 – 2.5}
22.54 {2.3}
24.5 – 34.3 {2.5 – 3.5}
29.4 {3.0}
34.3 – 44.1 {3.5 – 4.5}
39.2 {4.0}
44.1 – 53.9 {4.5 – 5.5}
49.0 {5.0}
58.8 – 78.4 {6.0 – 8.0}
68.6 {7.0}
93.1 – 122.5 { 9.5 – 12.5}
107.8 {11.0}
107.8 – 147.0 {11.0 – 15.0}
127.4 {13.0}
127.4 – 176.4 {13.0 – 18.0}
151.9 {15.5}
181.3 – 240.1 {18.5 – 24.5}
210.7 {21.5}
274.4 – 367.5 {28.0 – 37.5}
323.4 {33.0}
D65EX, PX-15
FOREWORD
STANDARD TIGHTENING TORQUE TABLE
5. Table of tightening torques for hoses (taper seal type and face seal type)
★ Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque
below.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm}
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
22
24
27
32
36
41
46
55
Range
34 – 54 { 3.5 – 5.5}
34 – 63 { 3.5 – 6.5}
54 – 93 { 5.5 – 9.5}
59 – 98 { 6.0 – 10.0}
84 – 132 { 8.5 – 13.5}
128 – 186 {13.0 – 19.0}
177 – 245 {18.0 – 25.0}
177 – 245 {18.0 – 25.0}
197 – 294 {20.0 – 30.0}
246 – 343 {25.0 – 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
–
14
–
18
22
24
30
33
36
42
Face seal
Nominal No. Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
thread
9/16-18UN
14.3
–
–
11/16-16UN
17.5
–
–
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
–
–
–
–
–
–
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
★ Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine
series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
Nm
10 ± 2
24 ± 4
43 ± 6
77 ± 12
—
kgm
1.02 ± 0.20
2.45 ± 0.41
4.38 ± 0.61
7.85 ± 1.22
—
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
★ Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series
to the torque below.
Thread size
mm
6
8
10
12
14
D65EX, PX-15
Tightening torque
Nm
8±2
10 ± 2
12 ± 2
24 ± 4
36 ± 5
kgm
0.81 ± 0.20
1.02 ± 0.20
1.22 ± 0.20
2.45 ± 0.41
3.67 ± 0.51
00-23
(8)
FOREWORD
STANDARD TIGHTENING TORQUE TABLE
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
★ Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine
series to the torque below.
Thread size
inch
1/16
1/8
1/4
3/8
1/2
3/4
1
00-24
(8)
Tightening torque
Nm
3±1
8±2
12 ± 2
15 ± 2
24 ± 4
36 ± 5
60 ± 9
kgm
0.31 ± 0.10
0.81 ± 0.20
1.22 ± 0.20
1.53 ± 0.20
2.45 ± 0.41
3.67 ± 0.51
6.12 ± 0.92
D65EX, PX-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the method
of using the conversion table, see the example given below.
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), and 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 2 lines cross as (C). This point (C) gives the value when converting from millimeters 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 it 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
(A)
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
D65EX, PX-15
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
00-25
(8)
FOREWORD
CONVERSION TABLE
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
1 kg = 2.2046 lb
6
7
8
9
13.23 15.43
17.64
19.84
35.27 37.48
39.68
41.89
57.32 59.53
61.73
63.93
79.37 81.57
83.78
85.98
101.41 103.62 105.82 108.03
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
0
10
20
30
40
0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321
1.585 1.849
2.113
2.378
3.963
4.227 4.491
4.755
5.019
6.604
6.869 7.133
7.397
7.661
9.246
9.510 9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
00-26
(8)
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
D65EX, PX-15
FOREWORD
CONVERSION TABLE
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540
1.760 1.980
3.520
3.740
3.950 4.179
5.719
5.939
6.159 6.379
7.919
8.139
8.359 8.579
10.119 10.339 10.559 10.778
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
7
50.6
123.0
195.3
267.6
340.0
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
100
110
120
130
140
723.3
730.5 737.8
745.0
752.2
759.5 766.7
773.9
781.2 788.4
795.6
802.9 810.1
817.3
824.6
831.8 839.0
846.3
853.5 860.7
868.0
875.2 882.4
889.7
896.9
904.1
911.4
918.6
925.8 933.1
940.3
947.5 954.8
962.0
969.2
976.5 983.7
990.9
998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
D65EX, PX-15
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1 kgm = 7.233 ft.lb
8
9
57.9
65.1
130.2 137.4
202.5 209.8
274.9 282.1
347.2 354.4
419.5
491.8
564.2
636.5
708.8
1142.8
1215.1
1287.5
1359.8
1432.1
426.8
499.1
571.4
643.7
716.1
1150.0
1222.4
1294.7
1367.0
1439.4
00-27
(8)
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2
7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
00-28
(8)
D65EX, PX-15
FOREWORD
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F
°F
–40.4
–37.2
–34.4
–31.7
–28.9
–40
–35
–30
–25
–20
–40.0
–31.0
–22.0
–13.0
–4.0
–11.7
–11.1
–10.6
–10.0
–9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
–28.3
–27.8
–27.2
–26.7
–26.1
–19
–18
–17
–16
–15
–2.2
–0.4
1.4
3.2
5.0
–8.9
–8.3
–7.8
–7.2
–6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
–25.6
–25.0
–24.4
–23.9
–23.3
–14
–13
–12
–11
–10
6.8
8.6
10.4
12.2
14.0
–6.1
–5.6
–5.0
–4.4
–3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
–22.8
–22.2
–21.7
–21.1
–20.6
–9
–8
–7
–6
–5
15.8
17.6
19.4
21.2
23.0
–3.3
–2.8
–2.2
–1.7
–1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
–20.0
–19.4
–18.9
–18.3
–17.8
–4
–3
–2
–1
0
24.8
26.6
28.4
30.2
32.0
–0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
–17.2
–16.7
–16.1
–15.6
–15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
–14.4
–13.9
–13.3
–12.8
–12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
D65EX, PX-15
00-29
(8)
GENERAL
01 GENERAL
Specification dimensions ........................................................................................................................... 01- 2
Specifications ............................................................................................................................................. 01- 3
Weight table ............................................................................................................................................... 01- 8
Table of fuel, coolant and lubricant ............................................................................................................ 01-10
D65EX, PX-15
01-1
GENERAL
SPECIFICATION DIMENSIONS
SPECIFICATION DIMENSIONS
D65EX-15 semi-U dozer with ROPS guard, cab, and air conditioner
D65PX-15 power tilt dozer with ROPS guard, cab, and air conditioner
D65WX-15 semi-U dozer with ROPS guard, cab, and air conditioner
Unit
D65EX-15
D65PX-15
D65WX-15
Machine weight
Item
kg
20,000
20,770
20,860
Engine name
—
Komatsu SA6D125E-3 diesel engine
kW {HP}/rpm
142 {190}/1,950
Rated engine output
A Overall length
mm
5,440
5,550
5,440
B Overall height (excluding antenna)
mm
3,220
3,255
3,220
C Overall width
mm
3,455
3,970
3,640
Travel speed
(1st/2nd/3rd gear speed)
01-2
(7)
Forward
km/h
3.9/6.8/10.6
Reverse
km/h
5.0/8.6/13.4
D65EX, PX-15
GENERAL
SPECIFICATIONS
SPECIFICATIONS
D65EX-15
Machine name and type
Semi-U dozer
Serial No.
Semi-U dozer
with wide gauge
Semi-U dozer
with long track
67001 and up
D65PX-15
D65WX-15
Power tilt dozer
Semi-U dozer
67001 and up 67001 and up
Machine mass
Mass
• Tractor unit
17,050
17,010
17,300
17,050
kg
19,270
20,130
20,010
20,040
20,130
• With work equipment and ROPS cab
kg
20,000
20,860
20,740
20,770
20,860
• With work equipment, ripper,
and ROPS cab
kg
(21,680)
(22,540)
(22,420)
—
(22,540)
Min. swing radius
m
— [Pivot turn]
— [Pivot turn]
— [Pivot turn]
— [Pivot turn]
— [Pivot turn]
Gradeability
deg.
30
30
30
30
30
Gear speed
Forward 1st
deg.
35
35
35
35
35
km/h
3.9
3.9
3.9
3.9
3.9
Forward 2nd
km/h
6.8
6.8
6.8
6.8
6.8
Forward 3rd
km/h
10.6
10.6
10.6
10.6
10.6
Reverse 1st
km/h
5.0
5.0
5.0
5.0
5.0
Reverse 2nd
km/h
8.6
8.6
8.6
8.6
8.6
Reverse 3rd
km/h
13.4
13.4
13.4
13.4
13.4
Tractor unit
kPa
{kg/cm2}
58.8
{0.60}
38.2
{0.39}
50.0
{0.51}
27.5
{0.28}
38.2
{0.39}
With work equipment
kPa
{kg/cm2}
69.6
{0.71}
45.1
{0.46}
58.8
{0.60}
31.4
{0.32}
45.1
{0.46}
With work equipment and ROPS cab
kPa
{kg/cm2}
71.6
{0.73}
47.1
{0.48}
60.8
{0.62}
32.4
{0.33}
47.1
{0.48}
With work equipment, ripper,
kPa
and ROPS cab {kg/cm2}
(77.5)
({0.79})
(51.0)
({0.52})
(65.7)
({0.67})
—
(51.0)
({0.52})
Tractor unit
mm
4,335
4,335
4,520
4,520
4,335
With work equipment
mm
5,440
5,440
5,845
5,550
5,440
Tractor unit
mm
2,390
2,890
2,390
3,000
2,890
With work equipment
mm
3,455
3,640
2,990
3,970
3,640
Up to exhaust pipe
mm
2,990
2,990
2,990
3,025
2,990
Up to top of operator’s seat
mm
2,315
2,315
2,315
2,350
2,315
When ROPS cab is installed
(excluding antenna)
mm
3,220
3,220
3,220
3,255
3,220
When ROPS canopy is installed
mm
3,220
3,220
3,220
3,255
3,220
When cab is installed
(excluding antenna)
mm
3,080
3,080
3,080
3,115
3,080
mm
1,880
2,050
1,880
2,050
2,050
Length of track on ground
mm
2,675
2,675
3,285
3,285
2,675
Track width (Standard track shoe)
mm
510
810
510
950
810
Minimum ground clearance
mm
405
405
405
510
405
Overall height
Overall Overall
width
length
Ground pressure
Performance
16,270
• With work equipment
Stability (Front, rear, left, right)
Dimensions
kg
Track gauge
aValues in ( ) are shown for reference.
D65EX, PX-15
01-3
(7)
GENERAL
SPECIFICATIONS
D65EX-15
Machine name and type
Semi-U dozer
Serial No.
Semi-U dozer
67001 and up 67001 and up
mm
l {cc}
Rated output
kW/rpm
{HP/
rpm}
142/1,950 {190/1,950}
Max. torque
Nm/rpm
{kgm/
rpm}
941/1,400 {96/1,400}
rpm
2,100 ± 50
rpm
825 ± 25
g/kWh
{g/HPh}
222 {163}
Performance
Engine
Power tilt dozer
Total displacement
High idling speed under no load
Low idling speed under no load
Min. fuel consumption ratio
Starting motor
24 V, 7.5 kW
Alternator
24 V, 50 A
Battery (*1)
12 V, 112 Ah, 2 units
Type of radiator core
D-6
Torque converter
3-element, 1-stage, 1-phase type
Transmission
Planetary gear, multiple disc, hydraulic, gear pump
forced lubrication, 3 forward/reverse gear speeds,
manual electronic type
Bevel gear shaft
Spiral bevel gear, gear pump forced lubrication type
HSS
Differential planetary gear, hydraulic motor drive,
manual electronic, hydraulic type
Brake
Wet multiple disc, spring-boosted, foot-operated,
hydraulic type
Final drive
1-stage spur gear/1-stage planetary gear reduction,
splash lubrication type
HSS unit
Power train
D65WX-15
SA6D125E-3
4-cycle, water-cooled, in-line, direct-injection diesel
engine with turbocharger and aftercooler
6 – 125 x 150
11.04 {11,040}
Type
Type of suspension
Semi-hard, equalizing beam type
Carrier roller
Track roller
Undercarriage
Semi-U dozer
with long track
67001 and up
Name
Number of cyl. – Bore x Stroke
Semi-U dozer
with wide gauge
D65PX-15
2 pieces on each side
7 pieces on each side
8 pieces on each side
7 pieces on each side
Track shoe
• Assembly type single grouser shoe
• Assembly type special swamp shoe
Width: 510 mm Width: 810 mm
39 pieces on
39 pieces on
each side
each side
Pitch: 203.2 mm Pitch: 203.2 mm
—
—
Width: 510 mm
45 pieces on
each side
Pitch: 203.2 mm
—
Width: 810 mm
39 pieces on
each side
Pitch: 203.2 mm
—
Width: 950 mm
45 pieces on
each side
Pitch: 203.2 mm
—
*1 : The battery capacity (Ah) is on 5-hours rate.
01-4
(7)
D65EX, PX-15
GENERAL
SPECIFICATIONS
D65EX-15
Machine name and type
Semi-U dozer
Serial No.
Semi-U dozer
with wide gauge
Semi-U dozer
with long track
67001 and up
D65PX-15
D65WX-15
Power tilt dozer
Semi-U dozer
67001 and up 67001 and up
HSS pump
• Type
• Theoretical capacity
cm3/rev
HPV95, variable-capacity piston, load sensing type
112
Hydraulic pump
Cooling fan pump
• Type
• Theoretical capacity
cm3/rev
LPV30, variable-capacity piston type
30
Power train and lubricating oil pump
• Type
• Theoretical capacity
cm3/rev
SAL (2) 45 + 45, gear type (Tandem)
43.7 x 2
• Type
• Theoretical capacity
cm3/rev
Gear type
61.2
HSS motor
Hydraulic motor
Hydraulic system
Scavenging pump
• Type
• Motor capacity
Cooling fan motor
• Type
• Motor capacity
Control valve
cm3/rev
HMF95, fixed-capacity piston type with brake valve
96
cm3/rev
LMF28, fixed-capacity piston type
28
Type and quantity
3-spool type, 1 piece
4-spool type, 1 piece (Machine with ripper: Optional)
Control method
Hydraulic assist type
Hydraulic tank
Hydraulic oil filter
Oil cooler
D65EX, PX-15
Box type (External control valve type)
Return side of tank
Air-cooled type (3A-CS)
01-5
(7)
GENERAL
SPECIFICATIONS
D65EX-15
Machine name and type
Semi-U dozer
Semi-U dozer
with wide gauge
Serial No.
67001 and up
Tilt and pitch cylinder
D65WX-15
Power tilt dozer
Semi-U dozer
67001 and up 67001 and up
Double-acting piston type
Cylinder bore
mm
95
95
95
Piston rod diameter
mm
65
65
65
Stroke
mm
1,165
1,105
1,165
Max. distance between pins
mm
1,685
1,905
1,685
Min. distance between pins
mm
520
800
520
Type
Double-acting piston type
Cylinder bore
mm
140
Piston rod diameter
mm
70
Stroke
mm
145
Max. distance between pins
mm
1,222
Min. distance between pins
mm
1,077
Type
Ripper cylinder
Work equipment hydraulic system
Lift cylinder
Type
Double-acting piston type
Cylinder bore
mm
140
—
140
Piston rod diameter
mm
70
—
70
Stroke
mm
330
—
330
Max. distance between pins
mm
1,080
—
1,080
Min. distance between pins
mm
750
—
750
Type
Power tilt dozer
Left: Brace, Right: Tilt cylinder
Performance
Max. lift (above ground)
Max. drop (below ground)
mm
440
Max. tilting distance
mm
870
Blade angle range
deg.
±7
±7
±7
Dimensions
Blade supporting method
mm
1,105
1,170
Blade width
mm
3,415
3,415
3,970
Blade height
mm
1,225
1,110
1,110
Blade angle
deg.
55
55
57
—
—
Type
470
440
890
Performance
Max. lift (above ground)
mm
1,105
1,105
1,180
Max. drop (below ground)
mm
440
440
565
Max. tilting distance
mm
855
820
680
Blade angle range
deg.
±7
±7
±7
Blade width
mm
3,455
3,640
3,460
Blade height
mm
1,480
1,410
1,480
Blade angle
deg.
55
55
55
(7)
—
—
Semi-U dozer
Left: Brace, Right: Tilt cylinder
Blade supporting method
01-6
1,205
870
Dimensions
Work equipment
Semi-U dozer
with long track
D65PX-15
1,105
—
440
820
±7
3,640
—
1,410
55
D65EX, PX-15
GENERAL
SPECIFICATIONS
D65EX-15
Machine name and type
Semi-U dozer
Serial No.
Semi-U dozer
with wide gauge
67001 and up
Type
Performance
Max. drop (below ground)
mm
460
Max. tilting distance
mm
400
Max. angle
deg.
25
Dimensions
Blade width
mm
3,970
Blade height
mm
1,120
Blade angle
deg.
55
mm
Semi-U dozer
67001 and up 67001 and up
1,180
—
—
—
—
—
—
—
—
Type
Power tilt, power pitch dozer
Blade supporting method
Dimensions
Power tilt dozer
Both sides: Brace
Max. lift (above ground)
Performance
Work equipment
D65WX-15
Angledozer
Blade supporting method
Left: Tilt cylinder, Right: Pitch cylinder
Max. lift (above ground)
mm
Max. drop (below ground)
mm
Max. tilting distance
mm
Blade angle range
deg.
Blade width
mm
Blade height
mm
Blade angle
deg.
Type
1,200
—
—
—
445
890
—
+9/–7
3,970
—
—
—
1,110
—
57
Parallelogram
Parallelogram
Beam length
mm
2,170
Number of shanks
piece
3
deg.
55/45
55/45
Changeable to 3 levels
Changeable to
3 levels
Digging angle (A/B)
Performance
Ripper
Semi-U dozer
with long track
D65PX-15
Digging depth
2,170
3
—
Max. digging depth
mm
Max. lift
mm
640
640
Shank position (Left/Right)
mm
950/950
950/950
D65EX, PX-15
595
—
595
01-7
(7)
GENERAL
WEIGHT TABLE
WEIGHT TABLE
k This weight table is for reference in handling or transporting components.
Unit: kg
Machine name and type
D65EX-15
Standard
Serial No.
Wide gauge
Long track
67001 and up
D65PX-15
D65WX-15
Standard
Wide gauge
67001 and up 67001 and up
Engine and damper assembly (Excluding coolant and oil)
1,300
1,300
1,300
1,300
1,300
• Engine assembly
1,200
1,200
1,200
1,200
1,200
• Damper assembly
25
25
25
25
25
• Engine-related parts (Wiring)
2
2
2
2
2
Universal joint
22
22
22
22
22
Cooling assembly (Excluding coolant and oil)
145
145
145
145
145
• Radiator assembly
125
125
125
125
125
• Hydraulic oil cooler
12
12
12
12
12
Cooling fan pump
28
28
28
28
28
Cooling fan motor
13
13
13
13
13
Fuel tank (Excluding fuel)
200
200
200
200
200
Power train unit assembly (Excluding oil)
1,435
1,435
1,435
1,435
1,435
• Torque converter and PTO assembly
290
290
290
290
290
• Transmission assembly
340
340
340
340
340
• Transmission ECMV assembly
13
13
13
13
13
• Main relief valve assembly
6
6
6
6
6
• HSS unit assembly
710
710
710
710
710
• Brake valve assembly
6
6
6
6
6
HSS motor
45
45
45
45
45
HSS pump
65
65
65
65
65
Power train and lubricating oil pump
20
20
20
20
20
Scavenging pump
5
5
5
5
5
Hydraulic tank (Excluding oil)
75
75
75
75
75
• 3-spool valve
84
84
84
84
84
• 4-spool valve (Machine with ripper: Optional)
95
95
95
95
95
Final drive assembly (Each side)
765
790
765
790
790
Sprocket (Each side)
8.3 x 9
8.3 x 9
8.3 x 9
8.3 x 9
8.3 x 9
Frame assembly
2,140
2,140
2,140
2,140
2,140
Engine underguard
105
105
105
105
105
Transmission underguard
30
30
30
30
30
Control valve
01-8
(7)
D65EX, PX-15
GENERAL
WEIGHT TABLE
Unit: kg
Machine name and type
D65EX-15
Standard
Serial No.
Wide gauge
Long track
67001 and up
D65PX-15
D65WX-15
Standard
Wide gauge
67001 and up 67001 and up
Track group assembly (Each side)
1,495
1,495
1,695
1,695
1,495
• Track frame
590
590
700
700
590
• Idler assembly (Each side)
200
200
200
200
200
• Recoil spring assembly (Each side)
250
250
250
250
250
• Single flange track roller assembly (Each side)
54 x 5
54 x 5
54 x 6
54 x 6
54 x 5
• Double flange track roller assembly (Each side)
61 x 2
61 x 2
61 x 2
61 x 2
61 x 2
• Carrier roller assembly (Each side)
30 x 2
30 x 2
30 x 2
30 x 2
30 x 2
• Single grouser shoe (510 mm)
1,310
—
1,580
—
—
• Single grouser shoe (810 mm)
—
1,735
—
—
1,735
• Swamp shoe (950 mm)
—
—
—
2,110
—
Pivot shaft (Each side)
90
100
90
100
100
Equalizer bar
125
145
125
145
145
Floor frame assembly
300
300
300
300
300
Operator’s seat
59
59
59
59
59
Cab assembly
410
410
410
410
410
ROPS guard assembly (for cab)
220
220
220
220
220
ROPS canopy assembly
410
410
410
410
410
Semi-U dozer
Power tilt dozer assembly
2,280
—
2,360
—
2,280
—
—
2,030
2,360
—
• Blade
1,355
1,325
1,355
1,190
1,325
• Straight frame (Each side)
285
285
285
285
285
• Tilt cylinder assembly
75
75
75
75
75
Lift cylinder assembly
95 x 2
95 x 2
95 x 2
95 x 2
95 x 2
Ripper assembly
1,530
1,530
1,530
—
1,530
Ripper cylinder assembly
75
75
75
—
75
Track shoe assembly (Each side)
D65EX, PX-15
01-9
(7)
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANT
TABLE OF FUEL, COOLANT AND LUBRICANT
Refilling position
Kind
of oil
–22
–30
–4
–20
Ambient temperature
14
32
50
68
86
–10
0
10
20
30
Specified
Refilled
oil
amount
oil
amount
104ºF 122ºF
(l)
(l)
40ºC 50ºC
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
44
38
68
48
SAE 15W-40
SAE 5W-30
Power train case
including torque converter,
transmission and bevel
gear case
SAE 30
Engine
oil
SAE 10W
Final drive case (each side)
EX: 24
EX: 24
PX,WX: 27 PX,WX: 27
Damper case
Idler (each)
SAE 30
Pivot shaft case (each side)
1.7
1.7
0.15
0.15
0.25
0.25
95
55
0.32
0.32
0.24
0.24
—
—
415
—
59
—
SAE 10W
Hydraulic oil
SAE 10W-30
SAE 15W-40
Track roller (each)
Carrier roller (each)
Gear
oil
Grease fitting
Grease
Fuel tank
Diesel
fuel
Cooling system
(Incl. reservoir tank)
Coolant
GO 140
NLGI No.2
ASTM D975 No.2
*1
Add antifreeze
*1. ASTM D975 No.1
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.
01-10
(7)
D65EX, PX-15
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANT
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 0ºC (32ºF), be sure to use engine
oil of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10ºC
(50ºF) 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.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API:
American Petroleum Institute
Fuel sulphur content
Change interval of oil in
engine oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
D65EX, PX-15
01-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Engine-related parts
Cooling system ........................................... 10- 2
Engine mount ............................................. 10- 4
Power train .................................................. 10- 5
Overall drawing of power train unit ............. 10- 7
Hydraulic piping of power train ................... 10- 9
Damper, universal joint ............................... 10- 10
Transmission, steering, brake control ......... 10- 12
Torque converter, PTO ................................ 10- 14
Transmission ............................................... 10- 19
Transmission ECMV ................................... 10- 30
Main relief valve .......................................... 10- 36
Lubrication relief valve ................................ 10- 38
Scavenging pump ....................................... 10- 39
Power train pump, lubrication pump ........... 10- 40
HSS system ................................................ 10- 41
Hydraulic, HSS pump ................................. 10- 43
HSS motor .................................................. 10- 61
Bevel gear shaft, HSS, brake ...................... 10- 68
Brake valve ................................................. 10- 83
Final drive ................................................... 10- 88
Frame assembly ......................................... 10- 93
Suspension ................................................. 10- 95
Track frame, recoil spring ............................ 10-101
Idler ............................................................. 10-105
Track roller .................................................. 10-107
Carrier roller ................................................ 10-108
Sprocket ...................................................... 10-109
Track shoe .................................................. 10-113
Work equipment hydraulic piping diagram .. 10-118
D65EX, PX-15
Work equipment control ............................. 10-120
Hydraulic tank ............................................ 10-122
Accumulator ............................................... 10-124
PPC lock valve ........................................... 10-125
Hydraulic cylinder ....................................... 10-126
Piston valve ................................................ 10-128
Quick drop valve ........................................ 10-129
Cooling fan pump ....................................... 10-131
Cooling fan motor ....................................... 10-139
PPC valve .................................................. 10-145
PCCS lever ................................................ 10-155
Control valve .............................................. 10-158
Self pressure reducing valve ...................... 10-190
Work equipment ......................................... 10-197
Cutting edge, end bit .................................. 10-201
Ripper ........................................................ 10-202
Cab mount ................................................. 10-203
Cab ............................................................ 10-204
Air conditioner piping ................................. 10-206
Engine control ............................................ 10-207
Engine control system ................................ 10-208
CRI engine control system ......................... 10-210
Cooling system control system .................. 10-212
Palm command control system .................. 10-214
System components .................................. 10-216
Engine controller ........................................ 10-218
Transmission and steering controller ......... 10-220
Monitor system ........................................... 10-222
Monitor panel ............................................. 10-224
Sensors ...................................................... 10-228
10-1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING SYSTEM
10-2
COOLING SYSTEM
Engine-related parts
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING SYSTEM
A: Power train oil cooler inlet
B: Power train oil cooler outlet
C: Hydraulic oil cooler inlet
D: Hydraulic oil cooler outlet
1.
2.
3.
4.
5.
6.
7.
8.
9.
Cooling fan motor
Radiator
Radiator inlet hose
Hydraulic oil cooler
Reservoir tank
Radiator outlet hose
Radiator cap
Cooling fan
Power train oil cooler
(built in radiator lower tank)
10. Drain plug
Specifications
Radiator
Power train oil cooler
Hydraulic oil cooler
Core type
D-6
PTO-OL
3A-CS
Fin pitch (mm)
4.0
—
3.5
Total heat dissipation surface (m2)
52.627
1.722
1.860
Pressure valve cracking pressure
(kPa {kg/cm2})
Vacuum valve cracking pressure
(kPa {kg/cm2})
88.3 ± 14.7
{0.9 ± 0.15}
0 – 4.9
{0 – 0.05}
—
—
—
—
D65EX, PX-15
10-3
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE MOUNT
ENGINE MOUNT
Unit: mm
No.
Check item
Clearance between bracket and
1
cushion
Criteria
Standard
size
60
2 Free height of mount rubber
10-4
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
–0.100
–0.300
+0.046
0
0.100 –
0.346
0.4
Standard size
Repair limit
90
88
Replace
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
POWER TRAIN
POWER TRAIN
Outline
•
•
•
The power generated by engine (1) has its torsional vibration dampened by damper (2), and
then passes through universal joint (3) and is
transmitted to torque converter (7).
The power from the engine is transmitted
through the oil by torque converter (7) to the
transmission input shaft in accordance with the
change in load.
Transmission (8) uses a combination of a planetary gear system and hydraulic clutches to reduce the speed and shift the gears (3 forward
gears and 3 reverse gears). It connects 2 sets of
clutches selected according to the change in
load and transmits the power to bevel gear (9)
from the bevel pinion at the rear end of the transmission.
•
•
•
•
D65EX, PX-15
The power transmitted to HSS unit (10) is transmitted through the bevel gear shaft to the HSS.
HSS pump (4) is driven by PTO (5), and output
oil of the HSS pump drives HSS motor (11).
The rotation of the pair of the HSS gears on the
right and left is controlled by HSS motor (11).
The steering direction is controlled by generating
a difference in speed on the right and left.
It is also possible to use the HSS mechanism to
rotate the right and left sides in opposite directions to carry out pivot turns.
Brake (12) built in HSS unit (10) is used for braking the machine. Brake (12) is a wet, multiple
disc clutch, spring boosted type.
The power sent from brake (12) is transmitted to
final drive (13).
Final drive (13) consists of a single-stage spur
gear and a single-stage planetary gear system.
It reduces the speed and rotates sprocket (14) to
drive track shoe (15) and move the machine.
Cooling fan motor (19) is rotated with the oil discharged from cooling fan pump (6) driven by
PTO (5).
10-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1. Engine
2. Damper
3. Universal joint
4. HSS pump
5. PTO
6. Cooling fan pump
7. Torque converter
8. Transmission
9. Bevel gear
10. HSS unit
10-6
POWER TRAIN
11. HSS motor
12. Brake
13. Final drive
14. Sprocket
15. Track shoe
16. Power train pump
17. Lubricating oil pump
18. Scavenging pump
19. Cooling fan motor
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
OVERALL DRAWING OF POWER TRAIN UNIT
OVERALL DRAWING OF POWER TRAIN UNIT
1. HSS pump
2. Cooling fan pump
3. HSS motor
4. Lubricating oil pump
5. Power train pump
6. Torque converter and PTO
7. Main relief valve
8. Transmission ECMV
9. Transmission
10. Brake valve
11. HSS unit
12. Scavenging pump
13. Power train oil strainer
D65EX, PX-15
Outline
•
•
The power train unit consists of the main components of torque converter and PTO (6), transmission (9), and HSS unit (11). Accordingly, after the
power train unit is removed, it can be divided into
torque converter and PTO (6), transmission (9),
and HSS unit (11).
HSS unit (11) consists of the bevel pinion unit,
bevel gear shaft, HSS motor (3), planetary gear
system, and brake.
10-7
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
OVERALL DRAWING OF POWER TRAIN UNIT
Unit: mm
No.
Check item
Clearance between bracket and
1
cushion
2
Clearance between steering case
cover and bushing
3 Free height of front mount rubber
4 Free height of rear mount rubber
10-8
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
60
–0.100
–0.300
+0.046
0
0.100 –
0.346
0.4
204
+0.096
+0.050
+0.046
0
–0.096 –
–0.004
Max. 0
Standard
size
Standard size
Repair limit
90
88
43
41
Replace
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC PIPING OF POWER TRAIN
HYDRAULIC PIPING OF POWER TRAIN
A: Load sensing oil pressure pickup port
B: Main pump discharge oil pressure pickup port
C: Transmission oil pressure pickup port
D: Torque converter outlet oil pressure pickup port
E: Torque converter inlet oil pressure pickup port
F: Brake oil pressure pickup port
D65EX, PX-15
1.
2.
3.
4.
5.
6.
7.
8.
9.
Centralized pressure pickup ports
Power train oil filter
Transmission ECMV
Brake valve
Power train pump
Lubricating oil pump
Main relief valve
Scavenging pump
Power train oil cooler
(Built in radiator lower tank)
10-9
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
10-10
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
DAMPER, UNIVERSAL JOINT
Unit: mm
No.
Check item
1
Inside diameter of contact
surfaces of coupling and oil seal
—
Facial and radial runout of
coupling
2. Breather
3. Oil filler plug
4. Inspection plug
5. Drain plug
6. Damper case
7. Coupling
8. Spider
9. Yoke
10. Shaft
11. Bearing
12. Drive plate
13. Torsion spring
14. Stopper pin
15. Friction plate
16. Friction spring
17. Hub
18. Cover
D65EX, PX-15
Criteria
Remedy
Standard size
Tolerance
Repair limit
85
0
–0.087
84.8
Facial runout: Max. 1.0 (at 148.38), Radial runout: Max. 1.5
(when damper shaft and transmission input shaft are rotated simultaneously)
Plate with hard
chromium or replace
Adjust
Outline
•
•
The damper is a wet friction spring type.
Stopper angle: 4º
Stopper torque: 2,670 Nm {272 kgm}
The damper damps the torsional vibration
caused by fluctuation of the engine torque and
the impact torque caused by sudden acceleration and heavy digging work to protect the torque
converter, transmission, and other power train
components.
10-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION, STEERING, BRAKE CONTROL
TRANSMISSION, STEERING, BRAKE CONTROL
a PCCS: Abbreviation for Palm Command Control System
10-12
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION, STEERING, BRAKE CONTROL
1. Brake pedal
2. Decelerator pedal
3. Brake valve
4. Transmission ECMV
5. Fuel control dial
6. Steering/directional/gear shift lever (PCCS lever)
7. Neutral safety limit switch
8. Transmission and steering controller
9. Rod
10. Brake potentiometer
11. Cable
12. Packing brake lever
Outline
•
•
•
•
•
The transmission, steering system, and brake
are controlled with steering/directional/gear shift
lever (PCCS lever) (6).
Steering/directional/gear shift lever (6) sends
electric signals to transmission and steering controller (8). Upon receiving these electric signals,
the transmission and steering controller sends
signals to the EPC valve of the control valve to
change the discharge of the HSS pump and control the HSS motor.
Brake pedal (1) operates brake valve (3) through
rod (9) to control the brake.
Parking brake lever (12) operates brake valve
(3), which is also used as the parking brake
valve, through cable (11).
If parking brake lever (12) is not set in the LOCK
position, neutral safety limit switch (7) does not
work, thus the engine does not start.
D65EX, PX-15
10-13
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO
a PTO: Abbreviation for Power Take Off
10-14
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
D65EX, PX-15
TORQUE CONVERTER, PTO
10-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
A: From transmission case
(To torque converter)
B: To oil cooler
C: From traffic accident
(To scavenging pump)
D: From transmission case
(To power train and lubricating oil pump)
E: To transmission case (Drain)
1. HSS pump mounting opening
2. Power train and lubricating oil pump mounting
opening
3. Scavenging pump mounting opening
4. PTO lubrication tube
5. Cooling fan pump mounting opening
6. Coupling
7. Input shaft
8. PTO drive gear (Number of teeth: 62)
9. PTO drive gear shaft
10. PTO idler gear (Number of teeth: 63)
11. PTO case
12. Drive case
13. Turbine
14. Stator
15. Pump
16. Stator shaft
17. Transmission input shaft
18. HSS and work equipment pump and fan pump
drive gear
(Number of teeth: 53)
19. Power train and lubricating oil pump drive gear
(Number of teeth: 53)
20. Scavenging pump drive gear
(Number of teeth: 56)
21. Scavenging pump strainer
22. Power train strainer
23. Sleeve
10-16
TORQUE CONVERTER, PTO
Outline
•
•
•
•
•
The torque converter is a 3-element, 1-stage,
and 1-phase type, which is combined with the
transmission into 1 unit.
Pump (15) is combined with coupling (6), input
shaft (7), PTO drive gear (8), and drive case (12)
into 1 unit and rotated by the engine power.
Turbine (13) is combined with transmission input
shaft (17) into 1 unit and rotated by the oil from
pump (15).
Stator (14) is combined with stator shaft (16) into
1 unit and fixed to PTO case (11).
Each pump installed to the PTO case is driven
with the power transmitted through PTO drive
gear (8), PTO idler gear (10), and pump drive
gears (18), (19), and (20).
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
D65EX, PX-15
TORQUE CONVERTER, PTO
10-17
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TORQUE CONVERTER, PTO
Unit: mm
No.
Check item
Criteria
1
Outside diameter of oil seal contact
surface of input coupling
Remedy
Standard size
Tolerance
Repair limit
110
0
–0.087
109.8
105
+0.035
0
105.5
2
Inside diameter of seal ring contact
surface of retainer
3
Backlash between PTO drive gear
and PTO idler gear
0.17 – 0.46
Backlash between PTO idler gear and
4 HSS pump and cooling fan pump
drive gear
0.16 – 0.42
Backlash between PTO idler gear and
5 power train and lubricating oil pump
drive gear
0.16 – 0.42
Backlash between PTO drive gear
and scavenging pump drive gear
0.17 – 0.46
6
Standard size
Fit tolerance of PTO
7
idler gear bearing
Fit tolerance of HSS
pump and cooling fan
8
pump drive gear
bearing
Fit tolerance of
10 scavenging pump
drive gear bearing
10-18
Shaft
Hole
–0.010
–0.035
0
–0.015
Outside diameter
110
Inside diameter
60
0
–0.019
+0.035
0
120
0
–0.015
55
+0.021
+0.002
120
0
–0.015
Inside diameter
55
+0.021
+0.002
0
–0.015
Outside diameter
72
0
–0.013
+0.030
0
Inside diameter
35
+0.011
–0.005
0
–0.010
Outside diameter
(Case side)
Inside diameter
Fit tolerance of power
train and lubricating oil
9
pump drive gear
bearing
Tolerance
0
–0.015
Outside diameter
(Cover side)
Outside diameter
(Cover side)
Outside diameter
(Case side)
Plate with hard
chromium or replace
Replace
+0.022
–0.013
0
–0.015
+0.035
0
+0.022
–0.013
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
TRANSMISSION
D65EX, PX-15
10-19
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
A: 1st clutch oil pressure pickup port
B: 3rd clutch oil pressure pickup port
C: R clutch oil pressure pickup port
D: 2nd clutch oil pressure pickup port
E: F clutch oil pressure pickup port
F: From power train pump (To brake valve)
G: To PTO case (To torque converter)
H: From oil cooler
J: To PTO case (To scavenging pump)
K: From PTO case (Drain)
L: To PTO case
(To power train and lubricating oil pump)
M: From steering case
N: From transmission ECMV (For R clutch)
P: From transmission ECMV (For 3rd clutch)
R: From transmission ECMV (For 1st clutch)
S: From transmission ECMV (For 2nd clutch)
T: From transmission ECMV (For F clutch)
10-20
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
*1. D65EX-15 Serial No. : 67137 and up
D65PX-15 Serial No. : 67136 and up
D65WX-15 Serial No. : 67001 and up
1. Main relief valve
2. Transmission ECMV cover
3. Transmission case
4. Transmission ECMV
5. Lubricating oil relief valve
6. Transmission input shaft
7. R sun gear (Number of teeth: 26)
8. R planetary pinion (Number of teeth: 22)
9. R ring gear (Number of teeth: 70)
10. Disc
11. Plate
12. Piston
13. F planetary pinion (Number of teeth: 23)
14. 3rd planetary pinion (Number of teeth: 30)
15. 3rd ring gear (Number of internal teeth: 76)
16. 2nd sun gear (Number of teeth: 33)
17. 1st planetary pinion (Number of teeth: 18)
18. 1st sun gear (Number of teeth: 39)
D65EX, PX-15
19. Output shaft
(3rd sun gear section, number of teeth: 17)
20. 1st carrier
21. 1st clutch housing
22. 1st ring gear (Number of internal teeth: 75)
23. 2nd clutch housing
24. 2nd planetary pinion (Number of teeth: 21)
25. 2nd ring gear (Number of internal teeth: 75)
26. 3rd clutch housing
27. 2nd and 3rd carrier
28. F clutch housing
29. F sun gear (Number of teeth: 29)
30. F ring gear (Number of internal teeth: 75)
31. F carrier
32. F clutch housing
33. Return spring
34. R ring gear (hub) (Number of internal teeth: 75)
35. R carrier
10-21
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
Outline
•
•
•
The transmission consists of planetary gear systems and disc clutches and has “3 forward gear
speeds and 3 reverse gear speeds”.
Among the 5 sets of planetary gear system and
disc clutches of the transmission, 2 clutches are
fixed hydraulically with the ECMV to select 1 rotating direction and rotating speed.
The transmission changes the speed of the power of the transmission input shaft to the forward
1st – 3rd or reverse 1st – 3rd gear speed with the
F and R clutches and 3 speed clutches, and then
transmits the converted power to the output
shaft.
Number of plates and discs
Clutch No.
R clutch
F clutch
3rd clutch
2nd clutch
1st clutch
*1
*2
*1
*2
*1
*2
*1
*2
Number of plates
Number of discs
6
5
6
7
8
3
4
5
3
4
5
2
3
4
*1. D65EX-15 Serial No. : 67001- 67136
D65PX-15 Serial No. : 67001- 67135
*2. D65EX-15 Serial No. : 67137 and up
D65PX-15 Serial No. : 67136 and up
D65WX-15 Serial No. : 67001 and up
Gear speeds and operated clutches
Operated clutches
Reduction ratio
Forward 1st
Gear speed
F x 1st
1.948
Forward 2nd
F x 2nd
1.096
Forward 3rd
F x 3rd
0.656
*
—
Neutral
Reverse 1st
R x 1st
1.462
Reverse 2nd
R x 2nd
0.823
Reverse 3rd
R x 3rd
0.492
*:
The 1st, 2nd, or 3rd clutch is filled with low-pressure oil.
10-22
(7)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
*1. D65EX-15 Serial No. : 67137 and up
D65PX-15 Serial No. : 67136 and up
D65WX-15 Serial No. : 67001 and up
D65EX, PX-15
10-23
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
Unit: mm
No.
Check item
Criteria
Standard size
Repair limit
Free length Installed length Installed load
1 R clutch spring (5 pcs.)
Remedy
Free length
Installed load
69.5
58.7
233.2 N
{23.8 kg}
65.3
198 N
{20.2 kg}
2 F clutch spring (5 pcs.)
77.0
63.6
95.2 N
{9.7 kg}
72.4
81 N
{8.2 kg}
3 3rd clutch spring (5 pcs.)
59.0
44.1
146.0 N
{14.9 kg}
55.5
125 N
{12.7 kg}
4 2nd clutch spring (5 pcs.)
59.0
44.5
142.1 N
{14.5 kg}
55.5
121 N
{12.3 kg}
5 1st clutch spring (5 pcs.)
59.0
44.3
144.1 N
{14.7 kg}
55.5
123 N
{12.5 kg}
Standard size
Tolerance
Repair limit
36.2
±0.33
32.2
*1
43.0
±0.36
37.4
*2
49.4
±0.39
43.8
*1
23.2
±0.26
20.0
*2
29.6
±0.30
26.4
*1
23.2
±0.26
20.0
*2
29.6
±0.30
26.4
*1
16.6
±0.22
14.2
*2
23.0
±0.26
20.6
11 Thickness of clutch disc
3.4
±0.1
2.6
12 Thickness of clutch plate
3.2
±0.1
2.9
Width
3.0
–0.01
–0.03
2.70
Thickness
2.3
±0.10
2.15
thickness of assembled 5
6 Total
R clutch discs and 6 plates
thickness of assembled 7
7 Total
F clutch discs and 6 plates
thickness of assembled 4
8 Total
3rd clutch discs and 3 plates
thickness of assembled 4
9 Total
2nd clutch discs and 3 plates
thickness of assembled 3
10 Total
1st clutch discs and 2 plates
of seal ring of
13 Wear
transmission input shaft
between R/F/2nd/1st
14 Backlash
sun gear and planetary pinion
0.11 – 0.30
between 3rd sun gear
15 Backlash
and planetary pinion
0.11 – 0.29
between planetary pinion and
16 Backlash
internal teeth of ring gear
0.12 – 0.33
between R carrier and
17 Backlash
internal teeth of ring gear
0.14 – 0.44
between F carrier and
18 Backlash
internal teeth of ring gear
0.14 – 0.38
between 1st carrier and
19 Backlash
internal teeth of ring gear
0.14 – 0.39
Replace
*1. D65EX-15 Serial No. : 67001- 67136
D65PX-15 Serial No. : 67001- 67135
*2. D65EX-15 Serial No. : 67137 and up
D65PX-15 Serial No. : 67136 and up
D65WX-15 Serial No. : 67001 and up
10-24
(7)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
Disc clutch
Structure
Clutch “OFF” (Released)
•
•
•
•
The disc clutch consists of piston (2), plate (3),
disc (4), pin (5), return spring (6), etc. to secure
ring gear (1).
The internal teeth of disc (4) are meshed with the
external teeth of ring gear (1).
Plate (3) is secured to clutch housing (7) with pin
(5).
•
When the oil sent from the ECMV is shut off, piston (2) is returned to the right by return spring
(6).
The friction force between plate (3) and disc (4)
is released and ring gear (1) is released.
Operation
Clutch “ON” (Fixed)
Oil passage in speed clutch
•
•
•
•
The oil sent from the ECMV flows through the oil
passage in housing (7) to the back side of piston
(2) to move piston (2) to the left.
Piston (2) presses plate (3) and disc (3) to fit
them together, and disc (4) is stopped by the friction force between it and plate (3).
Since the internal teeth of disc (4) are meshed
with the external teeth of ring gear (1), ring gear
(1) is fixed.
•
•
•
•
D65EX, PX-15
When the steering/directional/gear shift lever is
set in the NEUTRAL position, the 1st, 2nd, or 3rd
speed is selected.
The piston chamber of the clutch corresponding
to the selected gear speed is filled with oil by
electronically controlling the hydraulic circuit of
each clutch.
When the steering/directional/gear shift lever is
shifted from the NEUTRAL position to the FORWARD or REVERSE position, the pump is required to supply oil of quantity to fill the piston
chamber of the F clutch or R clutch.
When the gear speed is changed from FORWARD 1st to FORWARD 2nd, the pump is required to supply oil of only quantity to fit the plate
and disc of the 2nd clutch together since the F
clutch has been filled with the oil.
The time lag in the gear shifting operation is reduced by controlling the oil in the clutch circuit as
explained above.
10-25
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
Power train route
Forward 1st
•
•
•
•
When the transmission is set to FORWARD 1st,
the F clutch and 1st clutch are engaged. The
power transmitted from the torque converter to
input shaft (1) is then transmitted to output shaft
(21).
The F clutch is actuated by the hydraulic pressure applied to the F clutch piston, and holds F
ring gear (4). The 1st clutch is actuated by the
hydraulic pressure applied to the 1st clutch piston, and holds 1st ring gear (18).
The power from the torque converter is transmitted to input shaft (1), and then transmitted
through F sun gear (2) to F planetary pinion (3).
Since F ring gear (4) is held by the F clutch, the
power transmitted to F planetary pinion (3) to rotate F carrier (10) on the inside of F ring gear (4).
10-26
•
•
•
F carrier (10) and 2nd and 3rd carriers (11) are
connected by a spline, and rotate as one unit.
Accordingly, the rotation of F carrier (10) is transmitted through 2nd planetary pinion (13) to 2nd
ring gear (15).
Since 2nd ring gear (15) and 1st carrier (16) are
meshed with each other, the power transmitted
to 2nd ring gear (15) is transmitted to 1st planetary pinion (17).
Since 1st ring gear (18) is held by the 1st clutch,
the power transmitted to 1st planetary pinion
(17) is transmitted through 1st sun gear (20) to
output shaft (21).
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
Forward 2nd
•
•
•
•
When the transmission is set to FORWARD 2nd,
the F clutch and 2nd clutch are engaged. The
power transmitted from the torque converter to
input shaft (1) is then transmitted to output shaft
(21).
The F clutch is actuated by the hydraulic pressure applied to the F clutch piston, and holds F
ring gear (4). The 2nd clutch is actuated by the
hydraulic pressure applied to the 2nd clutch piston, and holds 2nd ring gear (15).
The power from the torque converter is transmitted to input shaft (1), and then transmitted
through F sun gear (2) to F planetary pinion (3).
Since F ring gear (4) is held by the F clutch, the
power transmitted to F planetary pinion (3) to rotate F carrier (10) on the inside of F ring gear (4).
D65EX, PX-15
•
•
F carrier (10) and 2nd and 3rd carriers (11) are
connected by a spline, and rotate as one unit.
Accordingly, the rotation of F carrier (10) is transmitted to 2nd planetary pinion (13).
Since 2nd ring gear (15) is held by the 2nd
clutch, the power transmitted to 2nd planetary
pinion (13) is transmitted through 2nd sun gear
(19) to output shaft (21).
10-27
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
Forward 3rd
•
•
•
•
When the transmission is set to FORWARD 3rd,
the F clutch and 3rd clutch are engaged. The
power transmitted from the torque converter to
input shaft (1) is then transmitted to output shaft
(21).
The F clutch is actuated by the hydraulic pressure applied to the F clutch piston, and holds F
ring gear (4). The 3rd clutch is actuated by the
hydraulic pressure applied to the 3rd clutch piston, and holds 3rd ring gear (14).
The power from the torque converter is transmitted to input shaft (1), and then transmitted
through F sun gear (2) to F planetary pinion (3).
Since F ring gear (4) is held by the F clutch, the
power transmitted to F planetary pinion (3) to rotate F carrier (10) on the inside of F ring gear (4).
10-28
•
•
F carrier (10) and 2nd and 3rd carriers (11) are
connected by a spline, and rotate as one unit.
Accordingly, the rotation of F carrier (10) is transmitted to 3rd planetary pinion (12).
Since 3rd ring gear (14) is held by the 3rd clutch,
the power transmitted to 3rd planetary pinion
(12) is transmitted to output shaft (21).
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION
Reverse 1st
•
•
•
•
When the transmission is set to REVERSE 1st,
the R clutch and 1st clutch are engaged. The
power transmitted from the torque converter to
input shaft (1) is then transmitted to output shaft
(21).
The R clutch is actuated by the hydraulic pressure applied to the R clutch piston, and holds
ring gear (7). The 1st clutch is actuated by the
hydraulic pressure applied to the 1st clutch piston, and holds 1st ring gear (18).
The power from the torque converter is transmitted to input shaft (1), and then transmitted
through R sun gear (5) to R planetary pinion (6).
Since ring gear (7) is meshed with carrier (8) and
held by the R clutch, R planetary pinion (6) rotates R ring gear (9). R ring gear (9) rotates F
carrier (10) in the opposite direction to input shaft
(1).
D65EX, PX-15
•
•
•
F carrier (10) and 2nd and 3rd carriers (11) are
connected by a spline, and rotate as one unit.
Accordingly, the rotation of F carrier (10) is transmitted through 2nd planetary pinion (13) to 2nd
ring gear (15).
Since 2nd ring gear (15) and 1st carrier (16) are
meshed with each other, the power transmitted
to 2nd ring gear (15) is transmitted to 1st planetary pinion (17).
Since 1st ring gear (18) is held by the 1st clutch,
the power transmitted to 1st planetary pinion
(17) is transmitted through 1st sun gear (20) to
output shaft (21).
10-29
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION ECMV
TRANSMISSION ECMV
a ECMV: Abbreviation for Electronic Control Modulation Valve
10-30
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION ECMV
P:
From power train pump
PF: F clutch oil pressure pickup port
PR: R clutch oil pressure pickup port
P1: 1st clutch oil pressure pickup port
P2: 2nd clutch oil pressure pickup port
P3: 3rd clutch oil pressure pickup port
CF: To F clutch
CR: To R clutch
C1: To 1st clutch
C2: To 2nd clutch
C3: To 3rd clutch
SDF: F fill switch drain
SDR: R fill switch drain
SD1: 1st fill switch drain
SD2: 2nd fill switch drain
SD3: 3rd fill switch drain
Dr: Drain
1. Fill switch (For 1st clutch)
2. Fill switch (For R clutch)
3. Fill switch (For F clutch)
4. Fill switch (For 3rd clutch)
5. Fill switch (For 2nd clutch)
6. Proportional solenoid (For 3rd clutch)
7. Proportional solenoid (For 1st clutch)
8. Proportional solenoid (For R clutch)
9. Proportional solenoid (For F clutch)
10. Proportional solenoid (For 2nd clutch)
11. Fill switch connector (For 1st clutch)
12. Fill switch connector (For R clutch)
13. Fill switch connector (For F clutch)
14. Fill switch connector (For 3rd clutch)
15. Fill switch connector (For 2nd clutch)
16. Proportional solenoid connector (For 1st clutch)
17. Proportional solenoid connector (For 3rd clutch)
18. Proportional solenoid connector (For R clutch)
19. Proportional solenoid connector (For 2nd clutch)
20. Proportional solenoid connector (For F clutch)
21. Filter
D65EX, PX-15
10-31
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
6.
7.
TRANSMISSION ECMV
Fill switch
Valve body (Upper)
Pressure control valve
Valve body (Lower)
Proportional solenoid
Oil pressure detection valve
Plug
10-32
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Outline of ECMV
• The ECMV consists of a pressure regulator valve
and a fill switch.
• Pressure control valve
Converts a current sent from the transmission
controller to the proportional solenoid valve, to
an oil pressure.
• Fill switch
Detects that the clutch is filled with oil. It has the
functions below.
1) When the clutch is filled with oil, a signal
(the fill signal) is sent to the controller to
notify that filling is finished.
2) While oil pressure is being applied to the
clutch, a signal (the fill signal) is sent to the
controller to notify that oil pressure is being
applied.
A range: Before shifting gear (when drained)
B range: Filling
C range: Pressure regulation
D range: Filling (triggering)
E point: Start of filling
F point: Finish of filling
TRANSMISSION ECMV
ECMV and proportional solenoid
• One proportional solenoid is installed for one
ECMV.
After receiving the command current from the
controller, it produces thrust shown in the graph
below.
By making the proportional solenoid-produced
thrust act on the pressure control valve spool, it
produces an oil pressure shown in the graph
below. By controlling the amount of command
current, the thrust is changed to operate the
pressure control valve, controlling the oil flow
and oil pressure.
Current-Thrust characteristics of proportional
solenoid
Thrust-Oil pressure characteristics of proportional solenoid
a The logic is such that the controller does not recognize finish of filling even if the fill switch is
turned "ON" during the triggering operation (D
range).
D65EX, PX-15
ECMV and fill switch
• One fill switch is installed for one ECMV.
If the clutch finishes filling, the fill switch is
turned "ON" by the pressure of the clutch. By
this signal, the oil pressure starts build-up.
10-33
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ECMV operation
• The ECMV is controlled with the command current sent from the controller to the proportional
solenoid and the output signal of the fill switch.
The relationship between the proportional command current for the ECMV, clutch input pressure, and output signal of the fill switch is shown
in the graph below.
Arange: Before shifting gear (when drained)
Brange: Filling
Crange: Pressure regulation
Drange: Filling (triggering)
Epoint: Start of filling
Fpoint: Finish of filling
TRANSMISSION ECMV
1. Before shifting gear (when drained)
(A range in chart)
When a current is not carried to the proportional
solenoid (1), the pressure control valve (2) is
draining the oil at the clutch port A through the
drain port Dr.
Since oil pressure is not applied to oil pressure
detector valve (3) at this time, fill switch (4) is
turned "OFF".
a The logic is such that the controller does not recognize finish of filling even if the fill switch is
turned "ON" during the triggering operation (D
range).
10-34
(7)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
2. Filling (B range in chart)
If you supply current to the proportional solenoid (1) with no oil in the clutch, an oil pressure
proportional to the solenoid force acts on the
chamber B, pushing the pressure control valve
(2) rightward. As a result, pump port P and
clutch port A are opened and oil starts filling the
clutch. If the clutch is filled with oil, fill switch (4)
is turned "ON".
D65EX, PX-15
TRANSMISSION ECMV
3. Pressure regulation (C range in chart)
If you supply current to the proportional solenoid (1), the solenoid produces thrust proportional to the current. Pressure is regulated by
balancing the thrust of the solenoid, the thrust
of clutch port A, and reaction force of the pressure control spring (5).
10-35
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
MAIN RELIEF VALVE
MAIN RELIEF VALVE
Main relief, torque converter relief valve
PP: From pump
TC: To torque converter
drT: Drain port (for torque converter relief)
dr1: Drain port
dr2: Drain port
P1: Main relief oil pressure detection port
P8: Torque converter relief oil pressure detection port
1.
2.
3.
4.
5.
Body
Piston
Torque converter relief valve
Piston
Main relief valve
Unit: mm
No.
Check item
Clearance between main relief
6
valve and valve body
7
Clearance between torque converter relief valve and valve body
Criteria
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
28
–0.035
–0.045
+0.013
0
0.035 –
0.058
0.078
22
–0.035
–0.045
+0.013
0
0.035 –
0.058
0.078
Installed load
Free length
Installed load
Standard size
8 Main relief valve spring (outer)
Remedy
Free length Installed length
Repair limit
128
75.3
508.6 N
{51.9 kg}
124.2
483.2 N
{49.3 kg}
9 Main relief valve spring (inner)
108
75.3
401.8 N
{41.0 kg}
104.8
382.5 N
{39.0 kg}
Torque converter relief valve
spring
50
42
153.0 N
{15.6 kg}
48.5
145.1 N
{14.8 kg}
10
10-36
Replace
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Outline
Torque converter relief valve
• The torque converter relief valve protects the
torque converter from abnormally high pressure
by keeping the oil pressure in the torque converter inlet port circuit below the set pressure.
Set pressure: 0.83 MPa {8.5 kg/cm2}
(Cracking pressure)
MAIN RELIEF VALVE
Operation of main relief valve
• The oil from the hydraulic pump passes through
the filter and enters port A of the relief valve. It
then passes through orifice a of spool (6) and enters chamber B.
When the oil from the pump fills the circuit, the oil
pressure starts to rise.
Main relief valve
• The main relief valve holds the oil pressure in the
transmission and brake at the set pressure.
Set pressure: 3.31 MPa {33.8 kg/cm2}
(Engine at rated speed)
Operation
Operation of torque converter relief valve
• The oil relieved by the main relief valve flows
from port C into the torque converter and the
same time, passes through orifice b of spool (2)
and enters chamber D.
When the circuit leading to the torque converter
becomes filled with oil, the oil pressure starts to
rise.
• As the oil pressure going to the torque converter
rises, the oil entering chamber D pushes piston
(9). The reaction force compresses valve spring
(3) and moves spool (2)to the right to open the
circuit between port C and port E.
When this happens, the oil at port C is relieved
to port E and drains to the oil tank.
The oil pressure at port C at this point is 0.83
MPa {8.5 kg/cm2} (cracking pressure)
D65EX, PX-15
•
As the oil pressure in the circuit rises, the oil entering chamber B pushes piston (4). The reaction force compresses valve spring (7) and
moves spool (6) to the left to open the circuit between port A and port C.
When this happens, the oil at port A is relieved
to port C and flows from port C to the torque converter.
The oil pressure at port A at this point is 3.31
MPa {33.8 kg/cm2} (engine at rated speed)
10-37
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
Outline
2. Piston
3. Spring
4. Forward clutch housing
•
A: From oil cooler
B: Drain
C: Drain
•
The oil leaving the torque converter passes
through the oil cooler built in the radiator lower
tank. It then goes through the lubrication relief
valve and lubricates the transmission and PTO.
The lubrication relief valve is installed to the right
side face of the forward clutch housing. And prevents any abnormal pressure in the lubrication
oil.
Specified value
2
Normal pressure (MPa {kg/cm })
0.05 – 0.15 {0.5 – 1.5}
Cracking pressure (MPa {kg/cm2})
0.29 {3.0}
Unit: mm
No.
Check item
Criteria
Standard size
1 Lubrication relief valve spring
Free length Installed length
26
10-38
23.7
Remedy
Repair limit
Installed load
12.0 N
{1.22 kg}
Free length
Installed load
25.2
11.4 N
{1.16 kg}
Replace
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SCAVENGING PUMP
SCAVENGING PUMP
Outline
•
•
The scavenging pump is installed to the lower
part of the PTO case and driven with the power
from the engine.
The scavenging pump draws oil collected in the
transmission case bottom through a strainer and
returns it to the steering case.
Specifications
Type
Theoretical capacity
(cc/rev)
Max. discharge pressure
(MPa {kg/cm2})
Max. speed
(rpm)
D65EX, PX-15
Gear pump
61.2
0.29 {3.0}
2,500
10-39
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
POWER TRAIN PUMP, LUBRICATION PUMP
POWER TRAIN PUMP, LUBRICATION PUMP
SAL (2) 45 + 45
1. Power train pump
2. Lubricating oil pump
Unit: mm
No.
Check item
3 Side clearance
4
Clearance between inside of plain
bearing and outside of gear shaft
Criteria
Type
Standard clearance
Clearance limit
SAL (2) 45
0.10 – 0.15
0.19
SAL (2) 45
0.060 – 0.125
0.20
Type
5 Driving depth of pin
SAL (2) 45
6 Rotating torque of spline
Discharge
—
Oil: SAE10W
Oil temperature: 45 – 55ºC
10-40
Remedy
Replace
Standard size
Tolerance
Repair limit
12
0
–0.5
—
5.8 – 13.8 Nm {0.6 – 1.4 kgm}
Type
Speed
(rpm)
Discharge
pressure
(MPa {kg/cm2})
Standard
discharge
(l/min)
Allowable
discharge
(l/min)
SAL (2) 45
3,000
2.94
{30}
126
115
—
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HSS SYSTEM
HSS SYSTEM
a HSS: Abbreviation for Hydrostatic Steering System
D65EX, PX-15
10-41
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1. Steering/directional/gear shift lever (PCCS lever)
2. Transmission and steering controller
3. Engine controller
4. Control valve
5. EPC valve
6. HSS pump
7. Servo valve
8. HSS motor
9. HSS circuit
10. Engine
11. Final drive
12. Sprocket
13. Hydraulic tank
Input and output signals
a.
b.
c.
d.
e.
Forward and reverse signals
Steering signal
Engine control information
Work equipment oil pressure signal
CAN communication network
10-42
HSS SYSTEM
Outline
•
•
•
•
The HSS system consists of control valve (4),
HSS pump (6), and HSS motor (8). It turns the
machine continuously without lowering the travel
speed by making a difference in speed between
both tracks.
Transmission-steering controller (2) controls
EPC valve (5) of control valve (4) to control the
rotating direction and speed of HSS motor (8)
according to the tilting direction and angle of
steering/directional/gear shift lever (1).
HSS motor (8) acts on the planetary gear mechanism of the bevel gear shaft to make a difference in speed between both sprockets (12). As
a result, the machine turns.
Transmission-steering controller (2) senses the
engine speed and oil pressure at each part and
controls HSS pump (6) and control valve (4) so
that engine (10) will not stall.
The engine speed signal and other engine control information items are sent and received
through the CAN communication network which
connects engine controller (3) and transmissionsteering controller (2).
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
HYDRAULIC, HSS PUMP
HPV95
Outline
This pump consists of a variable displacement swash plate type piston pump and LS valve.
PA:
Pump discharge port
PS:
Pump suction port
PD1:
Pump drain plug
PD2:
Pump drain
PLS1: Load pressure inlet port
PEN12: Control pressure detection plug
Specification
Model:
HPV95 (112 cm3/rev)
Theoretical
displacement capacity: 112 ± 1 cm3/rev
Rated speed:
2,280 rpm
Max. cut off pressure: 41.2 MPa {420 kg/cm2}
1. Piston pump
2. Servo valve
D65EX, PX-15
10-43
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
PISTON PUMP
PA:
Pump discharge port
PS:
Pump suction port
PA1: Pump pressure signal port
PD2: Pump drain
PNC1: Control pressure port
10-44
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
6.
7.
Shaft
Case
Cradle
Rocker cam
Shoe
Servo piston
Rod
D65EX, PX-15
HYDRAULIC, HSS PUMP
8. Piston
9. Cylinder block
10. Valve plate
11. End cap
12. Impeller
13. Spline
10-45
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Outline
•
•
The engine rotation and torque transmitted to the
pump shaft is converted to hydraulic energy and
pressurized oil is discharged according to the
load.
It is possible to change the discharge amount by
changing the swash plate angle.
Structure
•
•
•
•
•
Cylinder block (9) is supported to shaft (1) by a
spline (13), and shaft (1) is supported by the
front and rear bearings.
The end of piston (8) has a concave ball shape
and shoe (5) is calked to it to form one unit.
Piston (8) and shoe (5) from a spherical bearing.
Rocker cam (4) holds plane A, and shoe (5) is always pressed against this surface as it slides in
a circle.
Rocker cam (4) forms a static beaing sending
high pressure oil at cylindrical surface B of cradle (3), which is fixed to the case, and carries out
a sliding movement.
10-46
HYDRAULIC, HSS PUMP
•
•
•
•
Piston (8) carries out motion relative to the axial
direction inside each cylinder chamber of cylinder block (9).
The cylinder block (9) carries out rotation relative
to valve plate (10) while sealing the pressurized
oil, and this surface ensures that the hydraulic
balance is maintained correctly.
The oil inside each cylinder chamber of clinder
block (9) is sucked in and dischaged through
valve plate (10).
Impeller (12) is fixed to shaft (1), and rotates together with the shaft, it makes it easier for the oil
sucked in from the suction port to be sucked in
and sends it into the cylinder chamber by centrifugal force.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
Operation
1. Operation of pump
• Cylinder block (9) rotates toghther with shaft (1),
and shoe (5) slides on plane A.
When this happens, rocker cam (4) moves along
cylindrical surface B, so angle of center line X
of arocker cam (4) to the axial direction of cylinder block (9) changes.
This angle is called the swash plate angle.
•
•
•
•
•
When center line X of rocker cam (4) is the same
as the axial direction of cylinder block (9) (swash
plate angle = 0), the difference between volumes
E’ and F’ indside cylinder block (9) is 0, so pump
does not suction and discharge, and no pumping’s carried out.
Actually swash plate angle does not become 0.
The swash plate angle is proportional to pump
discharge volume.
With swash plate angle
formed by the angle
between center line X of rocker cam (4) to the axial direction of cylinder block (9), plane A acts as
a cam for shoe (5).
In this way, piston (8) slides inside cylinder block
(9), and as a result, a difference is generated between volumes E and F inside the cylinder block.
The amount of suction and discharge is equal to
difference F – E.
In other words, cylinder block (9) rotates, and the
volume of chamber E becomes smaller, so oil is
discharged during this process. At the same
time, the volume of chamber F becomes larger
and oil is sucked in this process.
D65EX, PX-15
10-47
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
2. Control of discharge amount
• If swash plate angle becomes larger, the difference between volumes E and F becomes larger,
and oil discharge Q is incleased. Swash plate
angle is changed by servo piston (6).
• Servo piston (6) carrise out reciprocal movement
in a straight line ( ) according to the command
from the servo valve single pressure. This
straight line movement is trasmitted to rocker
cam (4) through rod (7), and rocker cam (4),
which is supported on the cylindrical surface by
creadle (3) rotates on the cylindrical surface.
• The area receiving the pressure is different at
the left and right sides of servo piston (6), and
the receiving pressure at the small diameter piston end is always connected with main pump discharge pressure (self pressure) PP.
• Output pressure PNC of the servo valve is applied to the chamber receiving the pressure at
the large diameter piston end (which receives
pressure of the pump).
• The movement of servo piston (6) is controlled
by the relationship of the size of pump pressure
PP and the pressure at the large diameter piston
end, and the comparative size of the ratio of area
receiving the pressure at the large diameter piston end and small diameter piston end.
10-48
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
SERVO VALVE
PT:
Drain port
PA1:
Pump self pressure port
PLS1: Load pressure input port
PEN11: Control pressure port
PEN12: Control pressure detection port
D65EX, PX-15
10-49
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
LS VALVE
TCC VALVE
VARIABLE THROTTLE VALVE
1.
2.
3.
4.
5.
6.
7.
8. Plate
9. Piston
10. Sleeve
11. Spring
12. Spring
13. Piston
14. Lever
15. Valve body
16. Screw
17. Locknut
18. Spring
19. Seat
20. Spool
21. Block
22. Plug
Locknut
Plug
Spring
Spool
Sleeve
Piston
Plug
10-50
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
Function
1. LS valve
• The LS valve detects the load and controls the
discharge amount.
• This valve controls main pump discharge
amount Q according to differential pressure
PLS (= PP – PLS) (the difference between
main pump pressure PP and control valve outlet
port pressure PLS) {called the LS differential
pressure}.
• Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control valve
output enter this valve.
• The relationship between discharge amount Q
and differential pressure PLS, (the difference
between main pump pressure PP and LS pressure PLS) (= PP – PLS) changes as shown in
the diagram.
2. TCC valve
• When the pump discharge pressure PP is high,
the TCC valve controls the pump so that no more
oil than the constant flow (in accordance with the
discharge pressure) flows even if the stroke of
the control valve becomes larger.
• In this way, it carries out equal horsepower control so that the horsepower absorbed by the
pump does not exceed the engine horsepower.
• In other words, if the load during the operation
becomes larger and the pump discharge pressure rises, it reduces the discharge amount from
the pump; and if the pump discharge pressure
drops, it increases the discharge amount from
the pump.
• The relationship between pump discharge pressure PP and pump discharge amount Q when
this happens is shown in the diagram.
D65EX, PX-15
3. Variable throttle valve
• Because the main pump controls its own prssure, there is a tendency for the response speed
of the swash plate to be quick at high pressure
and slow at low pressure.
• The variable throttle valve has been installed for
the following reasons.
(1) To reduce the swash plate speed between
MIN and MAX at high pressure; to reduce
the impact force on the rod and other parts of
the main pump; and to prevent excessive response.
(2) To prevent cavitation at the suction port
caused by the sudden increase in the suction volume when changing from MIN to
MAX.
•
The characteristics of the variable throttle valve
are as shown in the diagram.
It has the function and property of maintaining
the response during operations at low pressure
by making the area of the opening smaller at
high pressure and the area of the opening larger
at low pressure, and by preventing the above
problems (1) and (2) at high pressure.
10-51
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
Operation
1. LS valve
(1) When control valve is at “neutral” position
•
•
•
The LS valve is a three-way selector valve,
with pressure PLS (LS pressure) from the
outlet port of the control valve brought to
spring chamber i, and main pump discharge
pressure PP brought to chamber j of plug
(6). The size of the LS pressure PLS + force
F of spring (3) and the main pump pressure
(self pressure) PP determines the position of
spool (4).
Before the engine is started, servo piston (1)
is pushed to the right by spring (7) installed
to rod (2). (See the diagram on the right)
When the engine is started and the control
lever is at the “NEUTRAL” position, LS pressure PLS is 0 MPa {0 kg/cm2}. (It is interconnected with the drain circuit through the
control valve spool.) At this point, spool (4) is
pushed to the left, and port d and port c are
connected. Pump pressure PP enters the
large diameter end of the piston from port h.
10-52
•
The same pump pressure PP also enters the
small diameter end of the piston, so the
swash plate is moved to the minimum angle
by the difference in area of piston (1).
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
(2) Operation in maximum direction for pump discharge amount
•
•
When the difference between main pump
pressure PP and LS pressure PLS, in other
words, LS differential pressure PLS becomes smaller (for example, when the area
of opening of the control valve becomes larger and pump pressure PP drops), spool (4) is
pushed to the right by the combined force of
LS pressure PLS and the force of spring (3).
When spool (4) moves, port b and port c are
joined and connected to the TCC valve.
When this happens, the TCC valve is connected to the drain port, so circuit c – h becomes drain pressure PT. (The operation of
the TCC valve is explained later.)
D65EX, PX-15
•
•
For this reason, the pressure at the large piston diameter end of servo piston (1) bec om es dra in pr es s ur e P T, an d p ump
pressure PP enters the small diameter end,
so servo piston (1) is pushed to the right.
Therefore, rod (2) moves to the right and
moves the swash plate in the direction to
make the discharge amount larger.
10-53
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
(3) Operation in minimum direction for pump discharge amount
•
•
•
The following explains the situation if servo
piston (1) moves to the left (the discharge
amount becomes smaller).
When LS pressure PLS becomes larger
(for example, when the area of opening of
the control valve becomes smaller and pump
pressure PP rises), pump pressure PP pushes spool (4) to the left.
When spool (4) moves, main pump pressure
PP flows from port d to port c, and from port
h, it enters the large piston diameter end.
10-54
•
•
Main pump pressure PP also enters the
small piston diameter end, but because of
the difference in area between the large piston diameter end of servo piston (1) and the
small piston diameter end, servo piston (1) is
pushed to the left.
As a result, rod (2) moves in the direction to
make the swash plate angle smaller.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
(4) When servo piston is balanced
•
•
•
Let us take the area receiving the pressure at
the large piston diameter end as A1, the
area receiving the pressure at the small diameter end as A0, and the pressure flowing
into the large piston diameter end as Pen.
If the main pump pressure PP of the LS valve
and the combined force of force F of spring
(3) and LS pressure PLS are balanced, and
the relationship is A0 x PP = A1 x Pen.
The servo piston (1) will stop in that position,
and the swash plate will be kept at an intermediate position. (It will stop at a position
where the opening from port b to port c and
from port d to port c of spool (4) is approximately the same.)
D65EX, PX-15
•
•
At this point, the relationship between the
area receiving the pressure at both ends of
piston (1) is A0:A1 = 1:2, so the pressure applied to both ends of the piston when it is balanced becomes PP:Pen C Pen 2:1.
The position where spool (4) is balanced and
stopped is the standard center, and the force
of spring (3) is adjusted so that it is determined when PP – PLS = 1.96 MPa {20 kg/
cm2}.
10-55
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
2. TCC valve
(1) When the load on the actuator is small and pump pressure PP is low
•
•
•
•
The spring load of springs (3) and (4) in the
TCC valve is determined by the swash plate
position.
When servo piston (9) moves, cam (7),
which is connected to rod (8), also moves.
When this happens, lever (6) is rotated by
the angle of cam (7), and position (5) moves
to the right and left.
If piston (5) moves to the right, spring (3) is
compressed, and if it moves further to the
right, spring (4) contacts seat (10), so both
spring (3) and spring (4) function.
In other words, the spring load is changed by
piston (5) extending or contacting springs (3)
and (4).
10-56
•
•
•
•
Port c of the TCC valve is connected to port
e of the LS valve (see 1. LS valve). Self
pressure PP enters port b, the small piston
diameter end of servo piston (9), and port a.
When pump pressure PP is small, piston (2)
is on the right.
At this point, port c and port d are connected, and the pressure entering the LS valve
becomes drain pressure PT.
If port h and port e of the LS valve are connected (see 1. LS valve), the pressure entering the large piston diameter end from
port f becomes drain pressure PT, and servo
piston (9) moves to the right.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
•
•
•
•
•
HYDRAULIC, HSS PUMP
In this way, the pump discharge amount
moves in the direction of increase.
As servo piston (9) moves further, piston (5)
is moved to the left by rod (8), cam (7) and lever (6). Springs (3) and (4) expand and the
spring force becomes weaker.
When the spring force becomes weaker, piston (2) moves to the left, so the connection
between port c and port d is cut, and the
pump discharge pressure is connected to
port b.
As a result, the pressure at port c rises, and
the pressure at the large piston diameter end
also rises, so the movement of piston (9) to
the right is stopped.
In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where for the force of springs (3) and
(4) and the pushing force created by pressure PP acting on piston (2) are in balance.
D65EX, PX-15
10-57
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
(2) When load on actuator is small and pump discharge pressure is high
•
•
•
When the load is large and pump discharge
pressure PP is high, the force pushing piston
(2) to the left becomes larger and piston (2)
moves to the position shown in the diagram
above.
When this happens, as shown in the diagram
above, part of the pressurized oil from port b
flows out to port d and the pressure oil flowing from port c to the LS valve becomes approximately half of main pump pressure PP.
When port h and port e of the LS valve are
connected (see 1. LS valve), the pressure
from port f enters the large piston diameter
end of servo piston (9), and servo piston (9)
stops.
10-58
•
•
•
•
•
If main pump pressure PP increases further
and piston (2) moves further to the left, main
pump pressure PP flows to port c and acts to
make the discharge amount the minimum.
When piston (9) moves to the left, piston (5)
is moved to the right by cam (7) and lever (6).
For this reason, springs (3) and (4) are compressed and push back piston (2).
Because of this force, piston (2) cuts of the
connection from port b to port c, and port c
and port d are connected.
As a result, the pressure at port c (= f) drops,
and piston (9) stops moving to the left.
The position in which piston (9) stops when
this happens is further to the left than the position when pump pressure PP is low.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
•
HYDRAULIC, HSS PUMP
The relation of pump pressure PP and the
position of servo piston (9) forms a bent line
because of the double-spring effect of
springs (3) and (4). The relationship between
pump pressure PP and pump discharge
amount Q is shown in the figure.
D65EX, PX-15
10-59
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC, HSS PUMP
3. Variable throttle valve
(1) Operation in maximum direction for pump
discharge amount
• Main pump pressure PP enters the variable
throttle valve through port a.
1) When main pump pressure PP is high
• If the pressure becomes higher than the
force of spring (3) because of the difference in sectional area of spool (4) in
chamber e, spool (4) moves to the right.
• If spool (4) moves to the right, the opening area between ports c and b is reduced by the notch at part A. Accordingly,
less oil flows from the large diameter end
of servo piston (1) and the moving speed
of servo piston (1) is lowered.
10-60
2) When main pump pressure PP is low
• Even if main pump pressure PP enters
chamber e through port a, spool (4)
pushes spring (3) less strongly and
moves to the right for shorter distance.
• At this point, the opening area of part A
increases and the oil flowing from the
large diameter end of servo piston (1)
through port c to port b is not limited and
the moving speed of servo piston (1) is
heightened.
(2) Operation to reduce pump discharge
• The hydraulic oil flows from port b through
port c to the large diameter side of servo piston (1).
• Spool (4) operates according to main pump
pressure PP as explained in the above section.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HSS MOTOR
HSS MOTOR
HMF95
Outline
•
Motor is composed of fixed capacity, fixed swash plate type piston motor, flashing shuttle valve, bypass valve
and charge relief valve.
1.
2.
3.
4.
HSS motor assembly
Counterbalance valve
Safety valve
Check valve
PA: From control valve
PB: From control valve
T2: To hydraulic tank
D65EX, PX-15
Specifications
Model:
HMF95
Theoretical displacement: 96.0 cc/rev
Rated output pressure:
38.2 MPa {390 kg/cm2}
Rated speed:
2,430 rpm
10-61
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
6.
7.
8.
9.
HSS MOTOR
10. Counterbalance valve
11. Safety valve
12. Check valve
13. Check valve spring
14. Sub bearing
15. Spline
16. Shoe
17. Main bearing
Output shaft
Motor case
Swash plate
Piston
Cylinde
Valve plate
End cover
Brake valve assembly
Spool return spring
Unit: mm
No.
Check item
Criteria
Standard size
18 Spool return spring
19 Check valve spring
10-62
Free length
x OD
Remedy
Repair limit
Free length
Installed load
40.5
192 N
{19.6 kg}
—
154 N
{15.7 kg}
32.9
1.27 N
{0.13 kg}
—
0.98 N
{0.10 kg}
Installed length
Installed load
42.7 x 30.0
43 x 13.8
Replace spring
if damaged or
deformed
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HSS MOTOR
Outline
•
Pressurized oil sent from pump is converted to
rotation torque and is transmitted to output shaft.
Structure
•
•
•
•
•
•
Cylinder block (5) is supported to shaft (1) by a
spline (15), and shaft (1) is supported by main
and sub bearings (17) and (14).
The end of piston (4) has a concave ball shape,
and shoe (16) is caulked to it to form one unit.
Piston (4) and shoe (15) form a spherical bearing.
Piston (4) carries out motion relative to the axial
direction inside each cylinder chamber of cylinder block (5).
Cylinder block (5) carries out rotation relative to
valve plate (6) while sealing the pressurized oil,
and this surface ensures that the hydraulic balance is maintained correctly.
The oil inside each cylinder chamber of cylinder
block (5) is sucked in and discharged through
valve plate (6).
D65EX, PX-15
10-63
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HSS MOTOR
Operation
1. Operation of motor
•
•
•
•
•
•
The pressurized oil sent from the pump enters cylinder block (5) and pushes piston (4)
from the back face.
In the case of the motor, the center line of
plate (3) is always at an angle (swash plate
angle a to the axial direction of cylinder block
(5).
As a result, if we take the example of one of
pistons (4), oil pressure is applied to the back
face of the right, and piston axial force FO is
generated.
With shoe (16), which is joined to piston (4)
by the spherical surface, reaction force FR in
a direction at right angles to plane A is generated. The combined force of FO and FR is
FP, and this becomes the force to rotate cylinder block (5).
2. Rotation speed and torque control
•
•
•
As flow Q from the HSS pump is increased,
motor speed N is heightened.
Since the swash plate angle of the HSS motor is fixed ( is constant), torque T is proportional to pressure P.
Swash plate angle is approx. 19º.
Q = qN
Q: Total flow
(q = E – F)
q: Flow per 1 turn
N: Rotation speed
Pq
P: Pressure
T=
2
T: Rotating torque
Shaft (1), which is meshed to cylinder block
(5) by spline (15) transmits this rotation
torque to the output side.
Cylinder block (5) rotates, and while the condition changes from volume E to volume F,
pressurized oil from the pump flows into the
cylinder chamber, and pressure P is generated according to the load.
On the other hand, when the condition goes
beyond volume F and changes to volume E,
the oil is pushed out and returned to the
pump.
10-64
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HSS MOTOR
OPERATION OF BRAKE VALVE
1. Counterbalance valve, check valve
•
Function
•
The brake valve consists of check valve (12),
counterbalance valve (10), and safety valve and
(11), and forms a circuit such as that shown below.
The function and operation of each component is
as given below.
•
•
When operation the steering on slopes, the
weight on the machine produces a force in the
downward direction which makes the machine
try to turn faster than the speed of the HSS motor.
Because of this, if the engine is run at low speed
and the steering is operated, the HSS motor will
overrun, and this will create an extremely dangerous condition.
To prevent this, this valve is installed to carry out
the steeting in accordance with the engine
speed (pump discharge volume).
Operation when oil is supplied
•
•
D65EX, PX-15
When the steering lever is operated, the pressurized oil from the control valve is supplied to port
PA. It pushes open check valve (12a), and flows
from HSS motor inet port MA to HSS motor outlet port MB.
However, the outlet port side of the HSS motor is
closed by check valve (12b) and spool (10), so
the pressure at the side where the oil is being
supplied rises.
10-65
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
•
•
The pressurized oil at the side where the oil is
being supplied flows from orifice E1 of spool (10)
into chamber S1. And when the pressure in
chamber S1 bcomes greater than the spool
switching pressure, spool (10) is pushed to the
right.
In this way, port MB and port PB are connected,
so the outlet port side of the HSS motor is
opened and the HSS motor starts to turn.
HSS MOTOR
Action of brakes when oprating steering on
downhill slopes
•
•
•
•
10-66
When the steering is operated on a down hill
slopes, if the machine attempts to run away, the
HSS motor will rotate under no load, and the oil
pressure at the inlet port of the HSS motor will
drop. This drop in pressure will pass through orifice E1, so the pressure in chamber S1 will also
drop.
If the pressure in chamber S1 drops below the
spool switching pressure, spool (10) is pushed to
the left by spring (9), and outlet port MB is throttled.
As a result, the pressure at the outlet port rises,
and this creates a resistance to the rotation of
the HSS motor which prevents the motor from
overrunning.
In other words, the spool moves to a position
where it balances the pressure at outlet port MB
with the force resulting from the weight of the
machine and the pressure at the inlet port.
In this way, it throttles the outlet port circuit and
controls the motor to a speed that matches the
amount of oil discharged from the pump.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HSS MOTOR
2. Safety valve
Function
•
•
•
When the operation of the steering stops, counterbalance valve (10) closes the circuit at the inlet and outlet ports of the HSS motor.
But the HSS motor continues to turn because of
inertia. As a result, the pressure at the outlet port
of the HSS motor becomes extremely high, and
this will damage the HSS motor and the piping.
The safety valve acts to release this abnormal
pressure to the inlet port of the HSS motor to
protect the equipment from damage.
•
If the pressure in chamber E (or chamber F)
goes above the set pressure, the force of /4
(D12 – D22) x pressure resulting from the difference in area of D1 and D2 (or the force of /4
(D32 – D12) x pressure resulting from the difference in area of D3 and D1) becomes greater
than the force of the spring and moves the poppet to the right. The oil then flows to chamber F
(or chamber E) in the circuit on the opposite side.
Operation
•
When the operation of the steering is stopped,
the check valve of the counterbalance valve closes chamber E (or chamber F) in the outlet port
circuit, but the pressure at the outlet port side
continues to rise because of inertia.
D65EX, PX-15
10-67
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
BEVEL GEAR SHAFT, HSS, BRAKE
a HSS: Abbreviation for Hydrostatic Steering System
10-68
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
D65EX, PX-15
BEVEL GEAR SHAFT, HSS, BRAKE
10-69
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
10-70
BEVEL GEAR SHAFT, HSS, BRAKE
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
1. Brake valve
2. HSS motor
3. Output shaft
4. Brake spring (Large)
5. Brake spring (Small)
6. Spacer
7. Hub
8. Cage
9. Piston
10. Cover
11. Plate (4 pieces on 1 side)
12. Disc (5 pieces on 1 side)
13. Brake drum
14. Brake hub
15. Gear A (Number of teeth: 38/55
16. Cage
17. Gear B (Number of teeth: 32)
18. Bevel gear shaft
19. Bevel gear (Number of teeth: 35)
20. Bearing
21. Shaft
22. Gear C (Number of teeth: 32)
23. Planetary pinion (Number of teeth: 26)
24. Ring gear (Number of teeth: 91)
25. Pinion shaft
26. Hub
27. Carrier
28. Gear D shaft
29. Gear D (Number of teeth: 48)
30. HSS motor drive gear (Number of teeth: 25)
31. Bevel pinion (Number of teeth: 23)
32. Cage
D65EX, PX-15
10-71
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
10-72
BEVEL GEAR SHAFT, HSS, BRAKE
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
Thickness
5.0
±0.1
4.7
Distortion
—
Max. 0.15
0.3
Repair or replace
Thickness
5.2
±0.1
4.7
Replace
Distortion
—
Max. 0.25
0.4
Repair or replace
Total thickness of assembled 4 brake
plates and 5 discs
46.0
±0.3
43.3
1 Brake plate
Replace
2 Brake disc
3
4 Backlash between gear A and gear B
Backlash between gear A and
5
planetary pinion
6
Backlash between planetary pinion
and ring gear
7
Preload on bevel gear shaft tapered
roller bearing
D65EX, PX-15
Standard clearance
Clearance limit
0.06 – 0.65
—
0.14 – 0.35
—
0.15 – 0.38
—
If starting torque is below 9.8 Nm {1.0 kgm}, adjust preload.
After adjustment, starting torque must be 10.3 – 14.7 Nm {1.05 – 1.50 kgm}.
Replace
Adjust
10-73
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
10-74
BEVEL GEAR SHAFT, HSS, BRAKE
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.09 – 0.64
—
Backlash between gear C and
gear D
0.15 – 0.49
—
3
Backlash between gear D and
HSS motor drive gear
0.10 – 0.40
—
4
Backlash between bevel pinion
and bevel gear
0.20 – 0.28
—
1
Backlash between gear A and
gear D
2
D65EX, PX-15
Replace
Adjust
10-75
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
Outline
Bevel gear shaft
Brake
•
•
•
•
The engine power is transmitted through the
torque converter to the transmission. Then, the
bevel gear shaft device engages bevel pinion
(31) with bevel gear (19) to turn the engine power at right angles into the lateral direction and reduce the revolving speed.
Bevel pinion (31) and bevel gear (19) of the bevel
gear shaft device are spiral bevel gears, which
area lubricated with oil splashed by the lubricating oil pump and scavenging pump.
The bevel gear shaft device consists of bevel
gear (19) meshed with bevel pinion (31), bevel
gear shaft (18), bearing (20) to support the bevel
gear shaft, and bevel gear shaft cage (16).
•
•
•
HSS
•
•
•
•
•
The HSS consists of the transfer unit to reverse
the revolution direction of HSS motor (2) and
transmit it to gear A (15) and the planetary gear
unit to increase or decrease the input for ring
gear (24) and gear A (15) and output it to carrier
(27).
The turning direction of the machine is changed
by stopping or changing the revolution direction
of HSS motor (2).
The transfer unit employs a spur gear speed reduction mechanism and is lubricated with oil
splashed by the scavenging pump and lubricating oil pump.
The planetary gear unit is lubricated forcedly
with oil supplied by the scavenging pump and lubricating oil pump.
The transfer unit consists of HSS motor drive
gear (30) connected to HSS motor (2) by spline,
gear D (29) meshed with the HSS motor drive
gear, gear C (22) meshed with gear D, gear B
(17) connected to shaft (21), gear A (15) supported by the bearing on the bevel gear shaft,
gear A (15) meshed with gear D (29), and cover
to support these parts.
The planetary gear unit consists of gear A (15),
planetary pinion (23), planetary shaft (25), hub
(26) connected to the bevel gear shaft and ring
gear (24) by spline, and carrier (27) connected to
brake hub (14).
10-76
•
The brake is installed to brake the machine and
connected to brake hub (14).
The brake is a wet-type, multiple disc clutchtype, spring-boosted brake. It is driven hydraulically by the brake valve operated with brake pedal.
The brake is lubricated forcedly with oil supplied
by the lubricating oil pump and scavenging
pump. The lubricating oil flows through the paths
in the steering case, cover (10), cage (8), disc
(12), and plate (11).
While the engine is stopped, even if the brake
pedal is not pressed, the back pressure of the
brake piston lowers and the brake is “applied”.
After the engine is started again, however, as the
hydraulic pressure in the circuit rises, the brake
is “released”. Accordingly, the parking brake
must be kept locked.
The brake consists of carrier (27), brake hub (14)
connected to hub (7), disc (12) meshed with the
brake hub, plate (11), the periphery of which is
connected to brake drum (13) by spline, piston
(9) and springs (4) and (5) to press the disc and
plate against each other, and cage (8), cover
(10), and output shaft (3) to support these parts.
Brake drum (13) and cover (10) are fixed to the
steering case.
Output shaft (3) is connected to hub (7) by spline
and fixed by spacer (6) in the axial direction.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
Operation of HSS
When steering lever is in neutral (Straight travel)
•
•
•
•
While the PCCS lever is in neutral, HSS motor
(1) is stopped and gears A (2) of the transfer unit
and planetary gear unit do not rotate.
Under this condition, the power from bevel gear
shaft (3) is transmitted through hub (4) to ring
gear (5).
The power transmitted to ring gear (5) is further
transmitted through planetary pinion (6) and
planetary pinion shaft (7) to carrier (8).
The power transmitted to carrier (8) is further
transmitted through brake hub (9) and hub (10)
to output shaft (11).
•
Accordingly, the output speeds on both sides are
the same and the machine travels straight.
Rotation direction of HSS motor
Steering operation of
PCCS lever
Neutral
Direction changing
operation of PCCS
lever
Any
Turning direction of
HSS motor seen from
left of chassis
Stopped
Turning to right
Neutral
Left
Forward Reverse
Left
Right
Turning to left
Neutral
Right
Forward Reverse
Right
Left
: Pivot turn
D65EX, PX-15
10-77
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
When steering lever is operated to right (Forward)
A: Transmission power
B: HSS motor power
C:Combined power
•
•
1: Transmission output speed
2: HSS motor output speed
3: Left bevel gear shaft output speed ( 1 + 2)
4: Right bevel gear shaft output speed ( 1 – 2)
•
If the steering lever is operated to the right while
the machine is traveling forward, HSS motor (1)
rotates counterclockwise as seen from the left
side of the machine. At the same time, left gear
A (2) rotates clockwise and right gear A (2) rotates counterclockwise.
10-78
Bevel gear shaft (1) and ring gear (5) connected
to rotate clockwise as seen from the left side of
the machine.
Accordingly, because of the difference in the rotating speed between both planetary gear units,
the rotating speed of left carrier (8) is higher than
when traveling straight forward by the amount of
the power of HSS motor. On the other hand, the
rotating speed of right carrier (8) is lower than
when traveling straight forward. As a result, the
machine travels forward and turns to the right,
where the output speed is lower.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
When steering lever is operated to right (Reverse)
A: Transmission power
B: HSS motor power
C:Combined power
•
•
1: Transmission output speed
2: HSS motor output speed
3: Left bevel gear shaft output speed ( 1 + 2)
4: Right bevel gear shaft output speed ( 1 – 2)
•
If the steering lever is operated to the right while
the machine is traveling in reverse, HSS motor
(1) rotates clockwise as seen from the left side of
the machine. At the same time, left gear A (2) rotates counterclockwise and right gear A (2) rotates clockwise.
D65EX, PX-15
Bevel gear shaft (1) and ring gear (5) connected
to rotate counterclockwise as seen from the left
side of the machine.
Accordingly, because of the difference in the rotating speed between both planetary gear units,
the rotating speed of left carrier (8) is higher than
when traveling straight in reverse by the amount
of the power of HSS motor. On the other hand,
the rotating speed of right carrier (8) is lower
than when traveling straight in reverse. As a result, the machine travels in reverse and turns to
the right, where the output speed is lower.
10-79
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
When steering lever is operated to left (Forward)
A: Transmission power
B: HSS motor power
C:Combined power
•
•
1: Transmission output speed
2: HSS motor output speed
3: Left bevel gear shaft output speed ( 1 – 2)
4: Right bevel gear shaft output speed ( 1 + 2)
•
If the steering lever is operated to the left while
the machine is traveling forward, HSS motor (1)
rotates clockwise as seen from the left side of
the machine. At the same time, left gear A (2) rotates counterclockwise and right gear A (2) rotates clockwise.
10-80
Bevel gear shaft (1) and ring gear (5) connected
to rotate clockwise as seen from the left side of
the machine.
Accordingly, because of the difference in the rotating speed between both planetary gear units,
the rotating speed of right carrier (8) is higher
than when traveling straight forward by the
amount of the power of HSS motor. On the other
hand, the rotating speed of left carrier (8) is lower
than when traveling straight forward. As a result,
the machine travels forward and turns to the left,
where the output speed is lower.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
When steering lever is operated to left (Reverse)
A: Transmission power
B: HSS motor power
C:Combined power
•
•
1: Transmission output speed
2: HSS motor output speed
3: Left bevel gear shaft output speed ( 1 – 2)
4: Right bevel gear shaft output speed ( 1 + 2)
•
If the steering lever is operated to the left while
the machine is traveling in reverse, HSS motor
(1) rotates counterclockwise as seen from the
left side of the machine. At the same time, left
gear A (2) rotates clockwise and right gear A (2)
rotates counterclockwise.
D65EX, PX-15
Bevel gear shaft (1) and ring gear (5) connected
to rotate counterclockwise as seen from the left
side of the machine.
Accordingly, because of the difference in the rotating speed between both planetary gear units,
the rotating speed of right carrier (8) is higher
than when traveling straight in reverse by the
amount of the power of HSS motor. On the other
hand, the rotating speed of left carrier (8) is lower
than when traveling straight in reverse. As a result, the machine travels in reverse and turns to
the left, where the output speed is lower.
10-81
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BEVEL GEAR SHAFT, HSS, BRAKE
Operation of brake
When brake is released
When brake is applied
(When brake pedal is depressed)
•
•
•
•
While the brake pedal is released, the brake
valve is in the neutral position and oil enters the
back-pressure port of piston (1).
As the oil pressure rises, piston (1) compresses
springs (2) and (3) to the left to release discs (4)
and plates (5).
The power transmitted from the bevel gear shaft
through the HSS to brake hub (7) is further transmitted through hub (8) and output shaft (9) to the
final drive.
•
•
•
10-82
If the brake pedal is depressed, the brake valve
switches and the oil in the back-pressure port of
piston (1) is drained.
As the pressure in the back-pressure port lowers, piston (1) is moved to the right by the tension
of springs (2) and (3) to press discs (4) and
plates (5) against brake drum (6). Brake drum (6)
is connected and fixed to the steering case.
The power of brake hub (7), or the power to output shaft (9), is restricted since discs (4) and
plates (5) are pressed together.
The hydraulic force applied to piston (1), or the
braking force, can be controlled by controlling
the depressing distance of the brake pedal.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BRAKE VALVE
BRAKE VALVE
P:
From power train pump
T1:
To steering case
T2:
To steering case
Br (R): To right brake
Br (L): To left brake
1.
2.
3.
4.
5.
6.
Parking brake valve
Body
Main brake valve
Piston
Shaft
Guide
D65EX, PX-15
Outline
•
•
•
•
The brake valve is in the circuit between the power train pump and the brake piston in the HSS
unit and installed to the top of the HSS unit.
If the brake pedal is depressed, main brake valve
(3) operates. If the parking brake lever is set in
the LOCK position, the parking brake valve operates.
If each valve operates, the oil flowing in the backpressure port of the brake piston is shut off and
the brake is applied.
In the case of the HSS, since the brakes are
used only for braking (the brakes have no connection with the steering control), the right and
left brakes are applied simultaneously.
10-83
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BRAKE VALVE
Unit: mm
No.
Check item
Clearance between brake valve
1
and body
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
19
–0.020
–0.030
+0.013
0
0.020 –
0.043
0.07
Standard
size
2
Clearance between brake valve
and piston
9
–0.030
–0.040
+0.015
0
0.030 –
0.055
0.08
3
Clearance between parking
brake valve and body
19
–0.034
–0.043
+0.013
0
0.034 –
0.056
0.08
Standard size
4 Brake modulating spring
Free length Installed length
Repair limit
Installed load
Free length
Installed load
48
36
75.3 N
{7.68 kg}
46.6
71.6 N
{7.3 kg}
5 Brake valve return spring
52
38
157.9 N
{16.11 kg}
50.4
150 N
{15.3 kg}
6 Parking brake valve return spring
36.5
28.5
16.7 N
{1.7 kg}
35.4
15.7 N
{1.6 kg}
10-84
Replace
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BRAKE VALVE
Operation
When brake is released (When brake pedal is released and parking brake lever in FREE position)
•
•
•
•
•
While the brake pedal is released (While it is not
depressed), parking brake valve (1) opens port P
and chamber A with the tension of return spring
(2).
Main brake valve (3) opens chamber B and port
Br with the tension of return spring (4).
The pressure of the oil from the power train
pump is regulated by the main relief valve, and
then the oil flows through port P, chambers A and
B, and port Br to the back-pressure port of the
brake piston.
The brake piston moves to the left and compresses the brake spring to release the brake.
At this time, the oil pressure is kept at 2.84 MPa
{29.0 kg/cm2} and can be measured at oil pressure pickup port Q.
D65EX, PX-15
10-85
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BRAKE VALVE
When brake is applied (When brake pedal is depressed and parking brake lever in FREE position)
•
•
•
•
•
•
If the brake pedal is depressed, guide (5) and
shaft (6) are pushed to the right.
As shaft (6) is pushed, it compresses modulating
spring (7) and its reaction force moves main
brake valve (3) to the right. As a result, ports Br
and chamber B are disconnected and ports Br
and T2 are connected.
The oil from the power train pump flows through
port P to chamber A and stops at chamber B.
A part of the oil which has flowed in the backpressure port of the brake piston is drained
through port T2. The other part flows through orifice a to chamber D.
If the oil after port Br is drained through port T2
and its pressure lowers, it enters chamber D and
pushes piston (8). Then, the force which has
pushed main brake valve (3) to the right is reduced and main brake valve (3) is moved to the
left by the tension of return spring (4).
If main brake valve (3) is moved to the left, ports
Br and T2 are disconnected so that the oil pressure after port Br will not lower.
10-86
•
•
•
If the brake pedal is pressed further, the above
operation is repeated. If main brake valve (3) is
moved to the stroke end, the brake is turned applied perfectly.
The oil pressure after port Br is decided by the
tension of return spring (6), the load on which
changes according to the stroke of the brake
pedal.
Accordingly, if the stroke of the brake pedal is
short, the oil pressure after port Br is high and
the brake is “half applied”. If the stroke is long,
the oil pressure is low and the brake is “applied”.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
BRAKE VALVE
When parking brake is applied (When brake pedal is released and brake lock lever is at LOCK position)
•
•
•
•
•
If the parking brake lever is set in the LOCK position, parking brake valve (1) is pulled to the left.
Then, ports P and A are disconnected and ports
A and C are connected.
The oil from the power train pump is stopped at
port P.
The oil which has flowed in the back-pressure
port of the brake piston is drained through port
Br, chambers B, A, and C, and port T1.
Since parking brake valve (1) is kept pulled to the
left, the oil pressure in the back-pressure port of
the brake piston continues lowering. As a result,
the brake is kept “applied”.
This condition is maintained even after the engine is started again.
D65EX, PX-15
10-87
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
FINAL DRIVE
FINAL DRIVE
Outline
•
•
•
•
The final drive is a single stage spur gear, single
stage planetary gear reduction type.
The lubrication is of splash type using the rotation of the gears.
The final drive can be removed and installed as
a single unit.
Floating seal (1) is installed to the rotating sliding
portion of the sprocket to prevent the entry of dirt
or sand and to prevent leakage of lubricating oil.
10-88
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
FINAL DRIVE
a The following drawing shows D65EX-15.
1.
2.
3.
4.
5.
6.
7.
8.
Pinion (Number of teeth: 13)
Carrier
Ring gear (Number of teeth: 68)
Floating seal
Cover
1st pinion cover
Final drive case
Bearing cage
D65EX, PX-15
9. 1st pinion (Number of teeth: 21)
10. 1st pinion (Number of teeth: 78)
11. Sprocket hub
12. Sprocket teeth
13. Hub
14. Planetary pinion (Number of teeth: 27)
15. Pinion shaft
10-89
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
FINAL DRIVE
a The following drawing shows D65EX-15.
10-90
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
FINAL DRIVE
Unit: mm
No.
Check item
Criteria
1
Backlash between 1st pinion and
1st gear
2
Remedy
Standard clearance
Clearance limit
0.23 – 0.61
1.0
Backlash between pinion and
planetary pinion
0.18 – 0.45
1.0
3
Backlash between planetary
pinion and ring gear
0.23 – 0.67
1.0
4
Outside diameter of oil seal contact surface of 1st pinion (Large)
5
Outside diameter of oil seal contact surface of 1st pinion (Small)
Interference between pinion shaft
6
and carrier
Standard size
Tolerance
Repair limit
80
0
–0.074
79.9
70
0
–0.074
69.9
Standard
size
56
Tolerance
Shaft
Hole
Standard
interference
Interference
limit
+0.051
+0.032
+0.030
0
0.002 –
0.051
0.002
7
Axial clearance of 1st pinion
bearing
0 – 0.1
8
Standard shim thickness of 1st
pinion bearing cage
1.5
9
Projection of ball from 1st pinion
cover
Wear of sprocket
10
tooth surface
D65EX, PX-15
Replace
Adjust
Standard size
Repair limit
5.2
1.5
Standard
bushing type
317
299
Rotary
bushing type
317
301
Replace
Repair by buildup welding or
replace
10-91
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
FINAL DRIVE
Power train route
a The following drawing shows D65EX-15.
•
•
•
The power from the HSS unit is transmitted to 1st
pinion (1), and then transmitted through 1st gear
(2) and pinion (3) to planetary pinion (4).
Planetary pinion (4) is meshed with ring gear (5).
Cover (6) and ring gear (5) are connected by hub
(7). Accordingly, planetary pinion (4) rotates on
its axis, revolving pinion (3) along ring gear (5).
10-92
•
•
The power transmitted to pinion (3) is transmitted to sprocket hub (9) as a force to rotate carrier
(8) which supports planetary pinion (4). The rotation direction of carrier (8) is the same as that
of pinion (3).
The rotation force transmitted sprocket hub (9) is
transmitted to sprocket teeth (10).
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
FRAME ASSEMBLY
FRAME ASSEMBLY
D65EX, PX-15
10-93
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
FRAME ASSEMBLY
Unit: mm
No.
Check item
Clearance between cylinder yoke
1
and bushing (Large)
2
3.
4.
5.
6.
Clearance between cylinder yoke
and bushing (Small)
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
85
–0.036
–0.090
+0.207
+0.120
0.156 –
0.297
0.5
65
–0.030
–0.076
+0.174
+0.100
0.130 –
0.250
0.5
Standard
size
Replace bushing
Frame assembly
Undercover
Engine mount
Power train unit mount
Outline
•
Frame assembly (3) has a hull frame structure,
on which the radiator guard, main frame, steering case, and transmission guard are assembled
into 1 unit.
10-94
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SUSPENSION
SUSPENSION
D65EX-15
D65EX-15 (Long track specification)
D65EX, PX-15
10-95
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1. Equalizer bar
2. Center pin
3. Side pin
4. Pivot shaft
5. Bushing
6. Seal
7. Seal
8. Bushing
9. Bushing (Large)
10. Plug (Oil filler)
11. Bushing (Small)
12. Cover
13. Seal
10-96
(7)
SUSPENSION
Outline
•
•
The track frame moves the front part of the track
frame up and down around pivot shaft (4) in its
rear.
Equalizer bar (1) rocks around center pin (2) and
is connected to both track frames by side pin (3).
D65EX-15
D65EX-15
(Long track specification)
Displacement at
center of equalizer
bar side pin (mm)
Upward
72.6
Downward
72.6
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SUSPENSION
Unit: mm
No.
Check item
Clearance between pivot shaft
14
and bushing (Large)
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
148
–0.045
–0.208
+0.063
0
0.145 –
0.271
1.0
15
Clearance between pivot shaft
and bushing (Small)
105
–0.120
–0.174
+0.054
0
0.120 –
0.228
1.0
16
Clearance between center pin
and bushing
70
–0.100
–0.146
+0.174
+0.100
0.200 –
0.320
0.5
17
Clearance between side pin and
bushing
60
–0.100
–0.146
+0.010
–0.020
0.080 –
0.156
0.5
18
Press fitting force of pivot shaft
bushing (Large)
0.98 – 22.6 kN {0.1 – 2.3 ton}
19
Press fitting force of pivot shaft
bushing (Small)
0.98 – 36.3 kN {0.1 – 3.7 ton}
—
Quantity of oil in pivot shaft
section
D65EX, PX-15
Replace bushing
—
4.5 l (Engine oil: SAE30)
10-97
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SUSPENSION
D65PX-15
D65EX-15 (Wide gauge specification)
D65WX-15
10-98
(7)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1. Equalizer bar
2. Center pin
3. Side pin
4. Pivot shaft
5. Bushing
6. Seal
7. Seal
8. Bushing
9. Bushing (Large)
10. Plug (Oil filler)
11. Bushing (Small)
12. Cover
13. Seal
D65EX, PX-15
SUSPENSION
Outline
•
•
The track frame moves the front part of the track
frame up and down around pivot shaft (4) in its
rear.
Equalizer bar (1) rocks around center pin (2) and
is connected to both track frames by side pin (3).
D65PX-15
D65EX-15
(Wide gauge specification)
D65WX-15
Displacement at
center of equalizer
bar side pin (mm)
Upward
81.9
Downward
81.9
10-99
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SUSPENSION
Unit: mm
No.
Check item
Clearance between pivot shaft
14
and bushing (Large)
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
148
–0.045
–0.208
+0.063
0
0.145 –
0.271
1.0
15
Clearance between pivot shaft
and bushing (Small)
105
–0.120
–0.174
+0.054
0
0.120 –
0.228
1.0
16
Clearance between center pin
and bushing
70
–0.100
–0.146
+0.174
+0.100
0.200 –
0.320
0.5
17
Clearance between side pin and
bushing
60
–0.100
–0.146
+0.010
–0.020
0.080 –
0.156
0.5
18
Press fitting force of pivot shaft
bushing (Large)
0.98 – 22.6 kN {0.1 – 2.3 ton}
19
Press fitting force of pivot shaft
bushing (Small)
0.98 – 36.3 kN {0.1 – 3.7 ton}
—
Quantity of oil in pivot shaft
section
10-100
Replace bushing
—
4.5 l (Engine oil: SAE30)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRACK FRAME, RECOIL SPRING
TRACK FRAME, RECOIL SPRING
D65EX-15
D65EX-15 (Wide gauge specification)
D65WX-15
1.
2.
3.
4.
5.
6.
7.
8.
9.
Idler
Carrier roller
Track frame
Sprocket teeth
Track roller guard
Track roller
Yoke
Seal
Piston
D65EX, PX-15
10. Recoil spring
11. Wear ring
12. U-packing
13. Cabin
14. Nut
15. Lubricator
16. Cylinder
17. Bushing
18. Holder
10-101
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRACK FRAME, RECOIL SPRING
Unit: mm
No.
Check item
Criteria
19 Deformation of track frame
Item
Repair limit
Bend
Twist
Opening of idler
7 (in length of 3,000)
3 (in length of 300)
5
Standard size
Repair limit
Free length x
Outside diameter
20 Recoil spring
Installed length
Installed load
634
189.5 kN
{19,320 kg}
791.5 x 239
Clearance between piston and
21
bushing
Remedy
Standard
size
90
Free length
Installed load
772
168.6 kN
{17,195 kg}
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
–0.039
–0.090
+0.270
+0.061
0.100 –
0.360
1.0
22 Press fitting force of idler yoke
— Quantity of grease
Repair
Replace
Replace bushing
392 kN {40 ton}
Adjust
140 cc (Grease: G2-LI)
—
Outline
•
Recoil spring (10) is used to adjust the track
shoe tension by supplying grease through lubricator (15) or discharge existing grease and moving piston (9) forward or in reverse. It also damps
sudden shocks applied to idler (1).
D65EX-15
D65EX-15
(Wide gauge specification)
D65WX-15
Q’ty on
each side
Flange type and arrangement
7 pcs.
S, S, D, S, D, S, S
S: Single flange
W: Double flange
10-102
(7)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRACK FRAME, RECOIL SPRING
D65PX-15
D65EX-15 (Long track specification)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Idler
Carrier roller
Track frame
Sprocket teeth
Track roller guard
Track roller
Yoke
Seal
Piston
D65EX, PX-15
10. Recoil spring
11. Wear ring
12. U-packing
13. Cabin
14. Nut
15. Lubricator
16. Cylinder
17. Bushing
18. Holder
10-103
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRACK FRAME, RECOIL SPRING
Unit: mm
No.
Check item
Criteria
19 Deformation of track frame
Item
Repair limit
Bend
Twist
Opening of idler
7 (in length of 3,000)
3 (in length of 300)
5
Standard size
Repair limit
Free length x
Outside diameter
20 Recoil spring
Installed length
Installed load
634
189.5 kN
{19,320 kg}
791.5 x 239
Clearance between piston and
21
bushing
Remedy
Standard
size
90
Free length
Installed load
772
168.6 kN
{17,195 kg}
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
–0.039
–0.090
+0.270
+0.061
0.100 –
0.360
1.0
22 Press fitting force of idler yoke
— Quantity of grease
Repair
Replace
Replace bushing
392 kN {40 ton}
Adjust
140 cc (Grease: G2-LI)
—
Outline
•
Recoil spring (10) is used to adjust the track
shoe tension by supplying grease through lubricator (15) or discharge existing grease and moving piston (9) forward or in reverse. It also damps
sudden shocks applied to idler (1).
Q’ty on
each side
Flange type and arrangement
8 pcs.
S, S, D, S, S, D, S, S
D65PX-15
D65EX-15
(Long track
specification)
S: Single flange
W: Double flange
10-104
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
IDLER
IDLER
D65EX, PX-15
10-105
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
IDLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
630
—
2 Outside diameter of tread
590
570
3 Depth of tread
20
30
4 Thickness of tread
15
5
5 Width of tread
44.5
48.5
6 Overall width
190
—
1 Outside diameter of projection
Clearance between shaft and
7
bushing
8
Clearance between shaft and
support
9 Axial play of shaft
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
65
–0.250
–0.350
+0.142
–0.008
0.242 –
0.492
—
64.7
–0.250
–0.350
+0.090
0
0.250 –
0.440
—
Standard
size
Standard clearance
Clearance limit
0.26 – 0.66
—
10
Clearance between guide plate
and support
2.0
—
11
Clearance between guide plate
and side plate
1.0
—
Standard shim thickness at side
12
plate fitting part
10-106
Repair by buildup welding or
replace
4.0
Replace
Repair by buildup welding or
replace
Adjust shim or
replace plate
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRACK ROLLER
TRACK ROLLER
a The following drawing shows the double-flange type.
Unit: mm
No.
Check item
1
Outside diameter of flange
(outside)
2
Outside diameter of flange
(inside)
Criteria
Remedy
Standard size
Repair limit
240
—
236
—
3 Outside diameter of tread
210
174
4 Thickness of tread
69
51
5 Width of flange (outside)
19.5
13.5
6 Width of flange (inside)
19.5
13.5
7
Width of tread
(Single-flange type)
47
—
8
Width of tread
(Double-flange type)
47.7
—
235
—
9 Overall width
Clearance between shaft and
10
bushing
11
Clearance between shaft and
collar
12 Axial play of roller
D65EX, PX-15
Tolerance
Repair by buildup welding or
replace
Shaft
Hole
Standard
clearance
Clearance
limit
65
–0.250
–0.350
+0.143
–0.007
0.243 –
0.493
—
64.7
–0.250
–0.350
–0.100
–0.150
0.100 –
0.250
—
Standard
size
Standard clearance
Clearance limit
0.26 – 0.66
—
Replace
10-107
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CARRIER ROLLER
CARRIER ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
215
—
2 Outside diameter of tread
185
163
3 Thickness of tread
37.5
26.5
4 Width of tread
49.5
55.5
5 Width of flange
21
15
1 Outside diameter of flange
Clearance between shaft and
6
support
Standard
size
61
Interference between shaft and
7
seal guard
Standard
size
61.5
8 Play in axial direction of shaft
10-108
Tolerance
Rebuild or
replace
Shaft
Hole
Standard
clearance
Clearance
limit
–0.100
–0.200
+0.300
0
0.100 –
0.500
—
Tolerance
Shaft
Hole
Standard
interference
Interference
limit
+0.150
+0.130
+0.030
0
0.100 –
0.150
—
Standard clearance
Clearance limit
0 – 0.22
—
Replace
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SPROCKET
SPROCKET
Unit: mm
No.
Check item
1 Wear of tooth root
2 Thickness of tooth root
D65EX, PX-15
Criteria
Remedy
Standard size
Repair limit
87
77
26
17
Rebuild or
replace
10-109
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SPROCKET
Full-scale drawing of sprocket tooth profile
a Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
10-110
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRACK SHOE
TRACK SHOE
*1. Single shoe
*2. Swamp shoe
a Part P is the link on the bushing fitting side.
D65EX, PX-15
10-113
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRACK SHOE
Unit: mm
No.
Check item
Criteria
1 Link pitch
Standard size
Repair limit
203.45
206.45
Turning over
Standard size
Light load
Heavy load
73
62.8
65.4
13.9
3.7
6.3
2 Outside diameter of bushing
3 Thickness of bushing
4 Height of link
5
Thickness of link
(Bushing fitting part)
a.
Regular
link
6 Shoe bolt
b.
Master
link
Interference between bushing
7
and link
8
Interference between regular pin
and link
Interference between regular pin
9
and bushing
10-114
Remedy
Turn over or
replace
Standard size
Repair limit
132
119.5
Repair or
replace
44.8
32.3
Replace
Tightening torque
(Nm {kgm})
Retightening angle
(deg.)
539 ± 49 {55 ± 5}
120 ± 10
Tightening torque
(Nm {kgm})
Retightening angle
(deg.)
Lower limit of torque
(Nm {kgm})
343 ± 39
{35 ± 4}
180 (0/–20)
784 {80}
Standard size
Tolerance
Standard
interference
Shaft
Hole
66.5
+0.404
+0.304
+0.074
0
0.230 – 0.404
44.4
+0.435
+0.285
+0.086
+0.024
0.199 – 0.411
Standard size
44.6
Tolerance
Shaft
Hole
+0.235
+0.085
+0.915
+0.415
Retighten
Adjust or
replace
Standard
clearance
0.180 – 0.830
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRACK SHOE
Single shoe
Unit: mm
No.
Check item
1 Height of grouser
2 Thickness of grouser
Criteria
Remedy
Standard size
Repair limit
65
25
77
37
Repair by buildup welding or
replace
Swamp shoe
Unit: mm
No.
Check item
1 Height of grouser
2 Thickness of grouser
D65EX, PX-15
Criteria
Remedy
Standard size
Repair limit
109.5
94.5
20
5
Repair by buildup welding or
replace
10-117
(5)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
10-118
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
1. Cooling fan motor
2. Quick drop valve
3. Tilt cylinder (PT, SEMI-U dozer)
Pitch cylinder (PTP dozer)
4. Lift cylinder
5. Radiator
6. Self-reducing pressure valve
7. HSS pump
8. Cooling fan pump
9. PPC lock valve
10. Power train oil filter
11. Control valve
12. Hydraulic tank
13. HSS motor
14. Transmission ECMV
15. Main relief valve
16. Blade PPC valve
17. Power train and lubricating oil pump
18. Accumulator
19. Tilt cylinder (PTP dozer)
20. Scavenging pump
D65EX, PX-15
10-119
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL
10-120
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
6.
WORK EQUIPMENT CONTROL
Work equipment lock lever
Blade PPC valve
Blade control lever
Ripper control lever (D65EX-15: If equipped)
Ripper PPC valve (D65EX-15: If equipped)
PPC lock valve
Outline
•
•
•
•
The work equipment control system is a PPC
system, which moves each spool of the control
valves through blade control lever (3) and blade
PPC valve (2) and through ripper control lever
(4) and ripper PPC valve (5).
If work equipment lock lever (1) is set in the
LOCK position, it is connected to PPC lock valve
(6) and the operator can move blade control lever (3) and ripper control lever (4) but cannot operate the work equipment.
If blade control lever (3) is set in the FLOAT position, the hydraulic detent of blade PPC valve
(2) works so that blade control lever (3) will hold
itself.
If work equipment lock lever (1) is set in the
LOCK position, the hydraulic detent is reset and
blade control lever (3) returns to the HOLD position automatically.
While the engine is stopped, the hydraulic detent
does not work even, if blade control lever (3) is
in the FLOAT position, and blade control lever
(3) returns to the HOLD position automatically.
D65EX, PX-15
10-121
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC TANK
HYDRAULIC TANK
10-122
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
6.
7.
HYDRAULIC TANK
Oil filler cap
Hydraulic tank
Element
Bypass valve
Strainer
Drain plug
Sight gauge
Specifications
Tank capacity (l)
80
Quantity of oil in tank (l)
55
Set pressure of bypass valve
(MPa {kg/cm2})
Cracking pressure of pressure valve
(kPa {kg/cm2})
Actuating pressure of vacuum valve
(kPa {kg/cm2})
0.15 ± 0.03
{1.5 ± 0.3}
38 ± 14
{0.39 ± 0.15}
0 – 4.5
{0 – 0.046}
D65EX, PX-15
10-123
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ACCUMULATOR
ACCUMULATOR
For PPC valve
1.
2.
3.
4.
5.
6.
Glass plug
Shell
Poppet
Holder
Bladder
Oil port
Outline
•
The accumulator is installed between the fan
pump and blade PPC valve. Even if the engine
stopped with the work equipment raised, the operator can send the pilot oil pressure to the control valve to have the work equipment lower with
its own weight by using the nitrogen gas pressure in the accumulator.
Specifications
Gas used:
Nitrogen gas
Quantity of gas:
300 cc
Charged gas pressure: 1.18 MPa {12 kg/cm2} (at 80ºC)
Max. using pressure: 6.86 MPa {70 kg/cm2}
10-124
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC LOCK VALVE
PPC LOCK VALVE
a PPC: Abbreviation for Proportional Pressure Control
1.
2.
3.
4.
5.
Lever
End cap
Ball
Seat
Body
Outline
•
D65EX, PX-15
The PPC lock valve is installed between the fan
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 operate the
work equipment.
10-125
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BLADE LIFT CYLINDER
D65EX-15
D65EX-15 (Wide gauge specification)
D65WX-15
BLADE LIFT CYLINDER
D65PX-15
D65EX-15 (Long track specification)
BLADE TILT CYLINDER
BLADE PITCH CYLINDER
*1. D65EX-15 (Serial No. : 67001- 67431)
D65PX-15 (Serial No. : 67001- 67401)
10-126
(7)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
RIPPER LIFT CYLINDER
D65EX-15
D65WX-15
*1. D65EX-15 (Serial No. : 67001- 67322)
Unit: mm
No.
Check item
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
65
–0.030
–0.104
+0.262
+0.067
0.097 –
0.366
0.666
Tilt
Pitch
70
–0.025
–0.064
+0.271
+0.075
0.105 –
0.375
0.675
Ripper
70
–0.025
–0.087
+0.271
+0.075
0.105 –
0.375
0.675
Spherical clearance between
piston rod and trunnion
Lift
S 85
–0.2
–0.3
+0.3
0
0.2 – 0.5
1.0
Spherical clearance between
2
piston rod and bracket
Tilt
Pitch
S 90 (Shaft)
S 91 (Hole)
–0.1
–0.3
+1.0
0
0.2 – 0.5
2.0
Clearance between piston rod
support shaft and bushing
Ripper
75
–0.030
–0.076
+0.174
+0.100
0.130 –
0.250
1.0
Clearance between cylinder
boss and bushing
Lift
55
–0.100
–0.174
+0.116
0
0.100 –
0.290
1.0
Tilt
Pitch
50
–0.200
–0.400
+0.142
+0.080
0.280 –
0.542
1.0
Ripper
75
–0.030
–0.076
+0.174
+0.100
0.130 –
0.250
1.0
Clearance between piston rod
1
and bushing
3 Clearance between cylinder
bottom support shaft and
bushing
Tightening torque of cylinder
head
4
Tightening torque of cylinder
head mounting bolt
Cylinder
name
Standard
size
Lift
Lift
735 ± 74.0 Nm {75.0 ± 7.5 kgm}
Tilt
Pitch
162 ± 14.7 Nm {16.5 ± 1.5 kgm}
Ripper
162 ± 14.7 Nm {16.5 ± 1.5 kgm}
Lift
1.08 ± 0.11 kNm {110 ± 11.0 kgm} (Width across flats: 50 mm)
Tilt
Pitch
3.97 ± 0.40 kNm {405 ± 40.5 kgm} (Width across flats: 80 mm)
Ripper
3.97 ± 0.40 kNm {405 ± 40.5 kgm} (Width across flats: 80 mm)
Replace
bushing
Adjust shim
or replace
Replace
bushing
Retighten
5
Tightening torque of cylinder
piston clamping nut
D65EX, PX-15
10-127
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PISTON VALVE
PISTON VALVE
(Blade lift cylinder)
Outline
•
•
The piston valve is installed to the piston of the
blade lift cylinder.
When the piston rod is at the stroke end, the oil
from the pump is sent to the port on the opposite
side to lower the oil pressure applied to the piston.
The oil is also sent to the port on the opposite
side before the piston rod reaches the stroke end
to lower the surge pressure and reduce the
shock made when the piston rod reaches the
stroke end.
Operation
When piston valve is closed
When piston valve is open
•
•
The oil from the pump acts on piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right to
seal the tapered part of piston valve seat (4).
As a result, the oil pressure in the cylinder rises
to move piston (2) to the right.
10-128
The end of piston valve (3) touches cylinder bottom (a) before piston rod (1) reaches the stroke
end, and then only piston (2) continues moving.
At this time, the oil which has been stopped by
piston valve (3) is sent through piston valve
seats (4) and (5) to the bottom side, thus the oil
pressure in the cylinder lowers.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
QUICK DROP VALVE
QUICK DROP VALVE
(Blade lift cylinder)
Unit: mm
No.
Check item
Clearance between valve and
1
body
2
Clearance between piston and
plug
Criteria
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
33
–0.034
–0.050
+0.025
0
0.034 –
0.075
0.080
25
–0.039
–0.054
+0.021
0
0.039 –
0.075
0.080
Standard size
3 Valve spring
4 Piston spring
5.
6.
7.
8.
Body
Valve
Piston
Plug
D65EX, PX-15
Remedy
Free length Installed length
Repair limit
Installed load
Free length
Installed load
108.3
26
88.2 N
{9.0 kg}
97.5
79.4 N
{8.1 kg}
27.3
26
4.6 N
{0.47 kg}
24.6
4.1 N
{0.42 kg}
Replace
VH: From control valve, blade LOWER
VB: From control valve, blade RAISE
CH2: To both blade lift cylinder heads
CB1: To left blade lift cylinder bottom
CB2: To right blade lift cylinder bottom
10-129
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
QUICK DROP VALVE
Outline
•
•
The quick drop valve is installed between the
control valve and blade lift cylinder. When the
blade control lever is set in the LOWER position,
the quick drop valve prevents a vacuum on the
cylinder bottom side and shortens the time lag in
starting digging.
The blade lowering speed is almost decided by
the pump discharge. It can be heightened, however, by installing the quick drop valve.
Operation
Start of lowering blade
While lowering blade
•
•
•
If the blade control lever is set in the LOWER position, the oil from the control valve flows in port
VB and further flows through ports CB1 and
CB2 to the cylinder bottom and pushes the cylinder piston.
The oil on the cylinder head side is pushed out
by the cylinder piston into port CH2, and then
flows through port VH and control valve to the
hydraulic tank.
•
•
•
10-130
The oil pushed out of the cylinder head side
flows through port CH2 to port VH. At this time,
the oil flow rate is reduced by orifice a and a
pressure difference is made between before and
after the orifice.
If the oil pressure in port CH2 rises higher than
the tension of springs (1) and (2), valve (3) and
piston (4) move to the right.
Since ports VB and CH2 are connected, a part
of the oil which has been flowing from port CH2
to port VH merges with the oil from the control
valve and flows into the cylinder bottom side.
Accordingly, the blade lowering speed is increased by the quantity of the oil flowing into the
cylinder bottom side and a vacuum on the bottom side is prevented.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN PUMP
COOLING FAN PUMP
LPV30
P1: Pump discharge pressure
PS: Pump suction
TO: Drain
D65EX, PX-15
T1:
Drain plug
PEPC: EPC valve main pressure
PCEPC: EPC valve output pressure detection plug
10-131
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN PUMP
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
10-132
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
Function
•
•
The rotation and torque of the engine are transmitted to the shaft of this pump and converted
into hydraulic energy in this pump. This pump
discharges the pressurized oil according to the
load.
The discharge of this pump can be changed by
changing the swash plate angle in it.
COOLING FAN PUMP
•
•
•
•
Structure
•
Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported by the
front and rear bearings.
D65EX, PX-15
•
The end of piston (6) has a spherical hollow
which is combined with shoe (5). Piston (6) and
shoe (5) form a spherical bearing.
Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slid circularly.
Rocker cam (4) slides around ball (11).
Piston (6) in each cylinder of cylinder block (7)
moves relatively in the axial direction.
Cylinder block (7) rotates relatively against valve
plate (8), sealing the pressurized oil, and the hydraulic balance is maintained properly.
The oil in each cylinder of cylinder block (7) can
be sucked and discharged through valve plate
(8).
10-133
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN PUMP
Operation
1. Operation of pump
•
•
•
•
Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane A. At this time, rocker cam (4) tilts around ball (11). As a result, angle
between center line X of rocker cam (4)
and the axis of cylinder block (7) changes. Angle
is called the swash plate angle.
If angle is made between center line X of rocker cam (7) and the axis of cylinder block (7),
plane A works as a cam for shoe (5).
Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between volumes E and F in cylinder block (7). As a result,
each piston (6) sucks and discharges oil by F –
E.
In other words, if cylinder block (7) rotates and
the volume of chamber E is decreased, the oil is
discharged from chamber E. On the other hand,
the volume of chamber F is increased and the oil
is sucked in chamber F. (In the figure, chamber F
is at the end of the suction stroke and chamber
E is at the end of the discharge stroke.)
10-134
•
•
If center line X of rocker cam (4) is equal to the
axial of cylinder block (7) (the swash plate angle
is 0), there is not a difference between volumes
E and F in cylinder block (7) and oil is not sucked
or discharged. (The swash plate angle is not set
to 0 actually, however.)
In short, swash plate angle is in proportion to
the pump discharge.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN PUMP
2. Control of discharge
•
•
If swash plate angle
is increased, the difference between volumes E and F is increased, or
discharge Q is increased. Swash plate angle
is changed with servo piston (10).
Servo piston (10) reciprocates straight according
to the signal pressure of the servo valve. This
straight motion is transmitted to rocker cam (4).
Then, rocker cam (4) supported on ball (11)
slides around ball (11).
D65EX, PX-15
10-135
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN PUMP
SERBO VALVE
P: EPC valve main pressure
T: Drain
PE: Control piston pressure
PH: Pump discharge pressure
1.
2.
3.
4.
5.
6.
7.
Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve
10-136
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
A: Drain side
B: Pump discharge pressure input side
D65EX, PX-15
COOLING FAN PUMP
C: EPC output pressure received
D: EPC output pressure
10-137
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN PUMP
Function
Operation
•
•
The servo valve controls the current input to the
EPC valve and the swash plate angle of the
pump so that they will be related as shown in the
figure.
•
•
•
•
•
The relationship between the input current to the
EPC valve and the output pressure of the EPC
valve is as follows.
10-138
•
The output pressure of the EPC valve is applied
to the piston chamber to push the piston. Piston
(6) pushes spool (5) until it is balanced with the
spring.
Then, the land of the servo piston pressure passage is connected to the pump discharge passages by the cut of spool (5) and the discharge
pressure is led to the servo piston.
The servo piston is raised by the rocker cam.
The position feedback is applied and the lever
moves to compress the spring.
If spool (5) is pushed back, the pump discharge
circuit and the servo piston circuit are shut off.
The pressure in the servo piston chamber lowers
and the rocker cam returns toward the maximum
swash plate angle.
These processes are repeated until the swash
plate is fixed to a position where the EPC output
is balanced with the spring force.
Accordingly, as the EPC output pressure is
heightened, the swash plate angle is decreased.
As the EPC output pressure is lowered, the
swash plate angle is increased.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN MOTOR
COOLING FAN MOTOR
LMF28
P: From fan pump
T: From oil cooler to hydraulic tank
TC: To hydraulic tank
D65EX, PX-15
Specifications
Model:
LMF28
Capacity:
28 cc/rev
Rated speed: 1,850 rpm
Rated flow rate: 51.8 l/min
Cracking pressure of check valve:
44.1 kPa {0.45 kg/cm2}
10-139
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
6.
7.
COOLING FAN MOTOR
8. Center spring
9. Check valve spring
10. Check valve
11. Pilot valve
12. Reversible valve spool
13. Reversible valve spring
14. Safety valve
Output shaft
Case
Thrust plate
Piston assembly
Cylinder block
Valve plate
End cover
Unit: mm
No.
Check item
Criteria
Standard size
9 Check valve spring
10-140
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
13.0 x 6.5
7.0
3.43 N
{0.35 kg}
—
2.55 N
{0.26 kg}
If damaged or
deformed,
replace spring
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN MOTOR
1. Hydraulic motor unit
Function
•
This hydraulic motor is called a swash plate-type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
Principle of operation
•
•
•
•
•
•
The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only 1 side of the Y – Y line
connecting the top dead center and bottom dead
center of the stroke of piston (4).
The oil sent to 1 side of cylinder block (5) presses pistons (4) (2 or 3 pieces) and generates
force F1 (F1 kg = P kg/cm2 x /4D2 cm2).
This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of degrees
to the output shaft (1), the force is divided into
components F2 and F3.
The radial component F3 generates torque
against the Y – Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
The resultant of this torque [T = (F3 x ri)] rotates the cylinder block (5) through the piston.
Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
revolves to transmit the torque.
D65EX, PX-15
10-141
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN MOTOR
2. Suction valve
Function
•
•
If the fan pump stops, the hydraulic oil does not
flow into the motor. Since the motor continues
revolution because of the force of inertia, however, the pressure on the outlet side of the motor
rises.
When the oil stops flowing in from inlet port P, the
suction valve sucks in the oil on the outlet side
and supplies it to the port MA where there is not
sufficient oil to prevent cavitation.
Operation
(2) When pump is stopped
• If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm, the hydraulic oil from the pump is not supplied to
port P any more. As the hydraulic oil is not
supplied to the MA side of the motor, the motor speed lowers gradually to stop.
• If the motor shaft is revolved by the force of
inertia while the oil flow in the port P is reducing, the oil in port T on the outlet side is sent
by the suction valve (1) to the MA side to prevent cavitation.
(1) When pump is started
• If the hydraulic oil from the pump is supplied
to port P and the pressure on the MA side
rises and starting torque is generated in the
motor, the motor starts revolution. The oil on
the outlet MB side of the motor returns
through port T to the tank.
10-142
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN MOTOR
3. OPERATION OF REVERSIBLE VALVE
(1) When ON-OFF solenoid for reversible valve
is turned OFF
• If ON-OFF solenoid (1) for reversible valve is
turned “OFF”, the hydraulic oil from the
pump is blocked by ON-OFF reversible valve
(2) and port C is connected to the tank circuit.
• Accordingly, reversible valve spool (3) is
pushed by reversible valve spool spring (4)
to the right to open motor port MA and then
the hydraulic oil flows in to revolve the motor
forward (clockwise).
D65EX, PX-15
(2) When ON-OFF solenoid for reversible valve
is turned ON
• If ON-OFF solenoid (1) for reversible valve is
turned “ON”, ON-OFF reversible valve (2)
changes to let the hydraulic oil from the
pump flow through port C into spool chamber D.
• The hydraulic oil in chamber D pushes reversible valve spool (3) against reversible
valve spool spring (4). As a result, motor port
MB opens and the hydraulic oil flows in to revolve the motor in reverse (counterclockwise).
10-143
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING FAN MOTOR
4. Safety valve
Function
•
•
When the engine is started, the pressure in port
P of the fan motor is heightened in some cases.
Safety valve (1) is installed to protect the fan system circuit.
Operation
•
If the pressure in port P rises above the cracking
pressure of safety valve (1), valve (2) of safety
valve (1) opens to release the hydraulic oil into
port T.
By this operation, generation of abnormal pressure in port P is prevented.
10-144
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC VALVE
PPC VALVE
FOR BLADE LIFT, BLADE TILT
a PPC: Abbreviation for Proportional Pressure Control
P: From self pressure reducing valve
T: To hydraulic tank
D65EX, PX-15
P1:
P2:
P3:
P4:
To blade lift valve port PA3
To blade lift valve port PB3
To blade tilt valve port PA2
To blade tilt valve port PB2
10-145
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC VALVE
1. Disc
2. Plate
3. Body
10-146
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC VALVE
OPERATION
1. At Neutral
1) For blade lift
• Ports PA3 and PB3 of the blade lift control
valve and ports P1 and P2 of the PPC valve
are connected to drain chamber D through
fine control hole f spool (1).
D65EX, PX-15
2) For blade tilt
• Ports PA2 and PB2 of the blade tilt control
valve and ports P3 and P4 of the PPC valve
are connected to drain chamber D through
fine control hole f of spool (1).
10-147
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
2. During fine control (Neutral o fine control)
•
•
•
•
•
•
When piston (4) is pushed by disc (5), retainer
(9) is pushed, and spool (1) is also pushed
through metering spring (2), and moves down.
As a result, if fine control hole f is shut off from
drain chamber D, at almost the same time, it is
connected with pump pressure chamber PP, and
the pilot pressure oil passes through fine control
hole f and flows from port P1 to port PA3.
When the pressure at port P1 becomes high, if
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP, at
almost the same time, it is connected with drain
chamber D and released the pressure at port P1.
As a result, spool (1) moves up and down so that
the force of metering spring (2) is balanced with
the pressure at port P1. The relation between
the positions of spool (1) and body (10) (fine control hole f is at the midpoint between drain chamber D and pump pressure chamber PP) does not
change until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed an
amount proportional to the movement of the control lever, so the pressure at port P1 also rises in
proportion to the movement of the control lever.
The control valve spool moves to a position
where the pressure in chamber PA3 (same as
pressure at port P1) is balanced with the force of
the return spring.
10-148
PPC VALVE
3. During fine control
(when control lever is returned)
•
•
•
•
When disc (5) starts to be returned, spool (1) is
pushed up by the pressure at port P1 and the
force of centering spring (3).
As a result, fine control hole f is connected to
drain chamber D, so the pressure oil at port P1 is
relieved.
If the pressure at port P1 goes down to far, spool
(1) is pushed down by metering spring (2).
Fine control hole f is shut off from drain chamber
D, and at almost the same time, it is connected
to pump pressure chamber PP. Pump pressure
is supplied until the pressure at port P1 recovers
to a pressure equivalent to the position of the lever.
When the control valve spool returns, the oil at
drain chamber D flows in from fine control hole f’
in the valve on the side that is not moving. It
passes through port P2, is taken to chamber
PB3, and the oil fills the chamber.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC VALVE
4. When lever is operated fully
5. When blade is operated to FLOAT
•
•
•
•
When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D and is
connected to pump pressure chamber PP.
Therefore, the pilot pressure oil passes through
fine control hole f, is taken from port P1 to chamber PA3, and pushes the control valve spool.
The return oil from chamber PB3 passes from
port P2 through fine control hole f’, and then
flows to drain chamber D.
•
•
•
•
•
•
D65EX, PX-15
When piston (4) at the port P1 LOWER side is
pushed by disc (5) and moves down, ball (11)
contacts protrusion a of the piston during the
stroke. (Detent starts to act.)
When piston (4) pushed in further, ball (11)
pushes up collar (12), which is being held by detent spring (13). While pushing up collar (12), it
escapes to the outside and passes over protrusion a of the piston.
When this happens, piston (4’) on the opposite
side is pushed up by spring (14).
As a result, the oil inside chamber F passes
through b and c, and flows to chamber E, and
piston (4’) follows disc (5). Passage d is connected to port P1, so more or less the same pressure
is applied as is applied to port P1.
Chamber E is normally connected to drain
chamber D, but if ball (11) passes over protrusion a of the piston, passage d and chamber E,
which were shut off, are connected and the pressure oil flows.
At the same time, the control valve also moves to
the FLOAT position and the circuit is set to the
FLOAT condition.
Piston (4’) is being pushed up by the oil pressure
inside chamber E, so even if the lever is released, it is held at the FLOAT position.
10-149
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC VALVE
6. When blade is released from FLOAT
•
•
When disc (5) is returned from the FLOAT position, it is pushed down by a force greater than the
hydraulic force in chamber E.
As a result, chamber E is shut off from passage
d and is connected to the drain chamber.
Therefore, the oil pressure inside chamber E is
lost, and the FLOATposition is canceled.
10-150
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC VALVE
FOR RIPPER
T:
P:
P1:
P2:
To hydraulic tank
From self pressure reducing valve
To ripper spool (To control valve port PB4)
To ripper spool (To control valve port PA4)
D65EX, PX-15
1.
2.
3.
4.
5.
6.
7.
8.
Spool
Metering spring
Centering spring
Piston
Lever
Plate
Retainer
Body
10-151
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC VALVE
Unit: mm
No.
Check item
Criteria
Standard size
9 Centering spring
10 Metering spring
10-152
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
33.9 x 15.3
28.4
125 N
{12.7 kg}
—
100 N
{10.2 kg}
22.7 x 8.10
22.0
16.7 N
{1.70 kg}
—
13.3 N
{1.36 kg}
If damaged or
deformed,
replace spring
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PPC VALVE
Operation
1. At neutral
2. During fine control (Neutral o fine control)
•
•
P1 and P2 ports of the operation valves A, B and
PPC valve are connected to drain room D via the
fine control hole f on the spool (1).
•
•
•
•
•
•
D65EX, PX-15
As the piston (4) is pushed by disk (5), the retainer (7) is pushed too. At the same time, the spool
(1) is also pushed down via the metering spring
(2).
By this move, connection of the fine control hole
f is switched from the drain room D to the pump
pressure room PP, and pilot pressure oil is conducted from P1 port to A port.
As P1 port pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure room PP to the drain room D, thereby
relieving P1 port pressure.
As the result, the spool (1) moves up and down
so that force of the metering spring (2) and P1
port pressure may be balanced.
Positional relationship between the spool (1) and
body (8) (fine control hole f is situated at mid
point between the drain room D and pump pressure room PP) remains unchanged until the retainer (7) is contacted against the spool (1).
The metering spring (2) is, therefore, compressed in proportion to strokes of the operation
lever. Thus, the P1 port pressure too, increases
in proportion to strokes of the operation lever.
As the result, the operation valve spool moves to
the position where the pressure of A room (the
same as P1 port pressure) is balanced against
force of the operation valve spool return spring.
10-153
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
3. During fine control
(when control lever is returned)
•
•
•
As the lever (5) starts returning, the spool (1) is
pushed up by force of the centering spring (3)
and P1 port pressure. By this move, the fine control hole f is connected to the drain room D and
relieves pressurized oil of P1 port to it.
If P1 port pressure goes excessively low, the
spool (1) is pushed down by the metering spring
(2), and passage between fine control hole f and
drain room D is shut down. And, almost at the
same time, the hole is connected to the pump
pressure room PP and starts supplying pump
the pressure. This supply continues until the P1
port pressure is recovered to the level equivalent
to the lever position.
When the operation valve spool returns, oil in the
drain room D flows in through the fine control
hole f’ on the not moving side valve. Oil is then
conducted via P2 port to the room B to fill it up.
10-154
PPC VALVE
4. At full stroke
•
•
•
When the disk (5) pushes down piston (4) and
the retainer (7) pushes down the spool (1), connection of the fine control hole f is switched from
the drain room D, to the pump pressure room PP.
Thus, pilot pressurized oil from the control pump
passes through fine control hole f and conducted
to A room via P1 port to push the operation valve
spool.
Return oil from B room is conducted from P2
port to the drain room D via the fine control hole
f’.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PCCS LEVER
PCCS LEVER
FOR STEERING
1.
2.
3.
4.
Boot
Bracket
Plate
Bolt
D65EX, PX-15
5. Screw
6. Lever
7. Connector
10-155
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PCCS LEVER
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 (Operating effort characteristics chart A).
10-156
(2) Operation for steering
• Free return (Operating effort characteristics chart B).
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PCCS LEVER
2. Output voltage characteristics
•
•
•
The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
The operating angle (stroke) of the control lever
is sensed with potentiometers and signal voltages are output to the transmission, steering controller.
A potentiometer is installed in each of longitudinal direction and lateral direction. Each potentiometer outputs 2 signal voltages which are
opposite to each other as shown in the figure at
right.
D65EX, PX-15
10-157
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
CONTROL VALVE
Outline
•
This manual explains the 3-spool valve (Blade lift
+ Tilt + Steering) and 4-spool valve (Ripper +
Blade lift + Tilt + Steering).
1. 3-spool valve
P:
From pump
T:
To hydraulic tank
A1:
To HSS motor
A2:
To tilt cylinder bottom
A3:
To lift cylinder head
B1:
To HSS motor
B2:
To tilt cylinder head
B3:
To lift cylinder bottom
LS:
To pump LS valve
PC:
Pump pressure plug
PI:
From self-pressure reducing valve
TS:
To hydraulic tank
PA1: Connector (From controller)
PA2: From PPC valve
PA3: From PPC valve
PB1: Connector (From controller)
PB2: From PPC valve
PB3: From PPC valve
PLSC: LS pressure plug
1. EPC valve
10-158
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
D65EX, PX-15
CONTROL VALVE
10-159
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
6.
7.
Cover
Lift spool
Tilt spool
Steering spool
Valve body
Steering priority valve
Load check valve
10-160
CONTROL VALVE
8. Pressure compensation valve
9. Main relief valve
10. LS relief valve (for steering valve)
11. Unload valve
12. LS relief valve (for work equipment valve)
13. LS check valve (for work equipment valve)
14. LS check valve (for steering valve)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Basic dimension
15 Spool return spring (for lift)
Remedy
Allowable limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
73.4 x 31
68.5
224 N
{22.8 kg}
—
178 N
{18.2 kg}
16
Spool return spring
(tilt, steering)
51.7 x 31.3
50
140 N
{14.3 kg}
—
112 N
{11.4 kg}
17
Spool return spring
(for lift FLOAT)
54.7 x 36.5
33.5
217 N
{22.1 kg}
—
173 N
{17.6 kg}
20.8 x 10.2
13.5
12.7 N
{1.3 kg}
—
9.81 N
{1.0 kg}
18 Road check valve spring
19
Pressure compensation valve
spring (steering valve)
70 x 26.5
61.8
216 N
{22 kg}
—
173 N
{17.6 kg}
20
Pressure compensation valve
spring (tilt valve)
70 x 26.5
61.8
216 N
{22 kg}
—
173 N
{17.6 kg}
21
Pressure compensation valve
spring (lift valve)
70 x 26.5
61.8
216 N
{22 kg}
—
173 N
{17.6 kg}
94.8 x 30
69.5
235 N
{24 kg}
—
188 N
{19.2 kg}
22 Unload valve spring
D65EX, PX-15
If damaged or
deformed,
replace spring
10-161
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
No.
Check item
Criteria
Standard size
4 Suction valve spring
10-162
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
64.9 x 12.5
56
6.4 N
{0.65 kg}
—
5.1 N
{0.52 kg}
If damaged or
deformed,
replace spring
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
2. 4-spool valve
P:
From pump
T:
To hydraulic tank
A1:
To HSS motor
A2:
To tilt cylinder bottom
A3:
To lift cylinder head
A4:
To ripper cylinder bottom
B1:
To HSS motor
B2:
To tilt cylinder head
B3:
To lift cylinder bottom
B4:
To ripper cylinder head
LS:
To pump LS valve
PC:
Pump pressure plug
PI:
From self-pressure reducing valve
TS:
To hydraulic tank
PA1: Connector (From controller)
PA2: From PPC valve
PA3: From PPC valve
PA4: From PPC valve
PB1: Connector (From controller)
PB2: From PPC valve
PB3: From PPC valve
PB4: From PPC valve
PLSC: LS pressure plug
1. EPC valve
D65EX, PX-15
10-163
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
10-164
CONTROL VALVE
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
6.
7.
8.
Valve block
Ripper spool
Lift spool
Tilt spool
Steering spool
Valve body
Steering priority valve
Load check valve
D65EX, PX-15
CONTROL VALVE
9. Pressure compensation valve
10. Main relief valve
11. LS relief valve (for steering valve)
12. Unload valve
13. LS relief valve (for work equipment valve)
14. LS check valve (for work equipment valve)
15. LS check valve (for steering valve)
10-165
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
73.4 x 31
68.5
224 N
{22.8 kg}
—
178 N
{18.2 kg}
17
Spool return spring
51.7 x 31.3
(For tilt and steering)
50
140 N
{14.3 kg}
—
112 N
{11.4 kg}
18
Spool return spring
(For lift “FLOAT”)
54.7 x 36.5
33.5
217 N
{22.1 kg}
—
173 N
{17.6 kg}
20.8 x 10.2
13.5
12.7 N
{1.3 kg}
—
9.81 N
{1.0 kg}
16 Spool return spring (For lift)
19 Load check valve spring
20
Pressure compensation valve
spring (Steering valve)
70 x 26.5
61.8
216 N
{22 kg}
—
173 N
{17.6 kg}
21
Pressure compensation valve
spring (Tilt valve)
70 x 26.5
61.8
216 N
{22 kg}
—
173 N
{17.6 kg}
22
Pressure compensation valve
spring (Lift valve)
70 x 26.5
61.8
216 N
{22 kg}
—
173 N
{17.6 kg}
23
Pressure compensation valve
spring (Ripper valve)
70 x 26.5
61.8
216 N
{22 kg}
—
173 N
{17.6 kg}
94.8 x 30
69.5
235 N
{24 kg}
—
188 N
{19.2 kg}
24 Unload spring
10-166
If damaged or
deformed,
replace spring
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
1. Suction valve
2. Preset check valve
3. LS bypass valve
4. Safety-suction valve
Unit: mm
No.
Check item
Criteria
Standard size
5 Suction valve spring
D65EX, PX-15
Remedy
Repair limit
Free length
x Outside
diameter
Installed
length
Installed
load
Free length
Installed
load
64.9 x 12.5
56
6.4 N
{0.65 kg}
—
5.1 N
{0.52 kg}
If damaged or
deformed,
replace spring
10-167
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
OPERATION OF MAIN CONTROL VALVE
1. AT HOLD (OPERATION OF UNLOAD VALVE)
Function
•
When the main spool is at the HOLD position, it
drains the excess oil discharged by the pump,
and prevents the pressure from being formed in
the circuit from rising.
Operation
•
•
When the main spool is at the HOLD position,
the pump pressure passes from chamber A
through throttle (4) to chamber D. Chambers C
and C’ are connected to the drain circuit.
When oil is supplied from the pump, the pressure
in chamber D rises, and spool (1) is pushed to
the right by pressure which is determined by the
cross-sectional area of piston (3) receiving the
pressure.
10-168
•
•
When FO becomes larger than set load FS of
spring (2), the spool moves to the right and connects the passage between chamber A and
chamber B, so the oil from the pump is drained.
Therefore, spool (1) is balanced at a position that
matches the supply of oil from the pump.
Actually, the amount of oil supplied from the
pump is small, so the pressure in the circuit is almost the same as the set load of spring (2).
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
2. CONTROL OF OIL FLOW
(1) Steering valve
Function
•
Use of the CLSS circuit (Closed Center Load Sensing System) makes it possible to control the oil flow by
adjusting the area of opening of the spool driven by the EPC valve regardless of the load.
1) At HOLD
Operation
•
•
When the spool is at the HOLD position, the
pump pressure is sent from chamber A through
the notch in spool (3) of the steering priority
valve, and passes through chamber B to chamber C.
Chamber G is drained through chamber H to
chamber F.
D65EX, PX-15
•
•
When this happens, the pump pressure is acting
on the left end of spool (3) of the steering priority
valve, so it pushes against the load of spring (4)
and moves to the right to the maximum stroke
position.
In this condition, the area of the opening to spool
(1) of the steering valve is at its minimum.
10-169
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
2) When turning to left
•
•
•
PLS = Differential pressure between ports K and J = 2.0 MPa (20 kg/cm2)
PLS’ = Differential pressure between ports I and D
PLS C PLS’
10-170
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Operation
•
•
•
•
•
•
•
•
•
•
When the steering lever is operated to turn the
machine to the left, pilot pressure PI acts on the
right end of spool (1) through the PPC valve.
When the pressure becomes greater than the
set load of spring (2), the spool to move to the
left. It becomes balanced at a position that
matches PPC output pressure PI.
Chamber C and chamber D are connected, and
the oil from the pump flows through ports A, B, C
and D to HSS motor (6).
At the same time, the load pressure in chamber
D passes through LS ofifice (5) and chamber H,
and is sent to chamber G. It is also sent from the
LS circuit O to pump servo valve (7).
The condition of the pressure of spool (3) is
chamber B pressure C chamber C pressure, and
chamber G pressure C chamber D pressure, so
spool (3) is controlled by the differential pressure
of spool (1) (chamber C pressure – chamber D
pressure), and balances with spring (4).
In other words, if the oil flow is too large, the differential pressure of spool (1) becomes larger,
so spool (3) moves in the direction to throttle the
oil flow;
On the other hand, if the oil flow is too small,
spool (3) moves in the direction to increase the
oil flow.
In addition, pump servo valve (7) is controlled so
that the differential pressure between pump
pressure P and LS pressure LS (LS differential
pressure: PLS) remains constant, so a suitable
amount of oil flows to ensure that the loss of
pressure at the control valve ( PLS’) is equal to
PLS.
The loss of pressure in the control valve is determined by the area of the opening of the main
spool, so the oil flow matches the opening of the
spool.
The return oil flow from the HSS motor (6) passes through chamber E and chamber F, and is
drained.
D65EX, PX-15
10-171
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
(2) Work equipment valve (tilt valve, lift valve, ripper valve)
a The diagram shows the blade lift valve.
10-172
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Operation
•
•
•
•
When spool (1) of the hydraulic valve is at the
HOLD position, the pump pressure (unload pressure) is sent to chambers D and D’.
The pressure is not formed in chambers H and
H’, so pressure compensation valve spool (3)
and steering compensation valve spool (4) are
pushed completely to the right.
The pump pressure passes through chambers A
and B of steering priority valve (4), and is sent to
chamber C of the main control valve. From here
it goes through chamber D and chamber E to
chamber F.
In the same way as for Item (1) Steering valve,
the position of pressure compensation valve
spool (3) is determined to match the opening of
spool (1) of the work equipment valve, and the oil
flow is determined so that the pressure loss of
the control valve becomes equal to the differential pressure LS of LS valve (7).
D65EX, PX-15
10-173
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
(3) Meter-out control when blade moves down under its own weight
10-174
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Function
•
If the blade moves down under its own weight,
the oil flow of return oil from cylinder is controlled
by the area of the opening of main spool (1).
Operation
•
•
•
•
When the spool port is opened by pilot pressure
PI, because of the weight of the blade, the oil at
the cylinder head passes through ports A, B, C
and D, and is drained to the tank.
When this happens, the flow of return oil from the
lift cylinder is throttled by the area of opening between ports A and B, so the downward speed is
controlled.
The oil flowing from the cylinder head end passes from the drain circuit through suction valve (2)
and is supplied to the bottom end of the cylinder.
The oil discharged from the pump passes
through ports A’, B’, C’, D’ and E’, and is supplied to the cylinder bottom.
D65EX, PX-15
10-175
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
(4) Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)
10-176
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Function
•
•
When the lift valve is at FLOAT, the cylinder port
and drain port are connected to put the circuit in
a no-load condition.
When the lift valve is in the FLOAT condition, the
pump passage and cylinder ports A3 and B3 are
separated so that the other control valves can be
operated.
Operation
•
•
•
•
•
When the work equipmentc control lever is at the
FLOAT position, if pressure PA3 becomes 3.4
MPa (35 kg/cm2) or more, lift spool (1) is moved
to the maximum stroke position.
In this condition, ports A3 and B3 and the LS
passage O are all connected to the drain circuit,
so there is no load on the lift cylinder.
If the cylinder is driven by the weight of the blade,
the oil entering from port A3 flows to ports A, B,
B’ and A’, while the rest of the oil flows through
ports C and D, and is drained.
When this happens, the oil flows is throttled by
the area of opening between ports A and B of
spool (1), and the cylinder speed is controlled.
The pump circuit chamber E and ports A3 and
B3 are separated, and pump pressure P is
formed, so it is possible to carry out compound
operations with other control valves.
D65EX, PX-15
10-177
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
3. AT RELIEF
(1) Steering valve
a The diagram shows the condition at relief for steering LS relief valve (5).
10-178
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
•
•
•
•
•
CONTROL VALVE
P1 = P3 + P4 = Differential pressure between ports M and E
P2 = Differential pressure between ports E and N
P3 = Differential pressure between ports M and B
P4 = Differential pressure between ports B and E
LS = P1 + P2 = Differential pressure between ports M and N = 2.0 MPa (20 kg/cm2)
Function
•
If specifies the maximum pressure when the
HSS is operated.
Operation
•
•
•
•
•
•
•
If the pressure of HSS motor (7) becomes higher, the poppet of steering LS relief valve (5) will
start to open and oil will be drained from LS circuit O. (Ports E, F, G, J, K and L)
As a result, there will be a drop in pressure in LS
passage O starting from LS sensing hole F, and
P2 will become larger.
For the same reason, if the pressure in chambers H and I drops, spool (2) will push against
spring (3) and move to the right, and will make
the opening between chambers B and C smaller,
so the flow to chambers B and C will be throttled
and P4 will become larger.
Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by the
flow at steering LS relief valve (5). P1 + P2
equal to LS differential pressure ( LS).
When this happens, pump LS valve (6) detects
the differential pressure generated by LS relief
valve (5), and moves the pump swash plate from
the maximum to the minimum position.
The pump swash plate is balanced at a position
where the LS differential pressure is 2.0 MPa (20
kg/cm2.)
When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil flow
is greater than the LS relief oil flow + leakage at
any part, the pressure is confined in the pump
circuit (between the pump and chambers A and
B), so the LS differential pressure rises.
If this differential pressure goes above the set
pressure for unload valve (4), the unload valve is
actuated to releive the excess oil flow and balance the circuit.
D65EX, PX-15
10-179
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
(2) Blade lift, tilt and ripper valve
a The diagram shows the relief condition of work equipment LS relief valve (5) with the blade tilt at the end
of its stroke.
10-180
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
•
•
•
•
•
CONTROL VALVE
P1 = P3 + P4 = Differential pressure between ports M and P
P2 = Differential pressure between ports P and N
P3 = Differential pressure between ports M and B
P4 = Differential pressure between ports B and P
LS = P1 + P2 = Differential pressure between ports M and N = 2.0 MPa (20 kg/cm2)
Operation
•
•
•
•
•
•
•
If blade tilt valve (1) is moved, and the pressure
of tilt cylinder (8) becomes higher, poppet of
work equipment LS relief valve (5) will start to
open and oil will be drained from LS circuit O.
(Ports E, F, G, J, K and L)
As a result, there will be a drop in pressure in LS
passage O starting from LS sensing hole F, and
P2 will become larger.
For the same reason, if the pressure in chambers H and I drops, spool (2) will push against
spring (3) and move to the right, and will make
the opening between chambers B and C smaller,
so the flow between chambers B and C will be
throttled and P4 will become larger.
Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by the
flow at hydraulic LS relief valve (5) P1 + P2
equal to LS differential pressure ( LS).
When this happens, pump LS valve (6) detects
the differential pressure generated by LS relief
valve (5), and moves the pump swash plate from
the maximum to the minimum position.
The pump swash plate is balanced at a position
where the LS differential pressure is 2.0 MPa (20
kg/cm2.)
When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil flow
is greater than the LS relief oil flow + leakage at
any part, the pressure is confined in the pump
circuit (between the pump and chambers A and
B), so the LS differential pressure rises.
If this differential pressure goes above the set
pressure for unload valve (4), the unload valve is
actuated to releive the excess oil flow and balance the circuit.
D65EX, PX-15
10-181
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
(3) Steering + work equipment valve (compound operations)
a The diagram shows the relief condition of LS relief valves (4) and (5) at steering stall with the blade tilt
at the end of its stroke.
10-182
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
•
•
•
CONTROL VALVE
= P – P2
PO = Differential pressure between ports H and K
Pressure P2 = LSO + PO
Function
•
When steering valve (1) and work equipment
valve (2) are relieved at the same time, the pump
pressure is separated by pressure compensation valve (3) in the work equipment valve, and
the port pressure is maintained at a constant value.
Operation
•
•
•
•
•
•
•
•
If HSS motor (6) reaches the stall condition, the
load pressure increases and LS relief valve (4)
for the steering valve is actuated, so the system
is cut off.
For details, see Item (1) Steering valve.
When this happens, the pump pressure is maintained at 38.2 MPa (390 kg/cm2), and this is sent
to chamber G of the work equipment valve.
When work equipment valve (2) is ooperated
and the load on the work equipment valve is
greater, work equipment LS relief valve (5) is actuated, and drain oil flow Q1 flows to LS circuit O.
As a result, a differential pressure is generated
on the left and right sides of pressure compensation valve (4) by LS throttle M of spool (2), and it
moves the full stroke to the right.
When this happens, the opening between chambers D and E is throttled to the minimum size
(pump pressure separated).
Oil flow Q1 is determined by pump pressure P
and the total pressure loss (P – LSO) of ports
C, D, E, F, G, I, J and K.
Furthermore, pressure P2 (the pressure in
chamber H) becomes the total (LSO + PO) of
the circuit pressure loss of ports H, I, J and K,
and the set pressure of work equipment LS relief
valve (5).
D65EX, PX-15
10-183
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
4. COMPOUND OPERATIONS
(1) Steering valve + work equipment valve
a The diagram shows the condition when the steering and blade lift valve are operated at the same time.
10-184
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Function
•
The steering valve is equipped with a steering
priority valve (3), so if the steering valve and the
downstream work equipment valve are operated
at the same time, priority is given to the flow of oil
to the steering valve, and the rest of the oil discharged from the pump goes to the work equipment valve.
Operation
•
•
•
•
•
•
When steering spool (1) is operated by pilot
pressure P1 and the oil flows, a differential pressure is created between chambers C and D.
Steering priority valve (3) is controlled by this differential pressure, and at the same time, the
pump swash plate angle is controlled at PLS =
2.0 MPa (20 kg/cm2), and the flow of oil to the
steering valve is fixed.
See Item 2 – (1) Steering valve.
In this condition, if downstream blade lift valve
(2) is operated, the pump pressure momentarily
drops.
At this point, the differential pressure between
chambers C and D becomes smaller, and steering priority valve (3) is moved to the left by the
pressure in chamber E in the direction to throttle
the opening to the hydraulic valve.
At the same time, PLS becomes smaller, so
the pump swash plate angle moves in the maximum direction to supply an oil flow to make up
the amount that the pressures drops.
2. When pump swash plate is at maximum angle
• When the maximum flow of oil from the pump
is smaller than the sum of the oil flow demanded by the steering valve and work
equipment valve.
(1) When steering valve load Z work equipment
valve load.
• An amount of oil that matches the opening of
steering spool (1) flows to the steering valve,
and the remaining oil flows to work equipment valve.
(2) When steering valve load work equipment
valve load.
• Pump pressure P is determined by the steering valve load, but in this condition, if the
downstream work equipment valve where
the load is smaller is operated the difference
in pressure will cause the oil to try to flow to
the work equipment valve, so the pump pressure will drop.
• When this happens, steering priority valve
(3) increases the size of the opening to the
steering system, while at the same time reducing the size of the opening to the work
equipment in order to ensure the flow of oil to
the steering system.
• In this condition, the flow of oil is divided in
proportion to the difference in pressure between differential pressure P – P1 and differential pressure P – P2.
The bigger P1 – P2 is, the smaller the flow of
oil to the steering system becomes.
1. When pump swash plate does not reach maximum angle
• When the maximum oil flow from the pump is
greater than the sum of the flow demanded
by the steering valve and work equipment
valve, an amount of oil that matches the
opening of steering spool (1) flows to the
steering valve;
• An amount of oil decided by the pump pressure and load pressure and area of opening
of the spool flows to the work equipment
valve.
D65EX, PX-15
10-185
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
(2) Compound operation of work equipment valve
a The diagram shows the condition when the blade lift and tilt valves are operated at the same time.
10-186
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Function
•
It consists of a parallel circuit, so when compound operations are carried out, the oil flow is
divided according to the size of each spool opening.
Operation
•
•
When tilt spool (1) and lift spool (2) are at the
HOLD position or are operated, steering priority
valve (3) is pushed completely to the right, and
the size of the opening to the downstream area
is at its maximum.
Tilt spool (1) and lift spool (2) are actuated by
PPC valve output pressure PA2 and PB3, and
each is balanced at a position that matches its
own pilot pressure.
1. When pressure P2 Z P3
• Lift valve load pressure P3 is sent to pump
LS valve (4) through LS passage O.
(1) When pump swash plate does not reach
maximum angle
• When the maximum flow of oil from the pump
is greater than the total of the oil flow demanded by the tilt valve and lift valve, an oil
flow that matches the opening of the spool
flows to both the tilt valve and lift valve.
(2) When pump swash plate is at maximum angle
• When the maximum flow of oil from the pump
is smaller than the total of the oil flow demanded by the tilt valve and lift valve, the
flow of oil to the tilt valve and lift valve is divided according to differential pressurse
PO – P2 and differential pressure PO – P3.
• In other words, more oil flows to P2 where
the load is small.
a In cases where the blade is raised in the air
and the tilt valve and lift valve (for raise) are
operated at the same time, the tilt valve load
pressure is smaller than the lift valve load
pressure, so the flow of oil to the tilt valve is
given priority. In addition, the oil flow demanded by the tilt valve is smaller, so the
condition is just as if priority was given to the
oil flow for the tilt valve.
2. When pressure P2 = pressure P3
• P – P2 C P – P3, so an oil flow proportional
to the size of the spool opening is distributed
to each spool.
D65EX, PX-15
10-187
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
5. UNLOAD VALVE PRESET SYSTEM
a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.
10-188
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CONTROL VALVE
Function
•
This improves the response of the systsem including the pump swash plate and pressure
compensation valve by sending the pilot presssure (basic pressure of PPC valve) to the LS circuit, and compensating the rise of the LS circuit
pressure.
Operation
•
•
•
•
•
•
•
•
When lift spool (1) is at the HOLD position, pilot
pressure P1 (basic pressure of PPC valve) is
sent through preset check valve (3) to the chamber F of the pressure compensation valve. This
pressure is called preset pressure P2.
At the same time, unload pressure P is being
sent to chamber B, but P1 + FO P (FO: load of
spring (4)), so pressure compensation spool (2)
moves to the left and the size of the opening between A and B becomes the maximum.
When spool (1) is switched. Unload pressure P
flows immediately through chambers A, B, C, D
and E to lift cylinder (8), so the pressure at the
port starts to rise and the time lag becomes
smaller.
At the same time, preset pressure P2 is supplied
to LS circuit O by the timing of the spool, and the
pressure in the LS circuit rises.
Because of this, unload valve (7) closes, and oil
is sent further to pump LS valve (6) to improve
the response of the pump swash plate angle.
This makes it possible to reduce the response
time for giving the necessary oil flow.
Check valve (5) is installed in the spool so that
preset pressure P2 will not be applied to the cylinder port.
If cylinder port pressure P3 rises higher than preset pressure P2, the oil pushes up check valve
(5) and flows through chamber F of the pressure
compensation valve to pump LS valve (6), and
then the normal PLS control starts.
At this time, check valve (3) prevents cylinder
port pressure P3 from entering the pilot pressure
circuit.
D65EX, PX-15
10-189
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE
T: To hydraulic tank
P1: From pump
P2: To fan motor
PR: Supply to PPC valve and EPC valve
10-190
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1.
2.
3.
4.
5.
Valve (sequence valve)
Spring
Screw
Poppet
Spring (pressure reducing valve pilot)
D65EX, PX-15
SELF PRESSURE REDUCING VALVE
6. Spring (pressure reducing valve main)
7. Valve (pressure reducing valve)
8. Spring (safety valve)
9. Ball
10. Filter
10-191
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
Unit: mm
No.
Check item
Criteria
Standard size
11
12
Repair limit
Free length
x O.D.
Installed length
Installed load
Free length
Installed load
19.2 x 7.20
16.1
19.6 N
{2.0 kg}
—
17.7 N
{1.80 kg}
Spring
17.8 x 7.20
(pressure reduction valve pilot)
12.1
31.4 N
{3.20 kg}
—
28.4 N
{2.90 kg}
71.0 x 18.0
59.0
200 N
{20.4 kg}
—
186 N
{19.0 kg}
16.1 x 7.80
13.4
61.7 N
{6.30 kg}
—
58.8 N
{6.0 kg}
Spring
(pressure reduction main)
13 Spring
14
Remedy
Spring
(safety valve)
Replace spring if
any damages or
deformations are
found
Function
The self pressure reducing valves reduces the discharge pressure of the fan pump and supplies it to
the PPC valve, the EPC valve, etc. as the control
pressure.
10-192
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
Operation
1. At engine stop (total low pressure)
•
•
•
The spring (6) pushes the poppet (5) the seat,
and the circuit between the ports PR and T is
closed.
The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports P1 and
PR is open.
The spring (3) pushes the valve (2) to the left
side, and the circuit between the ports P1 and P2
is closed.
D65EX, PX-15
10-193
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
2. When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve.
•
•
The spring (3) and the PR pressure (0 MPa {0
kg/cm2} at the time of engine stop) pushes the
valve (2) in the direction to close the circuit between the ports P1 and P2. When the hydraulic
oil enters the P1 port, the expression (P1 pressure C Spring (7) force + ( d area x PR pressure)) holds, and the self pressure reducing
valve will adjust the openings of the ports P1 and
P2 so that the P1 pressure can be maintained
higher than the PR pressure.
When the PR pressure rises above the set pressure, the poppet (5) will open and the hydraulic
oil flows through the route from the PR port, the
hole a in the spool (8), the poppet (5) opening to
the tank port T.
10-194
•
Therefore, there will occur a differential pressure
around the hold a in the spool (8) and the spool
will move in the direction to close the port P1 and
the PR opening. Then, the P1 pressure is reduced and adjusted to a certain pressure (set
pressure) with the opening and is supplied as the
PR pressure.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
3. At raise of load pressure P2
•
When the load pressure P2 rises due to digging
or other operations, the pump delivery will increase and the P1 pressure will rise. Then, the
expression (P1 pressure Spring (7) force + ( d
area x PR pressure)) will hold, and the valve (2)
will move to the right side till the stroke end. As a
result, the opening between the ports P1 and P2
will increase, the passage resistance will become smaller to reduce engine loss horsepower.
D65EX, PX-15
•
•
When the PR pressure rises above the set pressure, the poppet (5) will open and the hydraulic
oil will flow through the route from the PR port,
the hole a in the spool (8), the poppet (5) opening to the tank port T.
Therefore, there will occur a differential pressure
around the hold a in the spool (8) and the spool
will move in the direction to close the port P1 and
the PR opening. Then, the P1 pressure is reduced and adjusted to a certain pressure (set
pressure) with the opening and is supplied as the
PR pressure.
10-195
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
4. At occurrence of abnormal high pressure
•
When the PR pressure of the self pressure reducing valve rises abnormally high, the ball (10)
will separate from the seat against the spring (9)
force to flow the hydraulic oil to the output ports
PR o T so as to reduce the PR pressure. Then,
the equipment (PPC valve, solenoid valve, etc.),
to which the oil pressure is supplied, is protected
from the abnormal high pressure.
10-196
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
Power tilt dozer (PT)
Semi-U dozer (SEMI-U)
Power tilt, power pitch dozer (PTP)
1.
2.
3.
4.
5.
6.
7.
Cutting edge
Center brace
End bit
Straight frame
Trunnion
Blade
Left side: Brace (PT, SEMI-U)
Tilt cylinder (PTP)
Right side: Tilt cylinder (PT, SEMI-U)
Pitch cylinder (PTP)
D65EX, PX-15
10-197
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm
No.
Check item
Spherical clearance between
1
trunnion and cap
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+1.5
0
0.3 – 0.7
5.0
Shaft
Hole
S 140
–0.1
–0.5
2
Clearance between brace
mounting pin and bracket
50
–0.2
–0.4
+0.2
0
0.2 – 0.6
2.0
3
Clearance between brace
mounting pin and brace
50
–0.2
–0.4
+0.2
0
0.2 – 0.6
2.0
4
Spherical clearance between
bracket and brace
S 90 (Shaft)
S 91 (Hole)
–0.1
–0.3
+1.0
0
0.3 – 0.7
2.0
5
Spherical clearance between
bearing and bushing
S 90
–0.1
–0.5
+0.5
0
0.1 – 1.0
2.0
6
Clearance between frame
mounting pin and bracket
55
0
–0.3
+0.6
+0.2
0.2 – 0.9
2.0
7
Clearance between frame
mounting pin and bearing
55
0
–0.3
+0.5
+0.2
0.2 – 0.8
2.0
8
Clearance between center brace
mounting pin and bracket
50
–0.2
–0.4
+0.2
0
0.2 – 0.6
2.0
9
Clearance between center brace
mounting pin and brace
50
–0.2
–0.4
+0.2
0
0.2 – 0.6
2.0
10
Spherical clearance between
bracket and center brace
S 90 (Shaft)
S 91 (Hole)
–0.1
–0.3
+1.0
0
0.3 – 0.7
2.0
10-198
Adjust shim or
replace
Replace
Adjust shim or
replace
Replace
Adjust shim or
replace
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
WORK EQUIPMENT
Angledozer (A)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Center shaft
Cutting edge
C-frame
End bit
Trunnion
Joint
Blade
Arm
Brace
D65EX, PX-15
10-199
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm
No.
Check item
Spherical clearance between
1
trunnion and cap
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+1.5
0
0.1 – 2.0
8.0
Shaft
Hole
S 140
–0.1
–0.5
2
Clearance between arm
mounting pin and bracket (Large)
100
–0.6
–1.0
+1.5
+1.0
1.6 – 2.5
3.5
3
Clearance between arm
mounting pin and bracket (Small)
80
–0.6
–1.0
+1.5
+1.0
1.6 – 2.5
3.5
4
Clearance between brace
mounting pin and arm bracket
50
–0.3
–0.6
+0.7
0
0.3 – 1.3
2.0
5
Clearance between brace
mounting pin and brace
50
–0.3
–0.6
+0.2
0
0.3 – 0.8
2.0
6
Clearance between brace
mounting pin and joint
50
0
–0.3
+0.2
0
0 – 0.5
2.0
7
Clearance between brace
mounting pin and bearing
50
0
–0.3
+0.5
0
0 – 0.8
2.0
8
Clearance between joint
mounting pin and bracket
50
–0.1
–0.3
+0.3
0
0.1 – 0.6
2.0
9
Clearance between joint
mounting pin and joint
50
–0.1
–0.3
+0.2
0
0.1 – 0.5
2.0
10
Clearance between center shaft
and frame
79.5 (Shaft)
80 (Hole)
–0.2
–0.5
+0.5
–0.5
0.2 – 1.5
2.0
11
Clearance between center shaft
mounting pin and bracket
55
–0.1
–0.3
+0.3
0
0.1 – 0.6
2.0
12
Clearance between center shaft
mounting pin and center shaft
55 (Shaft)
60 (Hole)
–0.1
–0.3
+0.5
+0.1
5.2 – 5.8
7.0
10-200
Replace
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CUTTING EDGE, END BIT
CUTTING EDGE, END BIT
Unit: mm
No.
Check item
Criteria
Standard size
Repair limit
242
187
204
187
315
237
A (EX)
242
187
PT (EX)
330
300
325
300
540
515
A (EX)
330
300
PT (EX)
204
187
204
187
254
237
A (EX)
204
187
PT (EX)
102
85
102
85
102
85
102
85
PT (EX)
1
PT (PX)
Height of end bit
(outside) PTP (PX)
SEMI-U
(EX,WX)
2 Width of end bit
PT (PX)
PTP (PX)
SEMI-U
(EX,WX)
PT (PX)
PTP (PX)
Height of end bit
3
(inside) SEMI-U
(EX,WX)
Height of cutting edge PT (PX)
PTP (PX)
4
(From center of bolt SEMI-U
hole to end face)
(EX,WX)
A (EX)
Tightening torque of
5 end bit and cutting
edge
Remedy
PT (EX)
392.2 – 529.2 Nm {40 – 54 kgm}
PT (PX)
PTP (PX)
392.2 – 529.2 Nm {40 – 54 kgm}
SEMI-U
(EX,WX)
Cutting edge: 392.2 – 529.2 Nm {40 – 54 kgm}
End bit: 637 – 852.6 Nm {65 – 87 kgm}
A (EX)
392.2 – 490.3 Nm {40 – 50 kgm}
Replace
Retighten
PT: For power tilt dozer, PTP: For power tilt, power pitch dozer, SEMI-U: semi-U dozer, A: For angledozer
D65EX, PX-15
10-201
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
RIPPER
RIPPER
D65EX-15
D65WX-15
(If equipped)
Unit: mm
No.
Check item
Clearance between pin and
1
bushing
2 Wear of point
3.
4.
5.
6.
7.
8.
9.
Bracket
Upper link
Ripper cylinder
Beam
Shank
Point
Lower link
10-202
(7)
Criteria
Standard
size
56
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
–0.030
–0.076
+0.299
+0.169
0.199 –
0.375
1.0
Standard size
Repair limit
222
152
Replace
A: Pin hole A (Point digging angle: 55 deg.)
B: Pin hole B (Point digging angle: 45 deg.)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CAB MOUNT
CAB MOUNT
1. Support
2. Damper mount (front)
3. Damper mount (rear)
Outline
•
•
D65EX, PX-15
Viscous damper mounts (2) and (3) are installed
at two places at the front and two places at the
rear to secure the floor frame and cab.
An oil-filled damper mount is used to absorb the
vibration.
10-203
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CAB
CAB
1.
2.
3.
4.
Front wiper
Front glass
Rear wiper
Door
10-204
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CAB
ROPS GUARD
a ROPS: Abbreviation for ROllover Protective Structure
1. ROPS guard
D65EX, PX-15
10-205
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
AIR CONDITIONER PIPING
AIR CONDITIONER PIPING
1.
2.
3.
4.
5.
6.
7.
8.
Condenser
Valve (hot water outlet)
Hot water pick-up piping
Refrigerant piping
Receiver tank
Hot water return piping
Air conditioner compressor
Valve (hot water inlet)
10-206
9. Front window defroster
10. Air conditioner unit
11. Vent
12. Blower motor
13. Side window defroster
A. Fresh air
B. Recirculated air
C. Hot air/cold air
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE CONTROL
ENGINE CONTROL
1. Battery
2. Starting switch
3. Engine
4. Starting motor
5. Engine controller
6. Transmission and steering controller
7. Neutral safety relay
8. Limit switch
9. Parking brake lever
10. Electric lever
11. Steering/directional/gear shift lever (PCCS lever)
Function
•
A limit switch is installed to the linkage of the
parking brake. The transmission and steering
controller permits the engine to start only when
the parking brake is in the LOCK position and the
steering/directional/gear shift lever is in the N
(Neutral) position.
Input and output signals
a.
b.
c.
d.
e.
Battery power source
Engine start signal
Starting switch ACC signal
Parking brake signal
Neutral signal
D65EX, PX-15
10-207
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
1. Battery
2. Starting switch
3. Neutral safety relay
4. Fuel supply pump power relay
5. Engine controller
6. Transmission and steering controller
7. Monitor panel
8. Fuel control dial
9. Decelerator pedal
10. Engine
11. Engine speed sensor
12. Coolant temperature sensor
13. Engine oil pressure sensor
14. Injector
15. Fuel supply pump valve
10-208
Input and output signals
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
1st throttle signal (Fuel control dial signal)
2nd throttle signal (Decelerator pedal signal)
3rd throttle signal (Controller control signal)
Starting switch ACC signal
Controller power source
Engine speed signal
Coolant temperature signal
Engine oil pressure signal
Sensor signal
Monitor display signal
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE CONTROL SYSTEM
Engine speed control mechanism
•
•
•
•
The engine controller receives the 1st throttle
signal (fuel control dial signal) and 2nd throttle
signal (decelerator pedal signal). It also receives
the 3rd throttle signal (controller control signal)
from the transmission and steering controller,
and then selects the lowest command signal and
controls the fuel supply pump and injector.
The 3rd throttle signal has 1) Automatic deceleration (F3, R3).
The transmission and steering controller calculates proper engine speed from the information
of 1) and sends it as the 3rd throttle signal to the
engine controller.
The information from the engine controller is
owned jointly by the other controllers and transmitted so that the relationship between the engine and chassis will be optimized.
The automatic deceleration is a function of lowering the engine speed temporarily when the
travel direction is changed from F3 or R3 (for
protection of the transmission clutch).
Engine stop mechanism
•
•
If the starting switch is set in the OFF position,
the starting switch ACC signal to the engine controller is turned OFF. At this time, any current
does not flow in the coil of the fuel supply pump
power relay. As a result, the relay is turned OFF
to cut out the operating current of the engine
controller to prevent a malfunction.
The engine controller stops supplying fuel to the
engine to stop the engine.
D65EX, PX-15
10-209
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CRI ENGINE CONTROL SYSTEM
CRI ENGINE CONTROL SYSTEM
a CRI: Abbreviation for Common Rail Injection
SYSTEM DIAGRAM
1. Fuel tank
2. Fuel supply pump assembly
2a. PCV (Discharge control valve)
2b. High pressure pump
2c. Priming pump
2d. Feed pump
2e. Bypass valve
2f. G speed sensor
3. Fuel filter
4. Overflow valve
5. Common rail
10-210
6. Pressure limiter
7. Flow damper
8. Injector assembly
8a. Orifice
8b. Control chamber
8c. Hydraulic piston
8d. Injector
8e. Nozzle
9. Engine controller
10. NE speed sensor
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
CRI ENGINE CONTROL SYSTEM
Outline
•
•
The signals detected by various sensors are input to the engine controller.
The input signals are processed by the controller
and output to each actuator to control the fuel injection rate and fuel injection timing.
System configuration
•
•
•
•
•
•
•
•
The CRI system consists of fuel supply pump assembly (2), common rail (5), injector assembly
(8), engine controller (9) to control them, and
sensors.
The fuel supply pump assembly (2) generates
fuel pressure in the common rail. The fuel pressure is controlled by the fuel discharge rate of
the supply pump assembly (2). The discharge
rate is controlled by turning on and off PCV (discharge control valve) (2a) of the fuel supply
pump assembly (2) according to the electric signals from the engine controller.
The common rail (5) receives the pressurized
fuel from the fuel supply pump assembly (2) and
distributes it to the cylinders.
The fuel pressure is sensed by the common rail
(5) fuel pressure sensor installed to the common
rail and controlled by the feedback method so
that the actual fuel pressure will match to the
command pressure set according to the engine
speed and the load on the engine.
The fuel pressure in the common rail is applied
to the nozzle (8e) side of the injector assembly
(8) and control chamber (8b) through the fuel injection pipe of each cylinder.
The injector assembly (8) controls the fuel injection rate and fuel injection timing by turning on
and off the TWV (2-way solenoid valve).
If the TWV is turned on, the fuel circuit is so
changed that the high-pressure fuel in the control chamber (8b) will flow through orifice (8a).
The needle valve is raised to start fuel injection
by the nozzle (8e) cracking pressure applied as
the high-pressure fuel on the nozzle side.
If the TWV is turned OFF, high-pressure fuel is
supplied through orifice (8a) to control chamber
(8b). As a result, the needle valve of nozzle (8e)
lowers to stop fuel injection.
Accordingly, the fuel injection timing and fuel injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
D65EX, PX-15
10-211
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING SYSTEM CONTROL SYSTEM
COOLING SYSTEM CONTROL SYSTEM
1. Battery
2. Battery relay
3. Transmission and steering controller
4. Engine controller
5. Monitor panel
6. Cooling fan motor
7. Cooling fan pump
8. Fan rotation selector switch
9. Power train oil temperature sensor
10. Hydraulic oil temperature sensor
11. Engine
12. Engine speed sensor
13. Coolant temperature sensor
10-212
(7)
Input and output signals
a.
b.
c.
d.
e.
f.
g.
h.
i.
Controller power source
Fan rotation selector signal
Power train oil temperature signal
Hydraulic oil temperature signal
Engine speed signal
Coolant temperature signal
CAN signal
Pump control signal
Fan reverse signal
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
COOLING SYSTEM CONTROL SYSTEM
Outline
Selection of fan rotation mode
•
•
The transmission and steering controller monitors the coolant, power train oil, and hydraulic oil
temperatures and controls the fan speed according to those temperatures.
Function
Fan speed control
•
•
•
The transmission and steering controller controls the discharge of the cooling fan to set the
fan speed properly according to the information
from the coolant, power train oil, and hydraulic oil
temperature sensors.
The transmission and steering controller selects
the maximum target fan speed obtained from the
coolant, power train oil, and hydraulic oil temperatures and outputs it as the pump control signal
to the cooling fan pump.
The cooling fan pump changes its swash plate
angle to controls its oil discharge for the cooling
fan motor.
While the starting switch is in the ON position
and the engine is stopped, one of the following
fan rotation modes can be selected with the fan
rotation selector switch.
1) Forward rotation mode
2) Reverse rotation mode
3) Cleaning mode
The transmission and steering controller operates the reverse solenoid valve of the cooling fan
motor to change the rotation direction of the fan
according to the selected mode.
1) Forward rotation mode
In this mode, the reverse solenoid valve
does not operate and the fan rotates forward. The fan speed varies with the temperature sensor signal. This mode is selected
normally.
2) Reverse rotation mode
In this mode, the reverse solenoid valve operates and the fan rotates in reverse. The fan
can warm the operator’s cab as a substitute
for a reversible fan. Since the cooling efficiency is low in this mode, the engine overheats easily. Accordingly, this mode shall be
used only in cold weather.
3) Cleaning mode
In this mode, the fan rotates in reverse at
high speed to blow off dirt from the radiator
fins, regardless of the temperature sensor
signals. If this mode is used periodically, the
cleaning interval of the radiator fins can be
expanded.
Interlock for changing rotation mode
•
D65EX, PX-15
If the rotation direction of the fan is changed
while the fan is rotating, the fan drive circuit is
broken. To prevent this, the fan rotation selector
switch signal is ignored while the engine is running. In this case, the fan operation pilot lamp on
the monitor panel flashes.
10-213
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PALM COMMAND CONTROL SYSTEM
PALM COMMAND CONTROL SYSTEM
1.
2.
3.
4.
5.
6.
7.
8.
Monitor panel
Automatic shift-down switch
Preset mode switch
Steering/directional/gear shift lever (PCCS lever)
Engine controller
Transmission and steering controller
Engine speed sensor
Engine
10-214
9. Torque converter
10. Transmission
11. Transmission control valve
12. Transmission output shaft speed sensor
13. HSS unit
14. Control valve
14a. Steering control valve
15. HSS motor
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PALM COMMAND CONTROL SYSTEM
Preset mode function
Automatic shift-down function
•
•
The gear speed applied for forward travel and reverse travel can be set in advance.
Preset mode 1: F1-R1
Preset mode 2: F1-R2
Preset mode 3: F2-R2
Preset mode 4: F2-R3
1. How to use
1) Set the PCCS lever in the N (Neutral) position.
2) Set the preset mode switch (1) to the ON position.
3) Press the UP/DOWN switch of the PCCS lever to select a mode.
If the travel speed lowers because of the loading
condition, the transmission gear is shifted down
automatically.
1) The traction force (load on the chassis) is
calculated from the engine speed, transmission output shaft speed, and the throttle information sent from the transmission and
steering controller, and then the transmission gear is shifted down automatically according to the load and travel speed.
2) Once the transmission gear is shifted automatically, it is not shifted up again automatically. (It can be shifted up with the UP switch
of the PCCS lever, however.)
3) This function is applicable to both forward
and reverse travels.
1. How to use
1) Set the automatic shift-down switch (2) to the
ON position.
2. Display
• The selected mode is displayed on display
panel B of the monitor panel.
D65EX, PX-15
10-215
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SYSTEM COMPONENTS
SYSTEM COMPONENTS
Fuel control dial
1.
2.
3.
4.
5.
6.
Knob
Dial
Spring
Ball
Potentiometer
Connector
Function
•
•
•
10-216
(7)
The fuel control dial is installed to the left side of
the operator’s seat.
If knob (1) is turned, the shaft of potentiometer
(5) is turned to change the resistance of the variable resistor and send a throttle signal to the engine controller.
The hatched areas in the following graph is the
abnormality detection areas. In those areas, the
engine speed is reduced to a half.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SYSTEM COMPONENTS
Decelerator pedal potentiometer
1.
2.
3.
4.
5.
6.
7.
Lever
Shaft
Coupling
Body
Potentiometer
Stopper
Connector
D65EX, PX-15
Function
•
•
The decelerator pedal potentiometer is installed
under the front part of the floor and connected to
the decelerator pedal by the linkage.
If the decelerator pedal is operated, the shaft of
potentiometer (5) is turned through the linkage to
change the resistance of the variable resistor
and send a deceleration signal to the engine
controller.
10-217
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE CONTROLLER
ENGINE CONTROLLER
10-218
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE CONTROLLER
Input and output signals
DEUTSCH-24P [CN-EN1]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
Signal name
Service power source (+24 V)
Service power source (+24 V)
Model selection 1
NC
NC
NC
GND (Battery ground)
GND (Battery ground)
NC
NC
NC
Preheating
Input/Output
signal
—
—
Input
—
—
—
—
—
—
—
—
Output
Pin No.
13
14
15
16
17
18
19
20
21
22
23
24
Signal name
Starting switch (ACC)
NC
Engine oil pressure (H)
NC
NC
NC
Starting switch (ACC)
Starting switch (C)
Engine oil pressure (L)
NC
NC
NC
Input/Output
signal
Input
—
Input
—
—
—
Input
Input
Input
—
—
—
DEUTSCH-40P (1) [CN-EN2]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Signal name
NC
NC
NC
RS232C RX1
NC
NC
NC
NC
Sensor power source (+5 V)
Fuel control dial
NC
CAN shield
NC
RS232C TX1
G shield
Ne shield
Fuel temperature sensor
NC
Sensor power source (+5 V)
Boost pressure sensor
Input/Output
signal
—
—
—
Input
—
—
—
—
Output
Input
—
—
—
Output
—
—
Input
—
Output
Input
Pin No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Signal name
NC
CAN0 (L)
NC
Flash ROM write permission signal
G sensor (–)
Ne sensor (–)
Engine coolant temperature sensor (H)
NC
GND (Sensor)
NC
NC
CAN0 (H)
NC
GND (RS232C)
G sensor (+)
Ne sensor (+)
Engine coolant temperature sensor (L)
Decelerator pedal signal
GND (Sensor)
Common rail pressure sensor
Input/Output
signal
—
Input/Output
—
Input
Input
Input
Input
—
—
—
—
Input/Output
—
—
Input
Input
Input
Input
—
Input
DEUTSCH-40P (2) [CN-EN3]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Signal name
Power source (Injector, supply pump)
Power source (Injector, supply pump)
NC
NC
Injector 3 (+)
Injector 2 (+)
Transmission neutral signal 1
NC
NC
NC
GND (Battery ground)
Fuel supply pump 1 (+)
Fuel supply pump 2 (+)
Injector 1 (+)
Injector 3 (–)
Injector 2 (–)
Transmission neutral signal 2
NC
NC
NC
D65EX, PX-15
Input/Output
signal
—
—
—
—
Output
Output
Input
—
—
—
—
Output
Output
Output
Output
Output
Input
—
—
—
Pin No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Signal name
Power source (Injector, supply pump)
Fuel supply pump 1 (–)
Fuel supply pump 2 (–)
Injector 1 (–)
Injector 6 (+)
Injector 4 (+)
NC
NC
NC
NC
GND (Battery ground)
GND (Battery ground)
Injector 5 (–)
Injector 5 (+)
Injector 6 (–)
Injector 4 (–)
NC
NC
NC
NC
Input/Output
signal
—
Output
Output
Output
Output
Output
—
—
—
—
—
—
Output
Output
Output
Output
—
—
—
—
10-219
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION AND STEERING CONTROLLER
TRANSMISSION AND STEERING CONTROLLER
10-220
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
TRANSMISSION AND STEERING CONTROLLER
Input and output signals
DEUTSCH-24P [CN-ST1]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
Signal name
NC
Swing control lever potentiometer 1
Brake pedal potentiometer
GND (Signal)
NC
Service switch
Travel lever potentiometer 4
Pitch angle sensor
Hydraulic oil temperature sensor
NC
NC
Shift-up switch (NC)
Input/Output
signal
—
Input
Input
—
—
Input
Input
Input
Input
—
—
Input
Pin No.
13
14
15
16
17
18
19
20
21
22
23
24
Signal name
Travel lever potentiometer 3
NC
Alternator (R)
Sensor power source (+24 V)
NC
Shift-down switch (NO)
Travel lever potentiometer 2
NC
GND (Analog)
Sensor power source (+5 V)
NC
Shift-down switch (NC)
Input/Output
signal
Input
—
Input
Output
—
Input
Input
—
—
Output
—
Input
DEUTSCH-40P (1) [CN-ST2]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Signal name
NC
NC
NC
Flash ROM write (Rx)
Parking switch (NC)
Cursor switch 2
Fan reverse switch
Neutral safety relay
NC
Manual mode switch
NC
CAN shield
NC
Flash ROM write (Tx)
Parking switch (NO)
Cursor switch 1
Fan forward switch
Backup alarm relay
Transmission (N)
Immobilize signal
Input/Output
signal
—
—
—
Input
Input
Input
Input
Input
—
Input
—
—
—
Output
Input
Input
Input
Output
Output
Input
Pin No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Signal name
NC
CAN0 (L)
NC
Flash ROM write permission signal
Transmission reverse fill switch
Selector switch
NC
NC
GND (Pulse)
Transmission output shaft speed
NC
CAN0 (H)
NC
GND (Flash ROM write)
Transmission forward fill switch
Alarm buzzer cancel switch
Automatic shift-down switch
NC
NC
NC
Input/Output
signal
—
Input/Output
—
Input
Input
Input
—
—
—
Input
—
Input/Output
—
—
Input
Input
Input
—
—
—
DEUTSCH-40P (2) [CN-ST3]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Signal name
Power source (Controller)
Power source (Solenoid)
GND (Solenoid, common)
For driving battery relay
NC
1st gear speed ECMV
NC
NC
Shift-up switch (NO)
Pitch selector switch (NC)
Power source (Controller)
Power source (Solenoid)
GND (Solenoid, common)
Starting switch (ACC)
NC
2-spool ECMV
Pitch selector solenoid
Fan reverse solenoid
Transmission 1st gear fill switch
Pitch selector switch (NO)
D65EX, PX-15
Input/Output
signal
Input
Input
Input
Output
—
Output
—
—
Input
—
Input
Input
Input
Input
—
Output
Output
Output
Input
—
Pin No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Signal name
GND (Power source)
Power source (Solenoid)
GND (Solenoid, common)
Starting switch (ACC)
HSS spool (Left)
3rd gear speed ECMV
Forward ECMV
NC
Transmission 2nd gear fill switch
HSS specification selection
GND (Power source)
GND (Power source)
GND (Power source)
NC
HSS spool (Right)
Fan control solenoid
Reverse ECMV
NC
Transmission 3rd gear fill switch
C/B specification selection
Input/Output
signal
Input
Input
Input
Input
Output
Output
Output
—
Input
Input
—
—
—
—
Output
Output
Output
—
Input
Input
10-221
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
MONITOR SYSTEM
MONITOR SYSTEM
a.
b.
c.
d.
e.
Each sensor
Sensor signal
Engine controller
Transmission and steering controller
CAN signal
•
The monitor system notifies the operator of the
machine condition. It monitors the machine condition with the sensors installed to the machine
and processes and displays the obtained information on the monitor panel immediately.
The contents displayed on the panel are roughly
classified as shown bellow.
1. Travel direction, gear speed (Display panel A)
2. Engine speed, coolant temperature, hydraulic oil temperature, power train oil temperature, and fuel level (Gauge section)
3. Machine trouble alarm (Monitor section)
4. Current, voltage, error code, of each sensor
and solenoid (Display panel B)
10-222
f.
g.
h.
i.
j.
Controller signal
Battery
Power source
Buzzer
Buzzer signal
•
•
•
The monitor system consists of the monitor panel, controller, sensors, alarm buzzer, and power
supply.
The component parts are connected by wiring
harnesses and the monitor panel is powered by
the battery.
If the machine has any trouble (and a sensor detects it), the monitor and alarm lamp flash and
the alarm buzzer sounds to protect the machine.
The alarm buzzer can be turned OFF temporarily with the buzzer cancel switch.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
MONITOR SYSTEM
Processing in monitor panel (Common to all specifications)
Display of monitor panel
Contents and conditions of processing
Method
Flow of signals
1. Display of travel direction and gear speed
• Signals (F1, R3, etc.) are sent to the monitor panel according to the informa- CAN signal
tion of the transmission and steering controller.
2. Display of engine speed, coolant temperature, hydraulic oil temperature, power
train oil temperature, and fuel level by gauge
CAN signal
• The controller processes the sensor signals and converts them into gauge
levels and sends the result to the monitor panel.
3. Display of trouble
• If there is any trouble, its failure code signal is sent to the monitor panel.
• Information about sounding the buzzer and flashing the caution lamp is sent,
according to the contents of the trouble.
1) In normal state
An action code is displayed.
CAN signal
2) In failure history display mode
A failure code (6-characteristics code) and the following are displayed.
• Elapsed time after first occurrence
• Elapsed time after latest occurrence
• Number of occurrences
Each sensor/solenoid
O
Controller
O
Monitor panel
Display of monitor panel
Contents and conditions of processing
Method
1. Display of each sensor, each solenoid, communicating state of CAN signal, etc.
• The signals of the item No. and condition of each device are sent to the mon- CAN signal
itor panel.
2. Selection of each item with information switch, buzzer cancel switch, and up/
down (gear-shift) switch of the steering/directional/gear shift lever.
(When using a mode for service, turn the service switch ON.)
CAN signal
Flow of signals
Each sensor
O
Controller
O
Monitor panel
a For details of the operating method, see TESTING AND ADJUSTING, Special functions of monitor panel
(EMMS).
Other items
Contents and conditions of processing
Method
Flow of signals
1. Filter and oil maintenance mode
2. Pm clinic auxiliary mode
3. Failure code display mode
4. Adjustment mode (User)
5. Maintenance interval change mode
6. Electric system failure code display mode
7. Mechanical system failure code display mode
8. Adjustment mode (Service)
9. Load saving display mode
10. Real-time monitoring mode
11. Dual display monitoring mode
a For details of the operating method, see TESTING AND ADJUSTING, Special functions of monitor panel
(EMMS).
D65EX, PX-15
10-223
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
MONITOR PANEL
MONITOR PANEL
Outline
Check before starting
•
•
The monitor panel consists of the monitor section which outputs an alarm when the machine
has any trouble and the gauge section and display panel which display the machine condition
constantly.
The monitor panel has a microcomputer, which
processes and displays the signals from the sensors, solenoids, and controllers.
The items displayed on the monitor section and
gauge section are shown in DISPLAY OF MONITOR PANEL.
Operation
After the operation performed when the power is
turned ON, if there is any abnormal one in the
check-before-starting items, the lamp of that
item flashes or the contents of the abnormality
are displayed on display panel B.
Caution items
•
The caution items are checked constantly while
the engine is running.
If any item is abnormal, it and alarm lamp flash
synchronously. The alarm buzzer may sound at
this time.
When power is turned ON
(When starting switch is turned to ON position)
•
All the LC segments and lamps of the monitor
panel light up for 2 seconds and the alarm buzzer sounds for 2 seconds.
10-224
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
MONITOR PANEL
Buzzer cancel switch
•
If this switch is operated while the alarm buzzer
is sounding, the buzzer is turned OFF temporarily.
While the buzzer is turned OFF, if a new trouble
which turns on the buzzer is detected, the buzzer
sounds again.
a The lamp lights up and goes off at the intervals
of about 0.8 seconds.
a The flashing intervals of the lamp may change a
little when the temperature is low (below about
–10ºC). This does not indicate a trouble.
Input and output signals
AMP070-20P [CN-S03]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Signal name
Power source (24 V)
Power source (24 V)
GND
GND
Service power (24 V)
Service power (24 V)
Starting switch C terminal
Night lighting
Preheating
NC
NC
NC
NC
NC
NC
Service switch
NC
Alarm buzzer
NC
NC
D65EX, PX-15
AMP070-12P [CN-S04]
Input/Output
signal
Input
Input
—
—
Input
Input
Input
Input
Input
—
—
—
—
—
—
Input
—
Output
—
—
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
Signal name
CAN0-H
CAN0-H
CAN0-L
CAN0-L
CAN shield
NC
NC
NC
Alternator R terminal
Fuel level
NC
Power train oil level
Input/Output
signal
Input/Output
Input/Output
Input/Output
Input/Output
—
—
—
—
Input
Input
—
Input
10-225
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
MONITOR PANEL
Monitor panel display
10-226
(7)
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
MONITOR PANEL
Caution
lamp
Output
Alarm
buzzer
Output
Display
color
Remarks
-
-
Black
LCD
OFF
Red
LED
Flashing
OFF
OFF
ON
-
-
Black
LCD
OFF
Red
LED
Flashing
OFF
OFF
ON
-
-
Black
LCD
OFF
Red
LED
Flashing
OFF
OFF
ON
-
-
OFF
OFF
1: PCCS lever gear speed
Black
switch in "1st"
2: PCCS lever gear speed
Gear speed
switch in "2nd"
(1,2,3)
3: PCCS lever gear speed
switch in "3rd"
At corresponding segment
Gauge
See diagram at left
or lower all light up
[*1]
Time is counted while
Character
6
Display
panel
B
0
99999.9h
engine is running
display
(service meter)
(alternator is generating)
Lamp is OFF
OFF
OFF
(while engine is stopped)
When charge is abnormal
7
Charge level
(12V or lower)
Lamp is flashing
Flashing
OFF
(while engine is running)
Red
Caution
Lamp is OFF
OFF
OFF
Specified value or lower
(while engine is stopped)
8
Engine oil pressure
Lamp is flashing
(49kPa {0.5kg/cm2})
Flashing
ON
(while engine is running)
9
Pilot
Preheating
In preheating mode
Lamp is ON
OFF
OFF Green
Before 30h or more
OFF
After starting switch is
10
Maintenance
OFF
OFF Orange
turned "ON"
Before 30h - Replacement time
Lamp lights up for
30 seconds
11
Warning lamp
See the "Caution lamp output" column of this table
Red
Before 30h or more
OFF
Replacement time Before 30h - Replacement time
After starting switch Lamp
OFF
OFF Yellow
12
is ON
of filter and oil
is turned "ON"
FlashAfter replacement time
Caution
for 30 seconds
ing
• From when the starting switch is
turned "ON" in the fan reverse and
Lamp is ON
cleaning mode when the engine is
stopped
Check of operaOFF
OFF Orange
13
• Fan and selector switch are operated
tion of fan
while the engine is running
• Time to keep the power ON after the Flashing
starting switch is turned "OFF" in the
fan reverse and cleaning mode
*1: For details of the operation in the service mode, see Testing and adjusting, Special functions of monitor panel (EMMS).
LCD
No.
Display
section
1a
Gauge
1b
Caution
Display item
See diagram at left
Coolant temperature
2a
2b
3a
3b
4
Gauge
Caution
Gauge
102°C or lower
102°C - 108°C
108°C or higher
See diagram at left
Power train oil
level
Gauge
Caution
Display range
120°C or lower
120°C - 130°C
130°C or higher
See diagram at left
Hydraulic oil
temperature
Fuel level
100°C or lower
100°C - 110°C
110°C or higher
See diagram at left
Travel direction
(P,N,F,R)
5
[*1]
Display panel A
Indicator
(travel direction,
gear speed,
engine tachometer)
D65EX, PX-15
Display method
Corresponding segment
(1 place) All light up
OFF
Flashing
Flashing
Corresponding segment
(1 place) All light up
OFF
Flashing
Flashing
Corresponding segment
(1 place) All light up
OFF
Flashing
Flashing
At corresponding segment
or lower all light up
P: Parking brake lever in
"Lock" and PCCS lever in
Neutral: lamp is ON
N: PCCS lever in "Neutral":
lamp is ON
F: PCCS lever in "Forward":
lamp is ON
R: PCCS lever in "Reverse":
lamp is ON
Flashing
Flashing
Flashing
LED
10-227
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SENSORS
SENSORS
•
•
•
The signals from the sensors are input through the controller to the monitor panel.
The sensors are classified into 4 types of contact, resistance, electromagnetic, and capacitor.
Either side of each sensor of contact type is always connected to the chassis ground.
Name of sensor
Type of sensor
When normal
When abnormal
Engine oil pressure
Contact
OFF
ON
Coolant temperature
Resistance
—
—
Power train oil temperature
Resistance
—
—
Hydraulic oil temperature
Resistance
—
—
Fuel level
Resistance
—
—
Engine speed
Electromagnetic
—
—
Transmission output shaft speed
Electromagnetic
—
—
Capacitor
—
—
Pitch angle
ENGINE OIL PRESSURE SENSOR
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Function
•
10-228
The engine oil pressure sensor is installed to the engine cylinder block. Its diaphragm senses the oil pressure. If the oil pressure lowers below the specified level, the switch is turned ON.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SENSORS
COOLANT TEMPERATURE SENSOR (FOR MONITOR)
Power train oil temperature sensor
Hydraulic oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
•
The coolant temperature sensor (for monitor) is installed to the engine cylinder block. The power train oil
temperature sensor is installed to the transmission outlet piping. The hydraulic oil temperature sensor is installed to the hydraulic piping. These sensors sense the change of the temperature by the change of resistance of the thermistors in them.
The temperature signals are sent through the network to the transmission and steering controller and used
to control the cooling fan.
COOLANT TEMPERATURE SENSOR (FOR PREHEATING)
Fuel temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
•
The coolant temperature sensor (for preheating) is installed to the engine coolant piping and the fuel temperature sensor is installed to the engine fuel piping. These sensors sense the change of the temperature
by the change of resistance of the thermistors in them.
D65EX, PX-15
10-229
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SENSORS
FUEL LEVEL SENSOR
1.
2.
3.
4.
Connector
Float
Arm
Body
5. Spring
6. Contact
7. Spacer
Function
•
10-230
The fuel level sensor is installed to the side of the fuel tank. Its float moves up and down according to the
fuel level.
The movement of the float operates the variable resistor through the arm. As a result, signals of change in
resistance are generated.
D65EX, PX-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SENSORS
ENGINE SPEED SENSOR
1. Connector
2. O-ring
3. Sensor
Function
•
The engine speed sensor is installed to the ring gear of the flywheel housing. It generates pulse voltages as
the gear rotates.
TRANSMISSION OUTPUT SHAFT SPEED SENSOR
1. Magnet
2. Wire
3. Housing
4. Terminal
5. Boots
6. Connector
Function
•
The transmission output shaft speed sensor is installed to the bevel gear of steering case. It generates pulse
voltages as the gear rotates.
D65EX, PX-15
10-231
(7)
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SENSORS
PITCH ANGLE SENSOR
1. Body
2. Tube
3. Wire
4. Connector
Function
•
•
The pitch angle sensor is installed to the base of the ROPS in the filter cover on the right side of the chassis.
There are multiple electrodes and oil in this sensor. The changes of the oil level made by inclination of the
machine are sensed by the differences in electrostatic capacity between the electrodes, and then those differences are converted into voltage signals.
10-232
D65EX, PX-15
TESTING AND ADJUSTING
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE
Standard value table for engine ............................................................................................................ 20- 2
Standard value table for chassis ........................................................................................................... 20- 4
TESTING AND ADJUSTING ................................................................................................................... 20-101
TROUBLESHOOTING ............................................................................................................................ 20-301
a Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to
judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
D65EX, PX-15
20-1
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Item
Machine model
D65EX, PX, WX-15
Engine
SA6D125E-3
Measurement conditions
Unit
High idling
Engine speed
Low idling
rpm
Rated speed
kPa
{mmHg}
Air supply
At rated output
Exhaust gas color
At sudden acceleration
At high idling
Exhaust temperature
(Torbocharger inlet
temperature)
Whole speed range
(Ambient temperature 20ºC)
ºC
Valve clearance
Intake valve
Exhaust valve
mm
Bosch index
Compression pressure
(SAE30 or SAE15W-40)
Oil temperature: 40 – 60ºC
(Engine speed)
MPa
{kg/cm2}
(rpm)
Blow-by pressure
(SAE30 or SAE15W-40)
(Water temperature: Operating range)
At rated output
kPa
{mmH2O}
Standard value for
Service limit value
new machine
2,100 ± 50
2,100 ± 50
825 ± 50
825 ± 50
1,950
—
Min. 79.8
{Min. 600}
Max. 4.5
Max. 1.0
60
{450}
6.5
2.0
Max. 650
700
0.33
0.71
Min. 2.9
{Min. 30}
(150 – 200)
—
—
Max. 0.98
{Max. 100}
1.96
{200}
392 – 690
{4.0 – 7.0}
343 – 640
{3.5 – 6.5}
Min. 147
{Min. 1.5}
Min. 98
{Min. 1.0}
206
{2.1}
176
{1.8}
69
{0.7}
69
{0.7}
90 – 120
Min. 120
13
—
15 – 18
—
—
(Water temperature: Operating range)
At high idling (SAE30 or SAE15W-40)
Oil pressure
At high idling (SAE10W)
kPa
{kg/cm2}
At low idling (SAE30 or SAE15W-40)
At low idling (SAE10W)
Oil temperature
Whole speed range (Inside oil pan)
Belt tension
Deflection when
pressed with a
finger force of
approx. 58.8 N
{approx. 6 kg}
Deflection when
pressed with a
finger force of
approx. 98 N
{approx. 10 kg}
20-2
(7)
ºC
Alternatorcrankshaft pulley
mm
Air conditionercrankshaft pulley
D65EX, PX-15
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Machine model
Item
Measurement conditions
• Engine water temperature:
Decelerator pedal
Within operating range
speed
• Power train oil temperature:
Within operating range
• Hydraulic oil temperature:
Within operating range
Torque converter
• Decelerator pedal speed: Press pedal.
stall speed
• Torque converter stall speed: F3
Neutral o
Forward
Forward and
reverse
Neutral o
Reverse
• Stop engine.
• Set lever knob to center.
Neutral o
Left
Steering
Neutral o
Right
• Stop engine.
Decelerator pedal
• Set pedal to center.
• Engine: Low idling
Brake pedal
All stroke
• Set pedal to center.
Neutral o
Raise/Float
• Engine: Low idling
• Hydraulic oil temperature:
Neutral o
Blade lever
45 – 55ºC
Lower
• Set lever knob to center.
Neutral o
Left/Right tilt
• Engine: Low idling
Neutral o
Ripper lever
• Hydraulic oil temperature:
(If equipped)
45 – 55ºC Raise/Lower
• Set lever knob to center.
Neutral o
Forward
Neutral o
Reverse
Forward and
reverse
Forward o
Neutral
• Stop engine.
Reverse o
• Set lever knob to center.
Neutral
Neutral o
Left
Steering
Neutral o
Right
• Engine: Low idling
Decelerator pedal
• Set pedal to center.
• Engine: Low idling
Brake pedal
• Set pedal to center.
Neutral o
Raise/Lower
• Engine: Low idling
• Hydraulic oil temperature:
Neutral o
Blade lever
45 – 55ºC
Float
• Set lever knob to center.
Neutral o
Left/Right tilt
Neutral
o
• Engine: Low idling
Raise
Ripper lever
• Hydraulic oil temperature:
(If equipped)
45 – 55ºC Neutral o
• Set lever knob to center.
Lower
Unit
(7)
mm
PCCS lever
Stroke of control lever/pedal
Operating effort of control lever/pedal
20-4
Standard value
for new machine
Service
limit value
1,000 ± 25
1,000 ± 25
1,770 ± 100
1,650
30 ± 10
30 ± 10
30 ± 10
30 ± 10
40 ± 15
(Play: Max. 3)
40 ± 15
(Play: Max. 3)
40 ± 15
(Play: Max. 3)
40 ± 15
(Play: Max. 3)
52 ± 9
52 ± 9
79 ± 12
79 ± 12
72 ± 11
72 ± 11
52 ± 9
52 ± 9
54 ± 8
54 ± 8
54 ± 8
54 ± 8
56.9 ± 19.6
{5.8 ± 2.0}
56.9 ± 19.6
{5.8 ± 2.0}
51 ± 19.6
{5.2 ± 2.0}
51 ± 19.6
{5.2 ± 2.0}
24.5 ± 9.8
{2.5 ± 1.0}
27.4 ± 9.8
{2.8 ± 1.0}
73.5 ± 24.5
{7.5 ± 2.5}
510 ± 88
{52 ± 9.0}
29.4 ± 9.8
{3.0 ± 1.0}
74.5 ± 19.6
{7.6 ± 2.0}
25.5 ± 9.8
{2.6 ± 1.0}
25.5 ± 9.8
{2.6 ± 1.0}
25.5 ± 9.8
{2.6 ± 1.0}
24.5 ± 9.8
{2.5 ± 1.0}
27.4 ± 9.8
{2.8 ± 1.0}
73.5 ± 24.5
{7.5 ± 2.5}
666
{68}
29.4 ± 9.8
{3.0 ± 1.0}
74.5 ± 19.6
{7.6 ± 2.0}
25.5 ± 9.8
{2.6 ± 1.0}
25.5 ± 9.8
{2.6 ± 1.0}
25.5 ± 9.8
{2.6 ± 1.0}
rpm
PCCS lever
Engine speed
Category
D65EX, WX-15
N
{kg}
D65EX, PX-15
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
D65PX-15
Standard value
for new machine
Service
limit value
1,000 ± 25
1,000 ± 25
1,770 ± 100
1,650
30 ± 10
30 ± 10
30 ± 10
30 ± 10
40 ± 15
(Play: Max. 3)
40 ± 15
(Play: Max. 3)
40 ± 15
(Play: Max. 3)
40 ± 15
(Play: Max. 3)
52 ± 9
52 ± 9
79 ± 12
79 ± 12
72 ± 11
72 ± 11
52 ± 9
52 ± 9
54 ± 8
54 ± 8
—
—
56.9 ± 19.6
{5.8 ± 2.0}
56.9 ± 19.6
{5.8 ± 2.0}
51 ± 19.6
{5.2 ± 2.0}
51 ± 19.6
{5.2 ± 2.0}
24.5 ± 9.8
{2.5 ± 1.0}
27.4 ± 9.8
{2.8 ± 1.0}
73.5 ± 24.5
{7.5 ± 2.5}
510 ± 88
{52 ± 9.0}
29.4 ± 9.8
{3.0 ± 1.0}
74.5 ± 19.6
{7.6 ± 2.0}
25.5 ± 9.8
{2.6 ± 1.0}
24.5 ± 9.8
{2.5 ± 1.0}
27.4 ± 9.8
{2.8 ± 1.0}
73.5 ± 24.5
{7.5 ± 2.5}
666
{68}
29.4 ± 9.8
{3.0 ± 1.0}
74.5 ± 19.6
{7.6 ± 2.0}
25.5 ± 9.8
{2.6 ± 1.0}
—
—
—
—
D65EX, PX-15
20-5
(1)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Machine model
Performance of power train
HSS
pressure
Power train oil pressure
Category
20-6
(7)
D65EX, PX, WX-15
Standard value
for new machine
0.1 – 0.5
Engine:
{1 – 5}
Low idling
Torque converter
inlet pressure
Engine:
Max. 0.88
High idling
{Max. 9}
Engine:
0.05 – 0.29
Low idling
{0.5 – 3}
Torque converter
outlet pressure
Engine:
0.39 – 0.69
High idling
{4 – 7}
Engine:
3.13 ± 0.1
Transmission
Low idling
{32 ± 1.0}
main relief
Engine:
3.33 ± 0.1
pressure
High idling
{34.0 ± 1.0}
Engine:
3.13 ± 0.1
Low idling
{32 ± 1.0}
Transmission F
clutch pressure
Engine:
3.33 ± 0.1
High idling
{34.0 ± 1.0}
Engine:
3.13 ± 0.1
Low idling
{32 ± 1.0}
Transmission R
clutch pressure
Engine:
3.33 ± 0.1
• Power train oil temperature:
High idling
{34.0 ± 1.0}
70 – 80ºC Engine:
3.13 ± 0.1
Low idling MPa
{32 ± 1.0}
Transmission 1st
{kg/cm2}
clutch pressure
Engine:
3.33 ± 0.1
High idling
{34.0 ± 1.0}
Engine:
3.13 ± 0.1
Low idling
{32 ± 1.0}
Transmission 2nd
clutch pressure
Engine:
3.33 ± 0.1
High idling
{34.0 ± 1.0}
Engine:
3.13 ± 0.1
Low idling
{32 ± 1.0}
Transmission 3rd
clutch pressure
Engine:
3.33 ± 0.1
High idling
{34.0 ± 1.0}
Transmission
lubricating oil
Engine:
0.1 – 0.25
pressure
High idling
{1.0 – 2.5}
(For reference)
Engine:
2.75 – 2.94
Low idling
{28 – 30}
Brake pressure
Engine:
2.75 – 2.94
High idling
{28 – 30}
36.8 ± 2.0
Relief pressure
{375 ± 20}
• Hydraulic oil temperature: 45 – 55ºC
• Engine: High idling
34.8 ± 2.0
LS pressure
(Load sensing pressure)
{355 ± 20}
Item
Travel speed
Measurement conditions
Unit
Service
limit value
0.1 – 0.5
{1 – 5}
Max. 0.88
{Max. 9}
0.05 – 0.29
{0.5 – 3}
0.39 – 0.69
{4 – 7}
Min. 2.84
{Min. 29}
Min. 3.04
{Min. 31}
Min. 2.84
{Min. 29}
Min. 3.04
{Min. 31}
Min. 2.84
{Min. 29}
Min. 3.04
{Min. 31}
Min. 2.84
{Min. 29}
Min. 3.04
{Min. 31}
Min. 2.84
{Min. 29}
Min. 3.04
{Min. 31}
Min. 2.84
{Min. 29}
Min. 3.04
{Min. 31}
0.1 – 0.25
{1.0 – 2.5}
Min. 2.55
{Min. 26}
Min. 2.55
{Min. 26}
Min. 32.8
{Min. 335}
Min. 30.9
{Min. 315}
F1
3.5 ± 0.2
3.5 ± 0.2
F2
• Flat road
• Engine water temperature:
Within operating range F3
• Power train oil temperature: 70 – 80ºC
• Engine: High idling
R1
• Run up distance: 10 – 30 m
• Measuring distance: 20 m
R2
6.2 ± 0.3
6.2 ± 0.3
9.9 ± 0.5
9.9 ± 0.5
4.7 ± 0.3
4.7 ± 0.3
8.0 ± 0.4
8.0 ± 0.4
12.4 ± 0.6
12.4 ± 0.6
R3
km/h
D65EX, PX-15
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Ripper lift relief
pressure
LS pressure
(Load sensing
pressure)
Control circuit
main pressure
(HSS, PPC, fan)
PPC valve output
pressure
Work equipment speed
Work equipment
Blade lift
Blade tilt
Ripper lift
(If equipped)
Pitch speed
(If equipped)
20-8
(1)
3.43 +1.37
0
3.43 +1.37
0
{35 +14
0 }
Min. 19.6
{Min. 200}
23.5 ± 0.98
{240 ± 10}
Min. 19.6
{Min. 200}
23.5 ± 0.98
{240 ± 10}
Min. 19.6
{Min. 200}
23.5 ± 0.98
{240 ± 10}
21.6 ± 2.0
{220 ± 20}
21.6 ± 2.0
{220 ± 20}
{35 +14
0 }
Min. 19.6
{Min. 200}
19.6
{200}
Min. 19.6
{Min. 200}
19.6
{200}
Min. 19.6
{Min. 200}
19.6
{200}
17.6
{180}
17.6
{180}
4.27 ± 0.25
{43.5 ± 2.5}
4.27 ± 0.25
{43.5 ± 2.5}
3.53 – 4.41
{36 – 45}
3.53 – 4.41
{36 – 45}
Raise
2.6 +–0.2
0.5
3.1
Lower
1.7 ± 0.2
2.0
Left tilt
Work equipment oil pressure
Blade tilt relief
pressure
Service
limit value
Straight tilt
2.5 ± 0.3
3.0
Power tilt
—
—
Straight tilt
2.3 ± 0.3
2.8
—
—
Low idling
2.4 ± 0.2
2.9
High idling
1.4 ± 0.2
1.9
Low idling
1.9 ± 0.2
2.4
High idling
1.1 ± 0.2
1.6
Pitch in
—
—
Pitch back
—
—
Unit
Engine:
High idling
Unload pressure
Blade lift relief
pressure
Standard value
for new machine
Measurement conditions
Engine:
Low idling
• Hydraulic oil temperature:
Engine:
45 – 55ºC
High idling
• Unload pressure:
Engine:
Set all equipment in
Low idling
neutral.
Engine:
• Relief pressure:
High idling
Set cylinder to stroke
Engine:
end.
MPa
Low idling {kg/cm2}
• LS pressure:
Set cylinder to stroke
Engine:
end.
High idling
Engine:
Low idling
Engine:
High idling
• Hydraulic oil temperature: 45 – 55ºC
• Engine: High idling
aSee the figure A
• Hydraulic oil temperature:
45 – 55ºC
• Apply no load to blade.
• Between ground level and
rising end of blade
• Engine: High idling
aSee the figure B
• Hydraulic oil temperature:
45 – 55ºC
• Apply no load to blade.
• Between left tilt end and right
tilt end
• Engine: High idling
aSee the figure C
• Hydraulic oil temperature:
45 – 55ºC
• Apply no load to ripper.
• Between ground level and
rising end of blade
aSee the figure D
• Hydraulic oil temperature:
45 – 55ºC
• Apply no load to blade.
• Pitch in – pitch back
• Engine: High idling
Raise
Item
Lower
Category
D65EX-15
Right tilt
Machine model
Power tilt
sec
D65EX, PX-15
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
D65PX, WX-15
Standard value
for new machine
Service
limit value
3.43 +1.37
0
3.43 +1.37
0
{35 +14
0 }
Min. 19.6
{Min. 200}
23.5 ± 0.98
{240 ± 10}
Min. 19.6
{Min. 200}
23.5 ± 0.98
{240 ± 10}
—
—
—
—
21.6 ± 2.0
{220 ± 20}
21.6 ± 2.0
{220 ± 20}
{35 +14
0 }
Min. 19.6
{Min. 200}
19.6
{200}
Min. 19.6
{Min. 200}
19.6
{200}
—
—
—
—
17.6
{180}
17.6
{180}
4.27 ± 0.25
{43.5 ± 2.5}
4.27 ± 0.25
{43.5 ± 2.5}
3.53 – 4.41
{36 – 45}
3.53 – 4.41
{36 – 45}
2.4 +–0.2
0.5
2.9
1.4 ± 0.2
1.7
2.5 ± 0.3
3.0
2.5 ± 0.3
3.0
2.3 ± 0.3
2.8
2.3 ± 0.3
2.8
—
—
—
—
—
—
—
—
3.5 ± 0.5
4.2
3.5 ± 0.5
4.2
D65EX, PX-15
20-9
(7)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Machine model
Blade
HSS motor
Hydraulic drift
Hydraulic
drift of tilted
blade
Hydraulic
drift of lifted
ripper
Leakage from cylinder
Work equipment
Hydraulic
drift of lifted
blade
Blade tilt
cylinder
Ripper lift
cylinder
Leakage
Fan pump
pressure
20-10
(7)
• Hydraulic oil temperature: 45 – 55ºC
• Move lever to stroke end.
• Lower blade from max. rising position and
measure time after blade comes in contact
with ground until idler is lifted.
• Engine: High idling
aSee the figure E
• Hydraulic oil temperature: 45 – 55ºC
• Engine: Stopped
• Measure reduction of blade bottom height h
(for 15 minutes).
Left
aSee the figure F
tilt
• Hydraulic oil temperature: 45 – 55ºC
• Engine: Stopped
Right
• Reduction of blade tip height
tilt
aSee the figure G
• Hydraulic oil temperature: 45 – 55ºC
• Engine: Stopped
• Measure reduction of shank bottom height h
(for 15 minutes).
• Engine: High idling
• Hydraulic oil temperature: 45 – 55ºC
• Relieve cylinder and measure leakage for 1
minute.
Unit
Standard value
for new machine
Service
limit value
sec
Max. 1.3
Max. 1.6
Max. 100
Max. 100
Max. 200
Max. 200
Max. 200
Max. 200
Max. 50
—
4
16
4
16
mm/
15 min
cc/min
• Hydraulic oil temperature: 45 – 55ºC
• Steering lever: Full
• Transmission lever: Neutral
l/min
Max. 15
• Brake pedal: Pressed
• Engine: High idling
• Engine: Low idling
• Coolant temperature:
rpm
800 ± 50
Power train oil
• Hydraulic oil
temperature:
temperature:
Max. 80ºC
45 – 55ºC
• Engine: High
Standard
1,850 +100
• Fan forward
0
idling
• Fan 100%
For EU
1,600 +100
0
speed mode
spec.
• Hydraulic oil temperature:
19.6 – 22.5
Standard
45 – 55ºC
{200 – 230}
MPa
• Fan forward
2
{kg/cm }
15.7 – 18.6
• Fan 100% speed mode
For EU spec.
{160 – 190}
• Engine: High idling
Max. speed
Cooling fan
Fan speed
Measurement conditions
Min. speed
Item
Time lag
Category
D65EX-15
30
700
1,750
1,500
18.6
{190}
13.7
{140}
D65EX, PX-15
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
D65PX, WX-15
Standard value
for new machine
Service
limit value
Max. 1.3
Max. 1.6
Max. 100
Max. 100
Max. 200
Max. 200
Max. 200
Max. 200
—
—
4
16
4
16
Max. 15
30
800 ± 50
700
1,850 +100
0
1,750
1,600 +100
0
1,500
19.6 – 22.5
{200 – 230}
15.7 – 18.6
{160 – 190}
18.6
{190}
13.7
{140}
D65EX, PX-15
20-11
(7)
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Illustration related standard value table
Fig. A
Fig. E
Fig. B
Fig. F
Fig. C
Fig. G
Fig. D
20-12
(1)
D65EX, PX-15
TESTING AND ADJUSTING
TESTING AND ADJUSTING
Tools for testing, adjusting, and troubleshooting ..................................................................................... 20-103
Measuring engine speed ......................................................................................................................... 20-105
Measuring intake air pressure (boost pressure) ...................................................................................... 20-107
Measuring exhaust temperature .............................................................................................................. 20-109
Measuring exhaust gas color ................................................................................................................... 20- 110
Adjusting valve clearance ........................................................................................................................ 20- 112
Measuring compression pressure ........................................................................................................... 20- 114
Measuring blow-by pressure ................................................................................................................... 20- 116
Measuring engine oil pressure ................................................................................................................ 20- 117
Handling of fuel system devices .............................................................................................................. 20- 118
Releasing residual pressure from fuel system ............................................................................................ 20- 118
Measuring fuel pressure .......................................................................................................................... 20- 119
Bleeding air from fuel circuit .................................................................................................................... 20-120
Inspection of fuel circuit for leakage ........................................................................................................ 20-123
Reduced cylinder mode operation for engine .......................................................................................... 20-124
Testing and adjusting alternator belt tension ........................................................................................... 20-125
Testing and adjusting air conditioner compressor belt tension ................................................................ 20-125
Adjusting fuel control dial and decelerator pedal ..................................................................................... 20-126
Measuring power train oil pressure ......................................................................................................... 20-128
Adjusting transmission speed sensor (replacement procedure) ............................................................... 20-133
Simple method of testing brake performance .......................................................................................... 20-134
Adjusting brake pedal .............................................................................................................................. 20-135
Emergency escape method when power train has trouble ...................................................................... 20-138
Adjusting clearance of idler ..................................................................................................................... 20-141
Inspecting wear of sprocket ..................................................................................................................... 20-141
Testing and adjusting track shoe tension ................................................................................................. 20-142
Testing and adjusting work equipment and HSS oil pressure ................................................................. 20-143
Testing control circuit main pressure ....................................................................................................... 20-146
Measuring PPC valve output pressure .................................................................................................... 20-147
Adjusting play of work equipment PPC valve .......................................................................................... 20-149
Measuring internal leakage of work equipment cylinder .......................................................................... 20-150
Bleeding air from work equipment cylinder .............................................................................................. 20-150
Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed) .................... 20-151
Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed) .............. 20-151
Adjusting work equipment lock lever ....................................................................................................... 20-152
Measuring fan motor speed ..................................................................................................................... 20-153
Measuring fan pump circuit pressure ...................................................................................................... 20-154
Bleeding air from fan pump ..................................................................................................................... 20-155
Adjusting straight tiltdozer ....................................................................................................................... 20-156
Testing and adjusting operator’s cab ....................................................................................................... 20-158
Special functions of monitor panel (EMMS) ............................................................................................. 20-162
Handling of high-voltage circuit of engine controller ................................................................................ 20-199
Adjustment method of replaced controller ............................................................................................... 20-199
Preparation work for troubleshooting for electric system ......................................................................... 20-201
Pm clinic service ...................................................................................................................................... 20-203
Undercarriage troubleshooting report ...................................................................................................... 20-210
D65EX, PX-15
20-101
(8)
TESTING AND ADJUSTING
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safe-
ty pins and 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.
20-102
(1)
D65EX, PX-15
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or
measurement item
Boost pressure
Symbol
A
Water temperature,
Oil temperature,
Exhaust temperature
Part No.
1 799-201-2202
Boost gauge kit
2 790-301-1530
Elbow
B
799-101-1502
1 799-201-9001
Exhaust color
C
Valve clearance
Compression pressure
2
D
Engine oil pressure,
Fuel pressure,
Power train pressure,
HST pressure,
Work equipment pressure
Emergency escape when
power train has trouble
F
Digital temperature gauge
–99.9 – 1,299ºC
Handy smoke checker
Bosch index: Level 0 – 9
Commercially
available
Filler gauge
Intake valve: 0.33 mm,
Exhaust valve: 0.71 mm
Compression gauge
0 – 7 MPa {0 – 70 kg/cm2}
Kit part No.: 795-502-1205
Adapter
799-201-1504
Blow-by checker
0 – 5 kPa {0 – 500 mmH2O}
799-101-5002
Hydraulic tester
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204
Digital hydraulic tester
Pressure gauge:
60 MPa {600 kg/cm2}
Hydraulic gauge
Pressure gauge:
1 MPa {10 kg/cm2}
1
G
2 799-401-2320
1
H
19M-06-32820 Switch assembly
17M-06-41530 Wiring harness
2 790-190-1600
Pump assembly
3 144-865-6260
Elbow (R 3/8 x M18)
799-101-5002
Hydraulic tester
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204
Digital hydraulic tester
Pressure gauge:
60 MPa {600 kg/cm2}
799-401-3200
Adapter
Face seal type (#03)
02896-11009
O-ring
799-101-5002
Hydraulic tester
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204
Digital hydraulic tester
Pressure gauge:
60 MPa {600 kg/cm2}
799-401-3100
Adapter
Face seal type (#02)
02896-11008
O-ring
1
Control circuit main pressure J
2
1
PPC valve outlet pressure
K
2
–101 – 200 kPa {–760 – 1,500 mmHg}
Smoke meter
2 795-471-1410
Blow-by pressure
Remarks
Commercially
available
1 795-502-1590
E
Part name
Oil leakage of work
equipment cylinder
L
Commercially
available
Measuring cylinder
100 cc
Fan motor speed
M
799-205-1100
Tachometer kit
Digital display : 6 – 99999.9 rpm
D65EX, PX-15
20-103
(8)
TESTING AND ADJUSTING
Check or
measurement item
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
Pressure gauge:
2.5, 6, 40, 60 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204
Digital hydraulic tester
Pressure gauge:
60 MPa {600 kg/cm2}
799-401-3400
Adapter
Face seal type (#05)
1
Fan pump circuit oil pressure P
2
Operating effort
Q
02896-11015
O-ring
79A-264-0021
Push-pull scale
0 – 294 N {0 – 30 kg}
79A-264-0091
Push-pull scale
0 – 490 N {0 – 50 kg}
Scale
Stroke, hydraulic drift
R
Commercially
available
Work equipment speed
S
Commercially
available
Stopwatch
Measuring voltage,
resistance value
T
Commercially
available
Tester
799-601-7400
T-adapter kits
799-601-7360
1
Troubleshooting of wiring
harness, sensor
20-104
(8)
U
Remarks
Adapter
For relay (5-pin)
2 799-601-9000
T-adapter kits
For DT connector
3 799-601-9300
T-adapter kits
For DT connector (24-pin, 40-pin)
799-601-9410
Socket
For NE sensor, G sensor
4 799-601-9420
Adapter
For boost pressure sensor,
Fuel pressure sensor
799-601-9430
Socket
For PCV solenoid
D65EX, PX-15
TESTING AND ADJUSTING
MEASURING ENGINE SPEED
a Measure the engine speed under the following
condition.
• Engine water temperature:
Within operating range
• Hydraulic oil temperature:
Within operating range
• Power train oil temperature:
Within operating range
1. Preparation work
Turn the starting switch ON and set the monitor
panel in the “Monitoring mode” to prepare for
measurement of the engine speed.
a For the operating method, see “SPECIAL
FUNCTIONS OF MONITOR PANEL (EMMS)”.
• Monitoring code: 01000 (Engine speed)
2. Measuring low idling speed
1) Start the engine and set the fuel control dial
in the low idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the engine speed.
D65EX, PX-15
MEASURING ENGINE SPEED
3. Measuring high idling speed
1) Start the engine and set the fuel control dial
in the high idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the engine speed.
a The high idling speed measured in the “Monitoring mode” or in the “Pm Clinic auxiliary
mode” is the auto-deceleration speed.
a When measuring the high idling speed of the
engine, use the “Adjustment mode”.
Adjustment code:
0007 (Engine decelerator cut mode)
4. Measuring decelerator pedal speed
1) Start the engine and set the fuel control dial
in the high idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and press the decelerator pedal and measure the engine speed.
20-105
(1)
TESTING AND ADJUSTING
5. Measuring torque converter stall speed
1) Start the engine and set the fuel control dial
in the low idling position.
2) Press the brake pedal securely and set the
parking brake lever in the FREE position and
set the PCCS lever in the FORWARD and
3rd gear speed position.
a Before going to the next step, check that
the upper display unit of the monitor panel is set in the normal display state and it
displays [F3].
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the fuel
control dial in the high idling position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idling.
k Keep pressing the brake pedal securely
and keep your right foot on the decelerator pedal for safety until the work is finished.
5) Just after the power train oil temperature
gauge reads the top line of the green range,
return the direction of the PCCS lever into
neutral.
MEASURING ENGINE SPEED
a The engine speed can be measured in the “Pm
Clinic auxiliary mode” of the monitor panel (Measure the high idling speed of the engine in the
“Adjustment mode”, however).
6) Repeat above steps 2) – 5) 3 times.
7) Perform steps 2) – 4) again and measure the
engine speed about 5 seconds after the
power train oil temperature gauge reads the
top line of the green range.
a After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the power train oil temperature
with the engine at high idling.
20-106
(1)
D65EX, PX-15
TESTING AND ADJUSTING
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR
PRESSURE
(BOOST PRESSURE)
a Measuring instruments for intake air pressure
(boost pressure)
Symbol
A
Part No.
Name
1
799-201-2202
Boost gauge kit
2
790-301-1530
Elbow
k When installing and removing the measuring in-
strument, take care not to touch a hot part.
a Measure the intake air pressure (boost pressure)
under the following condition.
• Engine water temperature:
Within operating range
• Power train oil temperature:
Within operating range
• Hydraulic oil temperature:
Within operating range
4. Run the engine at medium or higher speed and
drain the oil from the hose.
a Insert the joint of the gauge and hose halfway and open the self-seal on the hose side
repeatedly, and the oil is drained.
a If Pm kit (A) is available, the air bleeding coupling (790-261-1130) in it may be used.
a If any oil is left in the hose, the gauge does
not move. Accordingly, be sure to drain the
oil.
5. Run the engine at high idling and stall the torque
converter and measure the intake air pressure
(boost pressure) at this time.
a For the procedure for stalling the torque converter, see MEASURING ENGINE SPEED.
a Normally, the intake air pressure (boost pressure) should be measured while the engine is
operated at the rated output. In the field, however, an approximate value can be obtained by
stalling the torque converter.
1. Open the left side cover of the engine.
2. Remove air intake connector boost pressure
pick-up plug (1).
6. After finishing measurement, remove the measuring instrument and return the removed parts.
3. Install elbow A2 and connect gauge [2] of boost
gauge kit A1.
D65EX, PX-15
20-107
(1)
TESTING AND ADJUSTING
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
a The boost pressure can be measured in the “Pm
Clinic auxiliary mode” of the monitor panel.
20-108
(1)
D65EX, PX-15
TESTING AND ADJUSTING
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE
a Measuring instrument for exhaust temperature
Symbol
Part No.
B
799-101-1502
Name
Digital thermometer
k Install and remove the measuring instrument af-
ter the exhaust manifold is cooled.
a Measure the exhaust temperature under the following condition.
• Engine water temperature:
Within operating range
• Power train oil temperature:
Within operating range
• Hydraulic oil temperature:
Within operating range
4. Procedure for measuring maximum exhaust
temperature for troubleshooting
Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the digital thermometer.
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it by
the following calculation.
• Corrected value [ºC] = Measured value +
2 x (20 – Outside air temperature)
1. Open the right side cover of the engine and remove turbocharger heat insulation cover (1).
2. Remove exhaust temperature pick-up plug (2).
3. Install sensor [1] and connect them to digital thermometer B.
a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part
during measurement.
D65EX, PX-15
5. Procedure for measuring exhaust temperature
periodically for preventive maintenance
a If the torque converter is stalled simply, the
torque converter oil temperature is overheated before the exhaust temperature is stabilized. Accordingly, measure according to the
following procedure.
1) Stall the torque converter fully to raise the
exhaust temperature to about 650ºC according to the following procedure (Condition a in
the figure).
i) Start the engine and set the fuel control
dial to the idling position, and then extract the blade tilt cylinder to the stroke
end with the blade control lever.
ii) Press the brake pedal securely and set
the PCCS lever in the FORWARD 3rd
gear speed position.
iii) Press the decelerator pedal and set the
fuel control dial to the high idling position.
iv) Return the decelerator pedal slowly and
run the engine at high idling. Then stall the
torque converter and relieve the blade tilt
circuit simultaneously.
k Press the brake pedal securely and keep
your right foot on the decelerator pedal
for safety until the work is finished.
20-109
(1)
TESTING AND ADJUSTING
2) Stop only relieving the ripper and lower the
exhaust temperature by only stalling the
torque converter (Condition b in the figure).
a If the temperature does not lower but rises, set the temperature in step 1).
3) After the temperature lowers and is stabilized, measure it (Condition c in the figure).
k Just after the power train oil temperature
gauge reads the red range, return the direction of the PCCS lever into neutral and lower
the power train oil temperature.
MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS
COLOR
a Measuring instrument for exhaust gas color
Symbol
C
Part No.
1
799-201-9001
2
Purchased
Name
Handy smoke checker
Smoke meter
k When installing and removing the measuring in-
strument, take care not to touch a hot part.
a If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
a Measure the exhaust gas color under the following condition.
• Engine water temperature:
Within operating range
6. After finishing measurement, remove the measuring instrument and return the removed parts.
1. Measuring with handy smoke checker C1
1) Stock a sheet of filter paper to C1.
2) Insert the exhaust gas intake pipe in the exhaust pipe.
3) Start the engine.
4) Accelerate the engine suddenly or run it at
high idling and operate the handle of smoke
checker C1 so that the filter paper will absorb
the exhaust gas.
5) Remove the filter paper and compare it with
the attached scale.
6) After finishing measurement, remove the
measuring instrument and return the removed parts.
20-110
(8)
D65EX, PX-15
TESTING AND ADJUSTING
2. Measuring with smoke meter C2
1) Insert probe [1] of smoke meter C2 in the
outlet of the exhaust pipe and fix it to the exhaust pipe with a clip.
MEASURING EXHAUST GAS COLOR
6) Start the engine.
7) Accelerate the engine suddenly or run it at
high idling and press the accelerator pedal of
smoke meter C2 and collect the exhaust gas
into the filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated value.
9) After finishing measurement, remove the
measuring instrument and return the removed parts.
2) Connect the probe hose, receptacle of the
accelerator switch, and air hose to smoke
meter C2.
a Limit the supplied air pressure to 1.5 MPa
{15 kg/cm2}.
3) Connect the power cable to a receptacle of
AC power supply.
a Before connecting the cable, check that
the power switch of the smoke meter is
turned off.
4) Loosen the cap nut of the suction pump and
fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter C2.
D65EX, PX-15
20-111
(1)
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE
a Adjusting instrument for valve clearance
Symbol
Part No.
D
Purchased
3. Remove all cylinder head covers (13) and seals
(14).
a Move the cylinder head covers and seals toward the air intake manifold without removing them from the high-pressure tube.
Name
Filler gauge
1. Open both engine side covers.
2. Air cleaner
1) Remove cap assembly (1) and cover (2).
2) Disconnect air intake hose (8) from the air
cleaner.
3) Remove band (9).
4) Remove air cleaner assembly (10).
a Turn the air cleaner assembly in the circumferential direction to let the end tube
out of the cut hole of the hood.
5) Remove bracket (11).
6) Remove air intake connector (12).
20-112
(8)
4. Rotate the crankshaft forward to bring the
stamped 1.6TOP line a to pointer (15) and set
the No. 1 cylinder to the top dead center.
a Use the damper mounting bolt to rotate the
crankshaft.
a When the No. 1 cylinder is at the compression top dead center, the rocker arms on
both intake side and exhaust side can be
moved by the valve clearance with the hand.
If the rocker arms cannot be moved, rotate
the crankshaft one more turn.
D65EX, PX-15
TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
5. Insert filler gauge D in clearance b between
rocker arm (4) and crosshead (5) and adjust the
valve clearance with adjustment screw (6).
a With the filler gauge inserted, turn the adjustment screw so that you can move the filler
gauge lightly.
3 Locknut:
6. Fixing adjustment screw (6), tighten locknut (7).
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the valve
clearance again.
7. Turn the crankshaft forward by 120 degrees each
time and adjust the clearances of the air intake
valve and exhaust valve of each cylinder according to the firing order by repeating steps 4 and 5.
a Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After finishing adjustment, return the removed
parts.
3 Cylinder head cover mounting bolt:
3 Air intake connector hose clamp bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
3 Air cleaner air intake hose clamp bolt:
6.8 ± 0.49 Nm {69 ± 5 kgcm}
3 Air cleaner band bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
D65EX, PX-15
20-113
(1)
TESTING AND ADJUSTING
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
6) Remove air intake connector (12).
a Measuring instruments for compression pressure
Symbol
E
Part No.
Name
1
795-502-1590
Compression gauge
2
795-471-1410
Adapter
k When measuring the compression pressure, take
care not to burn yourself on the exhaust manifold,
muffler, etc. or get caught in a rotating part.
a Measure the compression pressure after the engine is warmed up.
(Engine oil temperature: 40 – 60ºC)
1. Open both engine side covers.
3. Remove all of 6 fuel high-pressure tubes (3), and
then remove the all clamps so that the tubes can
be moved.
2. Air cleaner
1) Remove cap assembly (1) and cover (2).
4. Remove all of 6 cylinder head covers (4).
2) Disconnect air intake hose (8) from the air
cleaner.
3) Remove band (9).
4) Remove air cleaner assembly (10).
a Turn the air cleaner assembly in the circumferential direction to let the end tube
out of the cut hole of the hood.
5) Remove bracket (11).
20-114
(1)
D65EX, PX-15
TESTING AND ADJUSTING
5. Remove wiring harness (5) and injector assembly (6).
MEASURING COMPRESSION PRESSURE
7. Disconnect concentrated connector (7) (E21) for
the engine.
k Disconnect the concentrated connector for
safety, although the fuel high-pressure tube
is disconnected.
k Cover the connector on the controller side
with a vinyl sheet, etc. to prevent electric
leakage and grounding fault.
6. Install adapter E2 and connect it to compression
gauge E1.
a Leakage can be prevented by applying a little amount of engine oil to the fitting faces of
the adapter and gauge.
a Secure the adapter with the injector holder.
8. Crank the engine with the starting motor and
measure the compression pressure.
a Measure the pressure when the pointer of
the gauge is stabilized.
9. After finishing measurement, return the removed
parts.
3 Injector assembly mounting bolt:
3 Fuel high-pressure tube sleeve nut:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
3 Cylinder head cover mounting bolt:
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
3 Air intake connector hose clamp bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
3 Air cleaner air intake hose clamp bolt:
6.8 ± 0.49 Nm {69 ± 5 kgcm}
3 Air cleaner band bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
D65EX, PX-15
20-115
(1)
TESTING AND ADJUSTING
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
a Measuring instrument for blow-by pressure
Symbol
Part No.
F
799-201-1504
Name
a The blow-by pressure may vary largely with
the engine condition. If the measured value
is judged abnormal, check for increase of oil
consumption, bad exhaust gas color, deterioration of oil, high deterioration speed of oil,
etc. which are related to the abnormal blowby pressure.
Blow-by checker
a Measure the blow-by pressure under the following condition.
• Engine water temperature:
Within operating range
• Power train oil temperature:
Within operating range
• Hydraulic oil temperature:
Within operating range
1. Remove the radiator bottom cover.
2. Install nozzle [1] of blow-by checker F to blow-by
hose (1) and connect them to gauge [2].
4. After finishing measurement, remove the measuring instrument and return the removed parts.
3. Run the engine at high idling, stall the torque
converter, and measure the blow-by pressure.
a For the procedure for stalling the torque converter, see MEASURING ENGINE SPEED.
a Normally, the blow-by pressure should be
measured while the engine is operated at the
rated output. In the field, however, an approximate value can be obtained by stalling
the torque converter.
a If it is impossible to run the engine at the rated output or stall the torque converter, measure while the engine is running at high
idling.
The value obtained in this case is about 80%
of the blow-by pressure at the rated output.
20-116
(8)
D65EX, PX-15
TESTING AND ADJUSTING
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL
PRESSURE
3. Run the engine at low idling and high idling and
measure the engine oil pressure in each speed.
a Measuring instruments for engine oil pressure
Symbol
1
G
2
Part No.
Name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
(1 MPa {10 kg/cm2})
a Measure the engine oil pressure under the following condition.
• Engine water temperature:
Within operating range
1. Open the left side cover of the engine and remove plug (1) RC 1/8.
4. After finishing measurement, remove the measuring instruments and return the removed parts.
2. Install nipple [1] of hydraulic tester G1 and connect them to hydraulic tester G2.
D65EX, PX-15
20-117
(8)
TESTING AND ADJUSTING
HANDLING OF FUEL SYSTEM DEVICES
RELEASING RESIDUAL
PRESSURE
FROM
FUELDEVICES
SYSTEM
HANDLING
OF FUEL
SYSTEM
HANDLING OF FUEL SYSTEM DEVICES
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
a Precautions for testing and adjusting fuel system
The common rail fuel injection system (CRI) consists of more precise parts than the conventional
fuel injection pump and nozzle. If foreign matter
enters this system, it can cause a trouble.
When testing and adjusting the fuel system, take
care more than the past. If dust, etc. sticks to any
part, wash that part thoroughly with clean fuel.
a Precautions for replacing fuel filter cartrige
Be sure to use Komatsu genuine fuel filter cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent
foreign matter from entering it.
If a filter other than the genuine one is used, the
fuel system may have a trouble. Accordingly,
never use such a filter.
a Pressure is generated in the low-pressure circuit
and high-pressure circuit of the fuel system while
the engine is running.
Low-pressure circuit:
Feed pump – Fuel filter – Fuel supply pump
High-pressure circuit:
Fuel supply pump – Common rail – Fuel injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is
stopped.
a Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit
must be released completely. Accordingly, observe the following.
k Before testing the fuel system or removing its
parts, wait at least 30 seconds after stopping the
engine until the residual pressure in the fuel circuit is released. (Do not start the work just after
stopping the engine since there is residual pressure.)
20-118
(1)
D65EX, PX-15
TESTING AND ADJUSTING
MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE
a Measuring instrument for fuel pressure
Symbol
1
G
2
Part No.
3. Run the engine at high idling and measure the
fuel pressure.
a For the standard value, see Troubleshooting
when error code is displayed (Error code
AD10L3).
Name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
(1 MPa {10 kg/cm2})
a Measure only the fuel pressure in the low-pressure circuit from the feed pump to the fuel filter
and fuel supply pump.
k Since the pressure in the high-pressure circuit
from the fuel supply pump to the common rail
and fuel injector is very high, it cannot be measured.
4. After finishing measurement, remove the measuring instruments and return the removed parts.
1. Open the left side cover of the engine and remove fuel pressure pick-up plug (1).
2. Install nipple [1] of hydraulic tester G1 and connect them to hydraulic tester G2.
D65EX, PX-15
20-119
(8)
TESTING AND ADJUSTING
BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
a Bleeding the air as follows if the engine has run
out of fuel or the fuel circut equipment has been
removed and installed.
1. Remove fuel filter (1), fill with fuel, then install
again.
a When filling, use clean fuel and be careful
not to let dirt get in.
a Add fuel through inlet port portion a (8 places) of the filter. Portion b is the outlet port
(clean side) after the fuel has been filtered,
so never add fuel from here.
a If clean fuel is not available, do not remove
the filter. Operate the priming pump to fill the
filter with fuel.
20-120
(8)
D65EX, PX-15
TESTING AND ADJUSTING
2. Remove air bleed plug (2) of the fuel filter and
operate priming pump (4).
a Continue operating the priming pump until
flow out from the plug hole. When fuel comes
out, install the plug.
3 Air bleed plug:
7.8 – 9.8 Nm {0.8 – 1.0 Nm}
BLEEDING AIR FROM FUEL CIRCUIT
Air bleeding steps
i) Remove air bleeding plug (2) of fuel filter (1) and
operate priming pump (4).
• Continue to operate the priming pump until
fuel is confirmed to flow out of the air bleeding plug hole and then tighten it.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3. There are the following two cases that the engine
does not start up easily after bleeding air from
CRI, (Common Rail Injection System), i.e. even
after carrying out the Items 1 and 2 above.
a If air has not been removed completely, leaving some in the system, cranking up the engine with the engine starting motor cannot
get rid of the remaining air in a short span of
time. Thus the engine start-up becomes difficult.
1) In the cases that the fuel has run out, that the
fuel filter has been replaced or that some fuel
device has been removed and installed.
• Most of the fuel is left in the fuel circuit,
so the engine may be started after bleeding air with the air bleeding methods introduced in the Item 1 and 2 above.
2) In the case that a number of fuel devices
have been removed and installed in course
of engine overhauling.
• Little fuel is left in the fuel circuit, so air
cannot be get rid of completely with the
air bleeding methods introduced in the
Item 1 and 2 above (i.e. ordinary method). In that case, bleed air in the following manner.
D65EX, PX-15
ii) Remove fuel pressure measuring plug (3) for the
fuel filter and operate priming pump (4).
• Continue to operate the priming pump until
fuel is confirmed to flow out of the air bleeding plug hole and then tighten it.
3 Fuel pressure measuring plug:
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
iii) Loosen air bleeder (5) of the fuel supply pump
(only after loosening the lock nut) and operate
priming (4) 90 to 100 times.
• Continue to operate the priming pump until
fuel is confirmed to flow out of air bleeder (5)
and then tighten it.
3 Air bleeder:
•
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
Still continue to operate the priming pump
until it becomes harder to operate and a relief sound of overflow valve (6) in the fuel
supply pump is heard. (A high pitch sound) it
requires approx. 50 times of operation to
reach that stage.
iv) Push in the knob of priming pump (4) to tighten it.
v) Crank up the engine with the engine starting motor for start-up.
a Do not keep the engine starting motor running idly for more than 20 seconds. Moreover try to start up the engine only after two
minute pause.
a If the engine does not start up even after repeating to crank for 20 seconds 4 times, insufficient air bleeding is suspected of. In that
case, start the air bleeding steps once again
from the beginning.
20-121
(1)
TESTING AND ADJUSTING
BLEEDING AIR FROM FUEL CIRCUIT
4. Loosen air bleeder (5) of the fuel supply pump
and operate priming pump (4) 90 to 100 times.
a Continue operating the priming pump until
fuel flow out from the bleeder.
When fuel comes out, tighten the bleeder,
then operate several times until the priming
pump becomes stiff.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
5. Crank the engine with the starting motor and
start the engine.
a When the engine is cranked, the air in the
high-pressure circuit is automatically bled.
a If the engine does not start, the air has probably been not properly bled from the lowpressure circuit, so repeat the procedure
from Step 2.
20-122
(1)
D65EX, PX-15
TESTING AND ADJUSTING
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
8. Run the engine at high idling and apply a load to
it.
a Relieve the oil by tilting the blade or raising
the ripper.
k Very high pressure is generated in the high-pres-
sure circuit of the fuel system. If fuel leaks while
the engine is running, it is dangerous since it can
catch fire.
After testing the fuel system or removing its
parts, inspect it for fuel leakage according to the
following procedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
9. Inspect the fuel piping and devices for fuel leakage.
a Inspect around the high-pressure circuit parts
coated with the color checker for fuel leakage.
a If any fuel leakage is detected, repair it and
inspect again from step 2.
a If any fuel leakage is not detected, inspection
is completed.
1. Spray color checker (developer) over the fuel
supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and
stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel leakage.
a Inspect around the high-pressure circuit parts
coated with the color checker for fuel leakage.
a If any fuel leakage is detected, repair it and
inspect again from step 2.
4. Run the engine at low idling.
5. Inspect the fuel piping and devices for fuel leakage.
a Inspect around the high-pressure circuit parts
coated with the color checker for fuel leakage.
a If any fuel leakage is detected, repair it and
inspect again from step 2.
6. Run the engine at high idling.
7. Inspect the fuel piping and devices for fuel leakage.
a Inspect around the high-pressure circuit parts
coated with the color checker for fuel leakage.
a If any fuel leakage is detected, repair it and
inspect again from step 2.
D65EX, PX-15
20-123
(1)
TESTING AND ADJUSTING
REDUCED CYLINDER MODE OPERATION FOR ENGINE
REDUCED CYLINDER MODE
OPERATION FOR ENGINE
a Reduced cylinder mode operation for the engine
means setting the fuel injectors of a single cylinder or multiple cylinders electronically to the NO
injection condition to run the engine on a reduced number of cylinders.
The reduced cylinder mode operation is used
when it is though that one of the engine cylinders
is not giving normal output (combustion). It is a
method to determine which cylinder is not operating normally.
a The reduced cylinder mode operation is carried
out by using the reduced cylinder mode operation setting function on the monitor panel.
a For details of the method of operation, see the
TESTING AND ADJUSTING of chassis volume,
Special functions of monitor panel.
20-124
(1)
D65EX, PX-15
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING
TESTING AND
AIR CONDITIONER
ADJUSTING ALTERNATOR
COMPRESSORBELT
BELTTENSION
TENSION
TESTING AND ADJUSTING
ALTERNATOR BELT TENSION
TESTING AND ADJUSTING
AIR CONDITIONER COMPRESSOR BELT TENSION
Testing
• Press the intermediate point between alternator
pulley and drive pulley with a finger and measure
deflection a of the belt.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
Testing
• Press the intermediate point between air conditioner compressor pulley and drive pulley with a
finger and measure deflection a of the belt.
a Pressing force: Approx. 98 N {Approx. 10 kg}
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1. Loosen the 2 alternator mounting bolts and the 1
adjustment rod set bolt.
1. Loosen the 2 compressor bracket mounting bolts
(1).
2. Loosen locknut (1) and turn adjustment nut (2) to
move alternator (3) and adjust the belt tension.
2. Loosen locknut (2) and turn adjustment nut (3)
and adjust the belt tension.
3. Tighten the 2 alternator mounting bolts and the 1
adjustment rod set bolt.
3. Tighten the 2 compressor bracket mounting bolts
(1).
D65EX, PX-15
20-125
(1)
TESTING AND ADJUSTING
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
ADJUSTING FUEL CONTROL
DIAL AND DECELERATOR
PEDAL
1. Outline of fuel control system
• The following signals are input as rotation
command signals to the engine controller.
• Fuel control dial potentiometer signal
• Decelerator pedal potentiometer signal
• 3rd throttle signal
The engine controller controls the fuel control system of the engine (CRI system) according to the one of the above input signals
having the lowest engine speed.
• Adjust the deceleration slow rotation by adjusting the decelerator pedal linkage.
2. Preparation work
1) Start the engine, set the monitor panel in the
“Adjustment mode”, and prepare for measuring the engine speed.
a For the method of operation, see “Special functions of monitor panel (EMMS)”.
• Adjustment code:
0007 (Engine deceleration cut mode)
a The engine speed is displayed in 1 rpm.
[1] Fuel control dial
[2] Engine controller
[3] Steering and transmission controller
[4] Decelerator pedal
[5] Decelerator pedal potentiometer
[6] Engine (CRI system)
[7] 3rd throttle signal
[8] Rod
20-126
(1)
D65EX, PX-15
TESTING AND ADJUSTING
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
3. Adjusting decelerator pedal engine speed
With the fuel control dial in the high idling position, press decelerator pedal (1) to stopper bolt
(2) and check that the decelerator pedal engine
speed is normal.
• Decelerator pedal engine speed:
975 – 1,025 rpm
• Potentiometer output: 3.8 ± 0.1 V
a If the decelerator pedal engine speed is abnormal, adjust installed dimension a of stopper bolt (2).
• Standard installed dimension a of stopper bolt:
23 mm
4. High idling engine speed
Set the fuel control dial in the high idling position
and check that the high idling engine speed is
normal.
• High idling engine speed: 2,050 – 2,150 rpm
• Potentiometer output: 0.8 ± 0.1 V
• Standard installed dimension b of stopper bolt:
24 mm
a If the engine speed is abnormal, perform the
following.
• When the engine speed is above 2,150 rpm:
Lower the engine speed below 2,050 rpm
temporarily with stopper bolt (3) to eliminate
the play of the decelerator pedal, and then
adjust the engine speed to the high idling
speed.
• When the engine speed is below 2,050 rpm:
Adjust the engine speed to the high idling
speed with stopper bolt (3).
D65EX, PX-15
20-127
(1)
TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN
OIL PRESSURE
a Measuring instruments for power train pressure
Symbol
1
G
2
Part No.
Name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
(1 MPa {10 kg/cm2})
k Stop the machine on a level place, lower the
work equipment to the ground, and set the parking brake lever and safety lock lever in the LOCK
position.
a Measure the power train oil pressure under the
following condition.
• Power train oil temperature: 70 – 80ºC
a The centralized power train pressure pickup
ports are installed inside the inspection cover (1)
on the right outside of the operator’s cab.
a List of oil pressure measuring points and gauges
to be used
Gauge
(MPa {kg/cm2})
No.
Measured oil pressure
1
Steering brake pressure
6 {60}
2
Torque converter inlet
pressure
2.5 {25}
3
Torque converter outlet
pressure
1 {10}
4
Transmission main relief
pressure
6 {60}
1. Measuring brake pressure
1) Remove oil pressure pickup plug (1) and
connect oil pressure gauge [1] of hydraulic
tester G1.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
2) Run the engine and set the parking brake lever in the FREE position.
3) Measure the oil pressure while the engine is
running at low idling and high idling.
a Check that the oil pressure lowers to 0 when
the brake pedal is pressed or the parking
brake lever is set in the LOCK position.
4) After finishing measurement, remove the measuring instrument and return the removed
parts.
20-128
(8)
D65EX, PX-15
TESTING AND ADJUSTING
2. Measuring torque converter inlet pressure
1) Remove oil pressure pickup plug (2) and
connect oil pressure gauge [1] of hydraulic
tester G1.
a Use an oil pressure gauge of 2.5 MPa {25
kg/cm2}.
2) Start the engine and set the PCCS lever in
the full neutral position.
3) Measure the oil pressure while the engine is
running at low idling and high idling.
4) After finishing measurement, remove the
measuring instrument and return the removed parts.
a For the oil pressure gauge, see BPD11546.
MEASURING POWER TRAIN OIL PRESSURE
3. Measuring torque converter outlet pressure
1) Remove oil pressure pickup plug (3) and
connect hydraulic tester G2.
a Use an oil pressure gauge of 1 MPa {10 kg/
cm2}.
2) Start the engine and set the PCCS lever in
the full neutral position.
3) Measure the oil pressure while the engine is
running at low idling and high idling.
4) After finishing measurement, remove the
measuring instrument and return the removed parts.
D65EX, PX-15
20-129
(8)
TESTING AND ADJUSTING
4. Measuring transmission main relief pressure
1) Remove oil pressure pickup plug (4) and
connect oil pressure gauge [1] of hydraulic
tester G1.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
2) Start the engine and set the PCCS lever in
the full neutral position.
3) Measure the oil pressure while the engine is
running at low idling and high idling.
4) After finishing measurement, remove the
measuring instrument and return the removed parts.
a For the oil pressure gauge, see BPD11546.
20-130
(8)
MEASURING POWER TRAIN OIL PRESSURE
5. Measuring clutch pressure
• Remove the operator’s seat assembly and
measure the clutch pressure from the top of
the floor frame.
a List of oil pressure measuring points and
necessary gauges
Gauge
(MPa {kg/cm2})
No.
Measuring point
5
Transmission forward
clutch pressure
6 {60}
6
Transmission reverse
clutch pressure
6 {60}
7
Transmission 1st clutch
pressure
6 {60}
8
Transmission 2nd clutch
pressure
6 {60}
9
Transmission 3rd clutch
pressure
6 {60}
D65EX, PX-15
TESTING AND ADJUSTING
1) Measuring transmission forward clutch pressure
i) Remove oil pressure pickup plug (5) and
connect oil pressure gauge [1] of hydraulic tester G1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.
ii) Run the engine and set the parking
brake lever in the FREE position.
iii) Press the brake pedal and set the PCCS
lever in the FORWARD and 3rd gear
speed position.
iv) Measure the oil pressure while the engine is running at high idling.
k Since the torque converter will be
stalled, keep pressing the brake pedal securely.
v) After finishing measurement, remove the
measuring instrument and return the removed parts.
2) Measuring transmission reverse clutch pressure
i) Remove oil pressure pickup plug (6) and
connect oil pressure gauge [1] of hydraulic tester G1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.
ii) Run the engine and set the parking
brake lever in the FREE position.
iii) Press the brake pedal and set the PCCS
lever in the REVERSE and 3rd gear
speed position.
iv) Measure the oil pressure while the engine is running at high idling.
k Since the torque converter will be
stalled, keep pressing the brake pedal securely.
v) After finishing measurement, remove the
measuring instrument and return the removed parts.
D65EX, PX-15
MEASURING POWER TRAIN OIL PRESSURE
3) Measuring transmission 1st clutch pressure
i) Remove oil pressure pickup plug (7) and
connect oil pressure gauge [1] of hydraulic tester G1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.
ii) Run the engine and set the parking
brake lever in the FREE position.
iii) Press the brake pedal and set the PCCS
lever in the FORWARD and 1st gear
speed position.
iv) Measure the oil pressure while the engine is running at low idling.
k Since the torque converter will be
stalled, keep pressing the brake pedal securely.
k Do not run the engine at high idling
while measuring.
v) After finishing measurement, remove the
measuring instrument and return the removed parts.
4) Measuring transmission 2nd clutch pressure
i) Remove oil pressure pickup plug (8) and
connect oil pressure gauge [1] of hydraulic tester G1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.
ii) Run the engine and set the parking
brake lever in the FREE position.
iii) Press the brake pedal and set the PCCS
lever in the FORWARD and 2nd gear
speed position.
iv) Measure the oil pressure while the engine is running at low idling.
k Since the torque converter will be
stalled, keep pressing the brake pedal securely.
k Do not run the engine at high idling
while measuring.
v) After finishing measurement, remove the
measuring instrument and return the removed parts.
20-131
(8)
TESTING AND ADJUSTING
MEASURING POWER TRAIN OIL PRESSURE
5) Measuring transmission 3rd clutch pressure
i) Remove oil pressure pickup plug (9) and
connect oil pressure gauge [1] of hydraulic tester G1.
a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.
ii) Run the engine and set the parking
brake lever in the FREE position.
iii) Press the brake pedal and set the PCCS
lever in the FORWARD and 3rd gear
speed position.
iv) Measure the oil pressure while the engine is running at low idling.
k Since the torque converter will be
stalled, keep pressing the brake pedal securely.
k Do not run the engine at high idling
while measuring.
v) After finishing measurement, remove the
measuring instrument and return the removed parts.
20-132
(8)
D65EX, PX-15
TESTING AND ADJUSTING
ADJUSTING TRANSMISSION
SPEED SENSOR
(REPLACEMENT PROCEDURE)
ADJUSTING TRANSMISSION SPEED SENSOR
(REPLACEMENT PROCEDURE)
2) Pull the connector of sensor (3) out of the
flange hole of tube (6) and insert it in connector assembly (7) (securely until it clicks).
1. Remove the undercover of the fuel tank, and
then remove transmission speed sensor assembly (1) from steering case (2).
3 Mounting bolt:
3) Install connector assembly (7) to tube (6).
2. Measure dimension L of removed sensor (3).
a When replacing the sensor, be sure to measure dimension L.
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
4) Insert sensor (3) in the boss of tube (6) and
secure it with nuts (4) and (5).
a Installed dimension of sensor:
Dimension L measured when removed
± 0.2 mm
3 Locknut: 49 – 68.7 Nm {5 – 7 kgm}
2 Threads of sensor: Adhesive (LT-2)
4. Install sensor assembly (1) to steering case (2).
• Standard clearance between
bevel gear and sensor tip: 0.65 – 1.65 mm
3. Assembly procedure for sensor assembly
1) Remove only nut (4) from sensor (3) and insert sensor (3) in the opening at the end of
tube (6) from the connector side.
D65EX, PX-15
5. After finishing adjustment, set the monitor panel
in the “Monitoring display mode” and check that
it displays the transmission speed normally.
a For the operating method, see “Special functions of monitor panel (EMMS)”.
a Monitoring code: 31400 (Transmission speed)
20-133
(1)
TESTING AND ADJUSTING
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
a Carry out the simple test of brake performance
under the following condition.
• Power train oil temperature:
Within operating range
1. Set the blade and ripper (if equipped) in the travel position on a level place.
2. Run the engine and set the parking brake lever
in the FREE position.
3. Run the engine at low idling and press the brake
pedal and set the PCCS lever in the FORWARD
and 2nd gear speed position.
k If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd gear speed.
a Set the steering unit in neutral.
4. Press the decelerator pedal and set the fuel control dial in the high idling position.
5. Return the decelerator pedal slowly and check
that the machine does not start when the engine
speed reaches the high idling level.
k Since the torque converter will be stalled,
press the brake pedal securely and keep
your right foot on the decelerator pedal for
safety until the work is finished.
20-134
(1)
D65EX, PX-15
TESTING AND ADJUSTING
ADJUSTING BRAKE PEDAL
ADJUSTING BRAKE PEDAL
1
Tighten the locknuts of the rods and cables securely, and bend the cotter pins securely.
1. Adjust fitting dimension b of damper (2) so that
the soroke of brake pedal (1) will be dimension a.
• Pedal stroke a: 77.5 mm
• Fitting dimension b of damper: 25 mm
2. Adjust fitting dimension c of rod (3) on the valve
side, then connect to brake valve lever (4).
• Fitting dimension c of rod: 773 mm
a Fully screw joint (5) into the valve side.
3. Adjust fitting dimension d of rod (6) on the pedal
side, then connect to brake pedal (1).
• Fitting dimension d of rod: 175 mm
4. Lightly push rod (3) on the valve side toward the
rear of the machine, and turn only joint (7) to
connect rods (3) and (6).
a Push rod (3) with a force of about 9.8 – 19.6
N {1 – 2 kg}.
3 Joint: 34.3 – 58.8 Nm {3.5 – 6.0 kgm}
D65EX, PX-15
20-135
(1)
TESTING AND ADJUSTING
ADJUSTING BRAKE PEDAL
5. When brake pedal (1) released, adijust its play
with dimension e between the poins of rod assembly (8).
• Play of pedal: 3 – 8 mm (Center of pedal)
• Dimension e between pins of rod assembly:
978 mm
a Adjust by turning joints (5) and (7) in the
same direction.
6. With brake pedal (1) released, check that brake
pedal (1) is in contact with damper (2).
7. Checking brake oil pressure
Oil pressure
MPa {kg/cm2}
Remarks
Brake OFF
Min. 2.55 {Min. 26}
Engine at full
throttle
Brake ON
0
8. After adjusting the pedal, adjust the zero point of
the brake potentiometer (Adjustment mode:
0005).
a For the method of operation, see “Special
functions of monitor panel (EMMS)”.
20-136
(1)
D65EX, PX-15
TESTING AND ADJUSTING
ADJUSTING BRAKE PEDAL
Adjusting at parking brake lever
1. Assembling and installing lever assembly
1) Assemble lever assembly (1) and adjust the
operation of limit switch (2).
a When assembling the lever assembly,
disconnect the parking brake cable from
the lever.
• When lever is raised: OFF, lowered: ON
• Operation stroke of limit switch: 3 mm
2) Install lever assembly (1).
2. Adjusting length of parking brake cable
1) Connect parking brake cable (3) to the lever
and valve and adjust dimensions a and b.
• Dimension a of cable: 148.5 mm
• Dimension b of cable: 166 mm
2) Operate parking brake lever (4) between the
FREE and LOCK positions and adjust rod
end (6) so that spool stroke h of brake valve
(5) will be normal.
• Spool stroke h: 13.3 mm
D65EX, PX-15
3. Checking brake oil pressure
Check that the brake oil pressure is as follows
when the parking brake lever is set in the FREE
and ROCK positions.
a For the method of measuring the brake oil
pressure, see MEASURING POWER TRAIN
OIL PRESSURE.
• LOCK position: 0
FREE position: Specified pressure
4. Checking limit switch
Change the monitor panel to the monitoring display mode and set the parking brake lever in the
FREE and ROCK positions. Check that the limit
switch signal is normal at this time.
a For the operating method of the monitoring
display mode, see “SPECIAL FUNCTIONS
OF MONITOR PANEL (EMMS)”.
• Monitoring code:
40910 (Steering controller related switch input 1)
20-137
(1)
EMERGENCY ESCAPE METHOD WHEN POWER
TRAIN HAS TROUBLE
TESTING AND ADJUSTING
EMERGENCY ESCAPE
METHOD WHEN POWER
TRAIN HAS TROUBLE
a Devices used for emergency escape
Symbol
1
H
Part No.
Name
19M-06-32820 Switch assembly
17M-06-41530 Wiring harness
2
790-190-1600
Pump assembly
3
144-865-6260
Elbow (R 3/8 x M18)
1. Escape with switch box (Use H1)
a If the machine cannot be moved because of
a trouble in the electric system of the power
train control unit (travel direction, gear
speed, steering), escape according to the
following procedure.
a The engine must be startable for the following procedure. If the engine cannot be started, see EMERGENCY ESCAPE WITH
BRAKE RELEASING DEVICE.
1) Connect switch assembly [1] to wiring harness [2] of emergency escape device H1.
k Set the all gear speed switches of switch assembly [1] in the OFF position and the direction switch in the P position to prevent the
machine from starting suddenly.
20-138
(1)
2) Remove the cover on the left of the toe board
and connect wiring harness [2] to connectors
PL1 (1) and PL2 (2).
• Connector PL1 (1):
Connect to male side and female side.
• Connector PL2 (2):
Connect to female side.
a Since the male side of connector PL2 is
kept disconnected, mask it with a vinyl
sheet, etc.
3) Open the battery cover on the left of the cab
and remove the cover of relay box (3).
D65EX, PX-15
TESTING AND ADJUSTING
4) Disconnect the neutral safety relay (NSF)
and connect pins [3] and [5] of the connector
on the wiring harness side.
a If the connector (PL2) is disconnected, a
model selection error is made and the
neutral safety relay does not work. The
above work must be performed to avoid
this phenomenon.
k If the engine is started by this method,
the neutral safety function does not work.
Accordingly, before starting the engine,
set the parking brake lever in the LOCK
position and set the PCCS lever in the
full neutral position.
k Start the engine by this method only in
an emergency. If the engine does not
start in another case, be sure to carry out
troubleshooting and repair the trouble.
EMERGENCY ESCAPE METHOD WHEN POWER
TRAIN HAS TROUBLE
2. Escape with brake releasing device (Use H2)
a If the engine cannot be started and the parking brake cannot be released, escape according to the following procedure.
1) Assemble pump assembly H2.
2) Install volume pump [6] of pump assembly
H2 to the outside of the operator’s cab.
5) Start the engine and set the parking brake lever in the FREE position.
6) Operate switch assembly [1] and move the
machine to a safe place.
a The gear speed switch is so made that
the switch on the lower gear speed will
be operated first.
D65EX, PX-15
3) Remove the fuel tank undercover and plug
(5) (R 3/8) of the brake release pressure supply port of brake valve (4).
20-139
(1)
TESTING AND ADJUSTING
EMERGENCY ESCAPE METHOD WHEN POWER
TRAIN HAS TROUBLE
4) Install elbow H3 and connect end hose [7] of
pump assembly H2.
5) Turn the starting switch ON and set the parking brake lever in the FREE position.
6) Operate the vacuum pump to raise the brake
releasing oil pressure to the initial pressure.
• Initial pressure:
Approx. 2.74 MPa {28 kg/cm2}
a Since an accumulator is installed in the
circuit, the handle must be operated 30 –
50 times to raise the oil pressure.
a If the oil pressure does not rise above a
certain level, the relief valve may be set
to low pressure. In this case, adjust the
set pressure of the relief valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure lowers
gradually because of internal leakage
and the brake is applied again about 1
minutes after. Accordingly, work quickly.
a If the brake releasing pressure lowers to
about 1.5 MPa {16 kg/cm2}, the brake is
applied. In this case, operate the volume
pump again to raise the brake releasing
pressure to the intial pressure.
8) When disconnecting the hose after finishing
the work, loosen the screw slowly and do not
stand in the spouting direction of the oil.
20-140
(1)
D65EX, PX-15
TESTING AND ADJUSTING
ADJUSTING CLEARANCE OF IDLER
ADJUSTING
INSPECTINGCLEARANCE
WEAR OF SPROCKET
OF IDLER
ADJUSTING CLEARANCE OF
IDLER
INSPECTING WEAR OF
SPROCKET
a If the lateral guide of the idler are so worn that
the idler runs out or slants, adjust the clearance
of the idler according to the following procedure.
a Use the “Full-scale dimensions drawing of sprocket
profile” in “Sprocket” in STRUCTURE, OPERATION, AND MAINTENANCE STANDARD as a
gauge for measuring wear of the sprocket.
a Make a copy of the “Full-scale dimensions drawing of sprocket profile” on a transparent paper or
sheet and apply it directly to the sprocket to see
if the sprocket can be used.
1. Adjustment procedure
1) Drive the machine 1 – 2 m on flat ground,
and then measure clearance a between the
track frame and guide plate (at 4 places on
both sides, inside, and outside).
2) If clearance a is larger than 4 mm, loosen
bolt (1) and reduce shim (2).
• Standard clearance a on each side:
0.5 – 1.0 mm
• Shim thickness: 1.0 mm
D65EX, PX-15
20-141
(1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING
TRACK SHOE TENSION
Testing
1. Drive the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2. Place straight steel bar between the idler and
front carrier roller and measure clearance a between the bottom of the steel bar and shoe
grouser.
• Standard clearance a: 20 – 30 mm
Adjusting
a If the track shoe tension is abnormal, adjust it according to the following procedure.
1. Remove cover (1).
2. When the tension is too high
Loosen plug (2) to discharge the grease.
k Since the high-pressure grease may spout
out, do not loosen the plug more than 1 turn.
3 Plug: 59 – 88 Nm {6 – 9 kgm}
3. When tension is low
Add grease through grease fitting (3).
a If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
20-142
(1)
D65EX, PX-15
TESTING AND ADJUSTING WORK EQUIPMENT
AND HSS OIL PRESSURE
TESTING AND ADJUSTING
TESTING AND ADJUSTING
WORK EQUIPMENT
AND HSS OIL PRESSURE
a Testing and adjusting instruments for work
equipment and HSS oil pressure
Symbol
G1
Part No.
1. Measuring unload pressure
1) Remove oil pressure pickup plug (2) and
connect oil pressure gauge [1] of hydraulic
tester G1.
a Use an oil pressure gauge of 40 MPa
{400 kg/cm2}.
Name
795-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
k Stop the machine on a level place, lower the
work equipment to the ground, and set the parking brake lever and work equipment lock lever in
the LOCK position.
a Measure the work equipment and HSS oil pressure under the following condition.
• Hydraulic oil temperature:
Within operating range
a The centralized work equipment and HSS oil
pressure pickup ports are installed inside the inspection cover (1) on the right outside of the operator’s cab.
a Oil pressure measuring points
(2): Main pump pressure
(3): Load sensing pressure (LS pressure)
D65EX, PX-15
2) Running the engine at high idling, set the
blade lever and ripper lever in neutral and
measure the oil pressure.
3) After finishing measurement, remove the
measuring instrument and return the removed parts.
20-143
(8)
TESTING AND ADJUSTING
2. Measuring work equipment and HSS oil pressure
1) Connect oil pressure gauges [1] of hydraulic
tester G1 to pump oil pressure pickup port
(2) and load sensing pressure pickup port
(3).
a Use the following oil pressure gauges
Work equipment oil pressure:
40 MPa {400 kg/cm2}
HSS oil pressure:
60 MPa {600 kg/cm2}
TESTING AND ADJUSTING WORK EQUIPMENT
AND HSS OIL PRESSURE
HSS oil pressure
i) Run the engine, set the parking brake lever
in the FREE position, and press the brake
pedal.
k Since the steering circuit will be stalled,
keep pressing the brake pedal securely
and keep your right foot on the decelerator pedal for safety until the work is finished.
ii) Run the engine at high idling and steer to the
right or left with the PCCS lever. When the
steering circuit is relieved, measure the oil
pressure.
iii) After finishing measurement, remove the
measuring instrument and return the removed parts.
Work equipment oil pressure
i) Run the engine and set the work equipment
lock lever in the FREE position.
ii) Run the engine at high idling and operate the
blade lever and ripper lever. When each cylinder is relieved at the stroke end, measure
the oil pressure.
a Block the return hose of the blade lift cylinder.
iii) After finishing measurement, remove the
measuring instrument and return the removed parts.
20-144
(8)
D65EX, PX-15
TESTING AND ADJUSTING
3. Adjusting
1) LS pressure (Load sensing pressure) of work
equipment
Loosen locknut (4) of work equipment LS
valve (3) and rotate adjustment screw (5) to
adjust the LS pressure.
a If the adjustment screw is
• rotated to the right, the oil pressure is
heightened.
• rotated to the left, the oil pressure is
lowered.
a If the adjustment screw is rotated 1 turn,
the pressure is heightened or lowered by
17.6 MPa {179 kg/cm2}.
3 Locknut:
•
29.4 – 39.2 Nm {3 – 4 kgm}
After adjusting, check the relief pressure
and LS pressure of work equipment
again.
D65EX, PX-15
TESTING AND ADJUSTING WORK EQUIPMENT
AND HSS OIL PRESSURE
2) LS pressure (Load sensing pressure) of HSS
Loosen locknut (7) of HSS LS valve (6) and
rotate adjustment screw (8) to adjust the LS
pressure.
a If the adjustment screw is
• rotated to the right, the oil pressure is
heightened.
• rotated to the left, the oil pressure is
lowered.
a If the adjustment screw is rotated 1 turn,
the pressure is heightened or lowered by
15.1 MPa {154 kg/cm2}.
3 Locknut:
•
68.6 – 78.5 Nm {7 – 8 kgm}
After adjusting, check the relief pressure
and LS pressure of work equipment
again.
20-145
(1)
TESTING AND ADJUSTING
TESTING CONTROL CIRCUIT MAIN PRESSURE
TESTING CONTROL CIRCUIT
MAIN PRESSURE
4. Install nipple [1] of hydraulic tester J1 and connect oil pressure gauge [2].
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.
a Testing and adjusting instruments for control circuit main pressure
Symbol
1
J
2
Part No.
Name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3200
Oil pressure pickup adapter
(Size 03)
02896-11009
O-ring
a The control circuit main pressure is the pressure
lowered by the self-pressure reducing valve. It is
used commonly for blade PPC, fan pump control, steering EPC and ripper PPC (if equipped).
Measuring
k Stop the machine on a level place, lower the
work equipment to the ground, and set the parking brake lever and work equipment lock lever in
the LOCK position.
a Measure the control circuit main pressure under
the following condition.
• Hydraulic oil temperature:
Within operating range
5. Run the engine at high idling and set the blade
lever and ripper lever in neutral and measure the
oil pressure.
1. Open the main control valve cover on the right of
the operator’s cab.
2. Disconnect hose (1).
6. After finishing measurement, remove the measuring instrument and return the removed parts.
Adjusting
a The self-pressure reducing valve cannot be adjusted.
3. Install oil pressure pickup adapter J2 and connect the disconnected hose again.
20-146
(8)
D65EX, PX-15
TESTING AND ADJUSTING
MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE
OUTPUT PRESSURE
4. Install nipple [1] of hydraulic tester K1 and connect oil pressure gauge [2].
a Measuring instruments for PPC valve output
pressure
Symbol
1
K
2
Part No.
Name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3100
Oil pressure pickup adapter
(Size 02)
02896-11008
O-ring
k Stop the machine on a level place, lower the
work equipment to the ground, and set the parking brake lever and work equipment lock lever in
the LOCK position.
a Before measuring the PPC valve output pressure, check that the control circuit main pressure
is normal.
a Measure the PPC valve output pressure under
the following condition.
• Hydraulic oil temperature:
Within operating range
5. Start the engine and set the work equipment lock
lever in the FREE position.
6. Run the engine at high idling and operate the
control lever of the circuit to be measured and
measure the oil pressure.
a Measure the oil pressure with the lever at a
stroke end.
a When measuring the blade circuit, operate
the lever until the blade floats.
1. Open the main control valve cover on the right of
the operator’s cab.
2. Disconnect PPC valve output pressure hose (1).
Install oil pressure pickup adapters K2.
a For the circuits to be measured, see the
drawing on the next page.
7. After finishing measurement, remove the measuring instrument and return the removed parts.
3. Install oil pressure pickup adapter K2 and connect the disconnected hose again.
D65EX, PX-15
20-147
(8)
TESTING AND ADJUSTING
MEASURING PPC VALVE OUTPUT PRESSURE
1.
2.
3.
4.
5.
A.
B.
C.
D.
E.
F.
Main valve
Self-pressure reducing valve
PPC lock valve
Blade PPC valve
Ripper PPC valve (If equipped)
20-148
(1)
Blade LEFT TILT
Blade LOWER
Ripper RAISE
Ripper LOWER
Blade RAISE
Blade RIGHT TILT
D65EX, PX-15
TESTING AND ADJUSTING
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE
ADJUSTING PLAY OF WORK
EQUIPMENT PPC VALVE
a The ripper valve is not adjustable.
a If the end play of the blade lever is excessive, adjust it with their PPC valves according to the following procedure.
• Standard play a:
0.5 – 3.0 mm at 200 mm from revolution center of lever (in both longitudinal and lateral directions)
1. Remove boot (1).
2. Loosen locknut (2) and turn disc (3) to adjust the
play.
a Do not move the piston at this time.
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
3. Fix disc (3) and tighten locknut (2).
4. Install boot (1).
D65EX, PX-15
20-149
(1)
TESTING AND ADJUSTING
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER
MEASURING INTERNAL
LEAKAGE
OF WORK EQUIPMENT CYLINDER
BLEEDING
AIR FROM
MEASURING INTERNAL
LEAKAGE OF WORK
EQUIPMENT CYLINDER
a Measuring instruments for internal leakage of
work equipment cylinder
Symbol
Part No.
Name
L
Purchased
Measuring cylinder
3. Run the engine at high idling and apply the relief
pressure to the cylinder bottom side.
• Blade tilt cylinder:
Operate to tilt blade to left.
• Ripper lift cylinder:
Operate to lower ripper.
• Ripper tilt cylinder:
Operate to tilt ripper forward.
4. After 30 second, measure leakage in 1 minute.
a Measure the internal leakage of work equipment
cylinder under the following condition.
• Hydraulic oil temperature: 45 – 55ºC
a Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be measured.
5. After finishing measurement, return the removed
parts.
1. Extend the cylinder to be measured to the stroke
end and set the machine in the measuring position.
1) Blade tilt cylinder
Lower the blade tip to the ground.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper to
the end.
3) Ripper tilt cylinder
Tilt the ripper forward to the end.
a If the work equipment cylinder is removed and
installed or its piping is disconnected and connected, bleed air from its circuit according to the
following procedure.
2. Disconnect hose on the cylinder head side and
block the hose side with a plug.
a Remove the hose cover of the blade tilt cylinder.
k Take care not to disconnect the hose on the
bottom side.
20-150
(5)
BLEEDING AIR FROM WORK
EQUIPMENT CYLINDER
1. Run the engine at low idling for about 5 minutes.
2. Running the engine at low idling, extend and retract the cylinder to be bled 4 – 5 times.
a Move the piston rod to about 100 mm before
the stroke end and never relieve the oil.
3. Running the engine at high idling and carry out
the operation in 2.
4. Running the engine at low idling, move the cylinder to the stroke end to relieve the oil.
D65EX, PX-15
TESTING AND ADJUSTING
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER
(If PPC accumulator is installed)
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER
RELEASING RESIDUAL PRESSURE IN WORK
(If PPCEQUIPMENT
accumulator is CYLINDER
not installed)
RELEASING RESIDUAL
PRESSURE IN WORK
EQUIPMENT CYLINDER
RELEASING RESIDUAL
PRESSURE IN WORK
EQUIPMENT CYLINDER
(If PPC accumulator is installed)
(If PPC accumulator is not installed)
a When disconnecting the piping between the control valve and work equipment cylinder, release
the residual pressure in the circuit according to
the following procedure.
a When disconnecting the piping between the control valve and work equipment cylinder, release
the residual pressure in the circuit according to
the following procedure.
1. Loosen the hydraulic tank cap gradually to release the residual pressure in the tank.
1. Run the engine at low idling and lower the blade
and ripper to the ground without relieving each
hydraulic cylinder.
a Lower the blade gradually to the ground.
Just after the blade reaches the ground, set
the blade lever in the FLOAT position.
a Lower the ripper gradually to the ground.
2. Set the work equipment lock lever in the FREE
position and operate the blade lever and ripper
lever forward, backward, to the right, and to the
left.
a After the levers are operated 2 - 3 times, the
residual pressure in the accumulator is fully
released.
3.
Run the engine at low idling for about 5 seconds, and then stop it.
2. Turn the starting switch OFF and quickly operate
the blade lever and ripper lever forward, backward, to the right, and to the left.
a After turning the starting switch OFF, operate
the levers quickly until the engine stops completely.
4. Repeat above steps 2 and 3 by 2 - 3 times.
<If the engine was stopped while a hydraulic cylinder
was relieved at the stroke end, perform either of the
following operations.>
• Start the engine again and perform steps 1
and 2 (This operation is recommended).
• Wait for 5 - 10 minutes after stopping the engine, and then perform following steps 3 and 4.
3. Loosen the hydraulic tank cap gradually to release the residual pressure in the tank.
4. Apply cloths to the joint of the cylinder piping and
loosen the sleeve nut gradually to release the residual pressure, while shaking the hose slowly.
a Check that the residual pressure is released
and oil does not spout out any more, and
then disconnect the piping.
D65EX, PX-15
20-151
(8)
TESTING AND ADJUSTING
ADJUSTING WORK EQUIPMENT LOCK LEVER
ADJUSTING WORK EQUIPMENT LOCK LEVER
1. Adjust dimension a between pins of rod (1).
• Dimension a between pins: 330 mm
2. Connect rod (1) to work equipment lock lever (2)
and PPC lock valve (3).
a Install connecting pin (4) on the work equipment lock lever side with the cotter pin on the
outside of the machine.
20-152
(8)
D65EX, PX-15
TESTING AND ADJUSTING
MEASURING FAN MOTOR SPEED
MEASURING FAN MOTOR
SPEED
a Measuring instruments for fan motor speed
Symbol
Part No.
M
799-205-1100
6. Run the engine at high idling and low idling and
measure the fan motor speed.
k Be sure to close the radiator mask before
starting the engine. Do not start the engine
with the radiator mask open.
Name
Tachometer kit
1. Open the radiator mask.
2. Remove fan guard (1).
7. After finishing measurement, remove the measuring instrument and return the removed parts.
3. Stick 1 sheet of reflecting tape [1] to fan (2).
4. Set probe [2] of multitachometer [4] to stand [3],
matching it to reflecting tape [1], then connect it
to multitachometer [4].
k Take care that the probe will not interfere
with the fan.
5. Close the radiator mask, run the engine, and set
the monitor panel in the adjustment mode.
a For the method of operation in the adjustment mode, see “Special functions of monitor panel (EMMS)”.
a Adjustment code:
1005 (Fan 100% speed mode)
D65EX, PX-15
20-153
(8)
TESTING AND ADJUSTING
MEASURING FAN PUMP CIRCUIT PRESSURE
MEASURING FAN PUMP CIRCUIT PRESSURE
a Measuring instruments for fun pump circuit pressure
Symbol
1
P
2
Part No.
4. Install oil pressure pickup adapter P2 and connect hose (3) again. Install nipple [1] of hydraulic
tester P1 and connect oil pressure gauge [2].
a Use an oil pressure gauge which can measure 40 MPa {400 kg/cm2}.
Name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3400
Oil pressure pickup adapter
(Size 05)
02896-11015
O-ring
1. Open the radiator mask.
2. Remove fan guard (1).
5. Run the engine and set the monitor panel in the
adjustment mode.
a For the method of operation in the adjustment mode, see “Special functions of monitor panel (EMMS)”.
a Adjustment code:
1005 (Fan 100% speed mode)
6. Run the engine at high idling and measure the
fan circuit pressure.
3. Remove cover (2) and disconnect fan motor
drive circuit hose (3).
7. After finishing measurement, remove the measuring instruments and return the removed parts.
20-154
(8)
D65EX, PX-15
TESTING AND ADJUSTING
BLEEDING AIR FROM FAN PUMP
BLEEDING AIR FROM FAN
PUMP
a If the fan pump was removed and installed or its
piping was disconnected and connected, bleed
air from the pump case according to the following
procedure.
a Before performing the following procedure,
check that the hydraulic oil is at the specified level.
a Remove the operator’s seat.
1. Remove the inspection cover on the right of the
floor.
2. Loosen air bleeder (1) and leave it for 15 minutes.
3. After 15 minutes, run the engine at low idling.
4. When oil flows out of the air bleeder (1), tighten
air bleeder (1).
D65EX, PX-15
20-155
(1)
TESTING AND ADJUSTING
ADJUSTING STRAIGHT TILTDOZER
ADJUSTING STRAIGHT TILTDOZER
3) If the tilting distances are different remarkably, adjust installed dimension A of brace
(1) according to the following procedure.
• B1 B2:
Increase installed dimension A finely.
• B1 B2:
Decrease installed dimension A finely.
a If the blade was removed and installed or disassembled and assembled, adjust it according to
the following procedure.
1. Adjusting blade tilting distance
1) After installing the blade, adjust installed dimension A of brace (1) with handle (2).
• Installed dimension A of brace
A (mm)
PX
EX
1147
1151
2. Adjusting shims for blade assembly
1) After assembling the blade, adjust the shims
of tilt section (3), center section (4), lift section (5), and trunnion section (6).
Adjustment of shims
Adjustment
section
Tilt section
(3)
Center
section
(4)
Lift section
(5)
Trunnion
section
(6)
a
b
c
d
Item
2) Measure right and left tilting distances B1
and B2.
PX
EX
Clearance
Standard
clearance (Note)
Standard
thickness of shim
Right tilting
distance
B1 (mm)
Approx. 450
Approx. 440
Left tilting
distance
B2 (mm)
Approx. 450
Approx. 440
Unit: mm
0.2 – 0.7 0.2 – 0.7 0.2 – 0.7 0.2 – 1.2
5
5
4
10
Note: Play of spherical part in axial direction
2) Supply grease each adjustment section and
check that each part rotates smoothly.
2 Adjustment sections (3), (4), (5):
Grease (G1-T)
20-156
(1)
D65EX, PX-15
TESTING AND ADJUSTING
ADJUSTING STRAIGHT TILTDOZER
3. Adjusting center brace
a Adjust the center brace tension according to
the following procedure.
1) Adjust clearance b of ball joint (7) with shim
(8).
• Clearance b: 0.2 – 0.5 mm
2) Loosen bolt (9).
3) Operate the blade control lever to float the
blade.
k After operating the blade control lever, lock it
with the safety lever securely.
4) Insert a bar in the hole of center brace (10)
and turn it in the tensing direction.
a Tension adjustment torque of center brace
(10)
3 Center brace:
24.5 – 49 Nm {2.5 – 5 kgm}
5) Installed dimension of center brace (10)
Standard dimension C:
C (mm)
PX
EX
991.5
995
a Adjust center brace (10) so that clearances e between the track and frame on
both sides will be the same.
D65EX, PX-15
20-157
(1)
TESTING AND ADJUSTING
TESTING AND ADJUSTING
OPERATOR’S CAB
TESTING AND ADJUSTING OPERATOR’S CAB
a [a] side: Inside of cab (Pressurized)
[b] side: Out of cab
(Atmospheric pressure)
Check after installing cab assembly
1. Measuring pressure in cab
• Criterion:
Measured value X 58.9 Pa {6 mmH2O}
• Engine speed: High idling
• Fan speed: 100% mode
(See the User adjustment mode of the monitor panel)
• Fan switch of air conditioner: High
• EXTERNAL/INTERNAL air changeover
switch of air conditioner:
Fresh air position
a If the measured value is lower than the standard value, check the seals of the holes for
wiring harnesses and optional parts in the
cab.
1) A simple method of measuring the internal
pressure is as follows.
i) Prepare a transparent vinyl hose.
• Inside diameter: 6 mm,
Length:
3,000 mm
ii) Secure the inside end of the hose to the
top of the back seat with a tape.
iii) Remove bolt (1) under the left console
box. Pass the other end of the hose
through the bolt hole and take it out of inspection cover (2) on the left side of the
cab.
2. Check of searing performance
1) Close the all openings of the cab.
2) Splash water around the hatched part of the
cab at the rate of about 19 l/min for 10 minutes.
• At this time, it is not necessary to splash
pressurized water.
3) Splash water horizontally from a hose over
sealing surface (4).
4) Check around the dashboard carefully.
a If water leaks, caulk the leaking part and
check again.
iv) Seal the hole of bolt (1) with tape (3).
v) Fill the hose with water up to about the
half level and bend the hose in the shape
of letter U.
vi) Set the water level in the vinyl hose out
of the cab to that in the cab.
vii) Run the engine at high idling and measure water level difference c.
(Value c: Pa {mmH2O})
20-158
(5)
D65EX, PX-15
TESTING AND ADJUSTING
TESTING AND ADJUSTING OPERATOR’S CAB
3. Testing door lock
• Close the door and check the relationship
between the operator’s cab and door. If there
is any fault, repair it.
1) Check of condition
i) Check the installed height to damper
rubber (1). (Check both sides, 2 pieces
on each.)
• Stick adhesive tape 1 , etc. to the
contact face of damper rubber (1)
and open and close the door 2 – 3
times. Then, check the contact face
of adhesive tape 1 against the operator’s cab.
Normal:
When the door is closed, the
damper rubber comes in contact
lightly.
Abnormal: When the door is closed, the
damper rubber does not come in
contact or comes in contact so
strongly that adhesive tape is removed.
ii) Check the relationship between the door
notch and striker (on both sides).
• Close door (2) and check the engaging condition of latch (3) and striker
(4).
• Normal: Error of “a” must be 0.5 mm
or less.
a Check deviation a of latch center
y and striker center x from each
other from the direction of A.
D65EX, PX-15
2) Adjusting
i) Adjusting height of damper rubber
• Loosen the mounting bolts of damper rubber (1).
a You can remove and install the
shims without removing the
mounting bolts.
• Increase or decrease of shims (5)
under damper rubber (1) to adjust
the height of damper rubber (1) properly.
20-159
(5)
TESTING AND ADJUSTING
ii) Adjusting height of latch and striker
(1) Tighten the mounting bolt of striker
(4) temporarily bolt and close the
door 2 – 3 times to align latch (3) and
striker (4) with each other.
(2) Check the engaging condition of
latch (3) and striker (4).
(3) Tighten the mounting bolt of striker
(4) securely.
(4) Open and close the door and check
that it is locked and unlocked
smoothly. If the door is not locked
and unlocked smoothly (If the knob
is heavy), perform the adjustment
procedure from the first.
a Operating effort of knob:
49 ± 19.6 N {5 ± 2 kg}
iii) Apply grease (G2-LI) to latch (3).
a If latch (3) is not greased, the knob
becomes heavy. Accordingly, apply
grease sufficiently.
4. Testing open lock
• Lock the door open and check the relationship between the operator’s cab and door. If
there is any fault, repair it.
1) Check of condition
i) Check the relationship between open
lock latch (3) and striker (4) from the direction of B.
TESTING AND ADJUSTING OPERATOR’S CAB
ii) Check the installed height of stopper rubber. (Check both sides, 2 pieces on each.)
(1) Lock the door open and shake it in
the forward and reverse directions to
see if it has any play.
(2) Check that the operating effort of unlock lever is not heavy.
(3) Check that striker (4) does not slant
from center (d) of the latch.
(4) Check that the latch is not shifted
from center (e) of the striker.
• Normal: Error of “e” must be 0.5 mm
or less.
2) Adjusting
i) Adjusting latch and striker
• Loosen mounting bolt (7) of striker
(4), adjust striker (4) upright, and
tighten mounting bolt (7).
a Move the door in the opening direction to check the engagement of the
latch and striker.
20-160
(5)
D65EX, PX-15
TESTING AND ADJUSTING
TESTING AND ADJUSTING OPERATOR’S CAB
ii) Adjusting installed height of stopper rubber
(1) Loosen the locknut (10), (11) of the
stopper rubber upper side (8), lower
side (9).
(2) If there is any play, project (heighten)
the stopper rubber until the play is
eliminated.
a If the door is not locked easily or
the unlock lever is heavy, return
(lower) the stopper rubber in the
range that the door does not
hevy any play.
(3) Tighten the locknut.
D65EX, PX-15
20-161
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Display section of special
functions
1. Upper display section
(Gear speed display section)
2. Lower display section
(Multi-information section)
Operation section 1 of special
functions
(Basic operation)
3. Service switch
Operation section 2 of special
functions
(Changeover operation)
4. Buzzer cancel switch
5. Information switch
6. Shift-up switch
7. Shift-down switch
a EMMS: Equipment Management Monitoring System
20-162
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Normal function and special functions of monitor panel (EMMS)
The monitor panel (EMMS) has the normal function and special functions and displays information of various
types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed according to the operation of the switches.
1. Normal function: Operation mode
With this function, the operator can display and change the items displayed normally.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items with special switches for testing, adjusting, and troubleshooting.
Flow of modes and functions
Operator mode
1
Oil, filter maintenance mode
2
Pm clinic auxiliary mode
[U]
( )
3
Error code display mode
[T]
4
Adjustment mode
1
Oil, filter maintenance mode
Normal display (Default)
[>]
Travel direction/Gear speed
+
Shift mode/Service meter
[<]
[>]
Auxiliary menu: 4 items
[<]
[>]
[<]
[>]
(Automatic)
Maintenance item: 12 items
Adjustment menu: 4 items
[<]
Action code display function
[ON] & [U](
[T]
)
Service mode
5
Maintenance interval change
mode
[>]
[<]
6
Electric system error code
display mode
7
Mechanical system error code
display mode
8
Adjustment mode
9
Load memory display mode
[>]
[>]
[>]
[>]
Maintenance item: 12 items
[<]
[<]
Adjustment menu: 16 items
[<]
Display menu: 3 items
[<]
10 Real-time monitoring mode
[>]
[<]
11 Dual display monitoring mode
[>]
5
[<]
Maintenance interval change
mode
D65EX, PX-15
[ON]:
[U]:
[ T ]:
[ > ]:
[ < ]:
( ):
Service switch
Buzzer cancel switch (Left)
Buzzer cancel switch (Right)
Information switch (Right)
Information switch (Left)
Min. 2.5 sec
20-163
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Operation and display in operator mode
(Outline)
a In this section, only the outline of the operation
mode is described. For the details of the contents and operation method of each function and
mode, see Operation Manual.
Normal display mode (Default)
The monitor panel displays the following information
normally.
Gear speed display section (1):
• Front side: Travel direction (P·N·F·R)
• Rear side: Gear speed (1·2·3)
• Graphics: Engine speed
Multi-information section (2):
a Information is displayed in 2 lines of 16 characters each.
• Front side:
Gear shift mode (F1-R1·F1-R2·F2-R3)
(Displayed when preset mode is set)
• Rear side:
Service meter (Unit: 0.1h)
• Each time the information switch is set to the
right or left, the service meter and engine speed
are displayed alternately.
1. Maintenance mode
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replacement
of oils and filters is displayed on the multi-information section (2) and reset after the replacement.
a Gear speed display section (1) keeps displaying normally.
No.
Maintenance item
01
Engine oil
02
Engine oil filter
03
Fuel filter
04
Hydraulic oil filter
05
Corrosion resistor
06
Bypass filter a
07
Damper oil
08
Final drive oil
09
Hydraulic oil
10
Power train oil
11
Power train oil filter
12
HSS charge filter (HSS specification) a
The items marked with a are displayed but not
used for this machine.
20-164
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
2. Pm clinic auxiliary mode
(2-PM CLINIC MODE)
In this mode, the condition of the machine is displayed on multi-information section (2) as an
auxiliary function of the periodic diagnoses such
as the Pm clinic, even if any measuring instrument is not connected.
a Gear speed display section (1) keeps displaying normally.
No.
Pm clinic auxiliary item
01
Engine speed
02
Boost pressure
03
Work equipment pressure a
04
Battery voltage
Although the items marked with a are displayed,
they are not used for this machine.
3. Error code display mode
(3-ERROR CODE DISPLAY MODE)
In this mode, the contents of each fault in the machine are displayed by a 6-character error code
on the multi-information section (2).
When the user or the operator needs to be notified of the error code of each fault, this mode is
applied.
a Gear speed display section (1) keeps displaying normally.
a When a serviceman needs to check the error
codes for troubleshooting, the Electric system error code display mode and the Mechanical system error code display mode
should be used for more detailed information.
a Method of checking error code:
Turn buzzer cancel switch (4) to the [U] position on the screen shown at right, and the
all error codes detected currently are displayed at the interval of about 2 seconds. (To
finish displaying, turn the buzzer cancel
switch to the [ T ] position.)
a For the error codes list, see TROUBLESHOOTING.
D65EX, PX-15
20-165
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
4. Adjustment mode (4-USER ADJUST MODE)
In this mode, the display condition of the monitor
panel can be adjusted on the multi-information
section (2).
a Gear speed display section (1) keeps displaying normally.
No.
Brightness of LCD
02
Brightness of display
03
Contrast of display
20-166
(1)
Adjustment item
01
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Action code display function
If a fault to be notified to the operator occurs during
work, an action code and a phone No. are displayed
on the multi-information section (2).
a Gear speed display section (1) keeps displaying
normally.
a The phone No. is displayed for only important action codes. The display shown at right is an example. (The form of the displayed phone No.
depends on the form of the input No.)
a If an important action code is displayed, the caution lamp flashes and the caution buzzer sounds.
<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 error code in the “Electric system error
code display mode” and “Mechanical system error
code display mode” of the service mode.
Action codes table
Action
code
Contents of fault
Remedy
• Only action code is displayed.
• Backup alarm does not sound.
• Fan speed is kept at maximum.
• Automatic function stops or normal function stops partially but
machine can work.
• Call your Komatsu distributor for
repair.
• Action code is displayed.
• Caution lamp flashes.
• Caution buzzer sounds.
• Gear is not shifted up or down.
• Engine boost pressure is abnormal.
• Exhaust gas color is bad when
temperature is low.
• Stop engine and start it again,
and you can operate machine
without limiting function. You
must take care, however.
• Call your Komatsu distributor for
repair.
CALL E03
• Action code is displayed.
• Caution lamp flashes.
• Caution buzzer sounds.
• Engine water temperature is defective.
• Usable gear speeds are limited.
• Engine speed does not rise fully.
• Gear shifting shocks become
large.
• Steering performance lowers.
• Move machine to safe place.
• Call your Komatsu distributor for
repair.
CALL E04
• Action code is displayed.
• Caution lamp flashes.
• Caution buzzer sounds.
• Engine cannot be controlled.
• Machine cannot travel.
• Machine stops.
• Stop machine immediately.
• Call your Komatsu distributor for
repair.
E01
E02
Indication method of fault
D65EX, PX-15
20-167
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Operation and display in service mode
Method of changing to service mode
a When using the service mode, change the
screen by the following special operation.
1) Special operation of switches
Set the monitor panel in the service mode by operating service switch (3) and buzzer cancel
switch (4).
a Keeping the service switch in the ON position, hold the buzzer cancel switch in the [U]
position for 2.5 seconds.
a If the monitor panel is set in the service
mode, [1C] is displayed on the gear speed
display section (1).
a Each time the monitor panel is set in the service mode, the “Maintenance inter val
change mode” is displayed first.
2) Selecting and executing mode to be used
Select the mode to be used with information
switch (5) and execute it with buzzer cancel
switch (4).
• [ > ]: Next mode No.
• [ < ]: Previous mode No.
• [U]: Execute mode.
a For the details of operation in each mode,
see the following pages.
3) Finishing mode and function
The current mode and function can be finished
by either of the following method, regardless of
the current mode and hierarchy.
(1) When continuing the operation in another
mode or function or in the operator mode:
Return to the mode screen or function
screen to be used next by operating buzzer
cancel switch (4).
• [ T ]: Screen returns.
(2) When finishing the all operation:
Turn off the starting switch.
20-168
(1)
No.
Gear speed
display section
5
1C
Maintenance interval change mode
6
EE
Electric system error code display mode
7
bE
Mechanical system error code display
mode
8
Cb
Adjustment mode
9
Ld
Load memory display mode
10
5R
Real-time monitoring mode
11
dR
Dual display monitoring mode
Service mode item
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
5. Maintenance interval change mode
(5-EXCHG. INTVAL. SET MODE)
In this mode, you can check and set the maintenance interval times of various filters and oils
which are the bases of the maintenance display
function in the operator mode.
1) Selecting and executing mode
i) Select “Maintenance interval change
mode” on the mode selection screen.
a If the mode is selected, code (1C) is
displayed on gear speed display section (1) and the title is displayed on
multi-information section (2).
ii) Display the maintenance item selection
screen by operating buzzer cancel
switch (4).
• [U]: Execute mode.
2) Selecting and displaying maintenance item
i) Operate information switch (5) on the
maintenance item selection screen to
select a maintenance item.
• [ > ]: Next code
• [ < ]: Previous code
ii) Display the maintenance item selection
screen by operating buzzer cancel
switch (4).
• [U]: Execute item.
3) Contents of information section
The following items are displayed on the information section.
1 : Code
2 : Maintenance item
3 : Replacement interval time (Set time)
a The items shown at right are examples.
a If the replacement interval does not need
to be changed, finish the operation on
this screen.
a If the replacement interval needs to be
changed, go to step 4).
D65EX, PX-15
20-169
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
4) Changing replacement interval time
i) Change the set time by operating information switch (5), shift-up switch (6), and
shift-down switch (7).
• [ > ]: Move cursor to right.
• [ < ]: Move cursor to left.
• [UP]: Increase number.
• [DOWN]: Decrease number.
a If you do not use the maintenance
function, set the all times to 0.
ii) If the input time is correct, enter the
change of setting by operating buzzer
cancel switch (4).
• [U]: Enter change.
a If the change is finished normally, the
information display screen appears
after the screen shown at right.
a If the change is not finished normally,
the information display screen before
the change appears after the screen
shown at right. In this case, execute
the above operation again.
20-170
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Maintenance items table
Replacement interval time
Code
Maintenance item
1st time
(Cannot be changed)
2nd time and after
(Can be changed)
01
ENG OIL
Engine oil
0500h
0500h
02
ENG FILT
Engine oil filter
0500h
0500h
03
FUEL FILT
Fuel filter
0500h
0500h
04
HYD FILT
Hydraulic oil filter
2000h
2000h
05
CORR RES
Corrosion resistor
1000h
1000h
06
BYPS FILT
Bypass filter
—
—
07
DAMP OIL
Damper oil
2000h
2000h
08
FNL OIL
Final drive oil
1000h
1000h
09
HYD OIL
Hydraulic oil
2000h
2000h
10
POWL OIL
Power train oil
1000h
1000h
11
POWL FILT
Power train oil filter
0500h
0500h
12
HSS FILT
HSS charge filter (HSS specification)
—
—
a The first replacement interval is the same as the second and after replacement intervals, and the former
cannot be changed.
D65EX, PX-15
20-171
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
6. Electric system error code display mode
(6-ELEC. ERROR CODE MODE)
In this mode, you can check the electric system
error codes.
1) Selecting and executing mode
i) Select “Electric system error code display
mode” on the mode selection screen.
a If the mode is selected, code (EE) is
displayed on gear speed display section (1) and the title is displayed on
multi-information section (2).
ii) Display the error code display screen by
operating buzzer cancel switch (4).
• [U]: Execute mode.
2) Display in the case where no codes are recorded
If no error codes have been output up to now,
the information section displays as shown at
right.
3) Display in the case where 1 or more codes
are recorded
If any error code has been output up to now,
the information section displays as shown at
right.
1 : Record No. (Up to 20)
2 : Error code (Code being output currently
is flashing)
3 : Number of past occurrences
4 : Time measured by service meter after
first occurrence
5 : Time measured by service meter after
last occurrence
a The items shown at right are examples.
a For the error codes list, see TROUBLESHOOTING.
20-172
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
a Flashing and lighting of error code
Flashing: Code is being output currently.
Lighting: Code is not being output currently.
a Condition for detecting and keeping error
code
If a error code of any item other than
communication is output, it keeps flashing until the starting switch is turned off.
After the starting switch is turn on or the
engine is started again, the error code
keeps lighting until the same fault is detected.
A error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are
recorded.
When multiple codes are recorded, they can
be displayed one by one by operating information switch (5).
• [ > ]: Next code
• [ < ]: Previous code
a The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code
While a error code to be deleted, operate
shift-up switch (6) or shift-down switch (7).
• [UP] or [DOWN]: Delete error code.
a A error code which is being output currently (which is flashing) cannot be deleted.
D65EX, PX-15
20-173
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
7. Mechanical system error code display mode
(7-MACHINE ERROR CODE MODE)
In this mode, you can check the mechanical system error codes.
1) Selecting and executing mode
i) Select “Mechanical system error code
display mode” on the mode selection
screen.
a If the mode is selected, code (bE) is
displayed on gear speed display section (1) and the title is displayed on
multi-information section (2).
ii) Display the error code display screen by
operating buzzer cancel switch (4).
• [U]: Execute mode.
2) Display in the case where no codes are recorded
If no error codes have been output up to now,
the information section displays as shown at
right.
3) Display in the case where 1 or more codes
are recorded
If any error code has been output up to now,
the information section displays as shown at
right.
1 : No.
2 : Error code (Code being output currently
is flashing)
3 : Number of past occurrences
4 : Time measured by service meter after
first occurrence
5 : Time measured by service meter after
last occurrence
a The items shown at right are examples.
a For the error codes list, see TROUBLESHOOTING.
20-174
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
a Flashing and lighting of error code
Flashing: Code is being output currently.
Lighting: Code is not being output currently.
a Condition for detecting and keeping error
code
If a error code of any item other than
communication is output, it keeps flashing until the starting switch is turned off.
After the starting switch is turned on or
the engine is started again, the error
code keeps lighting until the same fault is
detected.
A error code of communication starts
lighting when the fault is solved, even if
the starting switch is turned off.
4) Operation to take when multiple codes are
recorded
When multiple codes are recorded, they can
be displayed one by one by operating information switch (5).
• [ > ]: Next code
• [ < ]: Previous code
a The error codes are displayed all of them
including no-failed modes in numerical
order.
5) Method of deleting error code
The mechanical system error codes cannot
be deleted.
D65EX, PX-15
20-175
(8)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
8. Adjustment mode
(8-SERVICE ADJUST MODE)
In this mode, you can adjust the control system
and various devices of the machine.
1) Selecting and executing mode
i) Select “Adjustment mode” on the mode
selection screen.
a If the mode is selected, code (Cb) is
displayed on gear speed display section (1) and the title is displayed on
multi-information section (2).
ii) Display the adjustment code input
screen by operating buzzer cancel
switch (4).
• [U]: Execute mode.
2) Selecting adjustment items
i) On the adjustment code input screen, input the 4-digit code of the item to be adjusted by operating information switch
(5), shift-up switch (6), and shift-down
switch (7).
• [ > ]: Move cursor to right.
• [ < ]: Move cursor to left.
• [UP]: Increase number.
• [DOWN]: Decrease number.
ii) After inputting the code, operate buzzer
cancel switch (4) to display the monitoring screen.
• [U]: Enter input code.
20-176
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
a If an incorrect code is input, the adjustment code input screen appears again
after the screen shown at right. In this
case, execute the above operation
again.
3) Contents of display on adjustment screen
1 : Code
2 : Adjustment item
3 : Related information
a For the detailed information and adjustment procedure, see “ADJUSTMENT
MODE TABLE AND ADJUSTMENT
PROCEDURE”.
4) When operating machine in adjustment mode
If the parking brake lever is set in the FREE
position, gear speed display section (1) displays normally and the machine can be operated normally.
a At this time, even if the shift-up or shiftdown switch is pressed with the PCCS
lever in the neutral position, the shift cannot be changed. (The displayed number
is the code of adjustment mode selection.)
To change the shift, set the PCCS lever
in the FORWARD or REVERSE position
and press the shift-up or shift-down
switch while the machine is traveling.
a To select another screen, return the
parking brake lever to the LOCK position
and perform the necessary procedure.
D65EX, PX-15
20-177
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
5) Changing adjustment item (Limited function)
Once the adjustment items are selected,
they can be selected with the information
switch without inputting the codes again.
• [ > ]: Next code
• [ < ]: Previous code
a This function is limited to the numbers
marked with a in the “ADJUSTMENT
ITEMS TABLE”.
a This operation is not accepted while the
parking brake lever is in the FREE position. Take care.
a An adjustment item can be selected by
returning to the input screen and inputting the code for that item.
Adjustment mode table and adjustment procedure
No.
Code
Adjustment item
Related
information
Disassembly/
Assembly
[1]
0001 INP TEL NO.
a[2]
0002 S/T S.CODE
Steering and transmission controller specification set
Code
q
a[3]
0004 BODY TYPE
Machine specification set
Code
q
a[4]
0005 BRAKE BASE
Brake potentiometer zero point adjustment
Voltage
q
a[5]
0007 ENG.FULL CH
Engine deceleration-cut mode
Speed
[6]
0008 INJ->123456
Common rail reduced cylinder mode
Speed
a[7]
0009 PITCH SENS.
Pitch angle sensor initial set
Voltage
a[8]
0010 FAN 70%MODE Fan 70% speed mode
Adjustment data
a[9]
1005 FAN100%MODE Fan 100% speed mode
Adjustment data
[10]
1012 S/T N-SET
[11]
1013 S/T M.L-SET
Steering lever left set
Voltage
[12]
1014 S/T M.R-SET
Steering lever right set
Voltage
[13]
2222 HSS ADJUST
HSS lever initial current set
Current
[14]
9997 HI IDLE SET
High idling limit mode
Speed
[15]
9998 SFT INHIBIT
Gear speed limit mode
Symbol
Phone No. input mode
Steering lever neutral set
Figure/Symbol
q
Voltage
k Items marked with q in the Disassembly/Assembly column of the above table must be adjusted after the
machine is assembled or any controller is replaced. (For the adjustment procedure, see “ADJUSTMENT AFTER REPLACEMENT OF CONTROLLER”.)
a The numbers marked with a can be displayed in order by setting the information switch in the “ > ” or “ < ”
position.
20-178
(6)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
[ 1 ] 0001: Phone number input mode
• This code inputs or changes a phone number to
be displayed simultaneously with when the user
code is displayed.
• The lower part displays a phone number and
symbols.
• Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ?
• Instructions for use:
1) By operating the information switch (5), shift
up switch (6), and shift down switch (7), input
a phone number and symbols.
• [ > ]: Moves the cursor rightward.
• [ < ]: Moves the cursor leftward.
• [UP]: Advance the numeric character or
character (in the order of available
characters).
• [DOWN]: Reverse the numeric character
or character (in the reverse order of available characters).
2) Set buzzer cancel switch (4) in the [U] position and check that the alarm buzzer sounds.
a Sixteen digits of numeric characters are provided. To avoid confusion, input symbols other than numeric characters at digits you will
not use.
a 0 (zero) is input at all places of the lower part
before shipment from our factory. (No phone
number is displayed under this condition.)
a The setting is enabled even after ending this
code.
[ 2 ] 0002: Steering and transmission controller specification set
• This code is used to initialize the specification
codes recognized by the steering controller and
the set values of the memory in the controller.
• The specification code is displayed on the lower
line.
• Adjustment method:
1) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
2) Check that the displayed specification code
has changed from [4 4] to [444].
a If specification code [444] is not displayed,
the controller wiring harness or the controller
unit may be defective.
a Even if this code is turned off, the setting is
effective.
D65EX, PX-15
20-179
(1)
TESTING AND ADJUSTING
[ 3 ] 0004: Machine specification set
• This code is used to have the machine specification recognized by the controllers which compose the system.
• The machine specification code is displayed on
the lower line.
• Adjustment method:
a Since this code is reset when “Steering and
transmission controller specification set” is
executed, adjust it after that.
1) Select the code of the machine specification
by setting shift up switch (6).
2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
k If the machine specification is different from
the setting in the controller, the machine may
move abnormally or an error may be made.
Accordingly, be sure to match the setting to
the machine specification.
a Even if this code is turned off, the setting is
effective.
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Code
Specification
000
Standard
008
For EU district
080
For cold
088
For EU district + For cold district
010
Pitch specification
018
For EU district + Pitch specification
090
For cold district + Pitch specification
098
For EU district + For cold district + Pitch
specification
[ 4 ] 0005: Brake potentiometer zero point adjustment
• This code is used to adjust the zero point of the
potentiometer of the brake pedal.
• The deviation from the standard is displayed by
voltage on the lower line (Display range: –2500 –
2500).
• Adjustment method:
With the brake pedal released, set buzzer cancel
switch (4) in the [U] position and check that the
caution buzzer sounds.
a Even if the neutral position of the brake pedal
is adjusted, the display of the lower line does
not change.
a Even if this code is turned off, the setting is
effective.
a This code is not for adjustment of the braking
performance, etc.
20-180
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
[ 5 ] 0007: Engine deceleration-cut mode
• This code is used to stop the auto-deceleration
function of the engine and check the high idling
speed of the engine singly.
• The engine speed is displayed on the lower line
(Display range: 0 – 3000).
• Using method:
While this code is displayed, its function is turned
on and the auto-deceleration function is turned
off.
a If this code is turned off, its function is turned off.
[ 6 ] 0008: Common rail reduced cylinder mode
a When the engine common rail system seems to
be faulty, this code is used to stop injecting fuel
into 1 or more cylinders (reduce the number of
effective cylinders) while the engine is running
and find out a faulty cylinder from the change of
the engine speed.
a Since a fault is detected by the difference of the
engine speed in the reduced cylinder mode operation from that in the normal mode operation,
use this function while the engine is running.
• The engine speed is displayed on the lower line
(Display range: 0 – 3000).
• Using method:
Select the cylinders to be turned off for the reduced cylinder mode operation by operating information switch (5) and buzzer cancel switch
(4).
Use this method to turn on the selected cylinders
again, too.
• [ > ]: Move cursor to right.
• [ < ]: Move cursor to left.
• [U]: Execute or stop reduced cylinder mode
operation.
a The figure at right is an example that No. 2
cylinder is turned off for reduced cylinder
mode operation and turned on again (The
cylinder No. lamp is turned off in the reduced
cylinder mode operation and on in the normal mode operation).
a Only one or more cylinders can be turned off
for the reduced cylinder mode operation.
a If this code is turned off, its function is turned
off.
D65EX, PX-15
20-181
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
[ 7 ] 0009: Pitch angle sensor initial set
• This code is used to adjust the zero point and installation error of the pitch angle sensor.
• The deviation from the standard neutral position
is displayed by voltage on the lower line (Display
range: –2500 – 2500).
• Adjustment method:
Stop the machine on level ground, then set buzzer cancel switch (4) in the [U] position and check
that the caution buzzer sounds.
a Even after adjustment, the display of the lower line does not change.
a Even if this code is turned off, the setting is
effective.
[ 8 ] 0010: Fan 70% speed mode
• This code forcedly sets the rpm of cooling fan at
approximately 70% of the maximum speed.
• The lower part displays data for adjustment.
• Instructions for use:
The function is enabled with this code displayed
to control the rpm of cooling fan to approximately
70% of the maximum speed.
a Ending this code disables the function.
20-182
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
[9] 1005: Fan 100% speed mode
• This code forcedly sets the rpm of cooling fan at
approximately 100% of the maximum speed.
• The lower part displays data for adjustment.
• Instructions for use:
The function is enabled with this code displayed
to control the rpm of cooling fan to approximately
100% of the maximum speed.
a Ending this code disables the function.
[10] 1012: Steering lever neutral set
• This code is used to adjust the steering potentiometer neutral position of the PCCS lever.
• The output signal of steering potentiometer from
displayed by voltage on the lower line (Display
range: 0 – 5000).
• Adjustment method:
1) Shift the PCCS lever in the steering neutral
position.
2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
a Even if this code is turned off, the setting
is effective.
a This code is not for adjustment of the
steering performance, etc.
a Even after adjustment, the display of the
lower line does not change.
D65EX, PX-15
20-183
(6)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
[11] 1013: Steering lever left set
• This code is used to adjust the maximum left
steering potentiometer position of the PCCS lever.
• The output signal of the steering potentiometer
from displayed by voltage on the lower line (Display range: 0 – 5000).
• Adjustment method:
1) Set the PCCS lever to the left steering stroke
end.
2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
a Even if this code is turned off, the setting is
effective.
a This code is not for adjustment of the steering performance, etc.
a Even after adjustment, the display of the lower line does not change.
[12] 1014: Steering lever right set
• This code is used to adjust the maximum right
steering potentiometer position of the PCCS lever.
• The output signal of steering potentiometer from
displayed by voltage on the lower line (Display
range: 0 – 5000).
• Adjustment method:
1) Set the PCCS lever to the right steering
stroke end.
2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
a Even if this code is turned off, the setting is
effective.
a This code is not for adjustment of the steering performance, etc.
a Even after adjustment, the display of the lower line does not change.
20-184
(6)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
[13] 2222: HSS lever initial current set
• When the steering start feeling is different by the
steering direction, this code is used to adjust the
turning radius at the start of steering.
• The current to drive the HSS EPC solenoid is
displayed on the lower line [Display range: –350
(Left end) – 0 – 350 (Right end)].
• Adjustment method:
1) Gradually turning the PPC lever to the left or
right, display and keep the current to be set.
• If the lever is turned to the left, the current becomes negative.
• If the lever is turned to the right, the current becomes positive.
2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
a As the set current is increased in the positive
or negative direction, the turning radius at
the start of steering is decreased (the machine turns more quickly).
a The figure at right is an example that the set
current for steering to the left is reduced to
increase the turning radius.
a Even if this code is turned off, the setting is
effective.
[14] 9997: High idling limit mode
• This code is used to limit the use high idling
speed.
• Limit range: High idling speed – approx. –200
rpm
• Using method:
1) Select a limit speed by setting information
switch (5) in the [ > ] position or [ < ] position.
2) Set buzzer cancel switch (4) in the [U] position and check that the caution buzzer
sounds.
a If the high idling speed is limited, the engine
speed is not raised to the normal high idling
level even if the fuel control dial is controlled
so.
a Even if this code is turned off, the setting is
effective.
D65EX, PX-15
20-185
(8)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
[15] 9998: Gear speed limit mode
• This code is used to limit the use of the 3 gear
speeds.
• The usable gear speeds are displayed by bits on
the lower line (in the order of the 3rd, 2nd, and
1st from the left).
• Using method:
Limit or allow the use of the maximum gear
speed by operating information switch (5) and
buzzer cancel switch (4).
• [ > ]: Do not prohibit shifting to 3rd gear speed.
• [ < ]: Prohibit shifting to 3rd gear speed.
• [U]: Enter the selection.
• Display on lower line [o]:
Gear speed is effective.
• Display on lower line [ ]:
Gear speed is not effective.
a If the use of a gear speed is limited, the
transmission is not shifted to that gear speed
even if the gear shift-up switch is operated.
a Even if this code is turned off, the setting is
effective.
20-186
(6)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
9. Load memory display mode
(9-LOAD MEMORY DISPLAY MODE)
In this mode, you can check the load on the machine, forward odometer, and reverse odometer.
1) Selecting and executing mode
i) Select “Load memory display mode” on
the mode selection screen.
a If the mode is selected, code (Ld) is
displayed on gear speed display section (1) and the title is displayed on
multi-information section (2).
ii) Display the adjustment code input screen
by operating buzzer cancel switch (4).
• [U]: Execute mode.
2) Changing information screen
Change the information screen by operating
information switch (5).
• [ > ]: Next screen.
• [ < ]: Previous screen.
No.
Displayed information
01
1,000 rpm service meter
02
Forward odometer
03
Reverse odometer
3) Display of 1,000 rpm service meter (01)
This code is used to display the service
meter which integrates the operation hours
only while the engine speed is higher than
1,000 rpm.
a The data cannot be reset.
D65EX, PX-15
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TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
4) Display of forward odometer (02)
On this screen, the integrated forward travel
distance is displayed.
a The data cannot be reset.
5) Display of reverse odometer (02)
On this screen, the integrated reverse travel
distance is displayed.
a The data cannot be reset.
6) When operating machine in load memory
display mode
If the parking brake lever is set in the FREE
position, gear speed display section (1) displays normally and the machine can be operated normally.
a At this time, even if the shift-up or shiftdown switch is pressed with the PCCS
lever in the neutral position, the shift cannot be changed. (The displayed number
is the code of load saving display mode.)
To change the shift, set the PCCS lever
in the FORWARD or REVERSE position
and press the shift-up or shift-down
switch while the machine is traveling.
a To select another screen, return the
parking brake lever to the LOCK position
and perform the necessary procedure.
20-188
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
10. Real-time monitoring mode
(10-REAL TIME MONITORING MODE)
In this mode, the speeds, oil pressures, oil temperatures, currents, voltages, etc. can be monitored by using the signals from sensors,
switches, and solenoids installed various parts of
the machine.
a This mode is used to monitor the items one
by one. When monitoring two items simultaneously, use the “Dual display monitoring
mode”.
1) Selecting and executing mode
i) Select “Real-time monitoring mode” on
the mode selection screen.
a If the mode is selected, code (5R) is
displayed on gear speed display section (1) and the title is displayed on
multi-information section (2).
ii) Display the monitoring code input screen
by operating buzzer cancel switch (4).
• [U]: Decide selection.
2) Selecting and entering monitored items
i) On the code input screen, input the 5digit code of the item to be monitored by
operating information switch (5), shift-up
switch (6), and shift-down switch (7).
• [ > ]: Move cursor to right.
• [ < ]: Move cursor to left.
• [UP]: Increase number.
• [DOWN]: Decrease number.
ii) After inputting the code, display the monitoring screen by operating buzzer cancel switch (4).
• [U]: Enter input code.
a If the input code is correct, the monitoring screen shown at right appears.
D65EX, PX-15
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TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
a If the input code is not correct, the code
input screen appears again after the
screen shown at right.
3) Contents of display on monitoring screen
(Right figure shows examples)
1 : Code
2 : Monitoring item
3 : Information
4 : Unit (Not displayed for some items)
a For the details, see the “MONITORING
MODE TABLE”.
4) Function of holding monitoring information
If an information item such as the engine
speed is not stabilized and cannot be read
easily in the monitoring mode, it can be held
and released by operating buzzer cancel
switch (4).
• [U]: Hold and release.
a While the monitored item is held, the letter “H” is displayed at the left end of the
lower line.
5) When operating machine in monitoring mode
If the parking brake lever is set in the FREE
position, gear speed display section displays
normally and the machine can be operated
normally.
a At this time, even if the shift-up or shiftdown switch is pressed with the PCCS
lever in the neutral position, the shift cannot be changed. (The displayed number
is the code of monitoring mode.)
To change the shift, set the PCCS lever
in the FORWARD or REVERSE position
and press the shift-up or shift-down
switch while the machine is traveling.
a To select another screen, return the
parking brake lever to the FREE position
and perform the necessary procedure.
20-190
(1)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
6) Changing monitored items (Limited function)
Once the monitoring screen is selected in
step 2), the monitored item can be changed
by operating only information switch (5) without inputting the code again.
• [ > ]: Next code
• [ < ]: Previous code
a This function is applicable to only the
numbers marked with .
a This operation is not accepted while the
parking brake lever is in the FREE position. Take care.
D65EX, PX-15
20-191
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Monitoring mode table
No. Code
Monitored item
Unit
Display range
1 01000 ENG. SPEED
Engine speed
rpm
0 – 3000
4 03000 FUEL DIAL
Voltage of fuel control dial
mV
0 – 5000
5 03001 FUEL DIAL
Acceleration ratio
%
0 – 100
6 03200 BATTERY
Battery voltage
mV
0 – 30000
7 04102 WATER HIGH
Engine water temperature (High temperature side)
ºC
0 – 150
8 04104 WATER LOW
Engine water temperature (Low temperature side)
ºC
–30 – 100
9 04200 FUEL SENS
Fuel level sensor voltage
mV
0 – 5000
10 04204 FUEL TEMP.
Fuel temperature
ºC
0 – 150
11 04401 HYD. TEMP.
Hydraulic oil temperature
ºC
0 – 150
12 04402 HYD. TEMP.
Hydraulic oil temperature voltage
mV
0 – 5000
13 10000 FAN REVO.
Command speed of cooling fan
rpm
0 – 2000
14 20000 ENG-MACHIN
Engine controller program No.
Character
15 20200 MON. PROGRM Monitor panel (Tachometer module) program No.
Character
16 20202 S/T. PROGRM
Character
Steering controller program No.
17 20203 ENG-PROGRM Engine controller program No.
Character
18 20300 KOMTRAX
KOMTRAX LED display
—
19 30100 T/C TEMP.
Torque converter oil temperature
ºC
0 – 150
20 31400 T/M OUT
Transmission speed
rpm
0 – 5000
21 31520 T/M-FILL
Input state of transmission-related fill switch
Bit
(See detailed information)
22 31602 1st CLUTCH
Output command current of 1st clutch ECMV
mA
0 – 1000
23 31603 2nd CLUTCH
Output command current of 2nd clutch ECMV
mA
0 – 1000
24 31604 3rd CLUTCH
Output command current of 3rd clutch ECMV
mA
0 – 1000
25 31606 Rev CLUTCH
Output command current of reverse clutch ECMV
mA
0 – 1000
26 31608 Frd CLUTCH
Output command current of forward clutch ECMV
mA
0 – 1000
27 31612 1 CLUTCH F
Output FB current of 1st clutch ECMV
mA
0 – 1000
28 31613 2 CLUTCH F
Output FB current of 2nd clutch ECMV
mA
0 – 1000
29 31614 3 CLUTCH F
Output FB current of 3rd clutch ECMV
mA
0 – 1000
30 31616 R CLUTCH F
Output FB current of reverse clutch ECMV
mA
0 – 1000
31 31622 F CLUTCH F
Output FB current of forward clutch ECMV
mA
0 – 1000
32 31623 FAN PUMP.O
Output command current of cooling fan pump solenoid
mA
0 – 1000
33 31624 FAN PUMP.F
Output FB current of cooling fan pump solenoid
mA
0 – 1000
34 32900 BODY ANGLE
Machine pitch angle
º
–30 – 30
35 36100 Q-INJECTOR
Command value of fuel injection rate
mm3/st –30 – 600
36 36200 CRI. PRESS
Command pressure of common rail
MPa
0 – 150
37 36300 CRI-TIMING
Fuel injection timing
CA
–30.0 – 30.0
38 36400 CRI. PRESS
Common rail pressure
MPa
0 – 200
39 36500 BOOST. PRES
Boost pressure
KPa
0 – 300
40 36600 CRI. CONTRL
Engine control mode
41 36700 CRI-TORQUE
Converted torque of engine
Character
%
0 – 100
42 36800 CRI-Q-MOD1
Fuel injection amount adjustment command value 1
Character 0123456789abcdef
43 36801 CRI-Q-MOD2
Fuel injection amount adjustment command value 2
Character 0123456789abcdef
44 40001 VEHICLE SP
Travel speed (Theoretical value)
km/h
0 – 100
45 40900 ENG-SW 1
Engine controller input signal 1
Bit
(See detailed information)
46 40901 ENG-SW 2
Engine controller input signal 2
Bit
(See detailed information)
20-192
(1)
D65EX, PX-15
TESTING AND ADJUSTING
No. Code
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Monitored item
Unit
Display range
47 40905 T/M-SW1
Transmission-related controller input signal 1
Bit
(See detailed information)
48 40906 T/M-SW2
Transmission-related controller input signal 2
Bit
(See detailed information)
49 40909 T/M SOL.2
Transmission-related controller output signal
Bit
(See detailed information)
50 40910 S/T-SW1
Steering-related controller input signal 1
Bit
(See detailed information)
51 40911 S/T-SW2
Steering-related controller input signal 2
Bit
(See detailed information)
52 40913 S/T-SW5
Steering-related controller input signal 5
Bit
(See detailed information)
53 40914 S/T SOL.1
Output signal of steering controller
Bit
(See detailed information)
54 50000 DESEL PEDAL Deceleration ratio
%
0 – 100
55 50100 SSC
3rd throttle
%
0 – 100
56 50101 SSC ORDER
3rd throttle command voltage
mV
0 – 5000
57 50200 T/M LEVER 1
Voltage of forward-reverse potentiometer 1
mV
0 – 5000
58 50201 T/M LEVER 2
Voltage of forward-reverse potentiometer 2
mV
0 – 5000
59 50300 S/T LEVER 1
Voltage of steering potentiometer 1
mV
0 – 5000
60 50301 S/T LEVER 2
Voltage of steering potentiometer 2
mV
0 – 5000
61 50400 BRAKE PEDL
Voltage of brake potentiometer
mV
0 – 5000
62 50600 HSS L.H.F
Output FB current of left HSS solenoid
mA
0 – 1000
63 50601 HSS R.H.F
Output FB current of right HSS solenoid
mA
0 – 1000
64 50602 HSS L.H.O
Output command current of left HSS solenoid
mA
0 – 1000
65 50603 HSS R.H.O
Output command current of right HSS solenoid
mA
0 – 1000
66 50900 N-SAFETY
Drive current of neutral safety relay
mV
0 – 30000
67 51000 SSC ORDER
3rd throttle command speed
rpm
0 – 3000
68 60000 TRACTION
Traction force (Theoretical value)
W
0–0
69 60100 BODY ANGLE
Machine pitch angle sensor voltage
mV
0 – 5000
70 60600 BR HOLD
Drive voltage of battery relay
mV
0 – 30000
71 60700 S/T MODE
Steering state code
Character
72 60800 FILL MODE
Variable for setting fill condition
Character
73 60909 MOD. MODE
Setting of modulation condition
Character
74 70000 CHG. P. MODE
Variable for setting condition of gear shift point
Character
75 70300 B.KNOB SW
Input signal of work equipment-related controller
Bit
(See detailed information)
76 70304 T/M SOL.1
Output signal of work equipment-related controller
Bit
(See detailed information)
77 70400 BACK ALARM
Drive voltage of back-up alarm relay
mV
0 – 30000
78 70500 Regulation
Reguration speed
rpm
0 – 2200
The numbers marked with
tion.
D65EX, PX-15
can be displayed in order by setting the information switch in the “ > ” or “ < ” posi-
20-193
(8)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Detailed information on bit display codes
Examples of display of bit information
a The display position of the bit information in the
“Real-time monitoring mode (Display of only 1
item)” is different from that in the “Dual display
monitoring mode (Simultaneous display of 2
items)”.
a The bit information is displayed by [ _ ] for OFF
and [o] for ON in the places 1 – 8 .
a The state of each item shown below is the condition for turning on the bit.
31520: Input state of transmission related fill switch
1 : Forward clutch fill switch: ON
2 : Reverse clutch fill switch: ON
3 : 1st clutch fill switch: ON
4 : 2nd clutch fill switch: ON
5 : 3rd clutch fill switch: ON
6 : (Unused)
7 : (Unused)
8 : (Unused)
40900: Engine controller input signal 1
1 : Starting switch signal C: Input
2 : (Unused)
3 : (Unused)
4 : Low engine oil pressure switch: ON
5 : High engine oil pressure switch: ON
6 : (Unused)
7 : (Unused)
8 : Model selection signal 1: ON
40901: Engine controller input signal 2
1 : Model selection signal 2: ON
2 : Model selection signal 3: ON
3 : (Unused)
4 : (Unused)
5 : N-signal 1: ON
6 : N-signal 2: ON
7 : (Unused)
8 : (Unused)
20-194
(8)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
40905: Transmission related controller input signal 1
1 : Gear shift-up switch: OFF
2 : Gear shift-up switch: ON
3 : Gear shift-down switch: OFF
4 : Gear shift-down switch: ON
5 : (Unused)
6 : (Unused)
7 : (Unused)
8 : (Unused)
40906: Transmission-related controller input signal 2
1 : Automatic gear shift-down switch: ON
2 : Fan reverse mode: ON
3 : Fan reverse 100% mode: ON
4 : (Unused)
5 : (Unused)
6 : (Unused)
7 : (Unused)
8 : (Unused)
40909: Transmission related controller output signal
1 : Transmission N-signal: ON
2 : N-signal 2: ON
3 : (Unused)
4 : Back-up alarm relay: ON
5 : Neutral safety relay: ON
6 : (Unused)
7 : (Unused)
8 : (Unused)
40910: Steering related controller input signal 1
1 : (Unused)
2 : (Unused)
3 : (Unused)
4 : (Unused)
5 : Parking brake lever switch: FREE
6 : Parking brake lever switch: LOCK
7 : (Unused)
8 : (Unused)
D65EX, PX-15
20-195
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
40911: Steering related controller input signal 2
1 : Buzzer cancel switch: At U
2 : Buzzer cancel switch: At T
3 : Information switch: At <
4 : Information switch: At >
5 : Service switch: ON
6 : (Unused)
7 : (Unused)
8 : (Unused)
40913: Steering related controller input signal 5
1 : ACC signal: ON
2 : (Unused)
3 : (Unused)
4 : Motoring signal: ON
5 : (Unused)
6 : (Unused)
7 : (Unused)
8 : (Unused)
40914: Output signal of steering related controller
1 : (Unused)
2 : (Unused)
3 : Fan reverse solenoid: ON
4 : (Unused)
5 : Battery relay drive: ON
6 : (Unused)
7 : (Unused)
8 : (Unused)
70300: Input signal of work equipment related controller
1 : (Unused)
2 : (Unused)
3 : Pitch switch: OFF
4 : Pitch switch: ON
5 : (Unused)
6 : (Unused)
7 : (Unused)
8 : (Unused)
20-196
(8)
D65EX, PX-15
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
70304: Output signal of work equipment related controller
1 : (Unused)
2 : Pitch solenoid: ON
3 : (Unused)
4 : (Unused)
5 : (Unused)
6 : (Unused)
7 : (Unused)
8 : (Unused)
D65EX, PX-15
20-196-1
(8)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
11. Dual display monitoring mode
(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be displayed
simultaneously.
a Note that only codes and monitoring information are displayed in this mode since the
usable display columns are limited. (Item
names and units cannot be displayed.)
1) Selecting and executing mode
i) Select “Dual display monitoring mode”
on the mode selection screen.
a If the mode is selected, code (dR) is
displayed on gear speed display section (1) and the title is displayed on
multi-information section (2).
ii) Display the monitoring code input screen
by operating buzzer cancel switch (4).
• [U]: Execute mode.
2) Selecting and entering monitored items
i) On the code input screen, input the 5digit codes of the items to be monitored
to the upper and lower lines by operating
information switch (5), shift-up switch (6),
and shift-down switch (7).
• [ > ]: Move cursor to right.
• [ < ]: Move cursor to left.
• [UP]: Increase number.
• [DOWN]: Decrease number.
ii) After inputting the codes, display the
monitoring screen by operating buzzer
cancel switch (4).
• [U]: Enter input code.
a If the input codes are normal, the
monitoring screen shown at right appears.
D65EX, PX-15
20-197
(1)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
a If the input codes are abnormal, the
code input screen appears again after the screen shown at right.
3) Contents of display on monitoring screen
(Right figure shows examples)
1 : Code 1
2 : Information 1
3 : Code 2
4 : Information 2
a For the details, see the “MONITORING
MODE TABLE”.
4) When operating machine in monitoring mode
If the parking brake lever is set in the FREE
position, gear speed display section (1) displays normally and the machine can be operated normally.
a At this time, even if the shift-up or shiftdown switch is pressed with the PCCS
lever in the neutral position, the shift cannot be changed. (The displayed number
is the code of monitoring mode.)
To change the shift, set the PCCS lever
in the FORWARD or REVERSE position
and press the shift-up or shift-down
switch while the machine is traveling.
a To select another screen, return the
parking brake lever to the FREE position
and perform the necessary procedure.
20-198
(1)
D65EX, PX-15
TESTING AND ADJUSTING
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLING OF
ADJUSTMENT
HIGH-VOLTAGE
METHOD
CIRCUIT
OF REPLACED
OF ENGINE CONTROLLER
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE
CONTROLLER
k The engine controller has a high-voltage circuit
(110 – 130 V) to drive the fuel injector. This circuit is connected to the wiring harness and connectors between the engine controller and fuel
injector.
a Normally, the engine controller outputs the high
voltage to the fuel injector only while the engine
is running and stops outputting if the engine
stops.
k If you touch the high-voltage circuit directly, you
may get an electric shock. To avoid this, observe
the following precautions.
ADJUSTMENT METHOD OF
REPLACED CONTROLLER
a After the machine is assembled or steering and
transmission controller is replaced, adjust the
system according to the following procedure.
k If the system is not adjusted, the machine may
not operate normally and may move suddenly.
Accordingly, be sure to adjust it.
a Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. Accordingly, take a record of the next replacement periods
of the oils and filters.
a Precautions for replacing a controller:
When replacing a controller, stop the machine in
a safe place and turn the starting switch off.
1. Setting system in service mode
Turn the starting switch on and set the monitor
panel in the “Adjustment mode” of the service
mode.
2. Adjusting steering and transmission controller
Select steering and transmission controller
specification set (0002) and adjust the steering
and transmission controller.
1. The following connectors are used in the highvoltage circuit.
• Engine controller connector: EN3
• Junction connector: E21
• Injector connectors:
CN-1, CN-2, CN-3, CN-4, CN-5, CN-6
• Injector head terminal (in head cover)
2. When disconnecting or connecting a connector
related to the high-voltage circuit, be sure to turn
off the starting switch.
3. If a T-adapter is inserted in or connected to a
connector related to the high-voltage circuit for
troubleshooting, do not start the engine.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
D65EX, PX-15
20-199
(1)
TESTING AND ADJUSTING
ADJUSTMENT METHOD OF REPLACED CONTROLLER
3. Turning power on again
Turn the starting switch off and on, then set the
monitor panel in the “Adjustment mode” of the
service mode again.
4. Adjusting machine specification
Select Machine specification set (0004) and adjust the machine specification.
5. Adjusting brake potentiometer
Select Brake potentiometer initial set (0005) and
adjust the brake potentiometer.
7. Turning power on again
Turn the starting switch off and on.
8. Checking error codes
1) Set the monitor panel in the “Electric system
error code display mode” of the service
mode.
2) See if any error code is being output currently. If any error code is not being output, delete the all error codes.
a If any error code is being output, remove its
cause by troubleshooting and execute steps
6 and 7 again.
a Precautions after replacing controller:
If any controller is replaced, the service meter in
the oil and filter maintenance mode is reset to 0.
As a result, the replacement period displayed on
the monitor panel may be different from the actual operating hours. To solve this problem, determine the first replacement periods of the oils and
filters after the replacement of the controller according to the replacement periods recorded before the replacement of the controller.
6. Adjusting pitch angle sensor
Select and adjust the initial setting (0009) of the
pitch angle sensor.
20-200
(1)
D65EX, PX-15
TESTING AND ADJUSTING
PREPARATION WORK FOR
TROUBLESHOOTING
FOR ELECTRIC SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING
FOR ELECTRIC SYSTEM
2. Engine controller
1) Remove left console box inspection cover
(3).
a When carrying out troubleshooting for an electric
circuit related to the monitor panel, engine controller or steering and transmission controller, expose the related connectors according to the
following procedure.
1. Monitor panel
1) Remove cover (1) above the dashboard.
2) Insert or connect T-adapters in or to connectors S03 and S04 on the back side of monitor
panel (2).
D65EX, PX-15
2) Insert or connect T-adapters in or to connectors EN1, EN2, and EN3 of engine controller
(4).
a If the connectors cannot be disconnected and connected easily, remove the
controller from the floor frame.
a Since the connectors are secured with
screws, loosen those screws before disconnecting.
a When connecting the connectors again,
tighten their screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}
20-201
(1)
TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING
FOR ELECTRIC SYSTEM
3. Steering and transmission controller
1) Insert or connect T-adapters in or to connectors ST1, ST2, and ST3 of steering and
transmission controller (5).
a If the connectors cannot be disconnected and connected easily, remove the
controller from the floor frame.
a Since the connectors are secured with
screws, loosen those screws before disconnecting.
a When connecting the connectors again,
tighten their screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}
20-202
(1)
D65EX, PX-15
TESTING AND ADJUSTING
PM CLINIC SERVICE
Pm CLINIC SERVICE
Model
Serial No.
Service meter
D65EX, PX, WX-15
h
User name
Date of clinic
Serviceman
Blade
Specifications
Attachment
Shoe width
Semi-U blade
Angle blade
Straight tilt blade
510 mm
560 mm
610 mm
660 mm
Multi-shank ripper
Towing winch
CAB
ROPS
810 mm
915 mm
950 mm
Operating conditions
Quarry, mine
Coal
Gold
Limestone
Construction
Construction, civil engineering
Roads, residential development
Tunnels
Type of soil (specific gravity )
Rock
Gravel
Sand
Clay
Type of work
Dozing, digging
Side cutting
Grading
Travel
%
%
%
%
Existence of abnormalities
Oil, water level check
Engine coolant level
Engine oil level
Hydraulic oil level
Engine coolant temperature Max. range
When necessary
Damper case
(
Power train
Final drive
)
Ambient temperature
Power train oil temperature Max. range
Max.
Min.
Height above sea level
m
Operator's opinion
Visual check results
Service code history
E
h
Content:
E
Content:
D65EX, PX-15
E
h
Content:
h
E
h
Content:
20-203
(7)
TESTING AND ADJUSTING
PM CLINIC SERVICE
Pm-clinic measuring points for D65EX, PX, WX-15 (1/2)
“Reference Page for Measurement Procedure” designated.
1. Engine speed: 20-105 page
2. Blow-by pressure: 20-116 page
3. Engine oil pressure: 20-117 page
4. Boost pressure: 20-107 – 108 page
5. Exhaust temprature: 20-109 – 110 page
20-204
(7)
D65EX, PX-15
TESTING AND ADJUSTING
PM CLINIC SERVICE
Pm-clinic measuring points for D65EX, PX, WX-15 (2/2)
“Reference Page for Measurement Procedure” designated.
6. Phenomenon related to torque converter: 20-129 page
7. Phenomenon related to transmission: 20-130 page
8. Phenomenon related to steering brake: 20-128 page
9. Phenomenon related to work equipment: 20-143 – 145 page
D65EX, PX-15
20-205
(7)
TESTING AND ADJUSTING
PM CLINIC SERVICE
Pm CLINIC CHECK SHEET
Work order No.
Date
Service meter
/
Item
D65EX, PX, WX-15
/
Standard value for
Service limit value Measurement results Pass
new machine
Unit
Low idling
Engine speed
Deceleration pedal depressed
High idling
rpm
Torque converter stall
kPa
<mmAq>
Engine
Blow-by pressure Torque converter stall
Engine oil
pressure
Boost pressure
Engine at low
idling
Engine at high
idling
Engine at low
idling
Engine at high
idling
SAE10W
MPa
<kg/cm2>
SAE15W-40 SAE30
kPa
<mmHg>
ºC
Torque converter stall
Exhaust temperature Torque converter stall
Outlet oil pressure
Inlet oil pressure
Engine at low idling
MPa
<kg/cm2>
Engine at high idling
Outlet oil pressure
Main relief
pressure
Fan speed
Measurement conditions
Transmission:
Neutral
Engine at low idling
Engine at high idling
• Engine: Low idling
• Coolant
temperature:
Power train oil
temperature:
Max. 80ºC
• Hydraulic oil
temperature:
45 – 55ºC
• Fan forward
• Engine: High Standard
idling
• Fan 100%
speed mode
Fan pump
pressure
20-206
(7)
• Hydraulic oil temperature:
45 – 55ºC
• Fan forward
• Fan 100% speed mode
• Engine: High idling
For EU
spec.
Standard
For EU
spec.
800 – 850
975 – 1025
2050 – 2150
2050 – 2150
1670 – 1870
Max. 0.98
<Max. 100>
Min. 0.10
<Min. 1.0>
0.34 – 0.64
<3.5 – 6.5>
Min. 0.15
<Min. 1.5>
0.39 – 0.69
<4.0 – 7.0>
Min. 79.8
<Min. 600>
Max. 650
1650
Max. 1.96
<Max. 200>
0.07
<0.7>
0.18
<1.8>
0.07
<0.7>
0.21
<2.1>
60
<450>
700
0.1 – 0.5
<1 – 5>
0.05 – 0.29
<0.5 – 3>
Max. 0.88
<Max. 9>
0.39 – 0.69
<4 – 7>
MPa
<kg/cm2>
rpm
3.03 – 3.23
<31 – 33>
Min. 2.84
<Min. 29>
3.23 – 3.43
<33 – 35>
Min. 3.04
<Min. 31>
800 ± 50
700
+100
1,750
+100
1,500
19.6 – 22.5
{200 – 230}
18.6
{190}
15.7 – 18.6
{160 – 190}
13.7
{140}
1,850 0
1,600 0
MPa
{kg/cm2}
Fail
Fail
0.1 – 0.5
<1 – 5>
0.05 – 0.29
<0.5 – 3>
Max. 0.88
<Max. 9>
0.39 – 0.69
<4 – 7>
Standard value for
Service limit value Measurement results Pass
new machine
Unit
Min. speed
Transmission
Transmission:
Neutral
Oil temperature:
70 – 90ºC
800 – 850
975 – 1025
Standard value for
Service limit value Measurement results Pass
new machine
Unit
Inlet oil pressure
Item
Cooling fan
Measurement conditions
Max. speed
Torque converter
Item
Serviceman
h
Measurement conditions
High idling
Serial No.
Fail
D65EX, PX-15
TESTING AND ADJUSTING
PM CLINIC SERVICE
Pm CLINIC CHECK SHEET
Work order No.
Date
/
Brake
Steering
Item
Service meter
/
Measurement conditions
Engine at high idling
Steering relief pressure
Brake actuating pressure
Brake performance
Work equipment
load sensing
pressure
32.8 – 36.8
<335 – 375>
34.8 – 38.8
<355 – 395>
2.75 – 2.94
<28 – 30>
MPa
<kg/cm2>
Apply brake and run engine at full throttle with
transmission gear in F2.
Engine at low idling
MPa
<kg/cm2>
Ripper lift relief
Blade tilt relief
Engine at high idling
PPC valve output
Blade tilt relief
pressure
Work equipment speed
Item
Min. 17.6
<Min. 180>
Min. 19.6
<Min. 200>
Min. 19.6
<Min. 200>
22.5 – 24.5
<230 – 250>
22.5 – 24.5
<230 – 250>
3.53 – 4.41
<36 – 45>
Min. 19.6
<Min. 200>
Min. 19.6
<Min. 200>
Min. 19.6
<Min. 200>
Min. 19.6
<Min. 200>
3.53 – 4.41
<36 – 45>
Standard value for
Service limit value Measurement results Pass
new machine
Unit
Max. 3.1
Max. 2.9
Engine at high idling
2.0 – 2.6
Max. 2.8
Engine at high idling
1.2 – 1.6
Max. 1.9
Engine at high idling
Single tilt (left o right)
Ripper RAISE
Fail
Fail
Sec.
Measurement conditions
Hydraulic oil temperature
Blade lift cylinder
19.6 – 23.6
<200 – 240>
EX: 2.1 – 2.8
PX: 1.9 – 2.6
Blade RAISE
Item
Hydraulic drift
Measurement conditions
Min. 30.9
<Min. 315>
Min. 32.8
<Min. 335>
Min. 2.55
<Min. 26.0>
Standard value for
Service limit value Measurement results Pass
new machine
Unit
Ripper lift relief
HSS and work
equipment pump
Fail
Machine must not move
Engine at high idling
Blade tilt relief
Serviceman
Standard value for
Service limit value Measurement results Pass
new machine
Unit
Engine at high idling
Measurement conditions
Serial No.
h
Steering load sensing pressure
Item
Hydraulic components
D65EX, PX, WX-15
Standard value for
Service limit value Measurement results Pass
new machine
Unit
ºC
Engine stopped
45 – 55
—
Max. 100
Max. 100
Max. 200
Max. 200
Fail
mm/15 min.
Ripper tilt cylinder
Item
Measurement conditions
Visual inspection of final drive drain plug Engine stopped
Unit
Standard value for
Service limit value Measurement results Pass
new machine
—
There must be no excessive
metal particles
Fail
Always fill in the record when repairing, adjusting, or replacing main parts.
Date
Service meter
D65EX, PX-15
Repair record
Date
Service meter
Repair record
20-207
(7)
TESTING AND ADJUSTING
PM CLINIC SERVICE
Pm CLINIC
UNDERCARRIAGE CHECK SHEET
Work order No.
Date
/
•
D65EX , WX-15
Serial No.
Service meter
/
Serviceman
h
Measure the bushing temperature immediately after operations
Left side of machine
Measurement
results
Pas
Fail
s
Measurement
results
Pas
Fail
s
Right side of machine
•
Opening of track link
20-208
(7)
Left track
A: Clearance between links
Pin No.
1.4
Right track
A: Clearance between links
Pin No.
1.4
D65EX, PX-15
TESTING AND ADJUSTING
PM CLINIC SERVICE
Pm CLINIC
UNDERCARRIAGE CHECK SHEET
Work order No.
Date
/
•
D65PX-15
Serial No.
Service meter
/
Serviceman
h
Measure the bushing temperature immediately after operations
Left side of machine
Measurement
results
Pas
Fail
s
Measurement
results
Pas
Fail
s
Right side of machine
•
Opening of track link
D65EX, PX-15
Left track
A: Clearance between links
Pin No.
1.4
Right track
A: Clearance between links
Pin No.
1.4
20-209
(1)
TESTING AND ADJUSTING
UNDERCARRIAGE TROUBLESHOOTING REPORT
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
(Program form No.: SELA195001)
Komatsu
Undercarriage Inspection
Y
Customer name:
Address:
Model
D65EX, PX, WX-15
Location
Soil condition
Working condition
L=l/4
RH
LH
master pin
master
i
Work Order No
Wet,AR,HD or Dry
Dealer
Shoe width (mm)
Insp.Date(yy/mm/dd)
New 100% Measured
Wear
mm
813.8 825.8
Shoe type
(yyyy/m/d)
Wear
%
New
SMR
Hours on
Rebuilt Parts:
Wet
SINGLE
Wear type
NORMAL
Comments/Observation
R
L
M
Equip No
SMR
Inspector
LH
LINK PITCH
Serial No
813.8 825.8
203.45 206.45
M
l
1.3
RH 203.45 206.45
H
LINK HEIGHT1.3
BUSHIN
G
d1
d
D is the smallest
ofd1,,d2 and,d3
d
LH
132.0
119.5
RH
132.0
119.5
LH
73.0
62.8
RH
73.0
62.8
LH
65.0
25.0
RH
65.0
185.0
25.0
163.0
185.0
185.0
163.0
163.0
185.0
20.0
163.0
30.0
20.0
20.0
30.0
30.0
LH
20.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
0.0
30.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
9.0
RH
0.0
9.0
New
Turned
New
Turned
1
GROUSER HIGHT
H
0
LH
CARRIER
CARRIER
Front
RH
LH
D
Rear
1.3
RH
LH
IDLER
IDLER
Front
RH
H
LH
Rear
1.3
TRACK ROLLER
D
h2
h1
D=2(h1-h2)
1.3
SPROCKET
H is the smallest of
h3
h1,h2,h3
h1
RH
1
LH
2
LH
3
LH
4
LH
5
LH
6
LH
7
LH
8
LH
9
LH
10
LH
1
RH
2
RH
3
RH
4
RH
5
RH
6
RH
7
RH
8
RH
9
RH
10
RH
h2
1.3
Remarks:
20-210
(7)
D65EX, PX-15
TESTING AND ADJUSTING
UNDERCARRIAGE TROUBLESHOOTING REPORT
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
(Program form No.: SELA195001)
Komatsu
Undercarriage Inspection
Y
Customer name:
Address:
Model
D65EX, PX, WX-15
Location
Soil condition
Working condition
L=l/4
RH
LH
master pin
master
i
Work Order No
Wet,AR,HD or Dry
Dealer
Shoe width (mm)
Insp.Date(yy/mm/dd)
New 100% Measured
Wear
mm
813.8 825.8
Shoe type
(yyyy/m/d)
Wear
%
New
SMR
Hours on
Rebuilt Parts:
Wet
SINGLE
Wear type
IMPACT
Comments/Observation
R
L
M
Equip No
SMR
Inspector
LH
LINK PITCH
Serial No
813.8 825.8
203.45 206.45
M
l
1.3
RH 203.45 206.45
H
LINK HEIGHT1.3
BUSHIN
G
d1
d
D is the smallest
ofd1,,d2 and,d3
d
LH
132.0
119.5
RH
132.0
119.5
LH
73.0
65.4
RH
73.0
65.4
LH
65.0
25.0
RH
65.0
185.0
25.0
163.0
185.0
185.0
163.0
163.0
185.0
20.0
163.0
30.0
20.0
20.0
30.0
30.0
LH
20.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
210.0
0.0
30.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
174.0
9.0
RH
0.0
9.0
New
Turned
New
Turned
1
GROUSER HIGHT
H
0
LH
CARRIER
CARRIER
Front
RH
LH
D
Rear
1.3
RH
LH
IDLER
IDLER
Front
RH
H
LH
Rear
1.3
TRACK ROLLER
D
h1
h2
D=2(h1-h2)
1.3
SPROCKET
H is the smallest of
h3
h1,h2,h3
h1
RH
1
LH
2
LH
3
LH
4
LH
5
LH
6
LH
7
LH
8
LH
9
LH
10
LH
1
RH
2
RH
3
RH
4
RH
5
RH
6
RH
7
RH
8
RH
9
RH
10
RH
h2
1.3
Remarks:
D65EX, PX-15
20-211
(7)
TROUBLESHOOTING
TROUBLESHOOTING
Points to remember when troubleshooting .............................................................................................. 20-302
Sequence of events in troubleshooting ................................................................................................... 20-303
Handling of electric equipment and hydraulic component ....................................................................... 20-304
Checks before troubleshooting ................................................................................................................ 20-312
Classification and procedures of troubleshooting .................................................................................... 20-313
Types and locations of connectors (D65EX, PX-15) ............................................................................... 20-316
Connector arrangement drawing ............................................................................................................. 20-322
Circuit drawing for engine controller system (E circuit) ........................................................................... 20-328
Circuit drawing for steering and transmission controller system (ST · TM circuit) ................................... 20-330
Circuit drawing for monitor panel system (M circuit) ................................................................................ 20-332
Connection table for connector pin numbers ........................................................................................... 20-334
T-branch box and T-branch adapter table ............................................................................................... 20-370
Troubleshooting when error code is displayed (Error code) .................................................................... 20-401
Troubleshooting of electrical system (E-mode) ....................................................................................... 20-601
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................................. 20-701
Troubleshooting of engine system (S-mode) ........................................................................................... 20-801
D65EX, PX-15
20-301
(8)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fit-
ted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, an important point is of course to understand the structure and function.
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
to disassemble the components.
If components are disassembled immediately
any failure occurs:
• Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in
accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Check the oil level
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.
20-302
(8)
5) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
4. Confirming failure
• Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation,
etc.
a When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measurement that may make the problem worse.
5. Troubleshooting
• Use the results of the investigation and inspection in Items 2 – 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
• Even if the failure is repaired, if the root
cause of the failure is not repaired, the same
failure will occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.
D65EX, PX-15
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
D65EX, PX-15
20-303
(1)
TROUBLESHOOTING
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried
out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving
the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling
hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric
equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely
to occur because the male connector is not
properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
Defective crimping or soldering of connectors
The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
20-304
(8)
D65EX, PX-15
TROUBLESHOOTING
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
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 soldering may be damaged, or the wiring may
be broken.
4)
High-pressure water entering connector
The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-circuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5)
Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is oil
or grease stuck to the connector, wipe it off
with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and water from the compressed air completely
before cleaning with compressed air.
D65EX, PX-15
20-305
(8)
TROUBLESHOOTING
3.
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
Removing, installing, and drying connectors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connectors apart.
a Never pull with one hand.
2]
•
When removing from clips
Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is installed.
•
When removing a connector from a
clip, pull the connector in a parallel direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3]
Action to take after removing connectors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
20-306
(8)
D65EX, PX-15
TROUBLESHOOTING
2)
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage 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 connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper
clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position,
adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
•
If the connector clamp has been
removed, be sure to return it to its
original position. Check also that
there are no loose clamps.
D65EX, PX-15
20-307
(8)
TROUBLESHOOTING
3)
Heavy duty wire connector (DT 8-pole, 12pole)
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
20-308
(8)
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
• Disconnection
• Connection (Example of
incomplete setting of
(a))
D65EX, PX-15
TROUBLESHOOTING
4)
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
Drying wiring harness
If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high-pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the compressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n t a c t
restorer and reassemble.
D65EX, PX-15
20-309
(8)
TROUBLESHOOTING
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector contacts with your hand.
4) During rainy weather, do not leave the controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
Points to remember when troubleshooting
electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably
defective contact in that circuit.
20-310
(8)
D65EX, PX-15
TROUBLESHOOTING
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
Points to remember when handling hydraulic equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2.
Disassembly and maintenance work in the
field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
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
entering. 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 onto the ground, but collect it and
ask the customer to dispose of it, or take it back
with you for disposal.
4.
Do not let any dirt or dust get in during
refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
D65EX, PX-15
20-311
(8)
TROUBLESHOOTING
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
5.
Change hydraulic oil when the temperature
is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried out
with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot
remove, so it is an extremely effective device.
20-311-1
(8)
D65EX, PX-15
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item
1.
Check fuel level
Add fuel
Check for impurities in fuel
—
Clean, drain
3.
Check hydraulic oil level
—
Add oil
4.
Check oil level in damper case
—
Add oil
5.
Check power train oil level
—
Add oil
6.
Check engine oil level (engine oil pan level)
—
Add oil
7.
Check coolant level
—
Add water
8.
Check dust indicator for clogging
—
Clean or replace
9.
Check travel of brake pedal
—
Adjust
10. Check for looseness, corrosion of battery terminal, wiring
—
Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring
—
Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring
—
Tighten or replace
13. Check for abnormal noise, smell
—
Repair
14. Check for oil leakage
—
Repair
15. Carry out air bleeding
—
Bleed air
17. Check battery electrolyte level
20 – 30 V
—
Replace
Add or replace
18. Check for discolored, burnt, exposed wiring
—
Replace
19. Check for missing wiring clamps, hanging wire
20. Check for water leaking on wiring (pay particularly careful attention
to water leaking on connectors or terminals)
21. Check for water on wiring
—
—
Repair
Disconnect connector
and dry
Replace
22. Check alternator voltage (engine running at 1/2 throttle or above)
After running for
several minutes:
27.5 – 29.5 V
23. Check operating sound of battery relay (starting switch ON, OFF)
(1)
—
Action
2.
16. Check battery voltage (engine stopped)
20-312
Judgement
Value
—
—
Replace
Replace
D65EX, PX-15
TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
Classification of Troubleshooting
Mode
Explanation
Error code
Troubleshooting when a service code is displayed
E Mode
Troubleshooting of the electrical system
H Mode
Troubleshooting of the hydraulic and mechanical systems
S Mode
Troubleshooting of the engine body
Troubleshooting Procedures
When any phenomenon supposed to be a failure appeared on the machine, select a Troubleshooting No. according to the procedures below and proceed to the text of the relevant troubleshooting:
1. Troubleshooting Procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display a error code in the error code display mode
(electrical system, mechanical system) on the monitor display (EMMS).
Execute a troubleshooting of the relevant [Error Code] in accordance with the displayed error code.
a Since a error code flashes when a problem was detected, the failure has not always been corrected even
if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when
the starting switch is set to ON.)
a When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the troubleshooting of the error code.)
2. Troubleshooting Procedures when error codes have been recorded:
When no action code is displayed on the monitor panel, check a error code in the error code display mode
(electrical system, mechanical system) on the monitor panel (EMMS).
When error codes have been recorded, execute a troubleshooting of the relevant [Error Code] in accordance with the error code.
a Since a error code flashes when a problem was detected, the failure has not always been corrected even
if it lights when the starting switch is set to ON. (For some codes, problems can be detected only when
the starting switch is set to ON.)
a When a error code has been recorded, be sure to reproduce the code and check if the problem of the
code has still remained or has already been corrected. (For the reproducing method, refer to the troubleshooting of the error code.)
3. Troubleshooting Procedures when no action code is displayed and error codes have not been recorded:
When error codes have not been recorded in the monitor panel (EMMS), a failure that the machine cannot
diagnose by itself is supposed to have occurred in the electrical system or the hydraulic/mechanical system.
In this case, check again a phenomenon supposed to be a failure and select the relevant phenomenon out
of the table of “Phenomena supposed to be Failures and Troubleshooting No”. Then, execute the troubleshooting in the [E Mode], [H Mode] or [S Mode] related to the phenomenon.
D65EX, PX-15
20-313
(1)
TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
Phenomena supposed to be Failures and Troubleshooting No.
Troubleshooting
No.
Phenomenon suppose to be Failure
Error
E Mode H Mode S Mode
Code
Phenomenon related to action code/error code
1
An action code is displayed on the monitor panel.
2
A error code is displayed in the error code display mode.
Check the error code.
q
Phenomenon related to engine
3
The engine does not start smoothly. (Engine starting takes a time all the time.)
4
5
The engine does not rotate.
S-1
E-1
S-2 a)
The engine does not start. The engine rotates but does not exhaust gas.
S-2 b)
The engine exhausts gas but does not rotate.
S-2 c)
6
7
The engine does not pick-up smoothly. (Poor follow-up performance)
S-3
8
The engine stops during operation.
S-4
9
The engine rotates abnormally. (Hunting)
S-5
10 Insufficient output or no power
S-6
11 Black exhaust (Imperfect combustion)
S-7
12 Large oil consumption or blue exhaust
S-8
13 Oil is contaminated fast.
S-9
14 Large fuel consumption
S-10
15 Oil mixes in coolant, spurts or water reduces.
S-11
16 Engine oil pressure drops.
S-12
17 Oil increases.
S-13
18 Water temperature rises too high. (Overheat)
S-14
19 An abnormal noise occurs.
S-15
20 Large vibration
S-16
21 The preheater does not work.
E-2
Phenomenon related to power train
22 The power train has no power (no drawbar pull).
H-1
23 The power train does not travel (in case of 2-spool or 3-spool).
H-2
24 The power train does not start at all gear speeds.
H-3
25 The power train travel forward or in reverse only
H-4
26 Large time lag at any gear speed or at forward-reverse shifting
H-5
27 Steering is not possible. (Left turn or right turn is impossible.)
H-6
28 The steering speed is slow or the steering system has no power.
H-7
29 The brake does not work.
H-8
30 The power train oil is overheated.
H-9
31 Abnormal noise around the HSS and work equipment pump or the HSS motor
H-10
S-6
Phenomenon related to work equipment
32 All the work equipment operates slowly.
H-11
33 All the work equipment does not operate.
H-12
34 The blade lift moves slowly or has no power.
H-13
35 The blade tilt moves slowly or has no power.
H-14
36 The ripper lift moves slowly or has no power.
H-15
37 Large hydraulic drift of the blade lift
H-16
38 Large hydraulic drift of the blade tilt
H-17
39 Large hydraulic drift of the ripper lift
H-18
20-314
D65EX, PX-15
(1)
TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING
Troubleshooting
No.
Phenomenon suppose to be Failure
Error
E Mode H Mode S Mode
Code
Phenomenon related to monitor panel (Operator mode: Normal screen)
40 When the starting switch is set to ON, no light on the monitor panel comes on.
E-3
41 When the starting switch is set to ON, all the lights on the monitor panel do not go out.
E-4
42 While the engine is operating, the battery charge caution items flash.
E-5
43 While the engine is operating, the emergency warning items flash.
E-6
44 While the preheater is operating, the preheating pilot lamp does not come on.
E-7
45 Indication of the engine water temperature gauge is abnormal.
E-8
46 Indication of the power train oil temperature gauge is abnormal.
E-9
47 Indication of the hydraulic oil temperature gauge is abnormal.
E-10
48 Indication of the fuel gauge is abnormal.
E-11
49 Indications of gear speed and engine speed are abnormal.
E-12
50 Indication of the preset mode service meter is abnormal.
E-13
51 The warning lamp does not flash or does not go out.
E-14
52 The alarm buzzer does not sound or does not stop.
E-15
53 Auto shift down is not possible or is not released.
E-16
54 The buzzer cancel switch does not work.
E-17
55 The information switch does not work.
E-18
56 The preset mode does not be operated or cancelled.
E-19
Phenomenon related to monitor panel (Service mode: Special function screen)
The monitor panel cannot be set in the service mode or cannot be set out of the
57 service mode.
E-20
Others
58 The back-up alarm does not sound.
E-21
59 The head lamp, rear lamp, and ripper point lamp on the panel do not come on.
E-22
60 The wiper malfunctions.
E-23
61 Washing water does not come out.
E-24
62 The air conditioner does not operate.
E-25
D65EX, PX-15
20-315
(1)
TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS (D65EX, PX-15)
TYPES AND LOCATIONS OF CONNECTORS (D65EX, PX-15)
a The addresses in the following table are the addresses used in the connector arrangement drawing (3-dimensional drawing) and electric circuit diagram.
Address
Connector
No.
Type
Number
of pins
1
DT
4
Intermediate connector [Cab specification]
I9
2
KES1
2
Rear speaker (Left) [Cab specification]
I8
4
KES1
2
Rear speaker (Right) [Cab specification]
H9
6
One-pin
connector
1
Heater wire glass [Cab specification]
H9
7
PA
9
Radio [Cab specification]
B9
8
DT
2
Accessory (12 V) [Cab specification]
B9
9
YAZAKI
3
Heater wire glass switch [Cab specification]
B8
9
M
2
Washer motor (Left)
D7
10
M
2
Additional light switch [Cab specification]
B8
10
M
2
Washer motor (Right)
D7
11
M
2
Wiper intermittent switch [Cab specification]
B9
11
M
2
Washer motor (Front)
D7
12
KES1
6
Rear wiper switch [Cab specification]
A9
12
M
2
Washer motor (Rear)
E7
13
KES1
6
Right door wiper switch [Cab specification]
A9
13
SWP
6
Intermediate connector (Washer motor)
E8
14
KES1
6
Front wiper switch [Cab specification]
A9
15
KES1
6
Left door wiper switch [Cab specification]
A9
16
KES1
2
Room lamp [Cab specification]
B7
17
DT
4
Right door wiper [Cab specification]
B7
18
DT
4
F8
19
DT
4
Intermediate connector [Cab specification]
Intermediate connector (Windshield washer motor)
[Cab specification]
C5, W2
20
DTHD#12
1
Cab power supply [Cab specification]
C5, W2
21
DTHD#8
1
Cab power supply (Battery direct) [Cab specification]
C6, V2
23
DT
6
Front wiper [Cab specification]
E8
24
DT
4
Left door wiper [Cab specification]
C5
25
4
For light [Cab specification]
C8
26
Relay
(YAZAKI)
Relay
(YAZAKI)
6
Left wiper intermittent relay [Cab specification]
C8
27
Relay
5
Left wiper intermittent selector relay [Cab specification]
C7
28
Relay
(YAZAKI)
6
Front wiper intermittent relay [Cab specification]
C8
29
Relay
5
Front wiper intermittent selector relay [Cab specification]
C7
30
Relay
(YAZAKI)
6
Right wiper intermittent relay [Cab specification]
C8
31
Relay
5
Right wiper intermittent selector relay [Cab specification]
C7
32
Relay
(YAZAKI)
6
Rear wiper intermittent relay [Cab specification]
C8
33
Relay
5
Rear wiper intermittent selector relay [Cab specification]
D8
20-316
(1)
Location
Arrange- Engine
ST
MON
ment
system system system
drawing diagram diagram diagram
D65EX, PX-15
TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS (D65EX, PX-15)
Address
Connector
No.
Type
Number
of pins
34
Relay
(YAZAKI)
4
Heater wire glass relay [Cab specification]
C8
35
M
4
Converter [Cab specification]
C8
36
One-pin
connector
1
Heater wire glass [Cab specification]
J8
37
KES1
4
Rear wiper [Cab specification]
I9
53
DT
2
Intermediate connector (Pitch selector solenoid) (If equipped)
O5
101
DT (Gr)
8
Intermediate connector
B5
203
DT
2
Right head lamp
B4
J8
204
DT
2
Left head lamp
B3
J8
205
Terminal
1
Horn
B3
214
DT (B)
12
Intermediate connector [Dashboard]
O2
B7
B6
215
DT (G)
12
Intermediate connector [Dashboard]
O2
D7
E6
217
DT
2
Caution buzzer
O4
C8
218
DT (Br)
12
Intermediate connector [Air conditioner]
O2
224
DT
2
Intermediate connector
J8
G8
228
DT
2
Rear lamp (If equipped)
K7
G8
244
DT
2
Backup alarm
K7
247
DT
2
Rear lamp (Rear left)
J8
250
Terminal
1
Starting switch (Terminal B)
N5
I9
255
Terminal
1
Starting switch (Terminal R1)
N4
J9
260
Terminal
1
Starting switch (Terminal BR)
M4
J9
C9
D1
262
DT
2
Horn switch
S9
270
Terminal
1
Starting switch (Terminal ACC)
M5
J9
D9
D1
280
Terminal
1
Starting switch (Terminal C)
N5
J9
D9
D1
423
DT
2
Fuel level sensor
K8
453
DT
2
Torque converter oil temperature sensor
AI2
800
DTHD#12
1
Service power supply
U1
1SOL
DT
2
1st clutch ECMV solenoid
AF6
K3
2SOL
DT
2
2nd clutch ECMV solenoid
AI3
K3
3SOL
DT
2
3rd clutch ECMV solenoid
AG6
K2
1SW
DT
2
1st clutch ECMV fill switch
AH7
K3
2SW
DT
2
2nd clutch ECMV fill switch
AI3
K3
3SW
DT
2
3rd clutch ECMV fill switch
AG6
K2
A/C
DT
2
Air conditioner compressor
Y2
AL/B
Terminal
1
Alternator terminal B
Y6
AL/E
Terminal
1
Alternator terminal E
Y6
D65EX, PX-15
Location
Arrange- Engine
ST
MON
ment
system system system
drawing diagram diagram diagram
B2
J7
A1
G8
C9
D1
D1
H8
J6
H8
20-317
(1)
TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS (D65EX, PX-15)
Address
Connector
No.
Type
Number
of pins
AL/R
Terminal
1
Alternator terminal R
Y6
AC1
MIC
17
Air conditioner unit
O6
AC2
AMP
16
Auto air conditioner controller
P1
AC3
AMP
12
Auto air conditioner controller
P1
ACC
YAZAKI
2
Accessory socket [Cab specification]
D6
ASD
KES1
4
Auto shift-down switch
N7
E8
BKA
Relay
5
Backup alarm relay
V1
F8
BRK
DT
3
Brake pedal potentiometer
R1
A2
BUZ
KES1
3
Buzzer cancel switch
P8
F8
C
Terminal
1
Battery relay power supply outlet
W4
I1
E1
CA2
DT
3
CAN terminating resistor
X1
L2
A8
B2
CA2
DT
3
CAN terminating resistor
I9
A8
C9
( 1) CAN
DT (Gr)
12
Intermediate connector [KOMTRAX]
Q9
CB1
One-pin
connector
2
Circuit breaker (20 A) (Starting switch)
M7
CIG
YAZAKI
2
Cigarette lighter
D6
CN-1
DT
2
Engine No. 1 injector
AB2
A3
CN-2
DT
2
Engine No. 2 injector
AC2
A2
CN-3
DT
2
Engine No. 3 injector
AC3
A2
CN-4
DT
2
Engine No. 4 injector
AD5
A1
CN-5
DT
2
Engine No. 5 injector
AD6
A2
CN-6
DT
2
Engine No. 6 injector
AD6
A2
CUR
KES1
3
Information switch
O7
DCL
DT
3
Decelerator pedal potentiometer
Q1
J8
DIAL
M
3
Fuel control dial potentiometer
V8
J8
E21
HD-24
31
Intermediate connector (Engine)
C1, AC9
C3
E22
HD-24
31
Intermediate connector (Engine)
D1, AD9
C7
E29
Terminal
1
Engine oil pressure sensor (High pressure)
Z1
E9
EN1
DRC-26
24
Engine controller
V1
A7
H1
K1
EN2
DRC-26
40
Engine controller
W1
A6
H1
K1
EN3
DRC-26
40
Engine controller
W1
A4
FAC
DT
2
Fan pump TVC solenoid
AF6
J7
FAM
KES1
4
Fan reverse mode switch
O7
D8
FAR
DT
2
Fan reverse solenoid
B2
A2
FFC
DT (Gr)
6
Intermediate connector
K5
FL
DT
2
Front additional light (Left)
G9
FL1
L
2
Fusible link
W2
FLS
X
4
Software writing connector (Engine controller)
W1
FR
DT
2
Front additional light (Right)
F8
Location
Arrange- Engine
ST
MON
ment
system system system
drawing diagram diagram diagram
E8
C1
J8
K1
C9
D8
E8
E8
I2
K6
L8
B1
G7
K2
B3
1. For KOMTRAX use.
20-318
(1)
D65EX, PX-15
TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS (D65EX, PX-15)
Address
Connector
No.
Number
of pins
Type
FS1
—
Fuse box
W4
G2
D2
A1
FS2
—
Fuse box
W3
G1
D2
A1
FSOL
DT
2
Forward clutch ECMV solenoid
AJ3
K4
FSW
DT
2
Forward clutch ECMV (Fill switch)
AI7
K4
FUSE1
Terminal
1
Fusible link (Battery side)
AA9
FUSE2
Terminal
1
Fusible link (Alternator side)
AA9
FWL
KES1
4
Head lamp switch
O7
G
090
2
Engine speed G sensor
AB2
( 1) G01
DRC-26
40
KOMTRAX control
R9
( 1) G02
x
1
Check connector (KOMTRAX)
P8
( 1) G03
x
1
Check connector (KOMTRAX)
P8
( 1) G04
x
1
Check connector (KOMTRAX)
P9
( 1) G05
x
1
Check connector (KOMTRAX)
P9
GND
Terminal
2
Intermediate connector (Intermediate connector to ground)
AA9
GND1
Terminal
1
Ground [Cab specification]
B9
GND1
Terminal
1
Ground (In cab)
B9
K1
GND2
Terminal
1
Ground (In cab)
B9
B7
GND2
Terminal
1
Ground [Engine]
A5
GND3
Terminal
1
Ground [Cab specification]
D7
GND3
Terminal
1
Ground [Engine]
Y2
GND4
Terminal
1
Ground
H9
GND01
Terminal
1
Ground [Floor]
T1
F1
GND03
Terminal
1
Ground [Fender]
K5
F1
GND04
Terminal
1
Ground [Flame]
B5
F1
H
Terminal
1
Battery relay power supply inlet
W4
HSA
DT
2
HSS-EPC (Left swing)
AG8
K7
HSB
DT
2
HSS-EPC (Right swing)
AE6
K6
HT/A
Terminal
1
Intake air heater relay (Terminal A)
AC9
B8
I1
HT/B
Terminal
1
Intake air heater relay (Terminal B)
AB9
B8
I1
HT/S
Terminal
1
Intake air heater relay (Terminal coil)
AB9
B8
I1
KEY
DT
6
Intermediate connector (Starting switch) [Canopy specification]
O9
( 1) KOM2
GT5
1
KOMTRAX controller
Q9
( 1) KOM3
BNC
1
KOMTRAX controller
Q9
( 1) KOM4
ML
1
KOMTRAX controller (Antenna)
H9
M26
M
6
Air conditioner unit
O6
MAM
KES1
4
Manual mode switch
O7
NE
090
2
Engine speed NE sensor
AD3
E9
NSF
Relay
5
Neutral safety relay
U1
L7
Location
Arrange- Engine
ST
MON
ment
system system system
drawing diagram diagram diagram
D8
E8
L8
B7
I1
I1
K1
I1
F1
J5
E1
E8
L8
F8
F6
1. For KOMTRAX use.
D65EX, PX-15
20-319
(1)
TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS (D65EX, PX-15)
Address
Connector
No.
Type
Number
of pins
NSW
DT
2
Safety lock switch
W7
P03
DT
6
Intermediate connector (Pitch selector switch) (If equipped)
S9
P04
DT
6
Intermediate connector (Pitch selector switch) (If equipped)
S9
PCV1
090
2
Fuel supply pump
AB2
PCV2
090
2
Fuel supply pump
AB2
PFUEL
AMP
3
Common rail fuel pressure switch
AD3
A8
PIM
090
3
Boost pressure sensor
AO7
A9
PL1
HD-24
23
Intermediate connector [Power train]
S1, AH2
I4
PL2
HD-24
31
Intermediate connector [Power train]
S1, AH2
I7
PPR
Relay
5
Supply pump power relay
V2
K7
PSL
Terminal
1
Engine oil pressure sensor (Low pressure)
Z1
E9
PT1
DT
3
Pitch angle sensor
Q9
R1
4
Air conditioner relay
O5
4
Air conditioner relay
O4
4
Air conditioner relay
O4
R4
Relay
(YAZAKI)
Relay
(YAZAKI)
Relay
(YAZAKI)
Relay
(YAZAKI)
4
Air conditioner relay
O4
RHR
Relay
5
Pre-heater relay
U1
RL
DT
2
Rear additional light (Left) [Cab specification]
I8
RR
DT
2
Rear additional light (Right) [Cab specification]
G9
RSOL
DT
2
Reverse clutch ECMV solenoid
AG7
K4
RSW
DT
2
Reverse clutch ECMV fill switch
AI7
K4
RWL
KES1
4
Rear lamp switch
O7
E8
S03
AMP070
20
Monitor panel
N9
A8
S04
AMP070
12
Monitor panel
N9
H8
S13
DT (Gr)
12
Intermediate connector
O3
I7
S24
Terminal
4
Service switch
SDS
DT
2
SFTD
C
SFTU
R2
R3
Location
Arrange- Engine
ST
MON
ment
system system system
drawing diagram diagram diagram
A2
A2
K8
D1
K7
E6
B8
C7
D6
M7
D9
D9
Hydraulic oil temperature sensor
AE2
J6
3
Shift-down switch
U9
K8
C
3
Shift-up switch
U9
K8
ST
DT
2
Starting motor
Y7
ST/B
Terminal
1
Starting motor (Terminal B)
Y8
ST1
DRC-26
24
Steering and transmission controller
W3
ST2
DRC-26
40
Steering and transmission controller
X3
ST3
DRC-26
40
Steering and transmission controller
STA
DT
6
STB
DT
STF
SW
20-320
(1)
H2
A7
A4
A6
A3
X3
A4
A3
Intermediate connector (HSS-EPC)
AG1
J7
6
Intermediate connector (HSS-EPC)
AF9
J7
X
4
Software writing connector (Steering and transmission controller)
X1
B8
Terminal
1
Battery relay terminal BR
W5
K2
J1
E1
D65EX, PX-15
TROUBLESHOOTING
TYPES AND LOCATIONS OF CONNECTORS (D65EX, PX-15)
Address
Connector
No.
Type
Number
of pins
SWG
Terminal
1
Battery relay ground
W5
J1
THL
DT
3
Fuel temperature sensor
AD3
E8
TL1
HD-24
23
Intermediate connector [Console]
V8
J7
TL2
DT (B)
8
Travel lever
V8
J9
TL3
DT
6
Intermediate connector [Shift switch]
V8
J8
TM1
DT
2
Transmission bevel speed sensor
AJ6
J6
TMV
HD-24
23
Intermediate connector [Transmission ECMV]
AG7
J4
TWH
DT
2
Engine water temperature sensor (High temperature)
Y6
B9
K8
TWL
DT
2
Engine water temperature sensor (Low temperature)
AB9
B9
K8
Location
Arrange- Engine
ST
MON
ment
system system system
drawing diagram diagram diagram
E1
I9
The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles) and (DT-12 poles) are as
follows.
(Gr) = Gray, (B) = Black, (G) = Green, (Br) = Brown
Type of connector
AMP
AMP070
Detail
Connector manufactured by NIPPON AMP
Connector of type 070 manufactured by NIPPON AMP
BNC
Connector of type BNC for coaxial cable
C
Connector of type C manufactured by CALSONIC KANSEI
DRC-26
DT
DRC type connector
DT type connector (08192-XXXXX)
DTHD
DTHD type connector (08192-XXXXX)
GT5
Connector of type GT5 for coaxial cable of GPS antenna
HD30
HD30 type connector (08191-XXXXX)
KES1
Connector of KES1 type (08027-1XXXX)
L
Connector of type L manufactured by YAZAKI (08056-2XXXX)
M
Connector of type M manufactured by YAZAKI (08056-0XXXX)
MIC
Connector of MIC type manufactured by NIPPON AMP
ML
L-connector of M type for coaxial cable
PA
Connector of PA type manufactured by YAZAKI
SUMITOMO
Connector manufactured by SUMITOMO DENSO
SWP
X
YAZAKI
One-pin connector
Connector of SWP type manufactured by YAZAKI (08055-1XXXX)
Connector of X type manufactured by YAZAKI (08055-0XXXX)
YAZAKI type connector
1-pole connector of pin type
Terminal
Round terminal or ordinary terminal
Relay
Connector of PH166-05020 type manufactured by SHINAGAWA JIDOSHA DENSEN
Relay (YAZAKI)
D65EX, PX-15
Connector manufactured by YAZAKI (For relay)
20-321
(1)
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
CONNECTOR ARRANGEMENT DRAWING
20-322
(1)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CONNECTOR ARRANGEMENT DRAWING
20-323
(1)
TROUBLESHOOTING
20-324
(1)
CONNECTOR ARRANGEMENT DRAWING
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CONNECTOR ARRANGEMENT DRAWING
20-325
(1)
TROUBLESHOOTING
20-326
(1)
CONNECTOR ARRANGEMENT DRAWING
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CONNECTOR ARRANGEMENT DRAWING
20-327
(1)
TROUBLESHOOTING
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM
(E CIRCUIT)
20-328
(1)
D65EX, PX-15
TROUBLESHOOTING
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
a This circuit diagram was drawn by extracting the engine controller system from the general electrical circuit
diagram.
D65EX, PX-15
20-329
(1)
TROUBLESHOOTING
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION
CONTROLLER SYSTEM (ST · TM CIRCUIT)
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION
CONTROLLER SYSTEM (ST · TM CIRCUIT)
20-330
(1)
D65EX, PX-15
TROUBLESHOOTING
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION
CONTROLLER SYSTEM (ST · TM CIRCUIT)
a This circuit diagram was drawn by extracting the steering and transmission controller system from the general electrical circuit diagram.
D65EX, PX-15
20-331
(1)
TROUBLESHOOTING
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM
(M CIRCUIT)
20-332
(1)
D65EX, PX-15
TROUBLESHOOTING
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
a This circuit diagram was drawn by extracting the monitor panel system, starting and filling systems, the lighting system and the communication network system from the general electrical circuit diagram.
D65EX, PX-15
20-333
(1)
TROUBLESHOOTING
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
Connection table for connector pin numbers
(Rev. 2007.12)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
20-334
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-335
(8)
TROUBLESHOOTING
20-336
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-337
(8)
TROUBLESHOOTING
20-338
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-339
(8)
TROUBLESHOOTING
20-340
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-341
(8)
TROUBLESHOOTING
20-342
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-343
(8)
TROUBLESHOOTING
20-344
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-345
(8)
TROUBLESHOOTING
20-346
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-347
(8)
TROUBLESHOOTING
20-348
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-349
(8)
TROUBLESHOOTING
20-350
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-351
(8)
TROUBLESHOOTING
20-352
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-353
(8)
TROUBLESHOOTING
20-354
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-355
(8)
TROUBLESHOOTING
20-356
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-357
(8)
TROUBLESHOOTING
20-358
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-359
(8)
TROUBLESHOOTING
20-360
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-361
(8)
TROUBLESHOOTING
20-362
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-363
(8)
TROUBLESHOOTING
20-364
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-365
(8)
TROUBLESHOOTING
20-366
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-367
(8)
TROUBLESHOOTING
20-368
(8)
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-369
(8)
TROUBLESHOOTING
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE
(Rev. 2007.12)
q
q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column
indicates a part number of harness checker assembly.
q
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
q
799-601-3200 T-box (for MS)
37
q
q
799-601-3380 Plate for MS (14-pin)
799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
q
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
q
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
q
799-601-2710 Adapter for MIC
5
MIC-5P
q q
q
799-601-2720 Adapter for MIC
13
MIC-13P
q q
q
799-601-2730 Adapter for MIC
17
MIC-17P
q q q
q q
q
799-601-2740 Adapter for MIC
21
MIC-21P
q q q
q q
q
799-601-2950 Adapter for MIC
9
MIC-9P
q q q
q
799-601-2750 Adapter for ECONO
2
ECONO2P
q q
799-601-2760 Adapter for ECONO
3
ECONO3P
q q
799-601-2770 Adapter for ECONO
4
ECONO4P
q q
799-601-2780 Adapter for ECONO
8
ECONO8P
q q
799-601-2790 Adapter for ECONO
12 ECONO12P q q
q
799-601-3470 Case
799-601-2810 Adapter for DLI
8
DLI-8P
q q
799-601-2820 Adapter for DLI
12
DLI-12P
q q
799-601-2830 Adapter for DLI
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
799-601-4350 T-box (for DRC 60, ECONO)
q
q
799-601-2850 Case
q
60
q
799-601-4360 Case
q
q
X2P
q q q
q
X3P
q q q
q
4
X4P
q q q
q
6
SW6P
q q q
q q q
799-601-7010 Adapter for X (T-adapter)
1
799-601-7020 Adapter for X
2
799-601-7030 Adapter for X
3
799-601-7040 Adapter for X
799-601-7050 Adapter for SWP
799-601-7060 Adapter for SWP
8
SW8P
799-601-7310 Adapter for SWP
12
SW12P
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-adapter)
1
q
q
q
q
q
q
799-601-7090 Adapter for M
2
M2P
q q q
q
799-601-7110 Adapter for M
3
M3P
q q q
q
20-370
(8)
D65EX, PX-15
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE
q q q
q
799-601-7150 Adapter for S (White)
10
S10P
q q q
q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
799-601-7170 Adapter for S (Blue)
16
S16P
q q q
799-601-7330 Adapter for S (White)
16
S16PW
799-601-7350 Adapter for S (White)
12
S12PW
Out of kit
S8P
799-601-4201
8
799-601-4101
799-601-7140 Adapter for S
799-601-9300
q
799-601-9200
q q q
M8P
799-601-9100
M6P
8
799-601-8000
6
799-601-7340 Adapter for M
799-601-7500
799-601-7130 Adapter for M
799-601-7400
q
799-601-7100
q q q
799-601-7000
M4P
799-601-2800
4
799-601-2700
799-601-7120 Adapter for M
Part name
799-601-2500
Identification
symbol
Part No.
799-601-9000
T-adapter kit
Number of pins
TROUBLESHOOTING
q
q
q
q
q
799-601-7180 Adapter for AMP040
8
A8P
799-601-7190 Adapter for AMP040
12
A12P
q
q
799-601-7210 Adapter for AMP040
16
A16P
q q q
q
799-601-7220 Adapter for AMP040
20
A20P
q q q
q
799-601-7230 Short connector for X
2
—
q q q
q
q q
799-601-7240 Case
q
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
q
799-601-7520 Adapter for 070
12
07-12
q
799-601-7530 Adapter for 070
14
07-14
q
799-601-7540 Adapter for 070
18
07-18
q
799-601-7550 Adapter for 070
20
07-20
q
799-601-7360 Adapter for relay
5
REL-5P
q
799-601-7370 Adapter for relay
6
REL-6P
q
799-601-7380 Adapter for JFC
2
—
799-601-9010 Adapter for DTM
2
DTM2
q
q
799-601-9020 Adapter for DT
2
DT2
q
q
799-601-9030 Adapter for DT
3
DT3
q
q
799-601-9040 Adapter for DT
4
DT4
q
q
799-601-9050 Adapter for DT
6
DT6
q
q
799-601-9060 Adapter for DT (Gray)
8
DT8GR
q
q
799-601-9070 Adapter for DT (Black)
8
DT8B
q
q
799-601-9080 Adapter for DT (Green)
8
DT8G
q
q
799-601-9090 Adapter for DT (Brown)
8
DT8BR
q
q
799-601-9110 Adapter for DT (Gray)
12
DT12GR
q
q
799-601-9120 Adapter for DT (Black)
12
DT12B
q
q
799-601-9130 Adapter for DT (Green)
12
DT12G
q
q
799-601-9140 Adapter for DT (Brown)
12
DT12BR
q
q
799-601-9210 Adapter for HD30-18
8
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
q
799-601-9250 Adapter for HD30-24
9
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin)
799-601-9320 T-box (for ECONO)
799-601-9330 Case
D65EX, PX-15
24
q q
q q
q q
q
q q
q
q
20-371
(8)
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE
Number of pins
TROUBLESHOOTING
q
799-601-9340 Case
799-601-9350 Adapter for DRC
40
DRC-40
q
799-601-9360 Adapter for DRC
24
DRC-24
q
799-601-9410* Socket for engine (CRI-T2)
2
G
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
3
A3
q q
2
P
q q
799-601-9440* Socket for engine (CRI-T2)
3
1,2,3
q
795-799-5520* Socket for engine (HPI-T2)
2
S
q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3)
Temperature sensor
2
C
q q
2
A
q q
795-799-5460 Cable for engine (HPI-T2)
3
—
q
795-799-5470 Cable for engine (HPI-T2)
3
—
q
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2)
Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2)
Socket for engine (CRI-T3) TIM
q
q
795-799-5480 Cable for engine (HPI-T2)
3
—
799-601-4110 Adapter for engine (140-T3) PIM
4
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
3
FCIN
q q
Adapter for engine (CRI-T3)
799-601-4140
Atomosphere pressure
3
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
3
FCIB
q q
Adapter for engine (CRI-T3)
799-601-4160
Oil pressure switch
2
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
3
4180
q q
799-601-4190*
Socket for engine (CRI-T3)
Commonrail pressure
3
1,2,3L
q q
799-601-4230*
Socket for engine (CRI-T3)
Air intake pressure/temperature
4
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
3
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
3
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
3
1,2,3,G
q q
Socket for engine (CRI-T3)
799-601-4340*
Pump actuator
2
2,PA
q q
4
1,2,3,4T
799-601-4260 Adapter for controller (ENG)
4
DTP4
q q
799-601-4380*
Socket for engine (CRI-T3)(95)
Air intake pressure/temperature
q
799-601-4211 Adapter for controller (ENG)
50
DRC50
q
799-601-4220 Adapter for controller (ENG)
60
DRC60
q
799-601-4390* Socket for controller (95 ENG)
60
—
q
799-601-4280 Box for controller (PUMP)
121
—
q
799-601-9720 Adapter for controller (HST)
16
HST16A
q
799-601-9710 Adapter for controller (HST)
16
HST16B
q
799-601-9730 Adapter for controller (HST)
26
HST26A
q
2,
3,
4,
—
q
799-601-9890
Multi-adapter for
DT2 – 4 and DTM2
“*” Shows not T-adapter but socket.
20-372
(8)
D65EX, PX-15
TROUBLESHOOTING
TROUBLESHOOTING WHEN
ERROR CODE IS DISPLAYED
(ERROR CODE)
Information described in troubleshooting list ........................................................................................... 20-406
Trouble code table ................................................................................................................................... 20-407
Error code
Failed section
Trouble
Action
code
Troubleshooting
page
1500L0
Transmission clutch
See the list. (L0)
CALL E03 20-408
15SAL1
Forward clutch
See the list. (L1)
CALL E03 20-409
15SALH
Forward clutch
See the list. (LH)
CALL E03 20-410
15SBL1
Reverse clutch
See the list. (L1)
CALL E03 20-411
15SBLH
Reverse clutch
See the list. (LH)
CALL E03 20-412
15SEL1
1st clutch
See the list. (L1)
CALL E03 20-413
15SELH
1st clutch
See the list. (LH)
CALL E03 20-414
15SFL1
2nd clutch
See the list. (L1)
CALL E03 20-415
15SFLH
2nd clutch
See the list. (LH)
CALL E03 20-416
15SGL1
3rd clutch
See the list. (L1)
CALL E03 20-417
15SGLH
3rd clutch
See the list. (LH)
CALL E03 20-418
A000N1
Engine
Overrun (N1)
—
20-419
AB00MA
Alternator
Malfunction (MA)
—
20-420
AD00L2
Common rail
See the list. (L2)
CALL E03 20-420
AD00MA
Common rail
Defective function (MA)
CALL E03 20-421
AD10L3
Fuel supply pump
See the list. (L3)
CALL E03 20-421
AD10MA
Fuel supply pump
Defective function (MA)
CALL E03 20-423
AD10MB
Fuel supply pump
Function reduction (MB)
CALL E03 20-423
AD11KA
Fuel supply pump solenoid 1
Disconnection (KA)
CALL E03 20-424
AD11KB
Fuel supply pump solenoid 1
Short circuit (KB)
CALL E03 20-425
AD51KA
Fuel supply pump solenoid 2
Disconnection (KA)
CALL E03 20-426
AD51KB
Fuel supply pump solenoid 2
Short circuit (KB)
CALL E03 20-427
ADA1KA
No.1 injector solenoid
Disconnection (KA)
ADAZKB
No.1, 2, and 3 injector solenoids
Short circuit (KB)
D65EX, PX-15
E02
20-428
CALL E03 20-429
20-401
(1)
TROUBLESHOOTING
Error code to display at the same time
Error code
Failed section
Trouble
Action
code
Troubleshooting
page
ADB1KA
No.2 injector solenoid
Disconnection (KA)
E02
20-431
ADC1KA
No.3 injector solenoid
Disconnection (KA)
E02
20-432
ADD1KA
No.4 injector solenoid
Disconnection (KA)
E02
20-433
ADDZKB
No.4, 5, and 6 injector solenoids
Short circuit (KB)
ADE1KA
No.5 fuel injector solenoid
Disconnection (KA)
E02
20-436
ADF1KA
No.6 fuel injector solenoid
Disconnection (KA)
E02
20-437
B@BAZG
Engine oil
Oil pressure reduction (ZG)
—
20-438
B@BCNS
Radiator coolant
Overheat (NS)
—
20-438
B@CENS
Power train oil
Overheat (NS)
—
20-439
B@HANS
Hydraulic oil
Overheat (NS)
—
20-439
D110KA
Battery relay
Short circuit (KA)
—
20-440
D110KB
Battery relay
Disconnection (KB)
—
20-441
D130KA
Neutral safety relay
Short circuit (KA)
E02
20-442
D130KB
Neutral safety relay
Disconnection (KB)
E02
20-444
D161KA
Back-up alarm relay
Short circuit (KA)
E01
20-446
D161KB
Back-up alarm relay
Disconnection (KB)
E01
20-448
D182KZ
Preheater relay coil
Disconnection or short circuit (KZ)
E01
20-450
D1D0KB
Engine controller load power supply relay
Short circuit (KB)
E02
20-452
D5ZFKA
Transmission neutral signal
Disconnection (KA)
E01
20-454
D5ZFKB
Transmission neutral signal
Short circuit (KB)
E01
20-455
DAFRKR
Monitor panel CAN communication
Defective communication (KR)
CALL E03 20-456
DAQ0KK
DB30KK
Steering and transmission controller
Source voltage reduction/input (KK)
CALL E04 20-458
DAQ0KT
Steering and transmission controller
Abnormality in controller (KT)
DAQ5KK
DB35KK
DAQ6KK
DB36KK
DAQ9KQ
DB39KQ
Steering and transmission controller sensor
5 V power supply
Source voltage reduction/input (KK)
CALL E03 20-460
Steering and transmission controller sensor
24 V power supply
Source voltage reduction/input (KK)
CALL E03 20-462
Steering and transmission controller type
collation
Type select signal inconsistency (KQ) CALL E04 20-463
DB3RKR
Steering and transmission controller CAN
communication
Defective communication (KR)
DB20KQ
Engine controller type collation
Type select signal inconsistency (KQ) CALL E03 20-466
DB20KT
Engine controller
Abnormality in controller (KT)
20-402
(1)
CALL E03 20-434
E02
20-459
CALL E03 20-464
CALL E03 20-467
D65EX, PX-15
TROUBLESHOOTING
Error code to display at the same time
Error code
Failed section
Trouble
Action
code
Troubleshooting
page
DB22KK
Engine controller load power supply
Source voltage reduction/input (KK)
DB29KQ
Engine controller type select
Type select signal inconsistency (KQ) CALL E03 20-470
DB2AMA
Fuel injection amount adjustment switch signal Malfunction (MA)
DB2RKR
Steering and transmission controller CAN
communication
Defective communication (KR)
CALL E04 20-472
DB2RMC
Engine controller CAN communication
Defective communication (MC)
CALL E03 20-474
Steering and transmission controller
Source voltage reduction/input (KK)
CALL E04 20-476
Steering and transmission controller sensor
5 V power supply
Source voltage reduction/input (KK)
CALL E03 20-476
Steering and transmission controller sensor
24 V power supply
Source voltage reduction/input (KK)
CALL E03 20-476
Steering and transmission controller type
collation
Type select signal inconsistency (KQ) CALL E04 20-476
DD11KB
Starting switch
Short circuit (KB)
DD12KA
Shift up switch
Disconnection (KA)
E02
20-478
DD12KB
Shift up switch
Short circuit (KB)
E02
20-480
DD13KA
Shift down switch
Disconnection (KA)
E02
20-482
DD13KB
Shift down switch
Short circuit (KB)
E02
20-484
Parking lever switch
Disconnection (KA)
CALL E03 20-486
Parking lever switch
Short circuit (KB)
CALL E03 20-488
DDE2L6
Engine oil pressure switch
Refer to table (L6)
E01
20-490
DDN7KA
Pitch control switch
Disconnection (KA)
E02
20-492
DDN7KB
Pitch control switch
Short circuit (KB)
E02
20-494
Parking lever switch
Disconnection (KA)
CALL E03 20-496
Parking lever switch
Short circuit (KB)
CALL E03 20-496
DGE2KX
Engine water temperature sensor (for high
temperature)
Input signal is out of normal range (KX)
E01
20-497
DGE3L6
Engine water temperature sensor (for low
temperature)
See table (L6)
E02
20-498
DGE4KX
Fuel temperature sensor
Input signal is out of normal range (KX)
E01
20-499
DGS1KX
Hydraulic oil temperature sensor
Input signal is out of normal range (KX)
—
20-500
DH30KX
Boost pressure sensor
Input is out of normal range (KX)
E02
20-502
DH40KX
Common rail pressure sensor
Input is out of normal range (KX)
CALL E03 20-504
DK10KX
Fuel control dial
Input is out of normal range (KX)
CALL E03 20-506
DK12KX
Deceleration potentiometer
Input is out of normal range (KX)
CALL E03 20-508
DB30KK
DAQ0KK
DB35KK
DAQ5KK
DB36KK
DAQ6KK
DB39KQ
DAQ9KQ
DD14KA
DDQ2KA
DD14KB
DDQ2KB
DDQ2KA
DD14KA
DDQ2KB
DD14KB
D65EX, PX-15
CALL E04 20-468
E02
20-471
CALL E04 20-477
20-403
(1)
TROUBLESHOOTING
Error code
Failed section
Trouble
Action
code
Troubleshooting
page
DK30KA
Steering potentiometer 1
Disconnection (KA)
CALL E03 20-510
DK30KB
Steering potentiometer 1
Short circuit (KB)
CALL E03 20-511
DK30KX
Steering potentiometer
Input signal is out of normal range (KX) CALL E04 20-512
DK30KZ
Steering potentiometer
Disconnection or short circuit
(Double trouble) (KZ)
CALL E04 20-512
DK30L8
Steering potentiometer 1
See table (L8)
CALL E03 20-513
DK31KA
Steering potentiometer 2
Short circuit (KA)
CALL E03 20-514
DK31KB
Steering potentiometer 2
Disconnection (KB)
CALL E03 20-515
DK40KA
Brake potentiometer
Disconnection (KA)
CALL E03 20-516
DK40KB
Brake potentiometer
Short circuit (KB)
CALL E03 20-517
DK55KX
Forward-reverse potentiometer
Input signal is out of normal range (KX) CALL E04 20-518
DK55KZ
Forward-reverse potentiometer
Disconnection or short circuit
(Double trouble) (KZ)
CALL E04 20-518
DK55L8
Forward-reverse potentiometer
See table (L8)
CALL E03 20-519
DK56KA
Forward-reverse potentiometer 1
Short circuit (KA)
CALL E03 20-520
DK56KB
Forward-reverse potentiometer 1
Disconnection (KB)
CALL E03 20-522
DK57KA
Forward-reverse potentiometer 2
Short circuit (KA)
CALL E03 20-524
DK57KB
Forward-reverse potentiometer 2
Disconnection (KB)
CALL E03 20-526
DKH1KA
Pitch angle sensor
Short circuit (KA)
CALL E03 20-528
DKH1KB
Pitch angle sensor
Disconnection (KB)
CALL E03 20-529
DLE3LC
Engine Ne speed sensor
See table (LC)
CALL E03 20-530
DLF1KA
Transmission output speed sensor
Disconnection (KA)
DLH1LC
Engine G speed sensor
See table (LC)
DV00KB
Caution buzzer
Short circuit (KB)
—
20-533
DW5AKA
Pitch control solenoid
Disconnection (KA)
E02
20-534
DW5AKB
Pitch control solenoid
Short circuit (KB)
E02
20-535
DW7BKA
Fan reverse solenoid
Disconnection (KA)
E01
20-536
DW7BKB
Fan reverse solenoid
Short circuit (KB)
E01
20-537
DWN1KA
HSS EPC solenoid right
Disconnection (KA)
CALL E03 20-538
DWN1KB
HSS EPC solenoid right
Short circuit (KB)
CALL E03 20-539
DWN2KA
HSS EPC solenoid left
Disconnection (KA)
CALL E03 20-540
20-404
(1)
E01
20-531
CALL E03 20-532
D65EX, PX-15
TROUBLESHOOTING
Error code
Failed section
Trouble
Action
code
Troubleshooting
page
DWN2KB
HSS EPC solenoid left
Short circuit (KB)
DWN5KA
Fan pump TVC solenoid
Disconnection (KA)
E01
20-542
DWN5KB
Fan pump TVC solenoid
Short circuit (KB)
E01
20-543
DXH4KA
1st clutch ECMV
Disconnection (KA)
CALL E03 20-544
DXH4KB
1st clutch ECMV
Short circuit (KB)
CALL E03 20-545
DXH5KA
2nd clutch ECMV
Disconnection (KA)
CALL E03 20-546
DXH5KB
2nd clutch ECMV
Short circuit (KB)
CALL E03 20-547
DXH6KA
3rd clutch ECMV
Disconnection (KA)
CALL E03 20-548
DXH6KB
3rd clutch ECMV
Short circuit (KB)
CALL E03 20-549
DXH7KA
Reverse clutch ECMV
Disconnection (KA)
CALL E03 20-550
DXH7KB
Reverse clutch ECMV
Short circuit (KB)
CALL E03 20-551
DXH8KA
Forward clutch ECMV
Disconnection (KA)
CALL E03 20-552
DXH8KB
Forward clutch ECMV
Short circuit (KB)
CALL E03 20-553
D65EX, PX-15
CALL E03 20-541
20-405
(1)
TROUBLESHOOTING
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
a The troubleshooting list and related circuit diagram summarize the following information. Understand their
contents well to advance troubleshooting.
Action code
Error code Controller code
Trouble Trouble that appeared on machine
Panel display
Panel display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of monitor
Action to be taken to protect the system and equipment when the monitor panel or controller detects a
panel or
trouble
controller
Problem that
Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or conappears on
troller (above)
machine
Related
Information related to a detected trouble or troubleshooting
information
Cause
1
2
Possible causes
and standard
value in normal
state
20-406
(1)
Standard value in normal state/Remarks on troubleshooting
<Described contents>
• Standard value in normal state required to judge the assumed cause
(good or not)
• Remarks required to judge whether the cause is good
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness is disconnected.
• Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Defective hot short
A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit.
• Defective short
A harness of an independent circuit abnormally comes into contact
with one of another circuit.
Cause by which a trouble is
assumed to be detected
3 (The order number indicates a
serial number, not a priority <Notes on troubleshooting>
sequence.)
(1) Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect the T-junction adapter as
shown below unless especially specified.
• When “male” or “female” is not indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
4
both the male and female.
• When “male” or “female” is indicated for a connector number, disconnect the connector, and insert the T-junction adapter in only
either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in the
5
front.
• Connect the minus (–) lead to a pin or harness indicated in the
rear.
D65EX, PX-15
TROUBLESHOOTING
TROUBLE CODE TABLE
Related circuit diagram
This is the excerpted circuit diagram related to trouble
• Connector No.: Indicates (Model-No. of pins) (Color).
• Arrow ( ): Roughly indicates mounting place on machine.
TROUBLE CODE TABLE
a Regarding trouble code provided with instruction “Refer to table”, check it against table below.
Trouble code
KA
Disconnection in wiring
L0
KB
KK
KQ
KR
Short circuit
Source voltage reduction/input
Type select signal inconsistency
Defective communication
L1
L2
L3
L4
KT
Abnormality in controller
L6
KX
Outside input signal range
Disconnection or short circuit
(Double trouble)
Malfunction
Performance reduction
Sliding
Overheat
Oil pressure reduction
Coolant level reduction
L8
Contents of trouble
Fill signals at two or more channels which are not set as
combination are turned ON at the same time.
Fill signal is ON when command current to ECMV is OFF.
Fuel pressure is above maxim specified value.
Object part is uncontrollable.
ON and OFF signals at two systems are inconsistent.
Engine rotation signal, terminal C signal, oil pressure switch
signal, water temperature sensor signal, etc. are inconsistent with operation state or stop state.
Analog signals in two systems are inconsistent.
LC
rpm signals in two systems are inconsistent.
LD
LH
Switch is pressed for usually unthinkable long time.
Fill signal is OFF when command current to ECMV is ON.
KZ
MA
MB
MW
NS
ZG
ZK
Contents of trouble
D65EX, PX-15
Trouble code
20-407
(1)
TROUBLESHOOTING
ERROR CODE 1500L0
ERROR CODE 1500L0 (TRANSMISSION CLUTCH: SEE THE LIST. (L0))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
20-408
(1)
Error code Controller code
Transmission clutch: See the list. (L0)
Trouble
(Steering and transmission controller system)
1500L0
Steering
• Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Gear speed is limited)
(1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of the error codes related to the transmission clutch, the following codes were displayed at the same
time. (Machine cannot travel)
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
(3) Either of [DXH6KA] or [DXH6KB] and (1) above
(4) [15SFL1] and [15SGL1]
(5) [15SFLH] and [15SGLH]
(6) [15SAL1], [15SBL1], and [15SEL1]
(7) [15SALH] and [15SBLH]
(8) [15SALH] and [15SELH]
(9) [15SBLH] and [15SELH]
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• The auto shift down function does not start.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to specific gear speeds.
• Machine cannot travel.
• Method of reproducing error code: Engine start + Run
Cause
Standard value in normal state/Remarks on troubleshooting
Confirm the error codes displayed at the same time, then carry out troubleshooting for the codes.
[15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
[15SGLH]
[DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA],
[DXH8KB]
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE 15SAL1
ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST. (L1))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
15SAL1
Controller code
Steering
Trouble
Forward clutch: See the list. (L1)
(Steering and transmission controller system)
• The fill switch signal is not set off at output stop of the transmission forward clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Decides that engine speed is neutral (N) at reverse operation.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1.
Related
information
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + Neutral running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective forward clutch fill
FSW (male)
PCCS lever
Resistance
switch (Internal short)
N
Min. 1 Mz
Between (1) –
chassis ground
F (Forward)
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness groundwithout turning starting switch ON.
ing (Contact with ground
Wiring harness between ST2 (female) (35) –
circuit)
Resistance Max. 1 Mz
FSW (female) (1) with chassis ground
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST2
PCCS lever
Voltage
transmission controller
N
5 – 11 V
Between (35) –
chassis ground
F (Forward)
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission forward clutch ECMV
D65EX, PX-15
20-409
(1)
TROUBLESHOOTING
ERROR CODE 15SALH
ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST. (LH))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
15SALH
Controller code
Steering
Trouble
Forward clutch: See the list. (LH)
(Steering and transmission controller system)
• The fill switch signal is not set off at output to the transmission forward clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Decides that engine speed is neutral (N) at forward operation.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to R1.
Related
information
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + Forward running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective forward clutch fill
FSW (male)
PCCS lever
Resistance
switch (Internal short)
N
Min. 1 Mz
Between (1) –
chassis ground
F (Forward)
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between ST2 (female) (35) –
Resistance Max. 1 z
connector)
FSW (female) (1)
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST2
PCCS lever
Voltage
transmission controller
N
5 – 11 V
Between (35) –
chassis ground
F (Forward)
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission forward clutch ECMV
20-410
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE 15SBL1
ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST. (L1))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
15SBL1
Controller code
Steering
Trouble
Reverse clutch: See the list. (L1)
(Steering and transmission controller system)
• The fill switch signal is not set off at output stop of the transmission reverse clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Decides that engine speed is neutral (N) at forward operation.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to R1.
Related
information
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + Forward running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective reverse clutch fill
RSW (male)
PCCS lever
Resistance
switch (Internal short)
N
Min. 1 Mz
Between (1) –
chassis ground
R (Reverse)
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness groundwithout turning starting switch ON.
ing (Contact with ground
Wiring harness between ST2 (female) (25) –
circuit)
Resistance Max. 1 Mz
RSW (female) (1) with chassis ground
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST2
PCCS lever
Voltage
transmission controller
N
5 – 11 V
Between (24) and (25)
– chassis ground
R (Reverse)
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission reverse clutch ECMV
D65EX, PX-15
20-411
(1)
TROUBLESHOOTING
ERROR CODE 15SBLH
ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST. (LH))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
15SBLH
Controller code
Steering
Trouble
Reverse clutch: See the list. (LH)
(Steering and transmission controller system)
• The fill switch signal is not set on at output to the transmission reverse clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Decides that engine speed is neutral (N) at reverse operation.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1.
Related
information
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + Forward running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective reverse clutch fill
RSW (male)
PCCS lever
Resistance
switch (Internal short)
N
Min. 1 Mz
Between (1) –
chassis ground
R (Reverse)
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between ST2 (female) (25) –
Resistance Max. 1 Mz
connector)
RSW (female) (1)
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST2
PCCS lever
Voltage
transmission controller
N
5 – 11 V
Between (25) –
chassis ground
R (Reverse)
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission reverse clutch ECMV
20-412
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE 15SEL1
ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST. (L1))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
15SEL1
Controller code
Steering
Trouble
1st clutch: See the list. (L1)
(Steering and transmission controller system)
• The fill switch signal is not set off at output stop of the transmission level 1 clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1 and R1.
• The input state (ON/OFF) from the level 1 clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + Forward running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective 1st clutch fill
1SW (male)
PCCS lever
Resistance
switch (Internal short)
Other
than
F1/R1
Min. 1 Mz
Between (1) –
chassis ground
F1·R1
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness groundwithout turning starting switch ON.
ing (Contact with ground
Wiring harness between ST3 (female) (19) –
circuit)
Resistance Max. 1 Mz
1SW (female) (1) with chassis ground
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST3
PCCS lever
Voltage
transmission controller
Other than F1/R1
5 – 11 V
Between (19) –
chassis ground
F1·R1
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission 1st clutch ECMV
D65EX, PX-15
20-413
(1)
TROUBLESHOOTING
ERROR CODE 15SELH
ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST. (LH))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
15SELH
Controller code
Steering
Trouble
1st clutch: See the list. (LH)
(Steering and transmission controller system)
• The fill switch signal is not set off at output to the transmission 1st clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• The auto shift down function does not start.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F2 and R2.
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + F1 or R1 running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective 1st clutch fill
1SW (male)
PCCS lever
Resistance
switch (Internal short)
Other
than
F1/R1
Min. 1 Mz
Between (1) –
chassis ground
F1·R1
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between ST3 (female) (19) –
Resistance Max. 1 Mz
connector)
1SW (female) (1)
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST3
PCCS lever
Voltage
transmission controller
Other than F1/R1
5 – 11 V
Between (19) –
chassis ground
F1·R1
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission 1st clutch ECMV
20-414
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE 15SFL1
ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST. (L1))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
15SFL1
Controller code
Steering
Trouble
2nd clutch: See the list. (L1)
(Steering and transmission controller system)
• The fill switch signal is not set off at stop of output of the transmission 2nd clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• The auto shift down function does not operate.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F2 and R2.
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + Neutral running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective 2nd clutch fill
2SW (male)
PCCS lever
Resistance
switch (Internal short)
Other
than
F2/R2
Min. 1 Mz
Between (1) –
chassis ground
F2·R2
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness groundwithout turning starting switch ON.
ing (Contact with ground
Wiring harness between ST3 (female) (29) –
circuit)
Resistance Max. 1 Mz
2SW (female) (1) with chassis ground
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST3
PCCS lever
Voltage
transmission controller
Other than F2/R2
5 – 11 V
Between (29) –
chassis ground
F2·R2
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission 2nd clutch ECMV
D65EX, PX-15
20-415
(1)
TROUBLESHOOTING
ERROR CODE 15SFLH
ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST. (LH))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
15SFLH
Controller code
Steering
Trouble
2nd clutch: See the list. (LH)
(Steering and transmission controller system)
• The fill switch signal is not set on at output to the transmission level 2 clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1 and R1.
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + F2 or R2 running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective 2nd clutch fill
2SW (male)
PCCS lever
Resistance
switch (Internal short)
Other
than
F2/R2
Min. 1 Mz
Between (1) –
chassis ground
F2·R2
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between ST3 (female) (29) –
Resistance Max. 1 Mz
connector)
2SW (female) (1)
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST3
PCCS lever
Voltage
transmission controller
Other than F2/R2
5 – 11 V
Between (29) –
chassis ground
F2·R2
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission 2nd clutch ECMV
20-416
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE 15SGL1
ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST. (L1))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
15SGL1
Controller code
Steering
Trouble
3rd clutch: See the list. (L1)
(Steering and transmission controller system)
• The fill switch signal is not set off at output stop of the transmission 3rd clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• The auto shift down function does not operate.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F3 and R3.
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + Neutral running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective 3rd clutch fill
3SW (male)
PCCS lever
Resistance
switch (Internal short)
Other
than
F3/R3
Min. 1 Mz
Between (1) –
chassis ground
F3·R3
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness groundwithout turning starting switch ON.
ing (Contact with ground
Wiring harness between ST3 (female) (39) –
circuit)
Resistance Max. 1 Mz
3SW (female) (1) with chassis ground
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST3
PCCS lever
Voltage
transmission controller
Other than F3/R3
5 – 11 V
Between (39) –
chassis ground
F3·R3
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission 3rd clutch ECMV
D65EX, PX-15
20-417
(1)
TROUBLESHOOTING
ERROR CODE 15SGLH
ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST. (LH))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
15SGLH
Controller code
Steering
Trouble
3rd clutch: See the list. (LH)
(Steering and transmission controller system)
• The fill switch signal is not set off at output to the transmission 3rd clutch solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1 and R1.
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
• Method of reproducing error code: Engine start + F3 or R3 running
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective 3rd clutch fill
3SW (male)
PCCS lever
Resistance
switch (Internal short)
Other
than
F3/R3
Min. 1 Mz
Between (1) –
chassis ground
F3·R3
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between ST3 (female) (39) –
Resistance Max. 1 z
connector)
3SW (female) (1)
aPrepare with starting switch OFF, then start the engine for troubleshooting.
Defective steering and
ST3
PCCS lever
Voltage
transmission controller
Other than F3/R3
5 – 11 V
Between (39) –
chassis ground
F3·R3
Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic pressure
system is assumed to be abnormal. Carry out the related troubleshootsystem
ing (H mode).
Circuit diagram related to transmission 3rd clutch ECMV
20-418
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE A000N1
ERROR CODE A000N1 (ENGINE: OVERRUN (N1))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D65EX, PX-15
Error code Controller code
Engine: Overrun (N1)
Trouble
(Engine controller system)
A000N1
Engine
• All the segments of the engine speed bar graph of the monitor panel lighted up to the red range and
the engine speed exceeded the specified speed (2,750 rpm).
• Saves the trouble but does not make any alarm.
• Stops fuel injection until the engine speed lowers below the specified speed.
• None in particular.
• Engine speed (rpm) can be checked in monitoring mode.
(Code 01000: Engine speed)
• Method of reproducing error code: Turn starting switch ON.
• Engine speed can be checked in monitoring mode.
Cause
Standard value in normal state/Remarks on troubleshooting
If any other error code is displayed and recorded at the same time, carry out troubleshooting for that
1
error code first.
2 Improper use
Instruct the using procedure again.
3 Defective engine controller
Check that engine speed is displayed normally.
20-419
(1)
ERROR CODE AB00MA,
ERRORCODE
CODE AB00MA
AD00L2
ERROR
TROUBLESHOOTING
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code
AB00MA
Controller code
—
Trouble
Alternator: Malfunction (MA)
(Mechanical system)
• During rotation of engine, charge level caution lamp flashes.
• Flashes caution lamp.
• If machine is operated as it is, battery may be discharged.
• Method of reproducing error code: Start engine.
Cause
Defective battery charge
1 (When system is in normal
state)
2
Defective charge level
caution lamp system
Standard value in normal state/Remarks on troubleshooting
It is suspected that problem causing defective battery charge is occurring at present or occurred in past. Investigate cause and damage condition, and correct it.
Carry out troubleshooting of charge level caution lamp system in accordance with “During running of engine, emergency caution item flashes”
in E mode.
ERROR CODE AD00L2 (COMMON RAIL: SEE THE LIST. (L2))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
AD00L2
Controller code
Engine
• Flashes caution lamp and turns on caution buzzer.
• Limits output for operation.
• Engine output reduces.
• The fuel state (fuel pressure) of common rail can be checked in monitoring mode.
(Code 36400: Common rail pressure)
• Method of reproducing error code: Engine start
1 Defective related system
20-420
(1)
Common rail: See the list. (L2)
(Engine controller system)
• The fuel pressure of common rail became high (level 1).
Cause
Possible causes
and standard
value in normal
state
Trouble
Standard value in normal state/Remarks on troubleshooting
Check the displayed error code. If another code is displayed, first carry
out troubleshooting for the code.
The fuel used may be inappropriate; directly check it.
2 Inappropriate fuel
Defective electric system of
3 common rail pressure
Carry out troubleshooting for error code [DH40KX].
sensor
Defective mechanical
The common rail pressure sensor is assumed to be defective mechan4 system of common rail
ically; directly check it.
pressure sensor
The overflow valve may cause spring damage, sheet abrasion, or ball
5 Defective overflow valve
fixing; directly check it.
6 Clogged overflow pipe
The overflow pipe is assumed to be clogged; directly check it.
The pressure limiter is assumed to be defective mechanically; directly
7 Defective pressure limiter
check it.
D65EX, PX-15
ERROR CODE AD00MA,
ERROR
ERRORCODE
CODE AD00MA
AD10L3
TROUBLESHOOTING
ERROR CODE AD00MA (COMMON RAIL: DEFECTIVE FUNCTION (MA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
AD00MA
Controller code
Engine
Trouble
Common rail: See the list. (MA)
(Engine controller system)
• The fuel pressure of common rail became high (level 2).
• Flashes caution lamp and turns on caution buzzer.
• Limits output and engine speed for operation.
• Engine output and speed reduces.
• The fuel state (fuel pressure) of common rail can be checked in monitoring mode.
(Code 36400: Common rail pressure)
• Method of reproducing error code: Engine start
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error code [AD00L2].
ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST. (L3))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
AD10L3
Controller code
Engine
Trouble
Fuel supply pump: See the list. (L3)
(Engine controller system)
• Non-pressure transmission (level 1) occurred in fuel supply pump.
• Flashes caution lamp and turns on caution buzzer.
• Limits output for operation.
• Engine output reduces.
• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring
mode. (Code 36400: Common rail pressure)
• Method of reproducing error code: Engine start
Cause
1
2
3
Possible causes
and standard
value in normal
state
4
5
6
7
8
9
D65EX, PX-15
Standard value in normal state/Remarks on troubleshooting
Check the displayed error code. If another code is displayed, first carry
Defective related system
out troubleshooting for the code.
Inappropriate fuel
The fuel used may be inappropriate; directly check it.
Defective low-pressure
The low-pressure circuit equipment is assumed to be defective; see
circuit equipment
Note 2 for troubleshooting.
The filter strainer is assumed to be clogged; see Note 1 for troubleClogged filter strainer
shooting.
Defective electric system of Carry out troubleshooting for error codes [AD11KA], [AD11KB],
fuel supply pump PCV
[AD51KA], and [AD51KB].
Defective fuel supply pump The fuel supply pump is assumed to be defective; directly check it.
Defective common rail
The common rail pressure sensor is assumed to be defective; directly
pressure sensor
check it.
The pressure limiter is assumed to be defective mechanically; directly
Defective pressure limiter
check it.
The fuel injector is assumed to be defective; see Note 3 for troubleDefective fuel injector
shooting.
20-421
(1)
TROUBLESHOOTING
Note 1. Check, clean, and replace the filters and
strainers according to the following procedure.
1) Gauze filter
Disassemble and check the filter. If it is
clogged, clean.
2) Upstream strainer of gauze filter
If the gauze filter is clogged, clean the
upstream strainer, too.
3) Fuel filter
If the trouble is not solved by performing
1) and 2) above, replace the fuel filter.
ERROR CODE AD10L3
Note 2. Check the low-pressure circuit parts for the
following items.
1) Remaining fuel
2) Sticking and wear of feed pump
3) Leakage and clogging of low-pressure
fuel piping
4) Defective operation of bypass valve or
installation of wrong parts to bypass
valve (See Fig. 1)
5) Oil pan oil mixed with fuel (fuel leakage
in head cover)
Fig. 1: Locations of overflow valve 1 bypass valve 2 , and fuel inlet joint (gauze filter) 3
• Overflow valve 1 : Spring is seen through one hole (on nut side).
• Bypass valve 2 : Spring is seen through both holes.
• Fuel inlet joint 3 : Gauze filter is seen through both holes.
Note 3. Method of measuring fuel spill rate
k Since the spilling fuel is hot (max. 90ºC),
take care.
1) Disconnect the hose from the collection
part of the return spill tube (at the rear of
the engine).
2) Connect a hose to the spill tube end to
receive the spilling fuel.
3) Start the engine and stall at each speed
and measure the quantity of the fuel
spilling in 1 minute.
20-422
(1)
Limit of fuel spill rate (Total of quantity spilling from 6
cylinders)
Stall speed (rpm)
1,600
1,700
1,800
1,900
2,000
Limit of spill rate (cc/min)
960
1,020
1,080
1,140
1,200
D65EX, PX-15
ERROR CODE AD10MA,
ERROR CODE AD10MA
AD10MB
TROUBLESHOOTING
ERROR CODE AD10MA (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
AD10MA
Controller code
Engine
Trouble
Fuel supply pump: Defective function (MA)
(Engine controller system)
• An abnormal pressure occurred in the common rail fuel pressure.
• Flashes caution lamp and turns on caution buzzer.
• Runs in normal control state.
• Engine output and speed reduces.
• The fuel state (fuel pressure) of common rail can be checked in monitoring mode.
(Code 36400: Common rail pressure)
• Method of reproducing error code: Engine start
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error code [AD10L3].
ERROR CODE AD10MB (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D65EX, PX-15
Error code
AD10MB
Controller code
Engine
Trouble
Fuel supply pump: Function reduction (MB)
(Engine controller system)
• Non-pressure transmission (level 2) occurred in the fuel supply pump.
• Flashes caution lamp and turns on caution buzzer.
• Limits output and engine speed for operation.
• Engine output reduces.
• The pressure transmission state (fuel pressure) of fuel supply pump can be checked in monitoring
mode. (Code 36400: Common rail pressure)
• Method of reproducing error code: Engine start
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error code [AD10L3].
20-423
(1)
TROUBLESHOOTING
ERROR CODE AD11KA
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
AD11KA
Controller code
Engine
Trouble
Fuel supply pump solenoid 1: Disconnection (KA)
(Engine controller system)
• Disconnection in wiring occurred in fuel supply pump solenoid 1 (PCV1).
• Flashes caution lamp and turns on caution buzzer.
• Limits engine and transmission operation.
• Stops output to fuel supply pump solenoid 1 circuit.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1 and R1.
• If codes [AD51KA] and [AD51KB] are displayed at the same time, engine stops.
• The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 1.
• Method of reproducing error code: Engine start
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel supply pump
PCV1 (male)
Resistance
solenoid 1 (Internal disconnection in wiring)
Between (1) – (2)
2.3 – 5.3 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN3 (female) (12) –
Resistance Max. 1 z
wiring or defective contact in PCV1 (female) (1)
connector)
Wiring harness between EN3 (female) (22) –
Resistance Max. 1 z
PCV1 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness groundwithout turning starting switch ON.
ing (Contact with ground
Wiring harness between EN3 (female) (22) –
circuit)
Resistance Min. 1 Mz
PCV1 (female) (2) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN3 (female)
Resistance
Defective engine controller
Between (12) – (22)
2.3 – 5.3 z
Between (12) (22) –
Min. 1 Mz
chassis ground
Circuit diagram related to fuel supply pump solenoid 1
20-424
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE AD11KB
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
AD11KB
Controller code
Engine
Trouble
Fuel supply pump solenoid 1: Short circuit (KB)
(Engine controller system)
• Overcurrent flowed in fuel supply pump solenoid 1 (PCV1) circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Stops output to fuel supply pump solenoid 1 circuit.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• When code [AD51KA] and [AD51KB] appear at the same time, engine stops.
• For troubleshooting of fuel supply pump solenoid 1, special adaptor (799-601-9430) is required.
• Method of reproducing error code: Start engine.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel supply pump
PCV1 (male)
Resistance
solenoid 1 (Internal short
circuit)
Between (1) – (2)
2.3 – 5.3 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring harness between EN3 (female) (12) –
(Contact with ground circuit)
Resistance Max. 1 Mz
PCV1 (female) (1) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short circuit in wiring
Wiring harness between EN3 (female) (12) –
harness
Voltage
Max. 1 V
PCV1 (female) (1) with chassis ground
(Contact with 24 V circuit)
Wiring harness between EN3 (female) (22) –
Voltage
Max. 1 V
PCV1 (female) (2) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN3 (female)
Resistance
Defective engine controller
Between (12) – (22)
2.3 – 5.3 z
Between (12) (22) –
Min. 1 Mz
chassis ground
Circuit diagram related to fuel supply pump solenoid 1
D65EX, PX-15
20-425
(1)
TROUBLESHOOTING
ERROR CODE AD51KA
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
AD51KA
Controller code
Engine
Trouble
Fuel supply pump solenoid 2: Disconnection (KA)
(Engine controller system)
• Disconnection in wiring occurred in fuel supply pump solenoid 2 (PCV2).
• Flashes caution lamp and turns on caution buzzer.
• Limits engine and transmission operation.
• Stops output to fuel supply pump solenoid 2 circuit.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1 and R1.
• If codes [AD11KA] and [AD11KB] are displayed at the same time, engine stops.
• The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 2.
• Method of reproducing error code: Engine start
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel supply pump
PCV2 (male)
Resistance
solenoid 2 (Internal disconnection in wiring)
Between (1) – (2)
2.3 – 5.3 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN3 (female) (13) –
Resistance Max. 1 z
wiring or defective contact in PCV2 (female) (1)
connector)
Wiring harness between EN3 (female) (23) –
Resistance Max. 1 z
PCV2 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness groundwithout turning starting switch ON.
ing (Contact with ground
Wiring harness between EN3 (female) (23) –
circuit)
Resistance Min. 1 Mz
PCV2 (female) (2) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN3 (female)
Resistance
Defective engine controller
Between (13) – (23)
2.3 – 5.3 z
Between (13) (23) –
Min. 1 Mz
chassis ground
Circuit diagram related to fuel supply pump solenoid 2
20-426
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE AD51KB
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
AD51KB
Controller code
Engine
Trouble
Fuel supply pump solenoid 2: Short circuit (KB)
(Engine controller system)
• Overcurrent occurred in fuel supply pump solenoid 2 (PCV2).
• Flashes caution lamp and turns on caution buzzer.
• Limits engine and transmission operation.
• Stops output to fuel supply pump solenoid 2 circuit.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1 and R1.
• If codes [AD11KA] and [AD11KB] are displayed at the same time, engine stops.
• The special adapter (799-601-9430) is necessary for troubleshooting of fuel supply pump solenoid 2.
• Method of reproducing error code: Engine start
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel supply pump
PCV2 (male)
Resistance
1 solenoid 2 (Internal disconnection in wiring)
Between (1) – (2)
2.3 – 5.3 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Defective harness groundwithout turning starting switch ON.
2 ing (Contact with ground
Wiring harness between EN3 (female) (13) –
circuit)
Resistance Max. 1 Mz
PCV2 (female) (1)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective harness hot short Wiring harness between EN3 (female) (13) –
3
Voltage
Max. 1 V
(Contact with 24 V circuit)
PCV2 (female) (1) with chassis ground
Wiring harness between EN3 (female) (23) –
Voltage
Max. 1 V
PCV2 (female) (2) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN3 (female)
Resistance
4 Defective engine controller
Between (13) – (23)
2.3 – 5.3 z
Between (13) (23) –
Min. 1 Mz
chassis ground
Circuit diagram related to fuel supply pump solenoid 2
D65EX, PX-15
20-427
(1)
TROUBLESHOOTING
ERROR CODE ADA1KA
ERROR CODE ADA1KA (NO.1 INJECTOR SOLENOID: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
ADA1KA
Controller code
Engine
Trouble
No.1 injector solenoid: Disconnection (KA)
(Engine controller system)
• Disconnection in wiring occurred in the No.1 injector solenoid (TWV#1) circuit.
• Flashes caution lamp and turns on caution buzzer.
• Stops output to the No.1 injector solenoid circuit.
• Engine output reduces.
• Method of reproducing error code: Engine start
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective No.1 injector sole- without turning starting switch ON.
1 noid (Internal disconnection
CN-1 (male)
Resistance
in wiring)
Between (1) and (2)
0.4 – 1.1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN3 (female) (14) –
Resistance Max. 1 z
2
wiring or defective contact in CN-1 (female) (1)
connector)
Wiring harness between EN3 (female) (24) –
Resistance Max. 1 z
CN-1 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective engine controller
EN3 (female)
Resistance
Between (14) and (24)
0.4 – 1.1 z
Circuit diagram related to No.1 injector solenoid
20-428
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE ADAZKB
ERROR CODE ADAZKB (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code Controller code
No.1, 2, and 3 injector solenoids: Short circuit (KB)
Trouble
(Engine controller system)
ADAZKB
Engine
• Overcurrent occurred in the No.1 injector solenoid (TWV#1), No.2 injector solenoid (TWV#2), or No.3
injector solenoid (TWV#3).
• Flashes caution lamp and turns on caution buzzer.
• Limits engine and transmission operations.
• Stops output to the No.1, 2, and 3 injector solenoid circuits.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1 and R1.
• Engine output reduces extremely.
• Method of reproducing error code: Engine start
Cause
Possible causes
and standard
value in normal
state
1
Defective No.1 injector
solenoid (Internal short)
2
Defective No.2 injector
solenoid (Internal short)
3
Defective No.3 injector
solenoid (Internal short)
Defective harness ground4 ing (Contact with ground
circuit)
D65EX, PX-15
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN-1 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1) (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN-2 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1) (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN-3 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1) (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN3 (female) (14) –
Resistance Min. 1 Mz
CN-1 (female) 1) with chassis ground
Wiring harness between EN3 (female) (24) –
Resistance Min. 1 Mz
CN-1 (female) (2) with chassis ground
Wiring harness between EN3 (female) (6) –
Resistance Min. 1 Mz
CN-2 (female) 1) with chassis ground
Wiring harness between EN3 (female) (16) –
Resistance Min. 1 Mz
CN-2 (female) (2) with chassis ground
Wiring harness between EN3 (female) (5) –
Resistance Min. 1 Mz
CN-3 (female) 1) with chassis ground
Wiring harness between EN3 (female) (15) –
Resistance Min. 1 Mz
CN-3 (female) (2) with chassis ground
20-429
(1)
TROUBLESHOOTING
ERROR CODE ADAZKB
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then turn starting switch ON for
troubleshooting.
Wiring harness between EN3 (female) (14) –
Voltage
Max. 1 V
CN-1 (female) (1) with chassis ground
Wiring harness between EN3 (female) (24) –
Voltage
Max. 1 V
CN-1 (female) (2) with chassis ground
Defective harness hot short Wiring harness between EN3 (female) (6) –
5
Voltage
Max. 1 V
(Contact with 24 V circuit)
CN-2 (female) (1) with chassis ground
Wiring harness between EN3 (female) (16) –
Voltage
Max. 1 V
CN-2 (female) (2) with chassis ground
Wiring harness between EN3 (female) (5) –
Voltage
Max. 1 V
CN-3 (female) (1) with chassis ground
Wiring harness between EN3 (female) (15) –
Voltage
Max. 1 V
CN-3 (female) (2) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Resistance 0.4 – 1.1 z
Between
EN3 (female) (14) – (24)
6 Defective engine controller
Resistance 0.4 – 1.1 z
Between EN3 (female) (6) – (16)
Resistance 0.4 – 1.1 z
Between EN3 (female) (5) – (15)
k Since high voltage (100 – 150 V) is used for the electric circuit of the fuel injector, refer to TESTING AND
ADJUSTING, Handling of high-voltage circuit of engine controller, and take care of an electric shock and an
electric leak.
Circuit diagram related to No.1, 2, and 3 injector solenoids
20-430
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE ADB1KA
ERROR CODE ADB1KA (NO.2 INJECTOR SOLENOID: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
ADB1KA
Controller code
Engine
Trouble
No.2 injector solenoid: Disconnection (KA)
(Engine controller system)
• Disconnection in wiring occurred in the No.2 injector solenoid (TWV#2) circuit.
• Flashes caution lamp and turns on caution buzzer.
• Stops output to the No.2 injector solenoid circuit.
• Engine output reduces.
• Method of reproducing error code: Engine start
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective No.2 injector sole- without turning starting switch ON.
1 noid (Internal disconnection
CN-2 (male)
Resistance
in wiring)
Between (1) and (2)
0.4 – 1.1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN3 (female) (6) –
Resistance Max. 1 z
2
wiring or defective contact in CN-2 (female) (1)
connector)
Wiring harness between EN3 (female) (16) –
Resistance Max. 1 z
CN-2 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective engine controller
EN3 (female)
Resistance
Between (6) and (16)
0.4 – 1.1 z
Circuit diagram related to No.2 injector solenoid
D65EX, PX-15
20-431
(1)
TROUBLESHOOTING
ERROR CODE ADC1KA
ERROR CODE ADC1KA (NO.3 INJECTOR SOLENOID: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
ADC1KA
Controller code
Engine
Trouble
No.3 injector solenoid: Disconnection (KA)
(Engine controller system)
• Disconnection in wiring occurred in the No.3 injector solenoid (TWV#3) circuit.
• Flashes caution lamp and turns on caution buzzer.
• Stops output to the No.3 injector solenoid circuit.
• Engine output reduces.
• Method of reproducing error code: Engine start
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective No.3 injector sole- without turning starting switch ON.
1 noid (Internal disconnection
CN-3 (male)
Resistance
in wiring)
Between (1) and (2)
0.4 – 1.1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN3 (female) (5) –
Resistance Max. 1 z
2
wiring or defective contact in CN-3 (female) (1)
connector)
Wiring harness between EN3 (female) (15) –
Resistance Max. 1 z
CN-3 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective engine controller
EN3 (female)
Resistance
Between (5) and (15)
0.4 – 1.1 z
Circuit diagram related to No.3 injector solenoid
20-432
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE ADD1KA
ERROR CODE ADD1KA (NO.4 INJECTOR SOLENOID: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
ADD1KA
Controller code
Engine
Trouble
No.4 injector solenoid: Disconnection (KA)
(Engine controller system)
• Disconnection in wiring occurred in the No.4 injector solenoid (TWV#4) circuit.
• Flashes caution lamp and turns on caution buzzer.
• Stops output to the No.4 injector solenoid circuit.
• Engine output reduces.
• Method of reproducing error code: Engine start
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective No.4 injector sole- without turning starting switch ON.
1 noid (Internal disconnection
CN-4 (male)
Resistance
in wiring)
Between (1) and (2)
0.4 – 1.1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN3 (female) (26) –
Resistance Max. 1 z
2
wiring or defective contact in CN-4 (female) (1)
connector)
Wiring harness between EN3 (female) (36) –
Resistance Max. 1 z
CN-4 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective engine controller
EN3 (female)
Resistance
Between (26) and (36)
0.4 – 1.1 z
Circuit diagram related to No.4 injector solenoid
D65EX, PX-15
20-433
(1)
TROUBLESHOOTING
ERROR CODE ADDZKB
ERROR CODE ADDZKB (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code Controller code
No.4, 5, and 6 injector solenoids: Short circuit (KB)
Trouble
(Engine controller system)
ADDZKB
Engine
• Overcurrent occurred in the No.4 injector solenoid (TWV#4), No.5 injector solenoid (TWV#5), or No.6
injector solenoid (TWV#6).
• Flashes caution lamp and turns on caution buzzer.
• Limits engine and transmission operations.
• Stops output to the No.4, 5, and 6 injector solenoid circuits.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, running is limited to F1 and R1.
• Engine output reduces extremely.
• Method of reproducing error code: Engine start
Cause
Possible causes
and standard
value in normal
state
1
Defective No.4 injector
solenoid (Internal short)
2
Defective No.5 injector
solenoid (Internal short)
3
Defective No.6 injector
solenoid (Internal short)
Defective harness ground4 ing (Contact with ground
circuit)
20-434
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN-4 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1) (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN-5 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1) (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN-6 (male)
Resistance
Between (1) – (2)
0.4 – 1.1 z
Between (1) (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN3 (female) (26) –
Resistance Min. 1 Mz
CN-4 (female) (1) with chassis ground
Wiring harness between EN3 (female) (36) –
Resistance Min. 1 Mz
CN-4 (female) (2) with chassis ground
Wiring harness between EN3 (female) (34) –
Resistance Min. 1 Mz
CN-5 (female) (1) with chassis ground
Wiring harness between EN3 (female) (33) –
Resistance Min. 1 Mz
CN-5 (female) (2) with chassis ground
Wiring harness between EN3 (female) (25) –
Resistance Min. 1 Mz
CN-6 (female) (1) with chassis ground
Wiring harness between EN3 (female) (35) –
Resistance Min. 1 Mz
CN-6 (female) (2) with chassis ground
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE ADDZKB
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then turn starting switch ON for
troubleshooting.
Wiring harness between EN3 (female) (26) –
Voltage
Max. 1 V
CN-4 (female) (1) with chassis ground
Wiring harness between EN3 (female) (36) –
Voltage
Max. 1 V
CN-4 (female) (2) with chassis ground
Defective harness hot short Wiring harness between EN3 (female) (34) –
5
Voltage
Max. 1 V
(Contact with 24 V circuit)
CN-5 (female) (1) with chassis ground
Wiring harness between EN3 (female) (33) –
Voltage
Max. 1 V
CN-5 (female) (2) with chassis ground
Wiring harness between EN3 (female) (25) –
Voltage
Max. 1 V
CN-6 (female) (1) with chassis ground
Wiring harness between EN3 (female) (35) –
Voltage
Max. 1 V
CN-6 (female) (2) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Resistance 0.4 – 1.1 z
Between
EN3 (female) (26) – (36)
6 Defective engine controller
Resistance 0.4 – 1.1 z
Between EN3 (female) (34) – (33)
Resistance 0.4 – 1.1 z
Between EN3 (female) (25) – (35)
k Since high voltage (100 – 150 V) is used for the electric circuit of the fuel injector, refer to TESTING AND
ADJUSTING, Handling of high-voltage circuit of engine controller, and take care of an electric shock and an
electric leak.
Circuit diagram related to No.4, 5, and 6 injector solenoids
D65EX, PX-15
20-435
(1)
TROUBLESHOOTING
ERROR CODE ADE1KA
ERROR CODE ADE1KA (NO.5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
ADE1KA
Controller code
Engine
Trouble
No.5 fuel injector solenoid: Disconnection (KA)
(Engine controller system)
• Disconnection occurred in No.5 fuel injector solenoid (TWV#5) circuit.
• Flashes caution lamp and turns on caution buzzer.
• Stops output to No.5 fuel injector solenoid circuit.
• Engine output lowers.
• Method of reproducing error code: Start engine.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective No.5 fuel injector
without turning starting switch ON.
1 solenoid (Internal disconCN-5 (male)
Resistance
nection)
Between (1) – (2)
0.4 – 1.1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN3 (female) (34) –
Resistance Max. 1 z
2
wiring or defective contact in CN-5 (female) (1)
connector)
Wiring harness between EN3 (female) (33) –
Resistance Max. 1 z
CN-5 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective engine controller
EN3 (female)
Resistance
Between (34) – (33)
0.4 – 1.1 z
Circuit diagram related to No.5 fuel injector solenoid
20-436
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE ADF1KA
ERROR CODE ADF1KA (NO.6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
ADF1KA
Controller code
Engine
Trouble
No.6 fuel injector solenoid: Disconnection (KA)
(Engine controller system)
• Disconnection occurred in No.6 fuel injector solenoid (TWV#6) circuit.
• Flashes caution lamp and turns on caution buzzer.
• Stops output to No.6 fuel injector solenoid circuit.
• Engine output lowers.
• Method of reproducing error code: Start engine.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective No.6 fuel injector
without turning starting switch ON.
1 solenoid (Internal disconCN-6 (male)
Resistance
nection)
Between (1) – (2)
0.4 – 1.1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN3 (female) (25) –
Resistance Max. 1 z
2
wiring or defective contact in CN-6 (female) (1)
connector)
Wiring harness between EN3 (female) (35) –
Resistance Max. 1 z
CN-6 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective engine controller
EN3 (female)
Resistance
Between (25) – (35)
0.4 – 1.1 z
Circuit diagram related to No.6 fuel injector solenoid
D65EX, PX-15
20-437
(1)
ERROR CODE B@BAZG,
ERROR CODE B@BCNS
B@BAZG
TROUBLESHOOTING
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code
B@BAZG
Controller code
Engine
Trouble
Engine oil: Oil pressure reduction (ZG)
(Mechanical system)
• During rotation of engine, engine oil pressure caution lamp flashes.
• Flashes caution lamp and turns on caution buzzer. (Function of monitor panel)
• If machine is operated as it is, engine may be damaged.
• Method of reproducing error code: Start engine.
Cause
Engine oil pressure reduc1 tion (When system is in
normal state)
Defective engine oil
2 pressure caution lamp
system
Standard value in normal state/Remarks on troubleshooting
It is suspected that problem causing engine oil pressure reduction is
occurring at present or occurred in past. Investigate cause and damage condition, and correct it.
Carry out troubleshooting of engine oil pressure caution lamp system
in accordance with “During running of engine, emergency caution item
flashes” in E mode.
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT (NS))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
20-438
(1)
Error code
B@BCNS
Controller code
Engine
Trouble
Radiator coolant: Overheat (NS)
(Mechanical system)
• During rotation of engine, radiator coolant temperature caution lamp flashes.
• Flashes caution lamp and turns on caution buzzer. (Function of monitor panel)
• If machine is operated as it is, engine may be damaged.
• Method of reproducing error code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
Engine water temperature It is suspected that problem causing engine water temperature over1 overheat (When system is in heat is occurring at present or occurred in past. Investigate cause and
normal state)
damage condition, and correct it.
Defective engine water
Carry out troubleshooting of engine water temperature caution lamp
2 temperature caution lamp
system in accordance with “During running of engine, emergency causystem
tion item flashes” in E mode.
D65EX, PX-15
ERROR CODE B@CENS,
ERROR CODE B@HANS
B@CENS
TROUBLESHOOTING
ERROR CODE B@CENS (POWER TRAIN OIL: OVERHEAT (NS))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code
B@CENS
Controller code
Steering
Trouble
Power train oil: Overheat (NS)
(Mechanical system)
• During rotation of engine, power train oil temperature caution lamp flashes.
• Flashes caution lamp and turns on caution buzzer. (Function of monitor panel)
• If machine is operated as it is, power train may be damaged.
• Method of reproducing error code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
Power train oil temperature It is suspected that problem causing power train oil temperature over1 overheat (When system is in heat is occurring at present or occurred in past. Investigate cause and
normal state)
damage condition, and correct it.
Defective power train oil
Carry out troubleshooting of power train oil temperature caution lamp
2 temperature overheat
system in accordance with “During running of engine, emergency caucaution lamp system
tion item flashes” in E mode.
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
B@HANS
Controller code
Steering
Trouble
Hydraulic oil: Overheat (NS)
(Mechanical system)
• During rotation of engine, hydraulic oil temperature caution lamp flashes.
• Flashes caution lamp and turns on caution buzzer. (Function of monitor panel)
• If machine is operated as it is, work equipment circuit units may be damaged.
• Method of reproducing error code: Start engine.
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
Hydraulic oil temperature
It is suspected that problem causing hydraulic oil temperature overheat
1 overheat (When system is in is occurring at present or occurred in past. Investigate cause and damnormal state)
age condition, and correct it.
Defective hydraulic oil
Carry out troubleshooting of hydraulic oil temperature caution lamp
2 temperature caution lamp
system in accordance with “During running of engine, emergency causystem
tion item flashes” in E mode.
D65EX, PX-15
20-439
(1)
TROUBLESHOOTING
ERROR CODE D110KA
ERROR CODE D110KA (BATTERY RELAY: SHORT CIRCUIT (KA))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
D110KA
Controller code
Steering
Trouble
Battery relay: Short circuit (KA)
(Steering and transmission controller system)
• Abnormal current flowed to battery relay circuit when outputting it.
• Stops output to battery relay circuit.
• Problem may occur in data writing to ROM (nonvolatile storage) of each controller.
• Output state (voltage) to battery relay can be checked in monitoring mode.
(Code 60600: Battery relay drive voltage)
• Method of reproducing error code: Switch starting switch from ON to OFF.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Battery relay
Continuity/resistance
Defective battery relay
1
Between terminals SW –
(Internal short circuit)
Continue
SWG terminal
Between terminal SW –
Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
2 ground in wiring harness
Wiring harness between ST3 (female) (4) –
(Contact with ground circuit) battery relay terminal SW – S13 (female) (10) Resistance Min. 1 Mz
with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
3
ST3
Starting switch
Voltage
transmission controller
Between (4) –
ON
20 – 30 V
chassis ground
Circuit diagram related to battery relay
20-440
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE D110KB
ERROR CODE D110KB (BATTERY RELAY: DISCONNECTION (KB))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
D110KB
Controller code
Steering
Trouble
Battery relay: Disconnection (KB)
(Steering and transmission controller system)
• Current does not flow when outputting it to battery relay circuit.
• Stops output to battery relay circuit.
• Problem may occur in data writing to ROM (nonvolatile storage) of each controller.
• Output state (voltage) to battery relay can be checked in monitoring mode.
(Code 60600: Battery relay drive voltage)
• Method of reproducing error code: Switch starting switch from ON to OFF.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective battery relay
Battery relay
Continuity
(Internal disconnection)
Between terminals SW –
Continue
SWG terminal
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (4) –
Resistance Max. 1 z
wiring or defective contact in battery relay SW terminal
connector)
Wiring harness between SWG terminal –
Resistance Max. 1 z
chassis GND03
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Hot short circuit in wiring
harness (Contact with 24 V Wiring harness between ST3 (female) (4) –
circuit)
battery relay terminal SW – S13 (female) (10) Voltage
Max. 1 V
with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3 (female)
Continuity
Between (4) – chassis ground
Continue
Circuit diagram related to battery relay
D65EX, PX-15
20-441
(1)
TROUBLESHOOTING
ERROR CODE D130KA
ERROR CODE D130KA (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
D130KA
Controller code
Steering
Trouble
Neutral safety relay: Short circuit (KA)
(Steering and transmission controller system)
• Abnormal current flowed in neutral safety relay circuit at the time of ground output.
• Flashes caution lamp and turns on caution buzzer.
• Stops ground output to neutral safety relay circuit.
• Engine does not start.
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
• Method of reproducing error code: Turn starting switch ON and operate parking lever (Lock position).
aThis error code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side)
Cause
Possible causes
and standard
value in normal
state
20-442
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective neutral safety
1
relay (Internal short circuit)
NSF (male)
Resistance
Between (1) – (2)
200 – 400 z
aPrepare with starting switch OFF, then turn starting switch ON and
Hot short circuit in wiring
carry out troubleshooting.
2 harness (Contact with 24 V
Wiring harness between ST2 (female) (8) – NSF
circuit)
Voltage
Max. 1 V
(female) (2) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
ST2
Parking lever
Voltage
3
transmission controller
Free
position
20
– 30 V
Between (8) –
chassis ground
Lock position
Max. 1 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE D130KA
Circuit diagram related to neutral safety relay
D65EX, PX-15
20-443
(1)
TROUBLESHOOTING
ERROR CODE D130KB
ERROR CODE D130KB (NEUTRAL SAFETY RELAY: DISCONNECTION (KB))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
D130KB
Controller code
Steering
Trouble
Neutral safety relay: Disconnection (KB)
(Steering and transmission controller system)
• 24 V is not generated when ground of neutral safety relay circuit is interrupted.
• Flashes caution lamp and turns on caution buzzer.
• Stops ground output to neutral safety relay circuit.
• Engine does not start.
• Engine can be started, regardless of position of parking brake lever.
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
• Method of reproducing error code: Turn starting switch ON and operate parking lever (Free position).
aThis error code detects abnormality in primary side (coil side) of neutral safety relay, but not in secondary side (contact side)
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-444
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective neutral safety relay (Internal disconnection)
NSF (male)
Resistance
Between (1) – (2)
200 – 400 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective disconnection in
wiring harness (Disconnec- Wiring harness between ST2 (female) (8) –
Resistance Max. 1 z
tion in wiring or defective
NSF (female) (2)
contact in connector)
Wiring harness between NSF (female) (1) –
Resistance Max. 1 z
starting switch ACC (270)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between ST2 (female) (8) –
Resistance Min. 1 Mz
ground in wiring harness
NSF (female) (2) with chassis ground
(Contact with ground circuit)
Wiring harness between NSF (female) (1) –
Resistance Min. 1 Mz
starting switch ACC (270) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
ST2
Parking lever
Voltage
transmission controller
Free
position
20
– 30 V
Between (8) –
chassis ground
Lock position
Max. 1 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE D130KB
Circuit diagram related to neutral safety relay
D65EX, PX-15
20-445
(1)
TROUBLESHOOTING
ERROR CODE D161KA
ERROR CODE D161KA (BACK-UP ALARM RELAY: SHORT CIRCUIT (KA))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
D161KA
Controller code
Steering
Trouble
Back-up alarm relay: Short circuit (KA)
(Steering and transmission controller system)
• Abnormal current flowed in back-up alarm relay circuit at the time of ground output.
• Stops output to back-up alarm relay circuit.
• Back-up alarm is not turned on.
• Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever NEUTRAL.
aThis error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in secondary side (contact side)
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective back-up alarm
1
relay (Internal short circuit)
BKA (male)
Resistance
Between (1) – (2)
200 – 400 z
aPrepare with starting switch OFF, then turn starting switch ON and
Hot short circuit in wiring
carry out troubleshooting.
2 harness (Contact with 24 V
Wiring harness between ST2 (female) (18) –
circuit)
Voltage
Max. 1 V
BKA (female) (2) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
ST2
Parking lever
Voltage
3
transmission controller
Neutral
position
20
– 30 V
Between (18) –
chassis ground
Reverse position
Max. 1 V
a PCCS: Abbreviation for Palm Command Control System.
20-446
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE D161KA
Circuit diagram related to back-up alarm relay
D65EX, PX-15
20-447
(1)
TROUBLESHOOTING
ERROR CODE D161KB
ERROR CODE D161KB (BACK-UP ALARM RELAY: DISCONNECTION (KB))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
D161KB
Controller code
Steering
Trouble
Back-up alarm relay: Disconnection (KB)
(Steering and transmission controller system)
• 24 V is not generated when ground output of neutral safety relay circuit is interrupted.
• Stops output to back-up alarm relay circuit.
• Back-up alarm is not turned on.
• Back-up alarm is turned on, regardless of positions of steering and forward-reverse lever and gearshift
lever.
• Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever NEUTRAL.
aThis error code detects abnormality in primary side (coil side) of back-up alarm relay, but not in secondary side (contact side)
Cause
1 Defective fuse FS2-9
2
3
Possible causes
and standard
value in normal
state
4
5
Standard value in normal state/Remarks on troubleshooting
If fuse is burnout, circuit probably has short circuit with chassis ground.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective back-up alarm relay (Internal disconnection)
BKA (male)
Resistance
Between (1) – (2)
200 – 400 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective disconnection in
wiring harness (Disconnec- Wiring harness between ST2 (female) (18) –
Resistance Max. 1 z
tion in wiring or defective
BKA (female) (2)
contact in connector)
Wiring harness between BKA (female) (1) –
Resistance Max. 1 z
FS2-9 outlet port
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between ST2 (female) (18) –
Resistance Min. 1 Mz
ground in wiring harness
BKA (female) (2) with chassis ground
(Contact with ground circuit)
Wiring harness between BKA (female) (1) –
Resistance Min. 1 Mz
FS2-9 outlet port with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
ST2
PCCS lever
Voltage
transmission controller
Neutral position
20 – 30 V
Between (18) –
chassis ground
Reverse position
Max. 1 V
a PCCS: Abbreviation for Palm Command Control System.
20-448
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE D161KB
Circuit diagram related to back-up alarm relay
D65EX, PX-15
20-449
(1)
TROUBLESHOOTING
ERROR CODE D182KZ
ERROR CODE D182KZ (PREHEATER RELAY COIL: DISCONNECTION OR SHORT
CIRCUIT (KZ))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
D182KZ
Controller code
Engine
Trouble
Preheater relay coil: Disconnection or short circuit (KZ)
(Engine controller system)
• The drive circuit of the preheater relay has a trouble of disconnection or short circuit.
• Stops ground output to preheater relay.
• Preheater relay cannot be driven.
• Preheater relay is driven, regardless of atmospheric temperature.
aThis error code detects abnormality in primary side (coil side) of preheater relay, but not in secondary
side (contact side).
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-450
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective preheater relay
(RHR) (Internal disconnec200 –
Resistance
Between RHR (female) (1) – (2)
tion or grounding fault)
400 z
Resistance Min. 1 Mz
Between RHR (female) (1) – ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between RHR (female) (2) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in EN1 (female) (12)
wiring or defective contact in Wiring harness between RHR (female) (1) –
Resistance Max. 1 z
connector)
270
Wiring harness between RHR (female) (1) –
Resistance Max. 1 z
EN1 (female) (13), (19)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between RHR (female) (2) –
Resistance Min. 1 Mz
ground in wiring harness
EN1 (female) (12) with chassis ground
(Contact with ground circuit)
Wiring harness between RHR (female) (1) –
Resistance Min. 1 Mz
EN1 (female) (13), (19) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Voltage
Defective controller
Max. 1 V
Between EN1 (female) When relay is driven
(12) – ground
When relay is
20 – 30 V
not driven
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE D182KZ
Circuit diagram related to preheater relay coil
D65EX, PX-15
20-451
(1)
TROUBLESHOOTING
ERROR CODE D1D0KB
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY: SHORT
CIRCUIT (KB))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
D1D0KB
Controller code
Engine
Trouble
Engine controller load power supply relay: Short circuit (KB)
(Engine controller system)
• Voltage is generated in controller load power supply circuit when starting switch is turned OFF.
• Flashes caution lamp and turns on caution buzzer.
• None in particular.
• Method of reproducing error code: Turn starting switch OFF.
aThis error code detects abnormality in secondary side (contact side) of engine controller load power
supply relay, but not in primary side (coil side)
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-452
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective engine controller
without turning starting switch ON.
load power supply relay
PPR (male)
Resistance
(Internal short circuit)
Between (3) – (5)
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between EN1 (female) (13)
Resistance Max. 1 z
connector)
(19) – 270
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short circuit in wiring
Wiring harness between EN3 (female) (1), (2),
harness (Contact with 24 V
Voltage
Max. 1 V
(21) – PPR (female) (3) with chassis ground
circuit)
Wiring harness between PPR (female) (1) –
Voltage
Max. 1 V
270 with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting with
starting switch OFF or ON.
EN3
Starting switch
Voltage
Defective engine controller
OFF
position
Max.
1V
Between (1), (2), (21)
– chassis ground
ON position
Max. 8 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE D1D0KB
Circuit diagram related to engine controller
D65EX, PX-15
20-453
(1)
TROUBLESHOOTING
ERROR CODE D5ZFKA
ERROR CODE D5ZFKA (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION (KA))
Action code
E01
Contents of
trouble
Action of
controller
Error code
D5ZFKA
Controller code
Steering
Trouble
Transmission neutral signal: Disconnection (KA)
(Steering and transmission controller system)
• Voltage is not generated when ground of transmission neutral safety relay circuit is interrupted.
• This signal line is for backing up (The main signal is transmitted through the CAN communication network).
• Stops outputting the transmission neutral signal.
Problem that
appears on
machine
• None in particular.
Related
information
• The state of the transmission neutral signal (ON/OFF) can be checked in monitoring mode
(Code: 40909 Transmission-related controller output signal) (Code: 40901 Engine controller input signal 2).
• Method of reproducing error code: Turn starting switch ON and shift transmission in N position.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between ST2 (female) (19) –
Resistance Max. 1 z
connector)
EN3 (female) (7), (17)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring harness between ST2 (female) (19) –
(Contact with ground circuit)
Resistance Min. 1 Mz
EN3 (female) (7), (17) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
Lever in N
Voltage
Max. 1 V
Between ST2
(19) – ground
Lever in F or R
Voltage
5 – 11 V
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective engine controller
Between EN3 (7), (17) – ground
Voltage
5 – 11 V
Circuit diagram related to transmission neutral signal
20-454
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE D5ZFKB
ERROR CODE D5ZFKB (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT (KB))
Action code
E01
Contents of
trouble
Action of
controller
Error code
D5ZFKB
Controller code
Steering
Trouble
Transmission neutral signal: Short circuit (KB)
(Steering and transmission controller system)
• Abnormal current flowed when ground signal of transmission neutral safety relay circuit is output.
• This signal line is for backing up (The main signal is transmitted through the CAN communication network).
• Stops outputting the transmission neutral signal.
Problem that
appears on
machine
• None in particular.
Related
information
• The state of the transmission neutral signal (ON/OFF) can be checked in monitoring mode
(Code: 40909 Transmission-related controller output signal) (Code: 40901 Engine controller input signal 2).
• Method of reproducing error code: Turn starting switch ON and shift transmission in N position.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then turn starting switch ON and
Hot short circuit in wiring
carry out troubleshooting.
harness (Disconnection in
1
wiring or defective contact in Wiring harness between ST2 (female) (19) –
Voltage
Max. 1 V
connector)
EN3 (female) (7), (17) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
2
transmission controller
Lever in N
Voltage
Max. 1 V
Between ST2
(19) – ground
Lever in F or R
Voltage
5 – 11 V
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
3 Defective engine controller
Between EN3 (7), (17) – ground
Voltage
5 – 11 V
Circuit diagram related to transmission neutral signal
D65EX, PX-15
20-455
(1)
TROUBLESHOOTING
ERROR CODE DAFRKR
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE
COMMUNICATION (KR))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DAFRKR
Controller code
MON
Trouble
Monitor panel CAN communication: Defective communication
(KR) (Monitor panel system)
• Monitor panel cannot recognize steering and transmission controller with CAN communication circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• System may not operate normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Method of reproducing error code: Turn starting switch ON.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
20-456
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
Disconnection in wiring
– ST2 (female) (32) – EN2 (female) (32) – CA2
Resistance Max. 1 z
harness (Disconnection in (female) (A) – CA2 (female) (A) – G01 (female)
wiring or defective contact in (8)
connector)
Wiring harness between S04 (female) (3) (4) –
ST2 (female) (22) – EN2 (female) (22) – CA2
Resistance Max. 1 z
(female) (B) – CA2 (female) (B) – G01 (female)
(7)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
– ST2 (female) (32) – EN2 (female) (32) – CA2
Resistance Min. 1 Mz
Short circuit with chassis
(female) (A) – CA2 (female) (A) – G01 (female)
ground in wiring harness
(8) with chassis ground
(Contact with ground circuit)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Resistance Min. 1 Mz
(female) (B) – CA2 (female) (B) – G01 (female)
(7) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between S04 (female) (1), (2)
– ST2 (female) (32) – EN2 (female) (32) – CA2
Hot short circuit in wiring
Voltage
Max. 1 V
(female) (A) – CA2 (female) (A) – G01 (female)
harness (Contact with 24 V
(8) with chassis ground
circuit)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Voltage
Max. 1 V
(female) (B) – CA2 (female) (B) – G01 (female)
(7) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective CAN terminal
resistance
CA2 (male), CA2 (male)
Resistance
Between (A) – (B)
100 – 140 z
Defective monitor panel or If no problem is found in causes 1 to 4, it is suspected that monitor pandefective steering and
el or steering and transmission controller is defective. (Troubleshooting
transmission controller
cannot be carried out since it is internal defect.)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DAFRKR
Circuit diagram related to CAN communication
D65EX, PX-15
20-457
(1)
TROUBLESHOOTING
ERROR CODE DAQ0KK DB30KK
ERROR CODE DAQ0KK DB30KK (STEERING AND TRANSMISSION CONTROLLER:
SOURCE VOLTAGE REDUCTION/INPUT (KK))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DAQ0KK
DB30KK
Controller code
Steering
Trouble
Steering and transmission controller: Source voltage reduction/input (KK) (Steering and transmission controller system)
• Source voltage of steering and transmission controller is below 17 V.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Monitor panel may not display normally.
• Relays and solenoids cannot operate, not allowing system operate normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel any more.
• Both of DAQ0KK and DB30KK are displayed.
• Charge level (voltage) of battery can be checked in monitoring mode.
(Code 03200: Battery voltage)
• Method of reproducing error code: Turn starting switch ON.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-458
(1)
Standard value in normal state/Remarks on troubleshooting
If any of fuses FS1-9 is broken, circuit probably has short circuit with
Defective fuse FS1-9
chassis ground.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ST3 (female) (1), (2),
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in (11), (12), (22) – FS1-9
wiring or defective contact in Wiring harness between FS1-1 – battery relay
Resistance Max. 1 z
connector)
terminal C
Wiring harness between ST3 (female) (21)
Resistance Max. 1 z
(31) (32) (33) – chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between ST3 (female) (1), (2),
Resistance Min. 1 Mz
ground in wiring harness
(11), (12), (22) – FS1-9 with chassis ground
(Contact with ground circuit)
Wiring harness between inlet FS1 – fusible link
Resistance Min. 1 Mz
– battery relay terminal C with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
ST3
Voltage
transmission controller
Between (1), (2), (11), (12), (22) –
20 – 30 V
(21), (31), (32), (33)
D65EX, PX-15
ERROR CODE DAQ0KK DB30KK,
ERROR CODE DAQ0KT
TROUBLESHOOTING
Circuit diagram related to Steering and transmission controller power supply
ERROR CODE DAQ0KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY
IN CONTROLLER (KT))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D65EX, PX-15
Error code
DAQ0KT
Controller code
Steering
Trouble
Steering and transmission controller: Abnormality in controller
(KT) (Steering and transmission controller system)
• Information of ROM (nonvolatile storage) of steering and transmission controller is not normal.
• Flashes caution lamp and turns on caution buzzer.
• Sets default internal adjustment value.
• Gear shift feeling of transmission may become worse.
• Method of reproducing error code: Turn starting switch ON.
Cause
1
Defective steering and
transmission controller
Standard value in normal state/Remarks on troubleshooting
Troubleshooting cannot be carried out since it is internal defect.
• Adjust once in the adjustment mode (Code: 0002).
(It is no problem even if you use controller unless no visible problem appears on machine.)
20-459
(1)
TROUBLESHOOTING
ERROR CODE DAQ5KK DB35KK
ERROR CODE DAQ5KK DB35KK (STEERING AND TRANSMISSION CONTROLLER
SENSOR 5 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Steering and transmission controller sensor 5 V power supply:
Error code Controller code
Trouble Source voltage reduction/input (KK)
DAQ5KK
Steering
DB35KK
(Steering and transmission controller system)
• Voltage of 5 V power supply circuit of steering and transmission controller sensor is below 4.5 V or
above 5.5 V.
• Abnormal current flowed in 5 V power supply circuit of steering and transmission controller sensor.
• Flashes caution lamp and turns on caution buzzer.
• Stops output to 5 V power supply circuit if abnormal voltage flows
• Limits operation of engine and transmission.
• System may not operate normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 an R1.
• Both of DAQ5KK and DB35KK are displayed.
• Method of reproducing error code: Turn starting switch ON.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
6
20-460
(1)
Standard value in normal state/Remarks on troubleshooting
When the connector shown at right is disconnected, if the
service code is lighted up (to indicate returning to normal),
Defective brake potentiomeBRK
the cause is an internal trouble.
ter (Internal short circuit)
connector
aPrepare with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective forward-reverse
TL2 (male)
Resistance
potentiometer (Internal
Between
(4)
–
(1)
3.2
kz ± 20%
short circuit)
Sensor
Between (4) –
Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering potentiTL1 (male)
Resistance
ometer (Internal short
Between (5) – (8)
3.2 kz ± 20%
circuit)
Sensor
Between (5) –
Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
ground in wiring harness
Wiring harness between ST1 (female) (22) – TL2
(Contact with ground circuit) (female) (5), – TL2 (female) (4), – BRK (female) Resistance Min. 1 Mz
(C) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short circuit in wiring
harness (Contact with 24 V Wiring harness between ST1 (female) (22) – TL2
circuit)
Voltage
Max. 1 V
(female) (5), – TL2 (female) (4), – BRK (female)
(C) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
ST1
Voltage
Between (22) – (21)
4.5 – 5.5 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DAQ5KK DB35KK
Circuit diagram related to steering and transmission controller 5 V power supply
D65EX, PX-15
20-461
(1)
TROUBLESHOOTING
ERROR CODE DAQ6KK DB36KK
ERROR CODE DAQ6KK DB36KK (STEERING AND TRANSMISSION CONTROLLER
SENSOR 24 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/
INPUT (KK))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Steering and transmission controller sensor 24 V power supError code Controller code
Trouble
ply: Source voltage reduction/input (KK)
DAQ6KK
Steering
DB36KK
(Steering and transmission controller system)
• Voltage of 24 V power supply circuit of steering and transmission controller sensor is below 17 V or
above 30 V.
• Abnormal current flowed in 24 V power supply circuit of steering and transmission controller sensor.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Stops output to 24 V power supply circuit if abnormal voltage flows.
• System may not operate normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Both of DAQ6KK and DB36KK are displayed.
• Method of reproducing error code: Turn starting switch ON.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
It is internal defect if service code lights on (reset display)
Defective angle of inclination
when disconnecting right connector.
PT2
1 sensor (Internal short
aDisconnect connector with starting switch OFF, then turn connector
circuit)
starting switch ON and carry out troubleshooting.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
2 ground in wiring harness
Wiring harness between ST1 (female) (16) –
(Contact with ground circuit) HHP (female) (B) – PT2 (female) (C) with
Resistance Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
3
transmission controller
ST1
Voltage
(16) – (21)
20 – 30 V
Circuit diagram related to steering and transmission controller 24 V power supply
20-462
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DAQ9KQ DB39KQ
ERROR CODE DAQ9KQ DB39KQ (STEERING AND TRANSMISSION CONTROLLER TYPE
COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Steering and transmission controller type collation: Type select
Error code Controller code
Trouble signal inconsistency (KQ)
DAQ9KQ
Steering
DB39KQ
(Steering and transmission controller system)
• Internal spec. setting of steering and transmission controller is inconsistent with spec. set signal.
(Steering and transmission controller cannot be recognized normally.)
• Flashes caution lamp and turns on caution buzzer.
• Stops all outputs to steering and transmission controller.
• Limits operation of engine, transmission, and brake.
• Machine does not operate at all.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel any more.
• Both of DAQ9KQ and DB39KQ are displayed.
• Method of reproducing error code: Turn starting switch ON.
Cause
Defective steering and
1 transmission controller
adjustment
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
It is normal if error code lights on (reset display) after carrying out adjustment mode.
• Adjustment code: 0002: Steering and transmission controller spec.
aPrepare with starting switch OFF, carry out troubleshooting without
Disconnection in wiring
turning starting switch ON.
harness (Disconnection in
2
wiring or defective contact in Wiring harness between ST3 (female) (30)
Resistance Max. 1 z
connector)
with GND01
aPrepare with starting switch OFF, carry out troubleshooting without
Short circuit with chassis
turning starting switch ON.
3 ground in wiring harness
Wiring harness between ST3 (female) (40) –
(Contact with ground circuit)
Resistance Max. 1 Mz
PL2 (18) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
ST3
Voltage
4
transmission controller
Between (30) – chassis ground
Max. 1 V
Between (40) – chassis ground
5 – 11 V
Circuit diagram related to steering and transmission controller type select
D65EX, PX-15
20-463
(1)
TROUBLESHOOTING
ERROR CODE DB3RKR
ERROR CODE DB3RKR (STEERING AND TRANSMISSION CONTROLLER CAN
COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Steering and transmission controller CAN communication:
Defective communication (KR)
DB3RKR
Steering
(Steering and transmission controller system)
• Steering and transmission controller cannot recognize monitor panel, or engine controller with CAN
communication circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• System may not operate normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Error code
Controller code
Trouble
• Method of reproducing error code: Turn starting switch ON.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
20-464
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
Disconnection in wiring
– ST2 (female) (32) – EN2 (female) (32) – CA2
Resistance Max. 1 z
harness (Disconnection in (female) (A) – CA2 (female) (A) – G01 (female)
wiring or defective contact in (8)
connector)
Wiring harness between S04 (female) (3) (4) –
ST2 (female) (22) – EN2 (female) (22) – CA2
Resistance Max. 1 z
(female) (B) – CA2 (female) (B) – G01 (female)
(7)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
– ST2 (female) (32) – EN2 (female) (32) – CA2
Resistance Min. 1 Mz
Short circuit with chassis
(female) (A) – CA2 (female) (A) – G01 (female)
ground in wiring harness
(8) with chassis ground
(Contact with ground circuit)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Resistance Min. 1 Mz
(female) (B) – CA2 (female) (B) – G01 (female)
(7) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between S04 (female) (1), (2)
– ST2 (female) (32) – EN2 (female) (32) – CA2
Hot short circuit in wiring
Voltage
Max. 1 V
(female) (A) – CA2 (female) (A) – G01 (female)
harness (Contact with 24 V
(8) with chassis ground
circuit)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Voltage
Max. 1 V
(female) (B) – CA2 (female) (B) – G01 (female)
(7) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective CAN terminal
resistance
CA2 (male), CA2 (male)
Resistance
Between (A) – (B)
100 – 140 z
Defective monitor panel,
If no problem is found in causes 1 to 4, it is suspected that monitor pandefective engine controller,
el, engine controller, or steering and transmission controller. (Troubledefective steering and
shooting cannot be carried out since it is internal defect.)
transmission controller
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB3RKR
Circuit diagram related to CAN communication
D65EX, PX-15
20-465
(1)
TROUBLESHOOTING
ERROR CODE DB20KQ
ERROR CODE DB20KQ (ENGINE CONTROLLER TYPE COLLATION: TYPE SELECT
SIGNAL INCONSISTENCY (KQ))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code Controller code
Engine controller type collation: Type select signal inconsistenTrouble
cy (KQ) (Engine controller system)
DB20KQ
Engine
• Type select signal directly acquired by engine controller is inconsistent with type select signal acquired
via communication.
• Flashes caution lamp and turns on caution buzzer.
• Controls it as default-set type.
• Limits operation of engine and transmission.
• Machine does not provide normal output.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Input state (ON/OFF) of engine controller type select signal can be checked in monitoring mode.
(Code 40900: Engine controller input signal 1, Code 40901: Engine controller input signal 2)
• Method of reproducing error code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
Installation of wrong engine
1
Check part No. (Controller and wiring harness)
controller
Installation of wrong
2 steering and transmission
Check part No. (Controller and wiring harness)
controller
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
3
wiring or defective contact in Wiring harness between EN1 (female) (3) –
Resistance Max. 1 z
connector)
chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
EN1
Voltage
4 Defective engine controller
Between (3) – chassis ground
Max. 1 V
Between (17), (23) –
5 – 11 V
chassis ground
Circuit diagram related to engine controller type select
20-466
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB20KT
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DB20KT
Controller code
Engine
Engine controller: Abnormality in controller (KT)
(Engine controller system)
• Problem occurred in engine controller.
• Flashes caution lamp and turns on caution buzzer.
• Cannot operate fuel injector solenoid well or stops output.
• Limits operation of engine and transmission.
• Engine may stop during operation or engine may not start.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Method of reproducing error code: Turn starting switch ON.
Cause
Possible causes
and standard
value in normal
state
Trouble
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
1
wiring or defective contact in Wiring harness between EN3 (female) (11),
Resistance Max. 1 z
connector)
(31), (32) with chassis ground
2 Defective engine controller Troubleshooting cannot be carried out since it is internal defect.
Circuit diagram related to engine controller power supply
D65EX, PX-15
20-467
(1)
TROUBLESHOOTING
ERROR CODE DB22KK
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE
VOLTAGE REDUCTION/INPUT (KK))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DB22KK
Controller code
Engine
Trouble
Engine controller load power supply: Source voltage reduction/input (KK) (Engine controller system)
• Load source voltage of engine controller is below 17 V.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Engine may stop during operation or engine may not start.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel any more.
• Charge level (voltage) of battery can be checked in monitoring mode.
(Code 03200: Battery voltage)
• Method of reproducing error code: Turn starting switch ON.
aThis error code detects abnormality in engine controller load power supply.
Cause
1 Defective fuse (FS2-7)
2
3
Possible causes
and standard
value in normal
state
4
5
6
20-468
(1)
Standard value in normal state/Remarks on troubleshooting
If fuse is burnout, circuit probably has short circuit with chassis ground.
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Defective engine controller
load power supply relay
If error code lights on (reset display) by replacing right con(Internal disconnection)
nector with other relay, engine controller load power supply
PPR
relay is defective.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN3 (female) (1), (2),
Resistance Max. 1 z
(21) – PPR (female) (3)
Wiring harness between PPR (female) (5) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in FS2-7 outlet port
wiring or defective contact in Wiring harness between FS2-7 inlet port –
Resistance Max. 1 z
connector)
battery relay terminal C
Wiring harness between PPR (female) (1) –
Resistance Max. 1 z
starting switch 270
Wiring harness between PPR (female) (2) –
Resistance Max. 1 z
GND03
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN3 (female) (1), (2),
Resistance Min. 1 Mz
(21) – PPR (female) (3) with chassis ground
Short circuit with chassis
Wiring harness between PPR (female) (5) –
Resistance Min. 1 Mz
ground in wiring harness
FS2-7 outlet port with chassis ground
(Contact with ground circuit)
Wiring harness between FS2-7 inlet port –
Resistance Min. 1 Mz
battery relay terminal C
Wiring harness between PPR (female) (1) –
Resistance Min. 1 Mz
starting switch 270 with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
Hot short circuit in wiring
without turning starting switch ON.
harness (Contact with 24 V
Wiring harness between EN1 (female) (13)
circuit)
Voltage
Max. 1 V
(19) – starting switch 270 with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Defective engine controller
EN3
Voltage
Between (1), (2), (21) –
20 – 30 V
(11), (31), (32)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB22KK
Circuit diagram related to engine controller power supply
D65EX, PX-15
20-469
(1)
TROUBLESHOOTING
ERROR CODE DB29KQ
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL
INCONSISTENCY (KQ))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code Controller code
Engine controller type select: Type select signal inconsistency
Trouble
(KQ) (Engine controller system)
DB29KQ
Engine
• Type select signal directly acquired by engine controller is inconsistent with type select signal saved in
controller.
• Flashes caution lamp and turns on caution buzzer.
• Controls it as default-set type.
• Limits operation of engine and transmission.
• Machine does not provide normal output.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Input state (ON/OFF) of engine controller type select signal can be checked in monitoring mode.
(Code 40900: Engine controller input signal 1, Code 40901: Engine controller input signal 2)
• Method of reproducing error code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
Installation of wrong engine
1
Check part No. (Controller and wiring harness)
controller
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
2
wiring or defective contact in Wiring harness between EN1 (female) (3) –
Resistance Max. 1 z
connector)
chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
EN1
Voltage
3 Defective engine controller
Between (3) – chassis ground
Max. 1 V
Between (7), (8) – chassis ground
5 – 11 V
Circuit diagram related to engine controller type select
20-470
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB2AMA
ERROR CODE DB2AMA (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL:
MALFUNCTION (MA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
D65EX, PX-15
Error code
DB2AMA
Controller code
Engine
Trouble
Fuel injection amount adjustment switch signal: Malfunction
(MA) (Engine controller system)
• Fuel injection amount adjustment switch is not set at correct position.
• Flashes caution lamp and turns on caution buzzer.
• Fuel injection amount adjustment setting cannot be changed.
• Method of reproducing error code: Turn starting switch ON.
Cause
Defective fuel injection
1 amount adjustment switch
setting
2 Defective engine controller
Standard value in normal state/Remarks on troubleshooting
If both fuel injection amount adjustment switches 1 and 2 are set at [F],
fuel injection amount adjustment switch setting is defective.
If no problem is found in above cause, it is suspected that engine controller is defective.
20-471
(1)
TROUBLESHOOTING
ERROR CODE DB2RKR
ERROR CODE DB2RKR (STEERING AND TRANSMISSION CONTROLLER CAN
COMMUNICATION: DEFECTIVE COMMUNICATION (KR))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Steering and transmission controller CAN communication:
Defective communication (KR)
DB2RKR
Steering
(Steering and transmission controller system)
• Steering and transmission controller cannot recognize engine controller with CAN communication circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• System may not operate normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Error code
Controller code
Trouble
• Method of reproducing error code: Turn starting switch ON.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
20-472
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
Disconnection in wiring
– ST2 (female) (32) – EN2 (female) (32) – CA2
Resistance Max. 1 z
harness (Disconnection in (female) (A) – CA2 (female) (A) – G01 (female)
wiring or defective contact in (8)
connector)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Resistance Max. 1 z
(female) (B) – CA2 (female) (B) – G01 (female)
(7)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
– ST2 (female) (32) – EN2 (female) (32) – CA2
Resistance Min. 1 Mz
Short circuit with chassis
(female) (A) – CA2 (female) (A) – G01 (female)
ground in wiring harness
(8) with chassis ground
(Contact with ground circuit)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Resistance Min. 1 Mz
(female) (B) – CA2 (female) (B) – G01 (female)
(7) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Wiring harness between S04 (female) (1), (2)
– ST2 (female) (32) – EN2 (female) (32) – CA2
Hot short circuit in wiring
Voltage
Max. 1 V
(female) (A) – CA2 (female) (A) – G01 (female)
harness (Contact with 24 V
(8) with chassis ground
circuit)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Voltage
Max. 1 V
(female) (B) – CA2 (female) (B) – G01 (female)
(7) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective CAN terminal
resistance
CA2 (male), CA2 (male)
Resistance
Between (A) – (B)
100 – 140 z
Defective steering and
If no problem is found in causes 1 to 4, it is suspected that steering and
transmission controller,
transmission controller, engine controller is defective.
defective engine controller (Troubleshooting cannot be carried out since it is internal defect.)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB2RKR
Circuit diagram related to CAN communication
D65EX, PX-15
20-473
(1)
TROUBLESHOOTING
ERROR CODE DB2RMC
ERROR CODE DB2RMC (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE
COMMUNICATION (MC))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code Controller code
Engine controller CAN communication: Defective communicaTrouble
tion (MC) (Engine controller system)
DB2RMC
Engine
• Engine controller cannot recognize steering and transmission controller with CAN communication circuit.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• System may not operate normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Method of reproducing error code: Turn starting switch ON.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
20-474
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
Disconnection in wiring
– ST2 (female) (32) – EN2 (female) (32) – CA2
Resistance Max. 1 z
harness (Disconnection in (female) (A) – CA2 (female) (A) – G01 (female)
wiring or defective contact in (8)
connector)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Resistance Max. 1 z
(female) (B) – CA2 (female) (B) – G01 (female)
(7)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S04 (female) (1), (2)
– ST2 (female) (32) – EN2 (female) (32) – CA2
Resistance Min. 1 Mz
Short circuit with chassis
(female) (A) – CA2 (female) (A) – G01 (female)
ground in wiring harness
(8) with chassis ground
(Contact with ground circuit)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Resistance Min. 1 Mz
(female) (B) – CA2 (female) (B) – G01 (female)
(7) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Wiring harness between S04 (female) (1), (2)
– ST2 (female) (32) – EN2 (female) (32) – CA2
Hot short circuit in wiring
Voltage
Max. 1 V
(female) (A) – CA2 (female) (A) – G01 (female)
harness (Contact with 24 V
(8) with chassis ground
circuit)
Wiring harness between S04 (female) (3), (4)
– ST2 (female) (22) – EN2 (female) (22) – CA2
Voltage
Max. 1 V
(female) (B) – CA2 (female) (B) – G01 (female)
(7) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective CAN terminal
resistance
CA2 (male), CA2 (male)
Resistance
Between (A) – (B)
100 – 140 z
Defective engine controller, If no problem is found in causes 1 to 4, it is suspected that engine condefective steering and
troller, steering and transmission controller is defective.
transmission controller
(Troubleshooting cannot be carried out since it is internal defect.)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB2RMC
Circuit diagram related to CAN communication
D65EX, PX-15
20-475
(1)
TROUBLESHOOTING
ERROR CODE DB30KK DAQ0KK, ERROR CODE DB35KK DAQ5KK,
ERROR CODE DB36KK DAQ6KK, ERROR
ERROR CODE
CODE DB39KQ
DB30KK DAQ9KQ
DAQ0KK
ERROR CODE DB30KK DAQ0KK (STEERING AND TRANSMISSION CONTROLLER:
SOURCE VOLTAGE REDUCTION/INPUT (KK))
a See DAQ0KK.
CALL E04
ERROR CODE DB35KK DAQ5KK (STEERING AND TRANSMISSION CONTROLLER
SENSOR 5 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))
a See DAQ5KK.
CALL E03
ERROR CODE DB36KK DAQ6KK (STEERING AND TRANSMISSION CONTROLLER
SENSOR 24 V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/
INPUT (KK))
a See DAQ6KK.
CALL E03
ERROR CODE DB39KQ DAQ9KQ (STEERING AND TRANSMISSION CONTROLLER TYPE
COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))
a See DAQ9KQ.
CALL E04
20-476
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD11KB
ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT (KB))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DD11KB
Controller code
Engine
Trouble
Starting switch: Short circuit (KB)
(Engine controller system)
• Signal C of starting switch is input during running of engine.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Engine cannot be accelerated.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel any more.
• Method of reproducing error code: Start engine.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting with
starting switch OFF or ON.
Defective starting switch
1
Starting switch
Starting switch
Resistance
(Internal short circuit)
Between 250 (B) –
When OFF/ON
Min. 1 Mz
280 (C)
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Hot short circuit in wiring
Wiring harness between EN1 (female) (20) –
Voltage
Max. 1 V
2 harness (Contact with 24 V
NSF (female) (5) with chassis ground
circuit)
Wiring harness between NSF (female) (3) –
Voltage
Max. 1 V
starting switch 280 with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
3 Defective engine controller
EN1
Voltage
Between (20) – chassis ground
Max. 1 V
Circuit diagram related to starting switch signal C
D65EX, PX-15
20-477
(1)
TROUBLESHOOTING
ERROR CODE DD12KA
ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DD12KA
Controller code
Steering
Trouble
Shift up switch: Disconnection (KA)
(Steering and transmission controller system)
• Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
• Flashes caution lamp and turns on caution buzzer.
• Recognizes that switch is not pressed.
• Shift up is not possible.
• Auto shift down does not function.
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
• Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
(Code 40905: Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift up switch.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-478
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Shift up switch
SFTU (male)
Defective shift up switch
OFF (Release)
ON (Press)
(Internal disconnection)
Resistance between
Max. 1 z
Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz
Max. 1 z
(2) – (1)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring
harness between ST1 (female) (12) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in SFTU (female) (3)
wiring or defective contact in Wiring harness between ST3 (female) (9) –
Resistance Max. 1 z
connector)
SFTU (female) (1)
Wiring harness between ST1 (female) (4) –
Resistance Max. 1 z
SFTU (female) (2)
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Hot short circuit in wiring
Wiring harness between ST1 (female) (12) –
harness (Contact with 24 V
Voltage
Max. 1 V
TL1 (female) (3) with chassis ground
circuit)
Wiring harness between ST1 (female) (9) –
Voltage
Max. 1 V
TL1 (female) (1) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Shift up switch
ST1, ST3
Defective steering and
OFF (Release)
ON (Press)
transmission controller
Voltage between
Max. 1 V
5 – 11 V
ST1 (12) – ST1 (4)
Voltage between
5 – 11 V
Max. 1 V
ST3 (9) – ST1 (4)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD12KA
Circuit diagram related to shift up switch and shift down switch
D65EX, PX-15
20-479
(1)
TROUBLESHOOTING
ERROR CODE DD12KB
ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DD12KB
Controller code
Steering
Trouble
Shift up switch: Short circuit (KB)
(Steering and transmission controller system)
• Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
• Flashes caution lamp and turns on caution buzzer.
• Recognizes that switch is not pressed.
• Shift up is not possible.
• Auto shift down does not function.
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
• Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
(Code 40905: Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift up switch.
Cause
Possible causes
and standard
value in normal
state
20-480
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Shift up switch
SFTU (male)
Defective shift up switch
OFF (Release)
ON (Press)
1
(Internal disconnection)
Resistance between
Max. 1 z
Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz
Max. 1 z
(2) – (1)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between ST1 (female) (12) –
Resistance Min. 1 Mz
2 ground in wiring harness
SFTU (female) (3) with chassis ground
(Contact with ground circuit)
Wiring harness between ST3 (female) (9) –
Resistance Min. 1 Mz
SFTU (female) (1) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Shift up switch
ST1, ST3
Defective steering and
OFF (Release)
ON (Press)
3
transmission controller
Voltage between
Max. 1 V
5 – 11 V
ST1 (12) – ST1 (4)
Voltage between
5 – 11 V
Max. 1 V
ST3 (9) – ST1 (4)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD12KB
Circuit diagram related to shift up switch and shift down switch
D65EX, PX-15
20-481
(1)
TROUBLESHOOTING
ERROR CODE DD13KA
ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DD13KA
Controller code
Steering
Trouble
Shift down switch: Disconnection (KA)
(Steering and transmission controller system)
• Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
• Flashes caution lamp and turns on caution buzzer.
• Recognizes that switch is not pressed.
• Shift down is not possible.
• Auto shift down does not function.
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
• Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
(Code 40905: Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift down switch.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-482
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Shift down switch
SFTD (female)
Defective shift down switch
OFF (Release)
ON (Press)
(Internal disconnection)
Resistance between
Max. 1 z
Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz
Max. 1 z
(2) – (1)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring
harness between ST1 (female) (24) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in SFTD (male) (3)
wiring or defective contact in Wiring harness between ST1 (female) (18) –
Resistance Max. 1 z
connector)
SFTD (male) (1)
Wiring harness between ST1 (female) (4) –
Resistance Max. 1 z
SFTD (male) (4)
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Hot short circuit in wiring
Wiring harness between ST1 (female) (24) –
harness (Contact with 24 V
Voltage
Max. 1 V
SFTD (male) (3) with chassis ground
circuit)
Wiring harness between ST1 (female) (18) –
Voltage
Max. 1 V
SFTD (male) (1) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Shift down switch
ST1
Defective steering and
OFF (Release)
ON (Press)
transmission controller
Voltage between
Max. 1 V
5 – 11 V
ST1 (24) – ST1 (4)
Voltage between
5 – 11 V
Max. 1 V
ST1 (18) – ST1 (4)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD13KA
Circuit diagram related to shift up switch and shift down switch
D65EX, PX-15
20-483
(1)
TROUBLESHOOTING
ERROR CODE DD13KB
ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DD13KB
Controller code
Steering
Trouble
Shift down switch: Short circuit (KB)
(Steering and transmission controller system)
• Signals of two systems of shift down switch circuit were turned ON (CLOSE) or OFF at the same time.
• Flashes caution lamp and turns on caution buzzer.
• Recognizes that switch is not pressed.
• Shift down is not possible.
• Auto shift down does not function.
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
• Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
(Code 40905: Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate shift up switch.
Cause
Possible causes
and standard
value in normal
state
20-484
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Shift down switch
SFTD (female)
Defective shift down switch
OFF (Release)
ON (Press)
1
(Internal disconnection)
Resistance between
Max. 1 z
Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz
Max. 1 z
(2) – (1)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between ST1 (female) (24) –
Resistance Min. 1 Mz
2 ground in wiring harness
SFTD (male) (3) with chassis ground
(Contact with ground circuit)
Wiring harness between ST1 (female) (18) –
Resistance Min. 1 Mz
SFTD (male) (1) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Shift down switch
ST1
Defective steering and
OFF (Release)
ON (Press)
3
transmission controller
Voltage between
Max. 1 V
5 – 11 V
ST1 (24) – ST1 (4)
Voltage between
5 – 11 V
Max. 1 V
ST1 (18) – ST1 (4)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD13KB
Circuit diagram related to shift up switch and shift down switch
D65EX, PX-15
20-485
(1)
TROUBLESHOOTING
ERROR CODE DD14KA DDQ2KA
ERROR CODE DD14KA DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DD14KA
DDQ2KA
Controller code
Steering
Trouble
Parking lever switch: Disconnection (KA)
(Steering and transmission controller system)
• Signals of two systems of parking lever switch circuit were turned OFF (OPEN) at the same time.
• Flashes caution lamp and turns on caution buzzer.
• Recognizes parking lever is in Free position.
• Limits operation of engine, transmission, and brake.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Engine cannot be started.
• Both of DD14KA and DDQ2KA are displayed.
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
• Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
(Code 40910: Steering controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate parking lever.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-486
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Parking lever
Parking lever switch
NSW (male)
(Internal short circuit)
Free position
Lock position
Between (A) – (B)
Max. 1 z
Min. 1 Mz
Between (A) – (C)
Min. 1 Mz
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ST2 (female) (15) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in NSW (female) (C)
wiring or defective contact in Wiring harness between ST2 (female) (5) –
Resistance Max. 1 z
connector)
NSW (female) (B)
Wiring harness between ST1 (female) (4) –
Resistance Max. 1 z
NSW (female) (A)
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Hot short circuit in wiring
Wiring harness between ST2 (female) (15) –
Voltage
Max. 1 V
harness (Contact with 24 V
NSW (female) (C) with chassis ground
circuit)
Wiring harness between ST2 (female) (5) –
Voltage
Max. 1 V
NSW (female) (B) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Parking lever
ST2
Defective steering and
Free position
Lock position
transmission controller
Between (15) –
Max. 1 V
5 – 11 V
chassis ground
Between (5) –
5 – 11 V
Max. 1 V
chassis ground
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD14KA DDQ2KA
Circuit diagram related to parking lever switch
D65EX, PX-15
20-487
(1)
TROUBLESHOOTING
ERROR CODE DD14KB DDQ2KB
ERROR CODE DD14KB DDQ2KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DD14KB
DDQ2KB
Controller code
Steering
Trouble
Parking lever switch: Short circuit (KB)
(Steering and transmission controller system)
• Signals of two systems of parking lever switch circuit were turned ON (CLOSE) at the same time.
• Flashes caution lamp and turns on caution buzzer.
• Recognizes parking lever is in Free position.
• Limits operation of engine, transmission, and brake.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Engine cannot be started.
• Both of DD14KB and DDQ2KB are displayed.
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
• Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
(Code 40910: Steering controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate parking lever.
Cause
Possible causes
and standard
value in normal
state
20-488
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Parking lever
Parking lever switch
NSW (male)
1
(Internal disconnection)
Free position
Lock position
Between (A) – (B)
Max. 1 z
Min. 1 Mz
Between (A) – (C)
Min. 1 Mz
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between NSW (female) (B) –
Resistance Min. 1 Mz
2 ground in wiring harness
ST2 (female) (5) with chassis ground
(Contact with ground circuit)
Wiring harness between NSW (female) (C) –
Resistance Min. 1 Mz
ST2 (female) (15) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Parking lever
ST2
Defective steering and
Free position
Lock position
3
transmission controller
Between (15) –
Max. 1 V
5 – 11 V
chassis ground
Between (5) –
5 – 11 V
Max. 1 V
chassis ground
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD14KB DDQ2KB
Circuit diagram related to parking lever switch
D65EX, PX-15
20-489
(1)
TROUBLESHOOTING
ERROR CODE DDE2L6
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DDE2L6
Controller code
Engine
Trouble
Engine oil pressure switch: Refer to table (L6)
(Engine controller system)
• Signals of engine oil pressure switch are inconsistent with engine state.
• None in particular.
• When engine oil pressure lowers, caution signal is not output.
• Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode.
(Code 40900: Engine controller input signal 1)
• Method of reproducing error code: Turn starting switch ON or start engine.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
20-490
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON or by starting engine.
Defective low engine oil
PSL
Engine
Resistance
pressure switch (Internal
disconnection/short circuit)
Stop
Max. 1 z
Between terminal –
chassis ground
Min. 600 rpm
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON or by starting engine.
Defective high engine oil
PSH
Engine
Resistance
pressure switch (Internal
disconnection/short circuit)
Stop
Max. 1 z
Between terminal –
chassis ground
Min. 1,300 rpm
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN1 (female) (21) –
Resistance Max. 1 z
wiring or defective contact in PSL
connector)
Wiring harness between EN1 (female) (15) –
Resistance Max. 1 z
PSH
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between EN1 (female) (15) –
Resistance Min. 1 Mz
ground in wiring harness
PSH with chassis ground
(Contact with ground circuit)
Wiring harness between EN1 (female) (21) –
Resistance Min. 1 Mz
PSL with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON or by starting engine.
EN1
Engine
Voltage
Stop
Max. 1 V
Defective engine controller
Between (21) –
chassis ground
Min. 600 rpm
20 – 30 V
Stop
Max. 1 V
Between (15) –
chassis ground
Min. 1,300 rpm
20 – 30 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DDE2L6
Circuit diagram related to low engine oil pressure switch & high engine oil pressure switch
D65EX, PX-15
20-491
(1)
TROUBLESHOOTING
ERROR CODE DDN7KA
ERROR CODE DDN7KA (PITCH CONTROL SWITCH: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DDN7KA
Controller code
Steering
Trouble
Pitch control switch: Disconnection (KA)
(Steering and transmission controller system)
• Signals of two systems of pitch control switch were turned OFF (OPEN) at the same time.
• Flashes caution lamp and turns on caution buzzer.
• Recognizes switch is not pushed.
• Pitch control cannot be performed.
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
• Input state (ON/OFF) from pitch control switch can be checked in monitoring mode.
(Code 70300: Work equipment-related controller input signal)
• Method of reproducing error code: Turn starting switch ON and operate pitch control switch.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-492
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Pitch control switch
P0A (male),
Defective pitch control
P0B (female)
OFF (Release)
ON (Press)
switch (Internal disconnecResistance
between
tion)
Max. 1 z
Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz
Max. 1 z
(2) – (1)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ST3 (female) (10) –
Resistance Max. 1 z
P0A (female) (3)
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (20) –
Resistance Max. 1 z
wiring or defective contact in P0A (female) (1) – P0B (male) (1)
connector)
Wiring harness between ST1 (female) (4) –
Resistance Max. 1 z
P0B (male) (2)
Wiring harness between P0A (female) (2) –
Resistance Max. 1 z
P0B (male) (3)
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Hot short circuit in wiring
Wiring harness between ST3 (female) (10) –
Voltage
Max. 1 V
harness (Contact with 24 V P0A (female) (3) with chassis ground
circuit)
Wiring harness between ST3 (female) (20) –
P0A (female) (1) – P0B (male) (1) with chassis Voltage
Max. 1 V
ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Pitch control switch
ST1, ST3
Defective steering and
OFF (Release)
ON (Press)
transmission controller
Voltage between
Max. 1 V
5 – 11 V
ST3 (10) – ST1 (4)
Voltage between
5 – 11 V
Max. 1 V
ST3 (20) – ST1 (4)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DDN7KA
Circuit diagram related to pitch control switch
D65EX, PX-15
20-493
(1)
TROUBLESHOOTING
ERROR CODE DDN7KB
ERROR CODE DDN7KB (PITCH CONTROL SWITCH: SHORT CIRCUIT (KB))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DDN7KB
Controller code
Steering
Trouble
Pitch control switch: Short circuit (KB)
(Steering and transmission controller system)
• Signals of two systems of pitch control switch were turned ON (CLOSE) at the same time.
• Flashes caution lamp and turns on caution buzzer.
• Recognizes switch is not pushed.
• Pitch control cannot be performed.
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
• Input state (ON/OFF) from pitch control switch can be checked in monitoring mode.
(Code 70300: Work equipment-related controller input signal)
• Method of reproducing error code: Turn starting switch ON and operate pitch control switch.
Cause
Possible causes
and standard
value in normal
state
20-494
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Pitch control switch
P0A (male),
P0B (female)
Defective pitch control
OFF (Release)
ON (Press)
1
switch (Internal short circuit) Resistance between
Max. 1 z
Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz
Max. 1 z
(2) – (1)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ST3 (female) (10) –
Resistance Min. 1 Mz
P0A (female) (3) with chassis ground
Short circuit with chassis
2 ground in wiring harness
Wiring harness between ST3 (female) (20) –
(Contact with ground circuit) P0A (female) (1) – P0B (male) (1) with chassis Resistance Min. 1 Mz
ground
Wiring harness between P0A (female) (2) –
Resistance Min. 1 Mz
P0B (male) (3) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Pitch control switch
ST1, ST3
Defective steering and
OFF (Release)
ON (Press)
3
transmission controller
Voltage between
Max. 1 V
5 – 11 V
ST3 (10) – ST1 (4)
Voltage between
5 – 11 V
Max. 1 V
ST3 (20) – ST1 (4)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DDN7KB
Circuit diagram related to pitch control switch
D65EX, PX-15
20-495
(1)
TROUBLESHOOTING
ERROR CODE DDQ2KA DD14KA,
DDQ2KB DD14KB
ERROR CODE DDQ2KA
DD14KA
ERROR CODE DDQ2KA DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA))
a See DD14KA.
CALL E03
ERROR CODE DDQ2KB DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB))
a See DD14KB.
CALL E03
20-496
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DGE2KX
ERROR CODE DGE2KX (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH
TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DGE2KX
Controller code
Engine
Trouble
Engine water temperature sensor (for high temperature):
Input signal is out of normal range (KX)
(Engine controller system)
• High engine water temperature sensor signal is out of normal range.
• Fixes water temperature signal output for monitor panel at 90ºC.
• Monitor panel does not display engine water temperature normally.
• When engine water overheats, caution signal is not output.
• Fan speed is limited to half.
• Engine water temperature (temperature) can be checked in monitoring mode.
(Code 04102: Engine water temperature (High temperature side))
• Method of reproducing error code: Start engine.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective high engine water
without turning starting switch ON.
temperature sensor (Internal
TWH (male)
Resistance
disconnection or short
Between (1) – (2)
3.5 k – 90 kz (10 – 100ºC)
circuit)
Between (1), (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN2 (female) (27) –
Resistance Max. 1 z
wiring or defective contact in TWH (female) (1)
connector)
Wiring harness between EN2 (female) (39) –
Resistance Max. 1 z
TWH (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
(Contact with ground circuit) Wiring harness between EN2 (female) (27) – Resistance Min. 1 Mz
TWH (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN2 (female)
Resistance
Defective engine controller
Between (27) – (39)
3.5 k – 90 kz (10 – 100ºC)
Between (27), (39) –
Min. 1 Mz
chassis ground
Circuit diagram related to high engine water temperature sensor
D65EX, PX-15
20-497
(1)
TROUBLESHOOTING
ERROR CODE DGE3L6
ERROR CODE DGE3L6 (ENGINE WATER TEMPERATURE SENSOR (FOR LOW
TEMPERATURE): SEE TABLE (L6))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DGE3L6
Controller code
Engine
Trouble
Engine water temperature sensor (for low temperature):
See table (L6) (Engine controller system)
• Low engine water temperature sensor signal is inconsistent with engine state.
• Flashes caution lamp and turns on caution buzzer.
• Exhaust gas color is bad at low temperature.
• Engine does not start easily at low temperature.
• Engine water temperature (temperature) can be checked in monitoring mode.
(Code 04104: Engine water temperature (Low temperature side))
• Method of reproducing error code: Start engine.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective low engine water
without turning starting switch ON.
temperature sensor (Internal
TWL (male)
Resistance
disconnection or short
Between (A) – (B)
0.3 k – 9 kz (10 – 100ºC)
circuit)
Between (A), (B) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN2 (female) (37) –
Resistance Max. 1 z
wiring or defective contact in TWL (female) (A)
connector)
Wiring harness between EN2 (female) (39) –
Resistance Max. 1 z
TWL (female) (B)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring
harness between EN2 (female) (37) –
(Contact with ground circuit)
Resistance Min. 1 Mz
TWL (female) (A) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN2 (female)
Resistance
Defective engine controller
Between (37) – (39)
0.3 k – 9 kz (10 – 100ºC)
Between (37), (39) –
Min. 1 Mz
chassis ground
Circuit diagram related to low engine water temperature sensor
20-498
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DGE4KX
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF
NORMAL RANGE (KX))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DGE4KX
Controller code
Engine
Trouble
Fuel temperature sensor: Input signal is out of normal range
(KX) (Engine controller system)
• Fuel temperature sensor signal is out of normal range.
• Operates with normal control.
• Engine output lowers a little at low temperature.
• Fuel temperature (temperature) can be checked in monitoring mode.
(Code 04204: Fuel temperature)
• Method of reproducing error code: Start engine.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel temperature
THL (male)
Resistance
sensor (Internal disconnection or short circuit)
Between (A) – (B)
0.3 k – 9 kz (10 – 100ºC)
Between (A), (B) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN2 (female) (17) –
Resistance Max. 1 z
wiring or defective contact in THL (female) (A)
connector)
Wiring harness between EN2 (female) (39) –
Resistance Max. 1 z
THL (female) (B)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring
harness between EN2 (female) (17) –
(Contact with ground circuit)
Resistance Min. 1 Mz
THL (female) (A) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN2 (female)
Resistance
Defective engine controller
Between (17) – (39)
0.3 k – 9 kz (10 – 100ºC)
Between (17), (39) –
Min. 1 Mz
chassis ground
Circuit diagram related to fuel temperature sensor
D65EX, PX-15
20-499
(1)
TROUBLESHOOTING
ERROR CODE DGS1KX
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS
OUT OF NORMAL RANGE (KX))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DGS1KX
Controller code
Steering
Trouble
Hydraulic oil temperature sensor: Input signal is out of normal
range (KX) (Steering and transmission controller system)
• Hydraulic oil temperature sensor signal is out of normal range.
• Hydraulic oil temperature gauge of monitor panel.
• Fan speed is limited to half.
• Hydraulic oil temperature (temperature) can be checked in monitoring mode.
(Code 04401: Hydraulic oil temperature)
• Method of reproducing error code: Turn starting switch ON or start engine.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
20-500
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective hydraulic oil
without turning starting switch ON.
temperature sensor (Internal
SDS (male)
Resistance
disconnection or short
Between (1) – (2)
3.5 k – 90 kz (10 – 100ºC)
circuit)
Between (1) (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST1 (female) (9) –
Resistance Max. 1 z
wiring or defective contact in SDS (female) (1)
connector)
Wiring harness between ST1 (female) (21) –
Resistance Max. 1 z
SDS (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring
harness between ST1 (female) (9) –
(Contact with ground circuit)
Resistance Min. 1 Mz
SDS (female) (1) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
Short circuit with power
out troubleshooting.
source in wiring harness
Wiring
harness between ST1 (female) (9) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
SDS (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST1 (female)
Resistance
transmission controller
Between (9) – (21)
3.5 k – 90 kz (10 – 100ºC)
Between (9) – chassis ground
Min. 1 Mz
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DGS1KX
Circuit diagram related to hydraulic oil temperature sensor
D65EX, PX-15
20-501
(1)
TROUBLESHOOTING
ERROR CODE DH30KX
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL
RANGE (KX))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DH30KX
Controller code
Engine
Trouble
Boost pressure sensor: Input is out of normal range (KX)
(Engine controller system)
• Boost pressure sensor signal is out of normal range.
• Flashes caution lamp and turns on caution buzzer.
• Machine is not affected seriously.
• Special adapter (799-601-9420) is necessary for troubleshooting for boost pressure sensor.
• Boost pressure (pressure) can be checked in monitoring mode.
(Code 36500: Boost pressure)
• Method of reproducing error code: Turn starting switch ON or start engine.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-502
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Defective boost pressure
PIM
Voltage
sensor (Internal trouble)
Between (1) – (3)
4.6 – 5.4 V
Between (2) – (3)
0.3 – 4.7 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN2 (female) (19) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in PIM (female) (1)
wiring or defective contact in Wiring harness between EN2 (female) (20) –
Resistance Max. 1 z
connector)
PIM (female) (2)
Wiring harness between EN2 (female) (39) –
Resistance Max. 1 z
PIM (female) (3)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN2 (female) (19) –
Resistance Min. 1 Mz
Short circuit with chassis
PIM (female) (1) with chassis ground
ground in wiring harness
Wiring harness between EN2 (female) (20) –
(Contact with ground circuit)
Resistance Min. 1 Mz
PIM (female) (2) with chassis ground
Wiring harness between EN2 (female) (39) –
Resistance Min. 1 Mz
PIM (female) (3) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
EN2
Voltage
Defective engine controller
Between (19) – (39)
4.6 – 5.4 V
Between (20) – (39)
0.3 – 4.7 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DH30KX
Circuit diagram related to boost presure sensor
D65EX, PX-15
20-503
(1)
TROUBLESHOOTING
ERROR CODE DH40KX
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL
RANGE (KX))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DH40KX
Controller code
Engine
Trouble
Common rail pressure sensor: Input is out of normal range
(KX) (Engine controller system)
• Common rail pressure sensor signal is out of normal range.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail pressure sensor.
• Common rail pressure (pressure) can be checked in monitoring mode.
(Code 36400: Common rail pressure)
• Method of reproducing error code: Turn starting switch ON or start engine.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-504
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
Defective common rail
PFUEL
Voltage
pressure sensor (Internal
trouble)
Between (1) – (3)
4.6 – 5.4 V
Between (2) – (3)
0.7 – 4.5 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN2 (female) (19) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in PFUEL (female) (1)
wiring or defective contact in Wiring harness between EN2 (female) (40) –
Resistance Max. 1 z
connector)
PFUEL (female) (2)
Wiring harness between EN2 (female) (39) –
Resistance Max. 1 z
PFUEL (female) (3)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN2 (female) (19) –
Resistance Min. 1 Mz
Short circuit with chassis
PFUEL (female) (1) with chassis ground
ground in wiring harness
Wiring harness between EN2 (female) (40) –
(Contact with ground circuit)
Resistance Min. 1 Mz
PFUEL (female) (2) with chassis ground
Wiring harness between EN2 (female) (39) –
Resistance Min. 1 Mz
PFUEL (female) (3) with chassis ground
aPrepare with starting switch OFF, turn starting switch ON and carry
out troubleshooting.
EN2
Voltage
Defective engine controller
Between (19) – (39)
4.6 – 5.4 V
Between (40) – (39)
0.7 – 4.5 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DH40KX
Circuit diagram related to common rail presure sensor
D65EX, PX-15
20-505
(1)
TROUBLESHOOTING
ERROR CODE DK10KX
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX))
Action code
CALL E03
Contents of
trouble
Error code
DK10KX
Controller code
Engine
Trouble
Fuel control dial: Input is out of normal range (KX)
(Engine controller system)
• Signal voltage of fuel control dial circuit is below 0.5 V or above 4.5 V.
Action of
controller
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of decelerator pedal potentiometer.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Inputting from fuel control dial (Voltage) can be checked in monitoring mode.
(Code 03000: Voltage of fuel control dial)
• Method of reproducing error code: Turn starting switch ON.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
20-506
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel control dial
DIAL (male)
Resistance
(Internal disconnection or
Between (A) – (C)
4.0 – 6.0 kz
short circuit)
Between (A) – (B)
0.5 – 4.5 kz
Between (B) – (C)
0.5 – 4.5 kz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between EN2 (female) (9) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in DIAL (female) (A)
wiring or defective contact in Wiring harness between EN2 (female) (10) –
Resistance Max. 1 z
connector)
DIAL (female) (B)
Wiring harness between EN2 (female) (29) –
Resistance Max. 1 z
DIAL (female) (C)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between EN2 (female) (9) –
Resistance Min. 1 Mz
ground in wiring harness
DIAL (female) (A) with chassis ground
(Contact with ground circuit)
Wiring harness between EN2 (female) (10) –
Resistance Min. 1 Mz
DIAL (female) (B) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Short circuit with power
Wiring harness between EN2 (female) (9) –
source in wiring harness
Voltage
Max. 1 V
DIAL (female) (A) with chassis ground
(Contact with 24 V circuit)
Wiring harness between EN2 (female) (10) –
Voltage
Max. 1 V
DIAL (female) (B) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
EN2
Voltage
Defective engine controller
Between (9) – (29)
4.6 – 5.4 V
Between (10) – (29)
0.5 – 4.5 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK10KX
Circuit diagram related to fuel control dial
D65EX, PX-15
20-507
(1)
TROUBLESHOOTING
ERROR CODE DK12KX
ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL
RANGE (KX))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DK12KX
Controller code
Engine
Trouble
Fuel control dial: Input is out of normal range (KX)
(Engine controller system)
• Signal voltage of deceleration potentiometer circuit is below 0.3 V or above 4.5 V.
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of fuel control dial.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Inputting from deceleration potentiometer (Voltage) can be checked in monitoring mode.
(Code 50001: Voltage of deceleration potentiometer)
• Method of reproducing error code: Turn starting switch ON.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
4
20-508
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective deceleration
DCL (male)
Resistance
potentiometer (Internal disBetween (A) – (C)
4.0 – 6.0 kz
connection or short circuit)
Between (A) – (B)
0.5 – 4.5 kz
Between (B) – (C)
0.5 – 4.5 kz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring
harness between EN2 (female) (9) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in DCL (female) (A)
wiring or defective contact in Wiring harness between EN2 (female) (38) –
Resistance Max. 1 z
connector)
DCL (female) (B)
Wiring harness between EN2 (female) (29) –
Resistance Max. 1 z
DCL (female) (C)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between EN2 (female) (9) –
Resistance Min. 1 Mz
ground in wiring harness
DCL (female) (A) with chassis ground
(Contact with ground circuit)
Wiring harness between EN2 (female) (38) –
Resistance Min. 1 Mz
DCL (female) (B) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Short circuit with power
Wiring harness between EN2 (female) (9) –
Voltage
Max. 1 V
source in wiring harness
DCL (female) (A) with chassis ground
(Contact with 24 V circuit)
Wiring harness between EN2 (female) (38) –
Voltage
Max. 1 V
DCL (female) (B) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
EN2
Voltage
Defective engine controller
Between (9) – (29)
4.6 – 5.4 V
Between (38) – (29)
0.3 – 4.5 V
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK12KX
Circuit diagram related to decel potentiometer
D65EX, PX-15
20-509
(1)
TROUBLESHOOTING
ERROR CODE DK30KA
ERROR CODE DK30KA (STEERING POTENTIOMETER 1: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Error code
DK30KA
Controller code
Steering
Trouble
Steering potentiometer 1: Disconnection (KA)
(Steering and transmission controller system)
• Signal voltage of steering potentiometer 1 system is above 4.5 V.
Action of
controller
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of steering potentiometer 2 system.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from steering potentiometer 1 can be checked in monitoring mode.
(Code 50300: Voltage of steering potentiometer 1)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5 V sensor power See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
1
source system
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering potentiTL2 (male)
Resistance
2 ometer 1 (Internal disconBetween (5) – (8)
3.2 kz ± 20%
nection or short circuit)
Between (7) – (5)
1 – 6 kz (Right – Left steering)
Between (7) – (8)
6 – 1 kz (Right – Left steering)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST1 (female) (21) –
Resistance Max. 1 z
3
wiring or defective contact in TL2 (female) (8)
connector)
Wiring harness between ST1 (female) (2) –
Resistance Max. 1 z
TL2 (female) (7)
aPrepare with starting switch OFF, then turn starting switch ON and
Hot short circuit in wiring
carry out troubleshooting.
4 harness (Contact with 24 V
Wiring harness between ST1 (female) (2) –
circuit)
Voltage
Max. 1 V
TL2 (female) (7) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
5
transmission controller
ST1
Voltage
Between (2) – (21)
0.5 – 4.5 V
Circuit diagram related to steering potentiometer
20-510
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK30KB
ERROR CODE DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Error code
DK30KB
Controller code
Steering
Trouble
Steering potentiometer 1: Short circuit (KB)
(Steering and transmission controller system)
• Signal voltage of steering potentiometer 1 system is below 0.5 V.
Action of
controller
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of steering potentiometer 2 system.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from steering potentiometer 1 can be checked in monitoring mode.
(Code 50300: Voltage of steering potentiometer 1)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5 V sensor power See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
1
source system
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering potentiTL2 (male)
Resistance
2 ometer 1 (Internal disconBetween (5) – (8)
3.2 kz ± 20%
nection or short circuit)
Between (7) – (5)
1 – 6 kz (Right – Left steering)
Between (7) – (8)
6 – 1 kz (Right – Left steering)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
3 ground in wiring harness
Wiring harness between ST1 (female) (2) –
(Contact with ground circuit)
Resistance Min. 1 Mz
TL2 (female) (7) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
4
transmission controller
ST1
Voltage
Between (2) – (21)
0.5 – 4.5 V
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
5
wiring or defective contact in Wiring harness between ST1 (female) (22) –
Resistance Max. 1 z
connector)
TL2 (female) (5)
Circuit diagram related to steering potentiometer
D65EX, PX-15
20-511
(1)
ERROR CODE DK30KX,
DK30KZ
ERROR CODE DK30KX
TROUBLESHOOTING
ERROR CODE DK30KX (STEERING POTENTIOMETER: INPUT SIGNAL IS OUT OF
NORMAL RANGE (KX))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code Controller code
Steering potentiometer: Input signal is out of normal range
Trouble
(KX) (Steering and transmission controller system)
DK30KX
Steering
• Either of error codes [DK30KA] and [DK30KB] of steering potentiometer systems 1 and 2 and either of
error codes [DK31KA] and [DK31KB] are displayed simultaneously.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine, transmission, and brake.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel any more.
• Input (Voltage) from steering potentiometers can be checked in monitoring mode.
(Code 50300: Voltage of steering potentiometer 1)
(Code 50301: Voltage of steering potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
ERROR CODE DK30KZ (STEERING POTENTIOMETER: DISCONNECTION OR SHORT
CIRCUIT (Double trouble) (KZ))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
20-512
(1)
Error code Controller code
Steering potentiometer: Disconnection or short circuit (KZ)
Trouble
(Steering and transmission controller system)
DK30KZ
Steering
• When starting switch is turned ON, either of steering potentiometer systems 1 and 2 is abnormal, then
either of error codes [DK30KA] and [DK30KB] and either of error codes [DK31KA] and [DK31KB] are
displayed simultaneously.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine, transmission, and brake.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel any more.
• Input (Voltage) from steering potentiometers can be checked in monitoring mode.
(Code 50300: Voltage of steering potentiometer 1)
(Code 50301: Voltage of steering potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK30L8
ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code Controller code
Steering potentiometer 1: See table (L8)
Trouble
(Steering and transmission controller system)
DK30L8
Steering
• Total signal voltage of each of steering potentiometer 1 system and 2 system is below 4.41 V or above
5.59 V.
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of normal one of steering potentiometer 1 system and 2.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from steering potentiometers can be checked in monitoring mode.
(Code 50300: Voltage of steering potentiometer 1)
(Code 50301: Voltage of steering potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
Possible causes
and standard
value in normal
state
D65EX, PX-15
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
20-513
(1)
TROUBLESHOOTING
ERROR CODE DK31KA
ERROR CODE DK31KA (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KA))
Action code
CALL E03
Contents of
trouble
Error code
DK31KA
Controller code
Steering
Trouble
Steering potentiometer 2: Short circuit (KA)
(Steering and transmission controller system)
• Signal voltage of steering potentiometer 2 system is above 4.5 V.
Action of
controller
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of steering potentiometer 1 system.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from steering potentiometer 2 can be checked in monitoring mode.
(Code 50301: Voltage of steering potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
Cause
Defective sensor power
1
source system
2
Possible causes
and standard
value in normal
state
3
4
5
Standard value in normal state/Remarks on troubleshooting
See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering potentiTL2 (male)
Voltage
ometer 2 (Internal disconBetween (5) – (8)
3.2 kz ± 20%
nection or short circuit)
Between (6) – (5)
6 – 1 kz (Right – Left steering)
Between (6) – (8)
1 – 6 kz (Right – Left steering)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST1 (female) (19) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
TL2 (female) (6) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
ST1
Voltage
Between (19) – (21)
0.5 – 4.5 V
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between ST1 (female) (21) –
Resistance Max. 1 z
connector)
TL2 (female) (8)
Circuit diagram related to steering potentiometer
20-514
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK31KB
ERROR CODE DK31KB (STEERING POTENTIOMETER 2: DISCONNECTION (KB))
Action code
CALL E03
Contents of
trouble
Error code
DK31KB
Controller code
Steering
Trouble
Steering potentiometer 2: Disconnection (KB)
(Steering and transmission controller system)
• Signal voltage of steering potentiometer 2 system is below 0.5 V.
Action of
controller
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of steering potentiometer 1 system.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from steering potentiometer 2 can be checked in monitoring mode.
(Code 50301: Voltage of steering potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for steering).
Cause
Defective sensor power
1
source system
2
Possible causes
and standard
value in normal
state
3
4
5
Standard value in normal state/Remarks on troubleshooting
See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering potentiTL2 (male)
Resistance
ometer 2 (Internal disconBetween (5) – (8)
3.2 kz ± 20%
nection or short circuit)
Between (6) – (5)
6 – 1 kz (Right – Left steering)
Between (6) – (8)
1 – 6 kz (Right – Left steering)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST1 (female) (22) –
Resistance Max. 1 z
wiring or defective contact in TL2 (female) (5)
connector)
Wiring harness between ST1 (female) (19) –
Resistance Max. 1 z
TL2 (female) (6)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring harness between ST1 (female) (19) –
(Contact with ground circuit)
Resistance Min. 1 Mz
TL2 (female) (6) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
ST1
Voltage
Between (19) – (21)
0.5 – 4.5 V
Circuit diagram related to steering potentiometer
D65EX, PX-15
20-515
(1)
TROUBLESHOOTING
ERROR CODE DK40KA
ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code
DK40KA
Controller code
Steering
Trouble
Brake potentiometer: Disconnection (KA)
(Steering and transmission controller system)
• Signal voltage of brake potentiometer circuit is below 0.5 V.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Auto shift-down mechanism does not work normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Input (Voltage) from brake potentiometer can be checked in monitoring mode.
(Code 50400: Voltage of brake potentiometer)
• Method of reproducing error code: Turn starting switch ON and operate brake pedal.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5 V sensor power See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
1
source system
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
• Defective brake potentiwithout turning starting switch ON.
ometer (Internal disconBRK (male)
Resistance
2
nection or short circuit)
Between (A) – (C)
4.0 – 6.0 kz
• Defective installation of
Between (A) – (B)
1.5 – 4.5 kz (Free – Stroke end)
potentiometer
Between (B) – (C)
4.5 – 1.5 kz (Free – Stroke end)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST1 (female) (22) –
Resistance Max. 1 z
3
wiring or defective contact in BRK (female) (C)
connector)
Wiring harness between ST1 (female) (3) –
Resistance Max. 1 z
BRK (female) (B)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
4 ground in wiring harness
Wiring harness between ST1 (female) (3) –
(Contact with ground circuit)
Resistance Min. 1 Mz
BRK (female) (B) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
5
transmission controller
ST1
Voltage
Between (3) – (21)
1.5 – 4.5 V
Circuit diagram related to brake potentiometer
20-516
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK40KB
ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code
DK40KB
Controller code
Steering
Trouble
Brake potentiometer: Short circuit (KB)
(Steering and transmission controller system)
• Signal voltage of brake potentiometer circuit is below 0.5 V or above 4.5 V.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Auto shift-down mechanism does not work normally.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Input (Voltage) from brake potentiometer can be checked in monitoring mode.
(Code 50400: Voltage of brake potentiometer)
• Method of reproducing error code: Turn starting switch ON and operate brake pedal.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5 V sensor power See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
1
source system
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
• Defective brake potentiwithout turning starting switch ON.
ometer (Internal disconBRK (male)
Resistance
2
nection or short circuit)
(A) – (C)
4.0 – 6.0 kz
• Defective installation of
(A) – (B)
1.5 – 4.5 kz (Free – Stroke end)
potentiometer
(B) – (C)
4.5 – 1.5 kz (Free – Stroke end)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
3 source in wiring harness
Wiring harness between ST1 (female) (3) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
BRK (female) (B) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
4
transmission controller
ST1
Voltage
Between (3) – (21)
1.5 – 4.5 V
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
5
wiring or defective contact in Wiring harness between ST1 (female) (21) –
Resistance Max. 1 z
connector)
BRK (female) (A)
Circuit diagram related to brake potentiometer
D65EX, PX-15
20-517
(1)
ERROR CODE DK55KX,
DK55KZ
ERROR CODE DK55KX
TROUBLESHOOTING
ERROR CODE DK55KX (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT
OF NORMAL RANGE (KX))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Error code Controller code
Forward-reverse potentiometer: Input signal is out of normal
Trouble
range (KX) (Steering and transmission controller system)
DK55KX
Steering
• Either of error codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and
either of error codes [DK57KA] and [DK57KB] are displayed simultaneously.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine, transmission, and brake.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel any more.
• Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
(Code 50201: Voltage of forward-reverse potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR
SHORT CIRCUIT (Double trouble) (KZ))
Action code
CALL E04
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
20-518
(1)
Error code Controller code
Forward-reverse potentiometer: Disconnection or short circuit
Trouble
(KZ) (Steering and transmission controller system)
DK55KZ
Steering
• When starting switch is turned ON, either of forward-reverse potentiometer systems 1 and 2 is abnormal, then either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and
[DK57KB] are displayed simultaneously.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine, transmission, and brake.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, it cannot travel any more.
• Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
(Code 50201: Voltage of forward-reverse potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK55L8
ERROR CODE DK55L8 (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code Controller code
Forward-reverse potentiometer: See table (L8)
Trouble
(Steering and transmission controller system)
DK55L8
Steering
• Total signal voltage of each of forward-reverse potentiometer 1 system and 2 system is below 4.41 V
or above 5.59 V.
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of normal one of forward-reverse potentiometer 1 system and 2.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from forward-reverse potentiometers can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
(Code 50201: Voltage of forward-reverse potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
Possible causes
and standard
value in normal
state
D65EX, PX-15
Cause
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
20-519
(1)
TROUBLESHOOTING
ERROR CODE DK56KA
ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DK56KA
Controller code
Steering
Trouble
Forward-reverse potentiometer 1: Short circuit (KA)
(Steering and transmission controller system)
• Signal voltage of forward-reverse potentiometer 1 system is above 4.5 V.
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of forward-reverse potentiometer 2 system.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from forward-reverse potentiometer 1 can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5 V sensor power See if error code [DB35KK] [DAQ5KK] is displayed. If it is displayed,
1
source system
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective forward-reverse
TL2 (male)
Resistance
potentiometer 1 (Internal
2
disconnection or short
Between (4) – (1)
3.2 kz ± 20%
circuit)
Between (3) – (4)
5.5 – 1.5 kz (Forward – Reverse)
Between (3) – (1)
1.5 – 5.5 kz (Forward – Reverse)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
3 source in wiring harness
Wiring harness between ST1 (female) (13) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
TL2 (female) (3) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
4
ST1
Voltage
transmission controller
Between (13) – (21)
0.5 – 4.5 V
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
5
wiring or defective contact in Wiring harness between ST1 (female) (21) –
Resistance Max. 1 z
connector)
TL2 (female) (1)
20-520
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK56KA
Circuit diagram related to forward-reverse potentiometer
D65EX, PX-15
20-521
(1)
TROUBLESHOOTING
ERROR CODE DK56KB
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION
(KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DK56KB
Controller code
Steering
Trouble
Forward-reverse potentiometer 1: Disconnection (KB)
(Steering and transmission controller system)
• Signal voltage of forward-reverse potentiometer 1 system is below 0.5 V.
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of forward-reverse potentiometer 2 system.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from forward-reverse potentiometer 1 can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5 V sensor power See if error code [DAQ5KK] is displayed. If it is displayed, carry out
1
source system
troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective forward-reverse
TL2 (male)
Resistance
potentiometer 1 (Internal
2
disconnection or short
Between (4) – (1)
3.2 kz ± 20%
circuit)
Between (3) – (4)
5.5 – 1.5 kz (Forward – Reverse)
Between (3) – (1)
1.5 – 5.5 kz (Forward – Reverse)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST1 (female) (22) –
Resistance Max. 1 z
3
wiring or defective contact in TL2 (female) (4)
connector)
Wiring harness between ST1 (female) (13) –
Resistance Max. 1 z
TL2 (female) (3)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
4 ground in wiring harness
Wiring harness between ST1 (female) (13) –
(Contact with ground circuit)
Resistance Min. 1 Mz
TL2 (female) (3) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
5
transmission controller
ST1
Voltage
Between (13) – (21)
0.5 – 4.5 V
20-522
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK56KB
Circuit diagram related to forward-reverse potentiometer
D65EX, PX-15
20-523
(1)
TROUBLESHOOTING
ERROR CODE DK57KA
ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DK57KA
Controller code
Steering
Trouble
Forward-reverse potentiometer 2: Short circuit (KA)
(Steering and transmission controller system)
• Signal voltage of forward-reverse potentiometer 2 system is above 4.5 V.
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of forward-reverse potentiometer 1 system.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from forward-reverse potentiometer 2 can be checked in monitoring mode.
(Code 50201: Voltage of forward-reverse potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
1
2
Possible causes
and standard
value in normal
state
3
4
5
20-524
(1)
Cause
Standard value in normal state/Remarks on troubleshooting
Disconnection in wiring
harness (Disconnection in See if error code [DB35KK] [DAQ5KK] is displayed. If it is displayed,
wiring or defective contact in carry out troubleshooting for it first.
connector)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective forward-reverse
TL2 (male)
Resistance
potentiometer 2 (Internal
disconnection or short
Between (4) – (1)
2 kz ± 20%
circuit)
Between (2) – (4)
1.5 – 5.5 kz (Forward – Reverse)
Between (2) – (1)
5.5 – 1.5 kz (Forward – Reverse)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST1 (female) (7) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
TL2 (female) (2) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
ST1
Voltage
Between (7) – (21)
0.5 – 4.5 V
aPrepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring
without turning starting switch ON.
harness (Disconnection in
wiring or defective contact in Wiring harness between ST1 (female) (21) –
Resistance Max. 1 z
connector)
TL2 (female) (1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK57KA
Circuit diagram related to forward-reverse potentiometer
D65EX, PX-15
20-525
(1)
TROUBLESHOOTING
ERROR CODE DK57KB
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION
(KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DK57KB
Controller code
Steering
Trouble
Forward-reverse potentiometer 2: Disconnection (KB)
(Steering and transmission controller system)
• Signal voltage of forward-reverse potentiometer 2 system is below 0.5 V.
• Flashes caution lamp and turns on caution buzzer.
• Continues controlling with signal of forward-reverse potentiometer 1 system.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Input (Voltage) from forward-reverse potentiometer 2 can be checked in monitoring mode.
(Code 50201: Voltage of forward-reverse potentiometer 2)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (for forward/reverse travel).
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 5 V sensor power See if error code [DB35KK] [DAQ5KK] is displayed. If it is displayed,
1
source system
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective forward-reverse
TL2 (male)
Resistance
potentiometer 2 (Internal
2
disconnection or short
Between (4) – (1)
3.2 kz ± 20%
circuit)
Between (2) – (4)
1.5 – 5.5 kz (Forward – Reverse)
Between (2) – (1)
5.5 – 1.5 kz (Forward – Reverse)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST1 (female) (22) –
Resistance Max. 1 z
3
wiring or defective contact in TL2 (female) (4)
connector)
Wiring harness between ST1 (female) (13) –
Resistance Max. 1 z
TL2 (female) (3)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
4 ground in wiring harness
Wiring harness between ST1 (female) (7) –
(Contact with ground circuit)
Resistance Min. 1 Mz
TL2 (female) (2) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
5
transmission controller
ST1
Voltage
Between (7) – (21)
0.5 – 4.5 V
20-526
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK57KB
Circuit diagram related to forward-reverse potentiometer
D65EX, PX-15
20-527
(1)
TROUBLESHOOTING
ERROR CODE DKH1KA
ERROR CODE DKH1KA (PITCH ANGLE SENSOR: SHORT CIRCUIT (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DKH1KA
Trouble
Pitch angle sensor: Short circuit (KA)
(Steering and transmission controller system)
• Signal voltage of pitch angle sensor is above 4.85 V.
• Flashes caution lamp and turns on caution buzzer.
• Cannot recognize pitch angle.
• Limits operation of engine and transmission.
• Shocks are made when gear is shifted on slope.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
(Code 60100: Voltage of pitch angle sensor)
• Method of reproducing error code: Turn starting switch ON.
1
2
Possible causes
and standard
value in normal
state
Controller code
Steering
3
4
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 24 V power source See if error code [DAQ6KK] [DB36KK] is displayed. If it is displayed,
system
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective pitch angle sensor
(Internal trouble)
PT1
Voltage
Between (B) – (A)
0.15 – 4.85 V
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST1 (female) (8) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
PT1 (female) (B) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
ST1
Voltage
Between (8) – (21)
0.15 – 4.85 V
Circuit diagram related to pitch angle sensor
20-528
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DKH1KB
ERROR CODE DKH1KB (PITCH ANGLE SENSOR: DISCONNECTION (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DKH1KB
Trouble
Pitch angle sensor: Disconnection (KB)
(Steering and transmission controller system)
• Signal voltage of pitch angle sensor is below 0.15 V.
• Flashes caution lamp and turns on caution buzzer.
• Cannot recognize pitch angle.
• Limits operation of engine and transmission.
• Shocks are made when gear is shifted on slope.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Input (Voltage) from pitch angle sensor can be checked in monitoring mode.
(Code 60100: Voltage of pitch angle sensor)
• Method of reproducing error code: Turn starting switch ON.
1
2
Possible causes
and standard
value in normal
state
Controller code
Steering
3
4
5
Cause
Standard value in normal state/Remarks on troubleshooting
Defective 24 V power source See if error code [DAQ6KK] [DB36KK] is displayed. If it is displayed,
system
carry out troubleshooting for it first.
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective pitch angle sensor
(Internal trouble)
PT1
Voltage
Between (B) – (A)
0.15 – 4.85 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST1 (female) (16) –
Resistance Max. 1 z
wiring or defective contact in PT1 (female) (C)
connector)
Wiring harness between ST1 (female) (8) –
Resistance Max. 1 z
PT1 (female) (B)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring harness between ST1 (female) (8) –
(Contact with ground circuit)
Resistance Min. 1 Mz
PT1 (female) (B) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
ST1
Voltage
Between (8) – (21)
0.15 – 4.85 V
Circuit diagram related to pitch angle sensor
D65EX, PX-15
20-529
(1)
TROUBLESHOOTING
ERROR CODE DLE3LC
ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: SEE TABLE (LC))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DLE3LC
Controller code
Engine
Trouble
Engine Ne speed sensor: See table (LC)
(Engine controller system)
• Cylinders cannot be identified by signal of engine Ne speed sensor.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Engine speed may become unstable or engine may stop.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Special adapter (799-601-9410) is necessary for troubleshooting for engine Ne speed sensor.
• Method of reproducing error code: Start engine.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective engine Ne speed
NE (male)
Resistance
sensor (Internal disconnection or short circuit)
Between (1) – (2)
85 – 210 z
Between (1), (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN2 (female) (36) –
Resistance Max. 1 z
wiring or defective contact in NE (female) (1)
connector)
Wiring harness between EN2 (female) (26) –
Resistance Max. 1 z
NE (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between EN2 (female) (36) –
Resistance Min. 1 Mz
ground in wiring harness
NE (female) (1) with chassis ground
(Contact with ground circuit)
Wiring harness between EN2 (female) (26) –
Resistance Min. 1 Mz
NE (female) (2) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN2
Resistance
Defective engine controller
Between (36) – (26)
85 – 210 z
Between (36), (26) –
Min. 1 Mz
chassis ground
Circuit diagram related to engine Ne speed sensor
20-530
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DLF1KA
ERROR CODE DLF1KA (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION
(KA))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DLF1KA
Controller code
Steering
Trouble
Transmission output speed sensor: Disconnection (KA)
(Steering and transmission controller system)
• Signal is not input from transmission output speed sensor.
• Flashes caution lamp and turns on caution buzzer.
• Assumes that transmission output speed is 0 rpm.
• Transmission speed cannot be monitored.
• Traction force cannot be calculated.
• Transmission output speed can be checked in monitoring mode.
(Code 31400: Transmission speed)
• Method of reproducing error code: Start engine and travel machine actually.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then turn starting switch ON and
Defective transmission
carry out troubleshooting.
output speed sensor
TM1 (male)
Resistance
(Internal disconnection or
Between (1) – (2)
400 – 1,000 z
short circuit)
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST2 (female) (30) –
Resistance Max. 1 z
wiring or defective contact in TM1 (female) (1)
connector)
Wiring harness between ST2 (female) (29) –
Resistance Max. 1 z
TM1 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring
harness between ST2 (female) (30) –
(Contact with ground circuit)
Resistance Min. 1 Mz
TM1 (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST2 (female)
Resistance
transmission controller
Between (30) – (29)
400 – 1,000 z
Between (30) – chassis ground
Min. 1 z
Circuit diagram related to transmission output speed sensor
D65EX, PX-15
20-531
(1)
TROUBLESHOOTING
ERROR CODE DLH1LC
ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: SEE TABLE (LC))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DLH1LC
Controller code
Engine
Trouble
Engine G speed sensor: See table (LC)
(Engine controller system)
• Cylinder cannot be identified from signal of engine G speed sensor.
• Flashes caution lamp and turns on caution buzzer.
• Limits operation of engine and transmission.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
• Special adapter (799-601-9410) is necessary for troubleshooting for engine G speed sensor.
• Method of reproducing error code: Start engine.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective engine G speed
G (male)
Resistance
sensor (Internal disconnection or short circuit)
Between (1) – (2)
1.4 k – 3.5 kz
Between (1), (2) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between EN2 (female) (35) – G
Resistance Max. 1 z
wiring or defective contact in (female) (1)
connector)
Wiring harness between EN2 (female) (25) – G
Resistance Max. 1 z
(female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between EN2 (female) (35) – G
Resistance Min. 1 Mz
ground in wiring harness
(female) (1) with chassis ground
(Contact with ground circuit)
Wiring harness between EN2 (female) (25) – G
Resistance Min. 1 Mz
(female) (2) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EN2 (female)
Resistance
Defective engine controller
Between (35) – (25)
1.4 k – 3.5 kz
Between (35), (25) –
Min. 1 Mz
chassis ground
Circuit diagram related to engine G speed sensor
20-532
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DV00KB
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB))
Action code
—
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DV00KB
Controller code
MON
Caution buzzer: Short circuit (KB)
(Monitor panel system)
• Abnormal current flowed when caution buzzer circuit output ground signal.
• Stops caution buzzer circuit from outputting ground signal.
• Caution buzzer does not sound.
• Method of reproducing error code: Turn starting switch ON (When it is turned ON, buzzer sounds for 1
second).
Cause
1
Possible causes
and standard
value in normal
state
Trouble
Defective caution buzzer
(Internal short circuit)
Short circuit with power
2 source in wiring harness
(Contact with 24 V circuit)
3 Defective monitor panel
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
217 (male)
Resistance
Between (1) – (2)
200 z
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between 217 (female) (1) –
Voltage
Max. 1 V
S03 (female) (18) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
S03
Caution buzzer
Voltage
When turned OFF
20 – 30 V
Between (18) –
When turned ON
chassis ground
Max. 3 V
(sounding)
Circuit diagram related to caution buzzer
D65EX, PX-15
20-533
(1)
TROUBLESHOOTING
ERROR CODE DW5AKA
ERROR CODE DW5AKA (PITCH CONTROL SOLENOID: DISCONNECTION (KA))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DW5AKA
Controller code
Steering
Trouble
Pitch control solenoid: Disconnection (KA)
(Steering and transmission controller system)
• Any current does not flow when power is output to pitch control solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting power to pitch control solenoid circuit.
• Pitch control cannot be performed.
• Output state (ON/OFF) to pitch control solenoid can be checked in monitoring mode.
(Code 70304: Work equipment-related controller output signal)
• Method of reproducing error code: Turn starting switch ON and operate pitch control switch.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective pitch control solenoid (Internal disconnection)
52 (male)
Resistance
Between (1) – (2)
20 – 30 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (17) –
Resistance Max. 1 z
wiring or defective contact in 52 (female) (1)
connector)
Wiring harness between ST3 (female) (3) –
Resistance Max. 1 z
52 (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (17) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
52 (female) (1) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
ST3
Voltage
Between (17) – (3)
20 – 30 V
Circuit diagram related to pitch control solenoid
20-534
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DW5AKB
ERROR CODE DW5AKB (PITCH CONTROL SOLENOID: SHORT CIRCUIT (KB))
Action code
E02
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DW5AKB
Controller code
Steering
Trouble
Pitch control solenoid: Short circuit (KB)
(Steering and transmission controller system)
• Abnormal current flowed when power is output to pitch control solenoid circuit.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting power to pitch control solenoid circuit.
• Pitch control cannot be performed.
• Output state (ON/OFF) to pitch control solenoid can be checked in monitoring mode.
(Code 70304: Work equipment-related controller output signal)
• Method of reproducing error code: Turn starting switch ON and operate pitch control switch.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective pitch control sole52 (male)
Resistance
noid (Internal short circuit)
Between (1) – (2)
20 – 30 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring harness between ST3 (female) (17) –
(Contact with ground circuit)
Resistance Min. 1 Mz
52 (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (17) –
harness)
Resistance Min. 1 Mz
52 (female) (1) with wiring harness between
ST3 (female) (3) – 52 (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3 (female)
Resistance
transmission controller
Between (17) – (3)
20 – 30 z
Between (17) – chassis ground
Min. 1 Mz
Circuit diagram related to pitch control solenoid
D65EX, PX-15
20-535
(1)
TROUBLESHOOTING
ERROR CODE DW7BKA
ERROR CODE DW7BKA (FAN REVERSE SOLENOID: DISCONNECTION (KA))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DW7BKA
Controller code
Steering
Trouble
Fan reverse solenoid: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to fan reverse solenoid circuit, any current does not flow.
• Stops outputting to fan reverse solenoid circuit.
• The fan reversing function cannot be used.
• Output (ON/OFF) to fan reverse solenoid can be checked in monitoring mode.
(Code 40914: Steering-related controller output signal)
• Method of reproducing service code: Turn starting switch ON and operate fan in reverse/cooling position.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan reverse solenoid (Internal disconnection)
FAR (male)
Resistance
Between (1) – (2)
34 – 44 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (18) –
Resistance Max. 1 z
wiring or defective contact in FAR (female) (1)
connector)
Wiring harness between ST3 (female) (13) –
Resistance Max. 1 z
FAR (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (18) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
FAR (female) (1) with chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective steering and
transmission controller
ST3 (female)
Voltage
Between (18) – (13)
15 – 25 V
Circuit diagram related to fan reverse solenoid
20-536
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DW7BKB
ERROR CODE DW7BKB (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DW7BKB
Controller code
Steering
Trouble
Fan reverse solenoid: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to fan reverse solenoid circuit, abnormal current flowed.
• Stops outputting to fan reverse solenoid circuit.
• The fan reversing function cannot be used.
• Output (ON/OFF) to fan reverse solenoid can be checked in monitoring mode.
(Code 40914: Steering-related controller output signal)
• Method of reproducing service code: Turn starting switch ON and operate fan in reverse/cooling position.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan reverse soleFAR (male)
Resistance
noid (Internal short circuit)
Between (1) – (2)
34 – 44 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
(Contact with ground circuit) Wiring harness between ST3 (female) (18) – Resistance Min. 1 Mz
FAR (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (18) –
harness)
FAR (female) (1) with wiring harness between Resistance Min. 1 Mz
ST3 (female) (13) – FAR (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3 (female)
Resistance
transmission controller
Between (18) – (13)
34 – 44 z
Between (18) – chassis ground
Min. 1 Mz
Circuit diagram related to fan reverse solenoid
D65EX, PX-15
20-537
(1)
TROUBLESHOOTING
ERROR CODE DWN1KA
ERROR CODE DWN1KA (HSS EPC SOLENOID RIGHT: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DWN1KA
Controller code
Steering
Trouble
HSS EPC solenoid right: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to HSS EPC solenoid right circuit, any current does not flow.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to HSS EPC solenoid right circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Output (Current) to HSS EPC solenoid right can be checked in monitoring mode.
(Code 50603: Right HSS solenoid output current)
• Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to
right).
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective HSS EPC solewithout turning starting switch ON.
noid right (Internal disconHSB (male)
Resistance
nection)
Between (1) – (2)
5 – 15 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (35) –
Resistance Max. 1 z
wiring or defective contact in HSB (female) (1)
connector)
Wiring harness between ST3 (female) (3) –
Resistance Max. 1 z
HSB (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (35) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
HSB (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3
Resistance
Between (35) – (3)
5 – 15 z
Circuit diagram related to HSS EPC solenoid right
20-538
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DWN1KB
ERROR CODE DWN1KB (HSS EPC SOLENOID RIGHT: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DWN1KB
Controller code
Steering
Trouble
HSS EPC solenoid right: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to HSS EPC solenoid right circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to HSS EPC solenoid right circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Output (Current) to HSS EPC solenoid right can be checked in monitoring mode.
(Code 50603: Right HSS solenoid output current)
• Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to
right).
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective HSS EPC soleHSB (male)
Resistance
noid right (Internal short
circuit)
Between (1) – (2)
5 – 15 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring harness between ST3 (female) (35) –
(Contact with ground circuit)
Resistance Min. 1 Mz
HSB (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (35) –
harness)
HSB (female) (1) with wiring harness between Resistance Min. 1 Mz
ST3 (female) (3) – HSB (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3
Resistance
transmission controller
Between (35) – (3)
5 – 15 z
Between (35) – chassis ground
Min. 1 Mz
Circuit diagram related to HSS EPC solenoid right
D65EX, PX-15
20-539
(1)
TROUBLESHOOTING
ERROR CODE DWN2KA
ERROR CODE DWN2KA (HSS EPC SOLENOID LEFT: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DWN2KA
Controller code
Steering
Trouble
HSS EPC solenoid left: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to HSS EPC solenoid left circuit, any current does not flow.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to HSS EPC solenoid left circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Output (Current) to HSS EPC solenoid left can be checked in monitoring mode.
(Code 50602: Left HSS solenoid output current)
• Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to
left).
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective HSS pump solewithout turning starting switch ON.
noid left (Internal disconnecHSA (male)
Resistance
tion)
Between (1) – (2)
5 – 15 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (25) –
Resistance Max. 1 z
wiring or defective contact in HSA (female) (1)
connector)
Wiring harness between ST3 (female) (3) –
Resistance Max. 1 z
HSA (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (25) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
HSA (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3
Resistance
Between (25) – (3)
5 – 15 z
Circuit diagram related to HSS EPC solenoid left
20-540
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DWN2KB
ERROR CODE DWN2KB (HSS EPC SOLENOID LEFT: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DWN2KB
Controller code
Steering
Trouble
HSS EPC solenoid left: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to HSS EPC solenoid left circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to HSS EPC solenoid left circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Output (Current) to HSS EPC solenoid left can be checked in monitoring mode.
(Code 50602: Left HSS solenoid output current)
• Method of reproducing service code: Turn starting switch ON and operate PCCS lever (for steering to
left).
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective HSS EPC soleHSA (male)
Resistance
noid left (Internal short
circuit)
Between (1) – (2)
5 – 15 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring harness between ST3 (female) (25) –
(Contact with ground circuit)
Resistance Min. 1 Mz
HSA (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (25) –
harness)
HSA (female) (1) with wiring harness between Resistance Min. 1 Mz
ST3 (female) (3) – HSA (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3 (female)
Resistance
transmission controller
Between (25) – (3)
5 – 15 z
Between (25) – chassis ground
Min. 1 Mz
Circuit diagram related to HSS EPC solenoid left
D65EX, PX-15
20-541
(1)
TROUBLESHOOTING
ERROR CODE DWN5KA
ERROR CODE DWN5KA (FAN PUMP TVC SOLENOID: DISCONNECTION (KA))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DWN5KA
Controller code
Steering
Trouble
Fan pump TVC solenoid: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to fan pump TVC solenoid circuit, any current does not flow.
• Stops outputting to fan pump TVC solenoid circuit.
• Fan speed is kept at maximum level.
• Output (Current) to fan pump TVC solenoid can be checked in monitoring mode.
(Code 31623, 31624: Cooling fan solenoid output current)
• Method of reproducing service code: Turn starting switch ON.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan pump solenoid
(Internal disconnection)
FAC (male)
Resistance
Between (1) – (2)
5 – 15 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (36) –
Resistance Max. 1 z
wiring or defective contact in FAC (female) (1)
connector)
Wiring harness between ST3 (female) (23) –
Resistance Max. 1 z
FAC (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (36) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
FAC (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3 (female)
Resistance
Between (36) – (23)
5 – 15 z
Circuit diagram related to fan pump TVC solenoid
20-542
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DWN5KB
ERROR CODE DWN5KB (FAN PUMP TVC SOLENOID: SHORT CIRCUIT (KB))
Action code
E01
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DWN5KB
Controller code
Steering
Trouble
Fan pump TVC solenoid: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to fan pump TVC solenoid circuit, abnormal current flowed.
• Stops outputting to fan pump TVC solenoid circuit.
• Fan speed is kept at maximum level.
• Output (Current) to fan pump TVC solenoid can be checked in monitoring mode.
(Code 31623, 31624: Cooling fan solenoid output current)
• Method of reproducing service code: Turn starting switch ON.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan pump solenoid
FAC (male)
Resistance
(Internal short circuit)
Between (1) – (2)
5 – 15 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
Wiring harness between ST3 (female) (36) –
(Contact with ground circuit)
Resistance Min. 1 Mz
FAC (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (36) –
harness)
FAC (female) (1) with wiring harness between Resistance Min. 1 Mz
ST3 (female) (23) – FAC (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3 (female)
Resistance
transmission controller
Between (36) – (23)
5 – 15 z
Between (36) – chassis ground
Min. 1 Mz
Circuit diagram related to fan pump TVC solenoid
D65EX, PX-15
20-543
(1)
TROUBLESHOOTING
ERROR CODE DXH4KA
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DXH4KA
Controller code
Steering
Trouble
1st clutch ECMV: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to 1st clutch solenoid circuit, any current does not flow.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission 1st clutch solenoid circuit.
• Limits operation of engine and transmission.
• Automatic shift-down function does not work.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F2 and R2.
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
(Code 31602, 31612: Output current of 1st clutch ECMV)
• Method of reproducing service code: Start engine and drive machine in F1 or R1.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 1st clutch ECMV
(Internal disconnection)
1SOL (male)
Resistance
Between (1) – (2)
5 – 25 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (6) –
Resistance Max. 1 z
wiring or defective contact in 1SOL (female) (1)
connector)
Wiring harness between ST3 (female) (23) –
Resistance Max. 1 z
1SOL (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (6) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
1SOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3 (female)
Resistance
Between (6) – (23)
5 – 25 z
Circuit diagram related to transmission 1st clutch ECMV
20-544
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DXH4KB
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Error code
DXH4KB
Controller code
Steering
Trouble
1st clutch ECMV: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission 1st clutch solenoid circuit.
• Limits operation of engine and transmission.
• Automatic shift-down function does not work.
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F2 and R2.
• Output (Current) to 1st clutch solenoid can be checked in monitoring mode.
(Code 31602, 31612: Output current of 1st clutch ECMV)
• Method of reproducing service code: Start engine and drive machine in F1 or R1.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 1st clutch ECMV
1SOL (male)
Resistance
(Internal short circuit)
Between (1) – (2)
5 – 25 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
(Contact with ground circuit) Wiring harness between ST3 (female) (6) –
Resistance Min. 1 Mz
1SOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (6) –
harness)
Resistance Min. 1 Mz
1SOL (female) (1) with wiring harness between ST3 (female) (23) – 1SOL (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3 (female)
Resistance
transmission controller
Between (6) – (23)
5 – 25 z
Between (6) – chassis ground
Min. 1 Mz
Circuit diagram related to transmission 1st clutch ECMV
D65EX, PX-15
20-545
(1)
TROUBLESHOOTING
ERROR CODE DXH5KA
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DXH5KA
Controller code
Steering
Trouble
2nd clutch ECMV: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to 2nd clutch solenoid circuit, any current does not flow.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission 2nd clutch solenoid circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
(Code 31603, 31613: Output current of 2nd clutch ECMV)
• Method of reproducing service code: Start engine and drive machine in F2 or R2.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 2nd clutch ECMV
(Internal disconnection)
2SOL (male)
Resistance
Between (1) – (2)
5 – 25 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (16) –
Resistance Max. 1 z
wiring or defective contact in 2SOL (female) (1)
connector)
Wiring harness between ST3 (female) (23) –
Resistance Max. 1 z
2SOL (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (16) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
2SOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3 (female)
Resistance
Between (16) – (23)
5 – 25 z
Circuit diagram related to transmission 2nd clutch ECMV
20-546
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DXH5KB
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DXH5KB
Controller code
Steering
Trouble
2nd clutch ECMV: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission 2nd clutch solenoid circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Output (Current) to 2nd clutch solenoid can be checked in monitoring mode.
(Code 31603, 31613: Output current of 2nd clutch ECMV)
• Method of reproducing service code: Start engine and drive machine in F2 or R2.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 2nd clutch ECMV
2SOL (male)
Resistance
(Internal short circuit)
Between (1) – (2)
5 – 25 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
(Contact with ground circuit) Wiring harness between ST3 (female) (16) – Resistance Min. 1 Mz
2SOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (16) –
harness)
Resistance Min. 1 Mz
2SOL (female) (1) with wiring harness between ST3 (female) (23) – 2SOL (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3 (female)
Resistance
transmission controller
Between (16) – (23)
5 – 25 z
Between (16) – chassis ground
Min. 1 Mz
Circuit diagram related to transmission 2nd clutch ECMV
D65EX, PX-15
20-547
(1)
TROUBLESHOOTING
ERROR CODE DXH6KA
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DXH6KA
Controller code
Steering
Trouble
3rd clutch ECMV: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to 3rd clutch solenoid circuit, any current does not flow.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission 3rd clutch solenoid circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
(Code 31604, 31614: Output current of 3rd clutch ECMV)
• Method of reproducing service code: Start engine and drive machine in F3 or R3.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 3rd clutch ECMV
(Internal disconnection)
3SOL (male)
Resistance
Between (1) – (2)
5 – 25 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (26) –
Resistance Max. 1 z
wiring or defective contact in 3SOL (female) (1)
connector)
Wiring harness between ST3 (female) (23) –
Resistance Max. 1 z
3SOL (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (26) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
3SOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3 (female)
Resistance
Between (26) – (23)
5 – 25 z
Circuit diagram related to transmission 3rd clutch ECMV
20-548
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DXH6KB
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DXH6KB
Controller code
Steering
Trouble
3rd clutch ECMV: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission 3rd clutch solenoid circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1 and R1.
Related
information
• Output (Current) to 3rd clutch solenoid can be checked in monitoring mode.
(Code 31604, 31614: Output current of 3rd clutch ECMV)
• Method of reproducing service code: Start engine and drive machine in F3 or R3.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 3rd clutch ECMV
3SOL (male)
Resistance
(Internal short circuit)
Between (1) – (2)
5 – 25 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
(Contact with ground circuit) Wiring harness between ST3 (female) (26) – Resistance Min. 1 Mz
3SOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (26) –
harness)
Resistance Min. 1 Mz
3SOL (female) (1) with wiring harness between ST3 (female) (23) – 3SOL (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3
Resistance
transmission controller
Between (26) – (23)
5 – 25 z
Between (26) – chassis ground
Min. 1 Mz
Circuit diagram related to transmission 3rd clutch ECMV
D65EX, PX-15
20-549
(1)
TROUBLESHOOTING
ERROR CODE DXH7KA
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DXH7KA
Controller code
Steering
Trouble
Reverse clutch ECMV: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to reverse clutch solenoid circuit, any current does not flow.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission reverse clutch solenoid circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1.
Related
information
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
(Code 31606, 31616: Output current of reverse clutch ECMV)
• Method of reproducing service code: Start engine and drive machine in reverse.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
Defective reverse clutch
without turning starting switch ON.
ECMV (Internal disconnecRSOL (male)
Resistance
tion)
Between (1) – (2)
5 – 25 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (37) –
Resistance Max. 1 z
wiring or defective contact in RSOL (female) (1)
connector)
Wiring harness between ST3 (female) (13) –
Resistance Max. 1 z
RSOL (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (37) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
RSOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3 (female)
Resistance
Between (37) – (13)
5 – 25 z
Circuit diagram related to transmission reverse clutch ECMV
20-550
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DXH7KB
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DXH7KB
Controller code
Steering
Trouble
Reverse clutch ECMV: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission reverse clutch solenoid circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to F1.
Related
information
• Output (Current) to reverse clutch solenoid can be checked in monitoring mode.
(Code 31606, 31616: Output current of reverse clutch ECMV)
• Method of reproducing service code: Start engine and drive machine in reverse.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective reverse clutch
RSOL (male)
Resistance
ECMV (Internal short circuit)
Between (1) – (2)
5 – 25 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
(Contact with ground circuit) Wiring harness between ST3 (female) (37) – Resistance Min. 1 Mz
RSOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (37) –
harness)
Resistance Min. 1 Mz
RSOL (female) (1) with wiring harness between ST3 (female) (13) – RSOL (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3 (female)
Resistance
transmission controller
Between (37) – (13)
5 – 25 z
Between (37) – chassis ground
Min. 1 Mz
Circuit diagram related to transmission reverse clutch ECMV
D65EX, PX-15
20-551
(1)
TROUBLESHOOTING
ERROR CODE DXH8KA
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DXH8KA
Controller code
Steering
Trouble
Forward clutch ECMV: Disconnection (KA)
(Steering and transmission controller system)
• When signal is output to forward clutch solenoid circuit, any current does not flow.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission forward clutch solenoid circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to R1.
Related
information
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
(Code 31608, 31622: Output current of forward clutch ECMV)
• Method of reproducing service code: Start engine and drive machine forward.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective forward clutch
ECMV (Internal short circuit)
FSOL (male)
Resistance
Between (1) – (2)
5 – 25 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
harness (Disconnection in Wiring harness between ST3 (female) (27) –
Resistance Max. 1 z
wiring or defective contact in FSOL (female) (1)
connector)
Wiring harness between ST3 (female) (13) –
Resistance Max. 1 z
FSOL (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and
Short circuit with power
carry out troubleshooting.
source in wiring harness
Wiring harness between ST3 (female) (27) –
(Contact with 24 V circuit)
Voltage
Max. 1 V
FSOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
transmission controller
ST3 (female)
Resistance
Between (27) – (13)
5 – 25 z
Circuit diagram related to transmission forward clutch ECMV
20-552
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DXH8KB
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))
Action code
CALL E03
Contents of
trouble
Action of
controller
Error code
DXH8KB
Controller code
Steering
Trouble
Forward clutch ECMV: Short circuit (KB)
(Steering and transmission controller system)
• When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.
• Flashes caution lamp and turns on caution buzzer.
• Stops outputting to transmission forward clutch solenoid circuit.
• Limits operation of engine and transmission.
Problem that
appears on
machine
• Once machine is stopped, engine speed is limited to medium (half).
• Once machine is stopped, travel is limited to R1.
Related
information
• Output (Current) to forward clutch solenoid can be checked in monitoring mode.
(Code 31608, 31622: Output current of forward clutch ECMV)
• Method of reproducing service code: Start engine and drive machine forward.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective forward clutch
FSOL (male)
Resistance
ECMV (Internal short circuit)
Between (1) – (2)
5 – 25 z
Between (1) – chassis ground
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
Short circuit with chassis
without turning starting switch ON.
ground in wiring harness
(Contact with ground circuit) Wiring harness between ST3 (female) (27) – Resistance Min. 1 Mz
FSOL (female) (1) with chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring harness (with another wiring
Wiring harness between ST3 (female) (27) –
harness)
Resistance Min. 1 Mz
FSOL (female) (1) with wiring harness between ST3 (female) (13) – FSOL (female) (2)
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective steering and
ST3 (female)
Resistance
transmission controller
Between (27) – (13)
5 – 25 z
Between (27) – chassis ground
Min. 1 Mz
Circuit diagram related to transmission forward clutch ECMV
D65EX, PX-15
20-553
(1)
TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E-MODE)
Information described in troubleshooting list ........................................................................................... 20-602
E- 1 The engine does not start .............................................................................................................. 20-603
E- 2 The preheater does not operate. ................................................................................................... 20-606
E- 3 The monitor panel does not come on at all when the starting switch is turned on. ....................... 20-608
E- 4 When the starting switch is turned on, the monitor panel completely remains lighted
and does not go out. ...................................................................................................................... 20-609
E- 5 While the engine is operating, the battery charge level caution lamp flashes. ............................... 20-610
E- 6 While the engine is operating, the emergency warning item flashes. ............................................ 20-612
E- 7 While the preheater is operating, the preheating pilot lamp does not come on. ............................ 20-615
E- 8 The engine water temperature gauge does not indicate normally. ................................................ 20-617
E- 9 Indication of the power train temperature gauge is abnormal. ....................................................... 20-618
E-10 The hydraulic oil temperature gauge does not indicate normally. .................................................. 20-619
E-11 Indication of the fuel gauge is abnormal. ....................................................................................... 20-620
E-12 Indications of gear speed and engine speed are abnormal. .......................................................... 20-621
E-13 Indication of the preset mode service meter is abnormal. ............................................................. 20-621
E-14 The warning lamp does not flash or does not go out. .................................................................... 20-621
E-15 The alarm buzzer does not sound or does not stop. ...................................................................... 20-622
E-16 Auto shift down is not possible or is not released. ......................................................................... 20-623
E-17 The buzzer cancel switch does not work. ...................................................................................... 20-624
E-18 The information switch does not work. ........................................................................................... 20-625
E-19 The preset mode does not operate or cannot be reset. ................................................................. 20-626
E-20 The monitor panel cannot be set in the service mode or cannot be set out of the service mode. . 20-627
E-21 The back-up alarm does not sound. .............................................................................................. 20-629
E-22 The head lamp and rear lamp do not light up. ............................................................................... 20-630
E-23 Malfunction of wipers ..................................................................................................................... 20-632
E-24 Washing water does not come out. ................................................................................................ 20-648
E-25 The air conditioner does not operate. ............................................................................................ 20-653
D65EX, PX-15
20-601
(1)
TROUBLESHOOTING
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
a Troubleshooting lists and related circuit diagrams contain the following information all together. Understand
the contents carefully and troubleshoot the machine.
Trouble
Related
information
Problem that appears on the machine.
Information related to problems occurred or troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting
<Described contents>
• Standard value in normal state required to judge the assumed cause
(good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness is disconnected.
• Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Defective hot short
A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit.
• Defective short
A harness of an independent circuit abnormally comes into contact
with one of another circuit.
2
Possible causes
and standard
value in normal
state
Cause by which a trouble is
assumed to be detected
(The order number indicates a
serial number, not a priority <Notes on troubleshooting>
sequence.)
(1) Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect the T-junction adapter as
shown below unless especially specified.
3
• When “male” or “female” is not indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
both the male and female.
• When “male” or “female” is indicated for a connector number, disconnect the connector, and insert the T-junction adapter in only
either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads as
shown below unless especially specified.
4
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in the
rear.
Related circuit diagram
This is the excerpted circuit diagram related to trouble
• Connector No.: Indicates (Model-No. of pins) (Color).
• Arrow ( ): Roughly indicates mounting place on machine.
20-602
(1)
D65EX, PX-15
TROUBLESHOOTING
E-1
E-1 THE ENGINE DOES NOT START
Trouble
Related
information
• The engine does not start.
• The engine start circuit has the neutral safety function, and the engine does not start unless the parking
lever is set to the lock position or the travel lever is in the neutral position.
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” when
the starting switch is set to ON, the main electric power supply system is supposed to be out of order.
So, inspect the main electric power supply system.
Cause
1
2
3
4
Possible causes
and standard
value in normal
state
5
6
7
D65EX, PX-15
Standard value in normal state/Remarks on troubleshooting
Battery voltage
Battery specific gravity
Insufficient battery capacity
Min. 25 V
Min. 1.26
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective starting switch
Starting switch
Switch position
Resistance
(internal disconnection)
OFF
Min. 1 Mz
Between 250 (B) and
280 (C)
START
Max. 1 z
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective parking lever
Parking lever
switch (Internal trouble deFree
position
Lock position
fect or defective adjustment)
Monitor panel
Other than “P” is
“P” is displayed
displayed
aPrepare with the starting switch OFF, then start the engine and carry
out troubleshooting.
Defective neutral safety relay
If the engine starts in accordance with the engine starting arrangement
(internal disconnection)
after the neutral safety relay (NSF) is replaced with another one while
the starting switch is set to OFF, the relay is defective.
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective alternator (internal
short circuit)
Alternator
Voltage
Between Terminal R and ground
Max. 12 V
aPrepare with the starting switch OFF, then start the engine and carry
out troubleshooting.
Starting motor
Voltage
Electric power supply: between
20 – 30 V
Terminal B and ground
Detective starting motor
Charge: between ST (2) and
Max. 12 V
(internal defect)
ground
Starting: between ST (1) and
20 – 30 V
ground
When the voltages of electric power supply, for charging and starting
are normal but the starting motor does not rotate, the starting motor is
defective.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring
harness between 280 (C) and NFS (feDisconnection in wiring
Resistance Max. 1 z
male) (3)
harness (disconnection in
wiring or defective contact in Wiring harness between NSF (female) (5) and
Resistance Max. 1 z
connector)
ST (female) (1)
Wiring harness between NSF (female) (5) and
Resistance Max. 1 z
EN1 (female) (20)
20-603
(1)
TROUBLESHOOTING
E-1
Cause
Possible causes
and standard
value in normal
state
20-604
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Hot short circuit of wiring
8 harness (Contact with 24 V Wiring harness between alternator R terminal
circuit)
and ST (female) (2) or ST1 (female) (15) or
Voltage
Max. 1 V
S04 (female) (9) with ground
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring harness between 280 (C) – NSF (feResistance Min. 1 Mz
Short circuit with chassis
male) (3) and chassis ground
9 ground in wiring harness
Wiring harness between NSF (female) (5) – ST
(Contact with ground circuit)
Resistance Min. 1 Mz
(female) (1) and chassis ground
Wiring harness between NSF (female) (5) –
Resistance Min. 1 Mz
EN1 (female) (20) and chassis ground
D65EX, PX-15
TROUBLESHOOTING
E-1
Engine start/charge-related circuit diagram
D65EX, PX-15
20-605
(1)
TROUBLESHOOTING
E-2
E-2 THE PREHEATER DOES NOT OPERATE.
Trouble
Related
information
• The preheater does not operate.
aThis troubleshooting describes the procedures to be followed when the manual preheating function
cannot heat the electrical intake air heater mounting section. (When the preheating lamp only does not
come on, carry out the troubleshooting of “The preheating lamp does not come on”.)
• For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are
available. When either function is performed, the preheating lamp comes on.
• If “the monitor panel does not come on” or “the battery relay does not cause operating sound” hen the
starting switch is turned ON, the main electric power supply system supposed to be out of order. So,
inspect the main electric power supply system.
Cause
1
Defective starting switch
(Internal disconnection)
2
Defective fuse
(FUSE, FS1, 2)
3
4
Possible causes
and standard
value in normal
state
5
6
7
20-606
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Starting switch
Switch position
Resistance
OFF
Min. 1 Mz
Between 250 (B) and
280 (C)
HEAT
Max. 1 z
If fuse is broken, circuit probably has a grounding fault, etc.
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective preheater relay
Disconnect
coolant sensor TWL with starting switch OFF and replace
(Internal disconnection)
preheater relay with another one, and then turn starting switch ON. If
preheating is started, preheater relay RHR is defective.
aPrepare with the starting switch OFF, then set the starting switch to
HEAT and carry out troubleshooting.
Heater relay
Voltage
Electric power supply: between
20 – 30 V
Defective heater relay
Terminal HT/B (B) and ground
(internal defect)
Signal: between Terminal
20 – 30 V
HT/S (C) and ground
When the both voltages of electric power supply and signal are normal
and no operating sound is caused, the heater relay is defective.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective electrical intake air
Electrical intake air heater
Continuity
heater (internal defect)
Between terminals
Continue
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring harness between starting switch 255
Resistance Max. 1 z
(R1) and RHR (female) (3) and HT/S (C)
Disconnection in wiring
harness (Disconnection in Wiring harness between RHR (female) (5) –
Resistance Max. 1 z
wiring or defective contact in FS1 (7)
connector)
Wiring harness between battery relay and CN-C
Resistance Max. 1 z
and ST/B and HT/B
Wiring harness between heater relay HT/A (A)
Resistance Max. 1 z
terminal and electrical intake air heater
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring harness between starting switch 255
Resistance Min. 1 Mz
(R1) – RHR (3) – HT/S (C) terminal and ground
Short circuit with chassis
Wiring harness between RHR (female) (5) –
Resistance Min. 1 Mz
ground in wiring harness
FS1 (7) and ground
(Contact with ground circuit)
Wiring harness between battery relay C –
Resistance Min. 1 Mz
ST/B terminal – HT/B and ground
Wiring harness between heater relay HT/A –
Resistance Min. 1 Mz
intake air heater terminal and ground
D65EX, PX-15
TROUBLESHOOTING
E-2
Engine preheat-related circuit diagram
D65EX, PX-15
20-607
(1)
TROUBLESHOOTING
E-3
E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING
SWITCH IS TURNED ON.
Trouble
Related
information
• If “operation sound of the battery is not heard” when the starting switch is turned ON, the main power
supply system may be defective. Accordingly, check the may power supply system.
• The monitor panel does not come on at all when the starting switch is turned ON.
• When the starting switch is turned ON, the gear speed indicator, the multi information section, the
gauge section and the lamp section come on for approximately 2 sec. and go out.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
Standard value in normal state/Remarks on troubleshooting
When the fuse FS2-(6) is cut off, the circuit may have possibly been
Defective fuse FS2-(6)
short-circuited with ground.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between S03 (female) (1) (2)
Resistance Max. 1 z
wiring or defective contact in and fuse FS2-(6)
connector)
Wiring harness between S03 (female) (3) (4)
Resistance Max. 1 z
and GND01 and ground
aPrepare with the starting switch OFF, then carry out troubleshooting
Ground fault of wiring
without turning the starting switch ON.
harness (Contact with
Wiring harness between S03 (female) (1), (2)
ground circuit)
Resistance Min. 1 Mz
– fuse FS2-(6) with ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective monitor panel
S03
Voltage
Between (1) (2) and (3) (4)
20 – 30 V
Circuit diagram related to ripper pin puller solenoid
20-608
(1)
D65EX, PX-15
TROUBLESHOOTING
E-4
E-4 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL
COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
Trouble
Related
information
Possible causes
and standard
value in normal
state
D65EX, PX-15
• When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
out.
• When the starting switch is turned ON, the gear speed indicator, the multi information section, the
gauge section and the lamp section come on for approximately 2 sec. and go out.
Cause
1 Defective monitor panel
Standard value in normal state/Remarks on troubleshooting
This internal defect cannot be diagnosed.
20-609
(1)
TROUBLESHOOTING
E-5
E-5 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION
LAMP FLASHES.
Trouble
Related
information
• The battery charge level caution lamp flashes.
• When any abnormality is detected during engine operation, the battery charge level caution lamp will
flash.
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
20-610
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then start the engine and carry
out troubleshooting.
Defective alternator (insuffiAlternator
Engine speed
Voltage
cient power generation)
Between Terminal R
Min. medium speed
20 – 30 V
and ground
(half)
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between S04 (female) (9) and
Resistance Max. 1 z
wiring or defective contact in alternator R terminal
connector)
Between wiring harness AL/F and GND03 and
Resistance Max. 1 z
ground
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Ground fault of wiring
harness (Contact with
Between wiring harness (between S04 (female)
ground circuit)
Resistance Min. 1 Mz
(9) and alternator R terminal, or STC1 (1) (female) (15)) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective monitor panel
S04
Engine speed
Voltage
Between (9) and
Medium speed (half)
20 – 30 V
ground
D65EX, PX-15
TROUBLESHOOTING
E-5
Engine start/charge-related circuit diagram
D65EX, PX-15
20-611
(1)
TROUBLESHOOTING
E-6
E-6 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM
FLASHES.
Trouble (1)
Related
information
• The engine oil pressure caution lamp flashes.
• When any abnormality is detected during engine operation, the engine oil pressure caution lamp will
flash and sound the alarm buzzer.
• The engine oil pressure switch signal is sent and received from the engine controller through communication.
• Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode.
(Code 40900: Engine controller input signal 1)
1
2
3
Possible causes
and standard
value in normal
state
4
5
6
Cause
Standard value in normal state/Remarks on troubleshooting
Drop of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is de(when the system is normal) tected.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the switch ON or after starting the engine.
The engine oil low pressure
PSL
Engine
Resistance
switch is defective.
(Internal short circuit)
Stop
Max. 1 z
Between terminal and
ground
Min. 600 rpm
Min. 1 Mz
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the switch ON or after starting the engine.
The engine oil high pressure
PSH
Engine
Resistance
switch is defective.
(Internal short circuit)
Stop
Max. 1 z
Between terminal and
ground
Min. 1,300 rpm
Min. 1 Mz
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Ground fault of wiring
Between wiring harness (between EN1 (female)
Resistance Min. 1 Mz
harness (Contact with
(21) and PSL) and ground
ground circuit)
Between wiring harness (between EN1 (female)
Resistance Min. 1 Mz
(15) and PSH) and ground
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the switch ON or after starting the engine.
EN1
Engine
Voltage
Stop
Max. 1 V
Defective engine controller
Between (21) and
ground
Min. 600 rpm
5 – 11 V
Stop
Max. 1 V
Between (15) and
ground
Min. 1,300 rpm
5 – 11 V
Defective monitor panel
This is an internal defect, which cannot be troubleshot.
Circuit diagram related to engine oil low pressure switch and engine oil high pressure switch
20-612
(1)
D65EX, PX-15
TROUBLESHOOTING
Trouble (2)
Related
information
• The engine water temperature caution lamp flashes.
• When any abnormality is detected during engine operation, the engine water temperature caution lamp
will flash and sound the alarm buzzer.
• The engine water temperature caution lamp flashes or goes out as it links with indication on the engine
water temperature gauge.
• Input state (temperature) from engine water temperature (high temperature side) sensor can be
checked in monitoring mode.
(Code 04102: Engine water temperature (high temperature side))
Cause
Overheated engine water
1 temperature (when the
system is normal)
Possible causes
and standard
value in normal
state
E-6
The engine water temperature sensor system is
2
defective. (Engine controller
system)
Standard value in normal state/Remarks on troubleshooting
As overheated engine water was detected, check the engine water
temperature. (When the water temperature is over 108ºC, the lamp
flashes.)
Check the indication on the engine water temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the
engine water temperature gauge is abnormal”.
aWater temperatures are guides for selecting
indications.
Water temperature
gauge
Red range
Goes out.
Flashes.
When Causes 1 and 2 are not applicable, the monitor panel is supposed
to be defective. (This is an internal defect, which cannot be troubleshot.)
Water temperature
lamp
3 Defective monitor panel
Trouble (3)
Related
information
Possible causes
and standard
value in normal
state
• The power train oil temperature caution lamp flashes.
• When any abnormality is detected during engine operation, the power tlain oil temperature caution
lamp will flash and sound the alarm buzzer.
• The power train oil temperature caution lamp flashes or goes out as it links with indication on the power
train oil temperature gauge.
• Input state (temperature) from power train oil temperature sensor can be checked in monitoring mode.
(Code 30100: Torque converter oil temperature)
Cause
Standard value in normal state/Remarks on troubleshooting
Overheated oil temperature As an overheated power train oil temperature was detected, check the
1 of power train (when the
power train oil temperature. (When the oil temperature is over 130ºC,
system is normal)
the lamp flash and sound the buzzer, over 120ºC, the lamp flashes.)
Check the indication on the power train oil temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the
power train oil temperature gauge is abnormal”.
aOil temperatures are guides for selecting indications.
The power train oil tempera2 ture sensor system is defective. (Monitor panel system)
Oil temperature
gauge
Red range
Goes out.
Flashes.
When Causes 1 and 2 are not applicable, the monitor panel is supposed
to be defective. (This is an internal defect, which cannot be troubleshot.)
Oil temperature
lamp
3 Defective monitor panel
D65EX, PX-15
White range/Green range
White range/Green range
20-613
(1)
TROUBLESHOOTING
Trouble (4)
Related
information
• The hydraulic oil temperature caution lamp flashes.
• When any abnormality is detected during engine operation, the hydraulic oil temperature caution lamp
will flash and sound the alarm buzzer.
• The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydraulic
oil temperature gauge.
• Input state (temperature) from hydraulic oil temperature sensor can be checked in monitoring mode.
(Code 04401: Hydraulic oil temperature)
Cause
Overheated hydraulic oil
1 temperature (when the
system is normal)
Possible causes
and standard
value in normal
state
E-6
The hydraulic oil tempera2 ture sensor system is defective. (Monitor panel system)
Standard value in normal state/Remarks on troubleshooting
As an overheated hydraulic oil temperature was detected, check the
hydraulic oil temperature. (When the oil temperature is over 130ºC, the
lamp flash and sound the buzzer, over 120ºC, the lamp flashes.)
Check the indication on the engine water temperature gauge. If the indication is abnormal, carry out the troubleshooting of “Indication on the
hydraulic oil temperature gauge is abnormal”.
aOil temperatures are guides for selecting indications.
Oil temperature
gauge
Red range
Goes out.
Flashes.
When Causes 1 and 2 are not applicable, the monitor panel is supposed
to be defective. (This is an internal defect, which cannot be troubleshot.)
Oil temperature
lamp
3 Defective monitor panel
20-614
(1)
White range/Green range
D65EX, PX-15
TROUBLESHOOTING
E-7
E-7 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES
NOT COME ON.
Trouble
Related
information
• While the preheater is operating, the preheating pilot lamp does not come on.
aThis troubleshooting describes the procedures to be followed when the preheating lamp doe not come
on. (When the preheater mounting section is not heated, carry out the troubleshooting of “The preheater does not work”.)
• For preheating, both the “Automatic Preheating Function” and the “Manual Preheating Function” are
available. Even when either function is performed, the preheating lamp comes on.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
Disconnection of wiring
without turning the starting switch ON.
harness (Disconnection in
1
wiring or defective contact in Wiring harness between S03 (female) (9) and
Resistance Max. 1 z
connector)
heater relay HT/A (A) terminal
aPrepare with the starting switch OFF, then carry out troubleshooting
Ground fault of wiring
without turning the starting switch ON.
2 harness (Contact with
Wiring harness between S03 (female) (9) and
ground circuit)
Resistance Min. 1 Mz
heater relay HT/A (A) terminal and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
S03
Voltage
3 Defective monitor panel
ON
Max. 1 V
Between (9) and
ground
R1
Min. 7 V
D65EX, PX-15
20-615
(1)
TROUBLESHOOTING
E-7
Engine preheat-related circuit diagram
20-616
(1)
D65EX, PX-15
TROUBLESHOOTING
E-8
E-8 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE
NORMALLY.
Trouble (1)
Related
information
• The engine water temperature gauge does not indicate normally.
• Signals of the engine water high temperature sensor are sent and received from the engine controller
through communication.
• When any abnormality occurred in the engine hot water temperature sensor system, the failure code
[DGE2KX] is displayed sometimes.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
6
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
The engine water high temwithout turning the starting switch ON.
perature sensor is defective.
TWH (male)
Resistance
(Internal disconnection or
Between
(1)
and
(2)
3.5
k
–
90
kz (10 – 100ºC)
short circuit)
Between (1) (2) and ground
Min. 1 Mz
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between EN2 (female) (27)
Resistance Max. 1 z
wiring or defective contact in and TWH (female) (1)
connector)
Wiring harness between EN2 (female) (39)
Resistance Max. 1 z
and TWH (female) (2)
aPrepare with the starting switch OFF, then carry out troubleshooting
Ground fault of wiring
without turning the starting switch ON.
harness (Contact with
Between wiring harness (between EN2 (female)
ground circuit)
Resistance Min. 1 Mz
(27) and TWH (female) (1)) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Hot short circuit of wiring
Between wiring harness (between EN2 (female)
harness (Contact with 24 V
Voltage
Max. 1 V
(27) and TWH (female) (1)) and ground
circuit)
Wiring harness between EN2 (female) (39) –
Voltage
Max. 1 V
TWH (female) (2) and ground
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective engine controller
EN2 (female)
Resistance
Between (27) and (39)
3.5 k – 90 kz (10 – 100ºC)
Defective monitor panel
This is an internal defect, which cannot be troubleshot.
Circuit diagram related to engine water high temperature sensor
D65EX, PX-15
20-617
(1)
TROUBLESHOOTING
E-9
E-9 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL.
Trouble
Related
information
• Indication of the power train temperature gauge is abnormal.
• Signals of the power train oil temperature sensor are sent and received through communication by the
monitor panel.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
The power train oil temperaTorque converter oil
453 (male)
Resistance
ture sensor is defective.
temperature
(Internal disconnection or
Between (1) and (2)
3.5 k – 90 kz
short circuit)
10 – 100ºC
Between (1) and
Min. 1 Mz
ground
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between S04 (female) (12) and
Resistance Max. 1 z
wiring or defective contact in 453 (female) (1)
connector)
Wiring harness between 453 (female) (2) and
Resistance Max. 1 z
S03 (female) (3)
aPrepare with the starting switch OFF, then carry out troubleshooting
Ground fault of wiring
without turning the starting switch ON.
harness (Contact with
Between wiring harness (between S04 (female)
ground circuit)
Resistance Min. 1 Mz
(12) and 453 (female) (1)) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Hot short circuit of wiring
Between wiring harness (between S04 (female)
harness (Contact with 24 V
Voltage
Max. 1 V
(12) and 453 (female) (1)) and ground
circuit)
Wiring harness between 453 (female) (2) –
Voltage
Max. 1 V
S03 (female) (3) and ground
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Torque converter oil
Defective monitor panel
S04 (female)
Resistance
temperature
Between (12) and
10 – 100ºC
3.5 k – 90 kz
ground
Circuit diagram related to power train oil temperature sensor
20-618
(1)
D65EX, PX-15
TROUBLESHOOTING
E-10
E-10 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE
NORMALLY.
Trouble
Related
information
• The hydraulic oil temperature gauge does not indicate normally.
• Signals of the hydraulic oil temperature sensor are received from the steering and transmission controller through communication.
• When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
[DGS1KX] is displayed sometimes.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
6
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
The hydraulic oil temperawithout turning the starting switch ON.
ture sensor is defective.
SDS (male)
Resistance
(Internal disconnection or
Between
(1)
and
(2)
3.5
k – 90 kz
short circuit)
Between (1) and ground
Min. 1 Mz
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between ST1 (female) (9) and
Resistance Max. 1 z
wiring or defective contact in SDS (female) (1)
connector)
Wiring harness between ST1 (female) (21) and
Resistance Max. 1 z
SDS (female) (2)
aPrepare with the starting switch OFF, then carry out troubleshooting
Ground fault of wiring
without turning the starting switch ON.
harness (Contact with
Between wiring harness (between ST1 (female)
ground circuit)
Resistance Min. 1 Mz
(9) and SDS (female) (1)) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Hot short circuit of wiring
Between wiring harness (between ST1 (female)
harness (Contact with 24 V
Voltage
Max. 1 V
(9) and SDS (female) (1)) and ground
circuit)
Wiring harness between ST1 (female) (21) –
Voltage
Max. 1 V
SDS (female) (2) and ground
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective transmission
controller
ST1 (female)
Resistance
Between (9) and (21)
3.5 k – 90 kz
Defective monitor panel
This is an internal defect, which cannot be troubleshot.
Circuit diagram related to hydraulic oil temperature sensor
D65EX, PX-15
20-619
(1)
TROUBLESHOOTING
E-11
E-11 INDICATION OF THE FUEL GAUGE IS ABNORMAL.
Trouble
Related
information
• Indication of the fuel gauge is abnormal.
• Signals of the fuel level sensor are sent and received through communication by the monitor panel.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective fuel level sensor.
423 (male)
Remained fuel level
Resistance
(Internal disconnection or
short circuit)
Full
About 4 z
Between (1) and (2)
(ground)
Empty
About 85 z
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between S04 (female) (10) and
Resistance Max. 1 z
wiring or defective contact in 423 (female) (1)
connector)
Wiring harness between 423 (female) (2) –
Resistance Max. 1 z
S03 (female) (3), (4) with ground
aPrepare with the starting switch OFF, then carry out troubleshooting
Ground fault of wiring
without turning the starting switch ON.
harness (Contact with
Between
wiring harness (between S04 (female)
ground circuit)
Resistance Min. 1 Mz
(10) and 423 (female) (1)) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Hot short circuit of wiring
Between wiring harness (between S04 (female)
harness (Contact with 24 V
Voltage
Max. 1 V
(10) and 423 (female) (1)) and ground
circuit)
Wiring harness between 423 (female) (2) –
Voltage
Max. 1 V
S03 (female) (3), (4) and ground
Defective monitor panel
This is an internal defect, which cannot be troubleshooting.
Circuit diagram related to fuel level sensor
20-620
(1)
D65EX, PX-15
TROUBLESHOOTING
E-12, E-13, E-14
E-12
E-12 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.
Trouble
Related
information
Possible causes
and standard
value in normal
state
• Indications of gear speed and engine speed are abnormal.
• Signals of gear speed and engine speed are sent and received through communication by the monitor
panel.
Cause
1 Defective monitor panel
Standard value in normal state/Remarks on troubleshooting
This is an internal defect, which cannot be troubleshot.
E-13 INDICATION OF THE PRESET MODE SERVICE METER IS ABNORMAL.
Trouble (1)
Related
information
• During engine operation, the service meter does not advance.
• The service meter measures time while the monitor panel is receiving engine drive signals (alternator
signals).
• The display data of the preset mode and service meter are sent and received through communication
by the steering and transmission controller.
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
When the battery charge level caution lamp flashes during engine opDefective alternator signals
1
eration, carry out the troubleshooting of “While the engine is operating,
system
caution items flash”.
Defective monitor panel
2
This is an internal defect, which cannot be troubleshot.
(Gauge or lamp module)
Trouble (2)
Related
information
• Shift mode and service meter are not displayed at all.
• The display data are sent and received through communication by the steering and transmission controller.
Possible causes
and standard
value in normal
state
Cause
1 Defective monitor panel
Standard value in normal state/Remarks on troubleshooting
This is an internal defect, which cannot be troubleshot.
E-14 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT.
Trouble
Related
information
Possible causes
and standard
value in normal
state
D65EX, PX-15
• The warning lamp does not flash or does not go out.
Cause
1 Defective monitor panel
Standard value in normal state/Remarks on troubleshooting
This is an internal defect, which cannot be troubleshot.
20-621
(1)
TROUBLESHOOTING
E-15
E-15 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.
Trouble
Related
information
• The alarm buzzer does not sound or does not stop.
• When a short circuit occurs in the alarm buzzer system, the failure code is displayed but no other failure
codes are displayed.
Cause
Defective circuit breaker
1
fuse FS2-(6)
2
Possible causes
and standard
value in normal
state
3
4
5
Standard value in normal state/Remarks on troubleshooting
When the fuse FS2-(6) is cut off, a ground fault may have possibly occurred in the circuit.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective alarm buzzer
217 (male)
Resistance
(Internal disconnection or
short circuit)
Between (2) and (1)
Min. 1 kz
Between (1), (2) and ground
Min. 1 Mz
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between S03 (female) (18) and
Resistance Max. 1 z
wiring or defective contact in 217 (female) (1)
connector)
Wiring harness between 217 (female) (2) and
Resistance Max. 1 z
FS2-(6)
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Ground fault of wiring
Wiring harness between FS2-(6) – 217 (feResistance Min. 1 Mz
harness (Contact with
male) (2) with ground
ground circuit)
Wiring harness between 217 (female) (1) –
Resistance Min. 1 Mz
S03 (female) (18) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective monitor panel
S03
Alarm buzzer
Voltage
(Gauge/lamp module)
At stop
20 – 30 V
Between (18) and
ground
At operation (sounding)
Max. 3 V
Circuit diagram related to alarm buzzer
20-622
(1)
D65EX, PX-15
TROUBLESHOOTING
E-16
E-16 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED.
Trouble
Related
information
• Auto shift down is not possible or is not released.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective auto shift down
ASD (male)
Auto shift down switch
Resistance
switch (Internal disconnection or short circuit)
OFF (0)
Min. 1 Mz
Between (2) and (3)
ON (1)
Max. 1 z
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between ST2 (female) (37) and
Resistance Max. 1 z
wiring or defective contact in ADS (female) (2)
connector)
Wiring harness between ADS (female) (3) and
Resistance Max. 1 z
ground
aPrepare with the starting switch OFF, then turn the starting switch
Ground steering and fault of
ON and carry out troubleshooting.
wiring harness (Contact with
Between
wiring harness (between ST2 (female)
ground circuit)
Resistance Min. 1 Mz
(37) and ASD (female) (2)) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective steering and
Voltage
Between ST2 (37) Auto shift down switch
transmission controller
and ST3 (21), (31),
OFF (0)
5 – 11 V
(32), (33)
ON (1)
Max. 1 V
Restriction of function by
When Causes 1 to 4 are not applicable, the steering and transmission
controller
controller may be restricting the function because of other causes.
Circuit diagram related to auto shift down switch
D65EX, PX-15
20-623
(1)
TROUBLESHOOTING
E-17
E-17 THE BUZZER CANCEL SWITCH DOES NOT WORK.
Trouble
Related
information
• The buzzer cancel switch does not work.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
BUZ (male)
Buzzer cancel switch
Resistance
Defective buzzer cancel
OFF
(0)
Min. 1 Mz
switch (Internal disconnecBetween (1) and (2)
tion or short circuit)
Max. 1 z
t
OFF (0)
Min. 1 Mz
Between (1) and (3)
Max. 1 z
U
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
Wiring harness between ST2 (36) and BUZ
Resistance Max. 1 z
harness (Disconnection in (female) (2)
wiring or defective contact in Wiring harness between ST2 (26) and BUZ
Resistance Max. 1 z
connector)
(female) (3)
Wiring harness between BUZ (female) (1) and
Resistance Max. 1 z
GND04
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Ground fault of wiring
Between
wiring harness (between ST2 (36)
harness (Contact with
Resistance Min. 1 Mz
and BUZ (female) (2)) and ground
ground circuit)
Between wiring harness (between ST2 (26)
Resistance Min. 1 Mz
and BUZ (female) (3)) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out the troubleshooting.
Steering and
Buzzer cancel switch
Voltage
transmission controller
Defective steering and
Between ST2 (female)
OFF (0)
5 – 11 V
transmission controller
(36) and ST3 (female)
Max. 1 V
U
(21), (31), (32), (33)
Between ST2 (female)
OFF (0)
5 – 11 V
(26) and ST3 (female)
Max. 1 V
t
(21), (31), (32), (33)
Circuit diagram related to buzzer cancel switch
20-624
(1)
D65EX, PX-15
TROUBLESHOOTING
E-18
E-18 THE INFORMATION SWITCH DOES NOT WORK.
Trouble
Related
information
• The information switch does not work.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
CUR (male)
Information switch
Resistance
Defective information switch
OFF
(0)
Min. 1 Mz
(Internal short circuit or
Between (1) and (2)
disconnection)
Max. 1 z
OFF (0)
Min. 1 Mz
Between (1) and (3)
Max. 1 z
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring
harness between ST2 (16) and CUR
Disconnection of wiring
Resistance Max. 1 z
harness (Disconnection in (female) (2)
wiring or defective contact in Wiring harness between ST2 (6) and CUR
Resistance Max. 1 z
connector)
(female) (3)
Wiring harness between CUR (female) (1) and
Resistance Max. 1 z
GND04
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Ground fault of wiring
Between wiring harness (between ST2 (16) and
Resistance Min. 1 Mz
harness (Contact with
CUR (female) (2)) and ground
ground circuit)
Between wiring harness (between ST2 (6) and
Resistance Min. 1 Mz
CUR (female) (3)) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Steering controller
Buzzer cancel switch
Voltage
Defective steering and
Between ST2 (16)
OFF (0)
5 – 11 V
transmission controller
and ST3 (21), (31),
Max. 1 V
(32), (33)
OFF (0)
5 – 11 V
Between (6) and
ground
Max. 1 V
Circuit diagram related to information switch
D65EX, PX-15
20-625
(1)
TROUBLESHOOTING
E-19
E-19 THE PRESET MODE DOES NOT OPERATE OR CANNOT BE RESET.
Trouble
Related
information
• The preset mode does not operate or cannot be reset.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
Standard value in normal state/Remarks on troubleshooting
aPreare with the starting OFF, then carry out troubleshooting without
turning the starting switch ON.
Defective manual mode
MAM (male)
Preset mode switch
Resistance
switch (Internal disconnection)
OFF (0)
Min. 1 Mz
Between (2) – (3)
ON (1)
Max. 1 z
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between ST2 (female) (10) –
Resistance Max. 1 z
wiring or defective contact in MAM (female) (2)
connector)
Wiring harness between MAM (female) (3) and
Resistance Max. 1 z
ground
aPrepare with starting switch OFF, then carry out troubleshooting
Ground fault of wiring
without turning starting switch ON.
harness (Contact with
Wiring
harness between ST2 (female) (10) –
ground circuit)
Resistance Min. 1 z
MAM (female) (2) with ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective steering and
ST2
Preset mode switch
Voltage
transmission controller
OFF (0)
5 – 11 V
Between (10) and
ground
ON (1)
Max. 1 V
Limitation of function by
When Causes 1 to 4 are not applicable, steering and transmission concontroller
troller may be limiting function because of another reason.
Circuit diagram related to preset mode
20-626
(1)
D65EX, PX-15
TROUBLESHOOTING
E-20
E-20 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE OR CANNOT
BE SET OUT OF THE SERVICE MODE.
Trouble
Related
information
• The monitor panel cannot be set in the service mode or cannot be set out of the service mode.
1
2
3
4
5
Possible causes
and standard
value in normal
state
6
7
8
9
D65EX, PX-15
Cause
Standard value in normal state/Remarks on troubleshooting
Since the buzzer cancel switch system is supposed to be out of order, carry
Defective buzzer cancel
out the troubleshooting of “The buzzer cancel switch does not work”.
switch system
Defective information switch Since the information switch system is supposed to be out of order, carsystem
ry out the troubleshooting of “The information switch does not work”.
When the fuse FS1 (10) is cut off, a ground fault may have possibly ocDefective fuse FS1 (10)
curred in the circuit.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective service switch
S24
Service switch
Resistance
(Internal short circuit or
disconnection)
OFF
Min. 1 Mz
Between (1) and (2),
Between (5) and (4)
ON
Max. 1 z
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring harness between FS1 (10) outlet and
Resistance Max. 1 z
Disconnection of wiring
S24 (1)
harness (Disconnection in
Wiring harness between S24 (4) and ground Resistance Max. 1 z
wiring or defective contact in
Wiring harness between S03 (female) (16) and
connector)
Resistance Max. 1 z
S24 (2)
Wiring harness between ST1 (female) (6) and
Resistance Max. 1 z
S24 (5)
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Ground fault of wiring
Wiring harness between FS1 (10) – S24 (1) –
Resistance Min. 1 Mz
harness (Contact with
S03 (female) (5), (6) with ground
ground circuit)
Wiring harness between S24 (5) – ST1 (feResistance Min. 1 Mz
male) (6) and ground
aPrepare with the starting switch OFF, then turn the starting switch
Hot short circuit of wiring
ON and carry out troubleshooting.
harness (Contact with 24 V
Wiring harness between S24 (2) – S03 (fecircuit)
Voltage
Max. 1 V
male) (16) and ground
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective monitor panel
S03
Service switch
Voltage
(Gauge/lamp module)
OFF
Max. 1 V
Between (16) and
ground
ON
20 – 30 V
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective steering and
ST1
Service switch
Voltage
transmission controller
OFF
5
– 11 V
Between (6) and
ground
ON
Max. 1 V
20-627
(1)
TROUBLESHOOTING
E-20
Circuit diagram related to monitor panel
20-628
(1)
D65EX, PX-15
TROUBLESHOOTING
E-21
E-21 THE BACK-UP ALARM DOES NOT SOUND.
Trouble
Related
information
• The back-up alarm does not sound.
• When a failure occurs on the primary side (coil side) of the back-up alarm relay, a relevant failure code
is displayed, but in case of failure on the secondary side (contact side), no failure code is displayed.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
Standard value in normal state/Remarks on troubleshooting
When the fuse is blown, a ground fault may have probably occurred in
Defective fuse (FS2-(9))
the circuit.
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective back-up relay
When the relay is replaced with another relay while the starting switch
(internal disconnection)
is set to OFF and the alarm sounds after the starting switch is turned
on and the machine is operated in reverse, the back-up alarm relay
(BKA) is defective.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring harness between FS2-(9) and BKA (feResistance Max. 1 z
male) (1), (3)
Disconnection of wiring
harness (Disconnection in Wiring harness between BKA (female) (2) –
Resistance Max. 1 Mz
wiring or defective contact in ST2 (female) (18)
connector)
Wiring harness between BKA (female) (5) and
Resistance Max. 1 z
back-up alarm positive (+) terminal
Wiring harness between back-up alarm negaResistance Max. 1 z
tive (–) terminal – and GND03
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Ground fault of wiring
Between wiring harness related to FS2-(9) and
Resistance Min. 1 Mz
harness (Contact with
BKA (female) (1), (3) and ground
ground circuit)
Between wiring harness (between BKA (female) (5) and back-up alarm positive (+) termi- Resistance Min. 1 Mz
nal) and ground
Defective back-up alarm
When Causes 1 to 4 are not applicable, the back-up alarm is supposed
(internal defect)
to be defective.
Circuit diagram related to back-up alarm
D65EX, PX-15
20-629
(1)
TROUBLESHOOTING
E-22
E-22 THE HEAD LAMP AND REAR LAMP DO NOT LIGHT UP.
Trouble (1)
Related
information
• The head lamp does not light up.
Cause
Defective head lamp
1
(Breakage of bulb)
2 Defective fuse (FS1-(8))
Possible causes
and standard
value in normal
state
Trouble (2)
Related
information
20-630
(1)
Since the head lamp may be defective, check its bulb for breakage.
If the fuse is broken, the circuit probably has a grounding fault, etc.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective head lamp switch
FWL (male)
Switch
Resistance
3
(Internal disconnection)
OFF
Min. 1 Mz
Between (2) – (3)
ON
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between FWL (female) (2) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in FS1-(8)
4
wiring or defective contact in Wiring harness between FWL (female) (3) –
Resistance Max. 1 z
connector)
203 (female) (2) and 204 (female) (2)
Wiring harness between 203 (female) (1) –
Resistance Max. 1 z
204 (female) (1) and GND04
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between FWL (female) (2) –
Resistance Min. 1 Mz
5 ground in wiring harness
FS1-(8) with ground
(Contact with ground circuit)
Wiring harness between FWL (female) (3) –
Resistance Min. 1 Mz
203 (female) (2), 204 (female) (2) and ground
• The rear lamp does not light up.
Cause
Defective rear lamp
1
(Breakage of bulb)
2 Defective fuse (FS1-(8))
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
Standard value in normal state/Remarks on troubleshooting
Since the rear lamp may be defective, check its bulb for breakage.
If the fuse is broken, the circuit probably has a grounding fault, etc.
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective rear lamp switch
RWL (male)
Switch
Resistance
3
(Internal disconnection)
OFF
Min. 1 Mz
Between (2) – (3)
ON
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between RWL (female) (2) –
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in FS1-(8)
4
wiring or defective contact in Wiring harness between RWL (female) (3) –
Resistance Max. 1 z
connector)
224 (female) (2) and 228 (female) (1)
Wiring harness between 224 (female) (1) –
Resistance Max. 1 z
228 (female) (2) and GND03
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit with chassis
Wiring harness between RWL (female) (2) –
Resistance Min. 1 Mz
5 ground in wiring harness
FS1-(8) with ground
(Contact with ground circuit)
Wiring harness between RWL (female) (3) –
Resistance Min. 1 Mz
224 (female) (2), 228 (female) (1) and ground
D65EX, PX-15
TROUBLESHOOTING
E-22
Circuit diagram related to panel lamp, head lamp and rear lamp
D65EX, PX-15
20-631
(1)
TROUBLESHOOTING
E-23
E-23 MALFUNCTION OF WIPERS
Trouble (1)
Related
information
• The front wiper does not operate (Continuous operation is defective).
• Carry out the following troubleshooting when only the front wiper is defective.
• If fuse (5) in the cab is broken, intermittent operation of the all wipers becomes defective.
• If any wiper does not operate, check the fusible link (FL1).
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch ON.
Cause
1
2
3
4
Possible causes
and standard
value in normal
state
5
6
7
20-632
(1)
Standard value in normal state/Remarks on troubleshooting
If the fusible link is broken, the circuit probably has a grounding fault,
Defective fusible link (FL1)
etc.
Since fuse (5) in the cab is used for the front wiper system and intermittent
Defective fuse (5) in cab
switch system, those systems probably have a grounding fault, etc.
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between CN23 (6) – ground
Voltage 20 – 30 V
Defective front wiper motor aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CN23 (female) (1) –
Resistance Max. 1 z
ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN14 (male)
Position of switch
Resistance
Defective front wiper switch
ON
Max. 1 z
Between (3) – (4)
OFF
Min. 1 Mz
• If the trouble is repaired by replacing the relay with relay CN27,
CN31, or CN33, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective front wiper
carry out troubleshooting.
intermittent selector relay
Between CN29 (3) – ground
Voltage 20 – 30 V
Between CN29 (6) – ground
Voltage 20 – 30 V
Between CN29 (1) – ground
Voltage
Max. 1 V
• If the trouble is repaired by replacing the relay with relay CN26,
CN30, or CN32, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective front wiper
carry out troubleshooting.
intermittent relay
Between CN28 (4) – ground
Voltage 20 – 30 V
Between CN28 (3) – ground
Voltage 20 – 30 V
Between CN28 (5) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring
harness between CN14 (female) (4) –
Disconnection or short
Resistance Max. 1 z
circuit with chassis ground in CN29 (female) (3)
wiring harness (Disconnec- Wiring harness between CN14 (female) (4) –
Resistance Min. 1 Mz
CN29 (female) (3) with ground
tion in wiring or defective
contact in connector or
Wiring harness between CN29 (female) (6) –
Resistance Max. 1 z
contact with ground circuit) CN28 (female) (4)
Wiring harness between CN29 (female) (6) –
Resistance Min. 1 Mz
CN28 (female) (4) with ground
D65EX, PX-15
TROUBLESHOOTING
E-23
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
Wiring harness between fuse (5) – CN14 (female) (2), (3) and between CN23 (female) (3) Resistance Max. 1 z
– CN28 (female) (3)
Wiring harness between fuse (5) – CN14 (female) (2), (3) and between CN23 (female) (3) Resistance Min. 1 Mz
Disconnection or short
circuit with chassis ground in – CN28 (female) (3) with ground
wiring harness (Disconnec- Wiring harness between CN28 (female) (5) – Resistance
Max. 1 z
7
CN23 (female) (6)
tion in wiring or defective
contact in connector or
Wiring harness between CN28 (female) (5) –
Resistance Min. 1 Mz
contact with ground circuit) CN23 (female) (6) with ground
Wiring harness between CN28 (female) (6) –
Resistance Max. 1 z
ground
Wiring harness between CN23 (female) (1) –
Resistance Max. 1 z
ground
D65EX, PX-15
20-633
(1)
TROUBLESHOOTING
Trouble (2)
Related
information
E-23
• The front wiper does not operate intermittently.
• Carry out the following troubleshooting when the ordinary operation is normal.
• When carrying out the troubleshooting, turn the wiper switch and intermittent switch ON.
• Stop about 5 seconds after the wiper goes and returns once.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-634
(1)
Standard value in normal state/Remarks on troubleshooting
• If the ordinary operation is normal and the other wiper do not operate
intermittently either, the intermittent switch is probably defective.
aPrepare with starting switch OFF, then carry out troubleshooting
Defective intermittent switch without turning starting switch ON.
CN11 (male)
Position of switch
Voltage
ON
Max. 1 z
Between (1) – (2)
OFF
Min. 1 Mz
• If the trouble is repaired by replacing the relay with relay CN27,
CN31, or CN33, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective front wiper
carry out troubleshooting.
intermittent selector relay
Between CN29 (1) – ground
Voltage 20 – 30 V
Between CN29 (5) – ground
Voltage 20 – 30 V
• If the trouble is repaired by replacing the relay with relay CN26,
CN30, or CN32, the relay is defective.
Defective front wiper
aPrepare with starting switch OFF, then turn starting switch ON and
intermittent relay
carry out troubleshooting.
Between CN28 (2) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CN11 (female) (2) –
Resistance Max. 1 z
CN29 (female) (1)
Disconnection or short
circuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance
Min. 1 Mz
wiring harness (Disconnec- CN29 (female) (1) with ground
tion in wiring or defective
Wiring harness between CN29 (female) (5) –
Resistance Max. 1 z
contact in connector or
CN28 (female) (2)
contact with ground circuit) Wiring harness between CN29 (female) (5) –
Resistance Min. 1 Mz
CN28 (female) (2) with ground
Wiring harness between CN29 (female) (2) –
Resistance Max. 1 z
ground
D65EX, PX-15
TROUBLESHOOTING
E-23
Circuit diagram related to wiper system
D65EX, PX-15
20-635
(1)
TROUBLESHOOTING
Trouble (3)
Related
information
E-23
• The rear wiper does not operate (Continuous operation is defective).
• Carry out the following troubleshooting when only the rear wiper is defective.
• If any wiper does not operate, check the fusible link (FL1).
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch ON.
Cause
1
2
3
4
Possible causes
and standard
value in normal
state
5
6
7
20-636
(1)
Standard value in normal state/Remarks on troubleshooting
If the fusible link is broken, the circuit probably has a grounding fault,
Defective fusible link (FL1)
etc.
Since fuse (4) in the cab is used for only the rear wiper system, this sysDefective fuse (4) in cab
tem probably has a grounding fault, etc.
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between CN37 (1) – ground
Voltage 20 – 30 V
Defective rear wiper motor aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CN37 (female) (2) –
Resistance Max. 1 z
ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN12 (male)
Position of switch
Resistance
Defective rear wiper switch
ON
Max. 1 z
Between (3) – (4)
OFF
Min. 1 Mz
• If the trouble is repaired by replacing the relay with relay CN27,
CN29, or CN31, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective rear wiper
carry out troubleshooting.
intermittent selector relay
Between CN33 (3) – ground
Voltage 20 – 30 V
Between CN33 (6) – ground
Voltage 20 – 30 V
Between CN33 (1) – ground
Voltage
Max. 1 V
• If the trouble is repaired by replacing the relay with relay CN26,
CN28, or CN30, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective rear wiper
carry out troubleshooting.
intermittent relay
Between CN32 (4) – ground
Voltage 20 – 30 V
Between CN32 (3) – ground
Voltage 20 – 30 V
Between CN32 (5) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring
harness between CN12 (female) (4) –
Disconnection or short
Resistance Max. 1 z
CN33
(female)
(3)
circuit with chassis ground in
wiring harness (Disconnec- Wiring harness between CN12 (female) (4) –
Resistance Min. 1 Mz
CN33 (female) (3) with ground
tion in wiring or defective
contact in connector or
Wiring harness between CN33 (female) (6) –
Resistance Max. 1 z
contact with ground circuit) CN32 (female) (4)
Wiring harness between CN33 (female) (6) –
Resistance Min. 1 Mz
CN32 (female) (4) with ground
D65EX, PX-15
TROUBLESHOOTING
E-23
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
Wiring harness between fuse (4) – CN12 (feResistance Max. 1 z
male) (2), (3)
Wiring harness between fuse (4) – CN12 (feResistance Min. 1 Mz
male) (2), (3) with ground
Wiring harness between fuse (4) – CN32 (feResistance Max. 1 z
male) (3) – CN37 (female) (3)
Disconnection or short
circuit with chassis ground in Wiring harness between fuse (4) – CN32 (fe- Resistance Min. 1 Mz
wiring harness (Disconnec- male) (3) – CN37 (female) (3) with ground
7
tion in wiring or defective
Wiring harness between CN32 (female) (5) –
Resistance Max. 1 z
contact in connector or
CN37 (female) (1)
contact with ground circuit) Wiring harness between CN32 (female) (5) –
Resistance Min. 1 Mz
CN37 (female) (1) with ground
Wiring harness between CN32 (female) (6) –
Resistance Max. 1 z
ground
Wiring harness between CN37 (female) (2) –
Resistance Max. 1 z
ground
D65EX, PX-15
20-637
(1)
TROUBLESHOOTING
Trouble (4)
Related
information
E-23
• The rear wiper does not operate intermittently.
• Carry out the following troubleshooting when the ordinary operation is normal.
• When carrying out the troubleshooting, turn the wiper switch and intermittent switch ON.
• Stop about 5 seconds after the wiper goes and returns once.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-638
(1)
Standard value in normal state/Remarks on troubleshooting
• If the ordinary operation is normal and the other wiper do not operate
intermittently either, the intermittent switch is probably defective.
aPrepare with starting switch OFF, then carry out troubleshooting
Defective intermittent switch without turning starting switch ON.
CN11 (female)
Position of switch
Voltage
ON
Max. 1 z
Between (1) – (2)
OFF
Min. 1 Mz
• If the trouble is repaired by replacing the relay with relay CN27,
CN29, or CN31, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective rear wiper
carry out troubleshooting.
intermittent selector relay
Between CN33 (1) – ground
Voltage 20 – 30 V
Between CN33 (5) – ground
Voltage 20 – 30 V
• If the trouble is repaired by replacing the relay with relay CN26,
CN28, or CN30, the relay is defective.
Defective rear wiper
aPrepare with starting switch OFF, then turn starting switch ON and
intermittent relay
carry out troubleshooting.
Between CN32 (2) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CN11 (female) (2) –
Resistance Max. 1 z
CN33 (female) (1)
Disconnection or short
circuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance
Min. 1 Mz
wiring harness (Disconnec- CN33 (female) (1) with ground
tion in wiring or defective
Wiring harness between CN33 (female) (5) –
Resistance Max. 1 z
contact in connector or
CN32 (female) (2)
contact with ground circuit) Wiring harness between CN33 (female) (5) –
Resistance Min. 1 Mz
CN32 (female) (2) with ground
Wiring harness between CN33 (female) (2) –
Resistance Max. 1 z
ground
D65EX, PX-15
TROUBLESHOOTING
E-23
Circuit diagram related to wiper system
D65EX, PX-15
20-639
(1)
TROUBLESHOOTING
Trouble (5)
Related
information
E-23
• The right door wiper does not operate (Continuous operation is defective).
• Carry out the following troubleshooting when only the right door wiper is defective. (If fuse (6) in the cab
is broken, the left door wiper does not operate either.)
• If any wiper does not operate, check the fusible link (FL1).
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch ON.
Cause
1
2
3
4
Possible causes
and standard
value in normal
state
5
6
7
20-640
(1)
Standard value in normal state/Remarks on troubleshooting
If the fusible link is broken, the circuit probably has a grounding fault,
Defective fusible link (FL1)
etc.
Since fuse (6) in the cab is used for the right door wiper system and left
Defective fuse (6) in cab
door wiper system, either of those systems probably has a grounding
fault, etc.
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between connector (3) just before motor –
Voltage 20 – 30 V
ground
Defective right door wiper
motor
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between connector (1) just beResistance Max. 1 z
fore motor – ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective right door wiper
CN13 (male)
Position of switch
Resistance
switch
ON
Max. 1 z
Between (3) – (4)
OFF
Min. 1 Mz
• If the trouble is repaired by replacing the relay with relay CN27,
CN29, or CN33, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective right door wiper
carry out troubleshooting.
intermittent selector relay
Between CN31 (3) – ground
Voltage 20 – 30 V
Between CN31 (6) – ground
Voltage 20 – 30 V
Between CN31 (1) – ground
Voltage
Max. 1 V
• If the trouble is repaired by replacing the relay with relay CN26,
CN28, or CN32, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective right door wiper
carry out troubleshooting.
intermittent relay
Between CN30 (4) – ground
Voltage 20 – 30 V
Between CN30 (3) – ground
Voltage 20 – 30 V
Between CN30 (5) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CN13 (female) (4) –
Disconnection or short
Resistance Max. 1 z
circuit with chassis ground in CN31 (female) (3)
wiring harness (Disconnec- Wiring harness between CN13 (female) (4) –
Resistance Min. 1 Mz
CN31 (female) (3) with ground
tion in wiring or defective
contact in connector or
Wiring harness between CN31 (female) (6) –
Resistance Max. 1 z
contact with ground circuit) CN30 (female) (4)
Wiring harness between CN31 (female) (6) –
Resistance Min. 1 Mz
CN30 (female) (4) with ground
D65EX, PX-15
TROUBLESHOOTING
E-23
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
Wiring harness between fuse (6) – CN13 (female) (2), (3) – CN17 (4) – connector (female) Resistance Max. 1 z
(4) just before motor – CN13 (female) (2), (3)
Wiring harness between fuse (6) – CN13 (female) (2), (3) – CN17 (4) – connector (female)
Resistance Min. 1 Mz
(4) just before motor – CN13 (female) (2), (3)
with ground
Wiring harness between fuse (6) – CN30 (feDisconnection or short
Resistance Max. 1 z
circuit with chassis ground in male) (3)
wiring harness (Disconnec- Wiring harness between fuse (6) – CN30 (fe- Resistance Min. 1 Mz
7
male) (3) with ground
tion in wiring or defective
contact in connector or
Wiring harness between connector (female) (3)
Resistance Max. 1 z
contact with ground circuit) just before motor – CN17 (3) – CN30 (female) (5)
Wiring harness between connector (female)
Resistance Min. 1 Mz
(3) just before motor – CN17 (3) – CN30 (female) (5) with ground
Wiring harness between CN30 (female) (6) –
Resistance Max. 1 z
ground
Wiring harness between connector (female)
Resistance Max. 1 z
(1) just before motor – CN17 (1) – ground
D65EX, PX-15
20-641
(1)
TROUBLESHOOTING
Trouble (6)
Related
information
E-23
• The right door wiper does not operate intermittently.
• Carry out the following troubleshooting when the ordinary operation is normal.
• When carrying out the troubleshooting, turn the wiper switch and intermittent switch ON.
• Stop about 5 seconds after the wiper goes and returns once.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-642
(1)
Standard value in normal state/Remarks on troubleshooting
• If the ordinary operation is normal and the other wiper do not operate
intermittently either, the intermittent switch is probably defective.
aPrepare with starting switch OFF, then carry out troubleshooting
Defective intermittent switch without turning starting switch ON.
CN11 (female)
Position of switch
Voltage
ON
Max. 1 z
Between (1) – (2)
OFF
Min. 1 Mz
• If the trouble is repaired by replacing the relay with relay CN27,
CN29, or CN33, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective right door wiper
carry out troubleshooting.
intermittent selector relay
Between CN31 (1) – ground
Voltage 20 – 30 V
Between CN31 (5) – ground
Voltage 20 – 30 V
• If the trouble is repaired by replacing the relay with relay CN26,
CN28, or CN32, the relay is defective.
Defective right door wiper
aPrepare with starting switch OFF, then turn starting switch ON and
intermittent relay
carry out troubleshooting.
Between CN30 (2) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CN11 (female) (2) –
Resistance Max. 1 z
CN31 (female) (1)
Disconnection or short
circuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance
Min. 1 Mz
wiring harness (Disconnec- CN31 (female) (1) with ground
tion in wiring or defective
Wiring harness between CN31 (female) (5) –
Resistance Max. 1 z
contact in connector or
CN30 (female) (2)
contact with ground circuit) Wiring harness between CN31 (female) (5) –
Resistance Min. 1 Mz
CN30 (female) (2) with ground
Wiring harness between CN31 (female) (2) –
Resistance Max. 1 z
ground
D65EX, PX-15
TROUBLESHOOTING
E-23
Circuit diagram related to wiper system
D65EX, PX-15
20-643
(1)
TROUBLESHOOTING
Trouble (7)
Related
information
E-23
• The left door wiper does not operate (Continuous operation is defective).
• Carry out the following troubleshooting when only the left door wiper is defective. (If fuse (6) in the cab
is broken, the right door wiper does not operate either.)
• If any wiper does not operate, check the fusible link (FL1).
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch ON.
Cause
1
2
3
4
Possible causes
and standard
value in normal
state
5
6
7
20-644
(1)
Standard value in normal state/Remarks on troubleshooting
If the fusible link is broken, the circuit probably has a grounding fault,
Defective fusible link (FL1)
etc.
Since fuse (6) in the cab is used for the left door wiper system and left
Defective fuse (6) in cab
door wiper system, either of those systems probably has a grounding
fault, etc.
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between connector (3) just before motor –
Voltage 20 – 30 V
ground
Defective left door wiper
motor
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between connector (1) just beResistance Max. 1 z
fore motor – ground
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective left door wiper
CN15 (male)
Position of switch
Resistance
switch
ON
Max. 1 z
Between (3) – (4)
OFF
Min. 1 Mz
• If the trouble is repaired by replacing the relay with relay CN29,
CN31, or CN33, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective left door wiper
carry out troubleshooting.
intermittent selector relay
Between CN27 (3) – ground
Voltage 20 – 30 V
Between CN27 (6) – ground
Voltage 20 – 30 V
Between CN27 (1) – ground
Voltage
Max. 1 V
• If the trouble is repaired by replacing the relay with relay CN28,
CN30, or CN32, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective left door wiper
carry out troubleshooting.
intermittent relay
Between CN26 (4) – ground
Voltage 20 – 30 V
Between CN26 (3) – ground
Voltage 20 – 30 V
Between CN26 (5) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CN15 (female) (4) –
Disconnection or short
Resistance Max. 1 z
circuit with chassis ground in CN27 (female) (3)
wiring harness (Disconnec- Wiring harness between CN15 (female) (4) –
Resistance Min. 1 Mz
CN27 (female) (3) with ground
tion in wiring or defective
contact in connector or
Wiring harness between CN27 (female) (6) –
Resistance Max. 1 z
contact with ground circuit) CN26 (female) (4)
Wiring harness between CN27 (female) (6) –
Resistance Min. 1 Mz
CN26 (female) (4) with ground
D65EX, PX-15
TROUBLESHOOTING
E-23
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
Wiring harness between fuse (6) – CN26 (female) (3) – CN24 (4) – connector (female) (4) Resistance Max. 1 z
just before motor
Wiring harness between fuse (6) – CN26 (female) (3) – CN24 (4) – connector (female) (4) Resistance Min. 1 Mz
just before motor with ground
Wiring harness between fuse (6) – CN15 (feDisconnection or short
Resistance Max. 1 z
circuit with chassis ground in male) (2), (3)
wiring harness (Disconnec- Wiring harness between fuse (6) – CN15 (fe- Resistance
Min. 1 Mz
7
male) (2), (3)
tion in wiring or defective
contact in connector or
Wiring harness between connector (female) (3)
Resistance Max. 1 z
contact with ground circuit) just before motor – CN24 (3) – CN26 (female) (5)
Wiring harness between connector (female) (3)
Resistance Min. 1 Mz
just before motor – CN24 (3) – CN26 (female) (5)
Wiring harness between CN26 (female) (6) –
Resistance Max. 1 z
ground
Wiring harness between connector (female)
Resistance Max. 1 z
(1) just before motor – CN24 (1) – ground
D65EX, PX-15
20-645
(1)
TROUBLESHOOTING
Trouble (8)
Related
information
E-23
• The left door wiper does not operate intermittently.
• Carry out the following troubleshooting when the ordinary operation is normal.
• When carrying out the troubleshooting, turn the wiper switch and intermittent switch ON.
• Stop about 5 seconds after the wiper goes and returns once.
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
20-646
(1)
Standard value in normal state/Remarks on troubleshooting
• If the ordinary operation is normal and the other wiper do not operate
intermittently either, the intermittent switch is probably defective.
aPrepare with starting switch OFF, then carry out troubleshooting
Defective intermittent switch without turning starting switch ON.
CN11 (female)
Position of switch
Voltage
ON
Max. 1 z
Between (1) – (2)
OFF
Min. 1 Mz
• If the trouble is repaired by replacing the relay with relay CN29,
CN31, or CN33, the relay is defective.
aPrepare with starting switch OFF, then turn starting switch ON and
Defective left door wiper
carry out troubleshooting.
intermittent selector relay
Between CN27 (1) – ground
Voltage 20 – 30 V
Between CN27 (5) – ground
Voltage 20 – 30 V
• If the trouble is repaired by replacing the relay with relay CN28,
CN30, or CN32, the relay is defective.
Defective left door wiper
aPrepare with starting switch OFF, then turn starting switch ON and
intermittent relay
carry out troubleshooting.
Between CN26 (2) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CN11 (female) (2) –
Resistance Max. 1 z
CN27 (female) (1)
Disconnection or short
circuit with chassis ground in Wiring harness between CN11 (female) (2) – Resistance
Min. 1 Mz
wiring harness (Disconnec- CN27 (female) (1) with ground
tion in wiring or defective
Wiring harness between CN27 (female) (5) –
Resistance Max. 1 z
contact in connector or
CN26 (female) (2)
contact with ground circuit) Wiring harness between CN27 (female) (5) –
Resistance Min. 1 Mz
CN26 (female) (2) with ground
Wiring harness between CN27 (female) (2) –
Resistance Max. 1 z
ground
D65EX, PX-15
TROUBLESHOOTING
E-23
Circuit diagram related to wiper system
D65EX, PX-15
20-647
(1)
TROUBLESHOOTING
E-24
E-24 WASHING WATER DOES NOT COME OUT.
Trouble (1)
Related
information
• Washing water of the front washer does not come out.
• Carry out the following troubleshooting when the front wiper operates normally. (If the wiper does not
operate either, carry out troubleshooting in E-23 THE WIPER DOES NOT OPERATE first.
Cause
Possible causes
and standard
value in normal
state
20-648
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (Switch position: W/ )
Wiring harness between 11 (female) (1) – ground Resistance Max. 1 z
Defective front washer
1
motor
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between 11 (2) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN14 (female)
Position of switch
Resistance
2 Defective front wiper switch
W/ or W/
Max. 1 z
Between (2) – (1)
OFF
Min. 1 Mz
aDisconnection or short circuit with chassis ground in wiring harness
(Disconnection in wiring or defective contact in connector or contact
with ground circuit)
Wiring harness between fuse (5) – CN14 (feResistance Max. 1 z
Disconnection or short
male) (2)
circuit with chassis ground in Wiring harness between fuse (5) – CN14 (feResistance Min. 1 Mz
wiring harness (Disconnecmale) (2) with ground
3
tion in wiring or defective
Wiring harness between CN14 (female) (1) –
contact in connector or
Resistance Max. 1 z
contact with ground circuit) 19 (3) – 13 (3) – 11 (female) (2)
Wiring harness between CN14 (female) (1) –
Resistance Min. 1 Mz
19 (3) – 13 (3) – 11 (female) (2) and ground
Wiring harness between 11 (female) (1) –
Resistance Max. 1 z
ground
D65EX, PX-15
TROUBLESHOOTING
E-24
Circuit diagram related to washer system
D65EX, PX-15
20-649
(1)
TROUBLESHOOTING
Trouble (2)
Related
information
E-24
• Washing water of the rear washer does not come out.
• Carry out the following troubleshooting when the rear wiper operates normally. (If the wiper does not
operate either, carry out troubleshooting in E-23 THE WIPER DOES NOT OPERATE first.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (Switch position: W/ )
Wiring harness between 12 (female) (1) – ground Resistance Max. 1 z
1 Defective rear washer motor
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between 12 (2) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CN12 (female)
Position of switch
Resistance
2 Defective rear wiper switch
W/ or W/
Max. 1 z
Between (2) – (1)
OFF
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse (4) – CN12 (feResistance Max. 1 z
male) (2)
Disconnection or short
circuit with chassis ground in Wiring harness between fuse (4) – CN12 (fe- Resistance
Min. 1 Mz
wiring harness (Disconnec- male) (2) with ground
3
tion in wiring or defective
Wiring harness between CN12 (female) (1) –
Resistance Max. 1 z
contact in connector or
19 (4) – 13 (4) – 12 (female) (2)
contact with ground circuit) Wiring harness between CN12 (female) (1) –
Resistance Min. 1 Mz
19 (4) – 13 (4) – 12 (female) (2) and ground
Wiring harness between 12 (female) (1) –
Resistance Max. 1 z
ground
For the electric circuit diagram of each system, see Trouble (1).
20-650
(1)
D65EX, PX-15
TROUBLESHOOTING
Trouble (3)
Related
information
E-24
• Washing water of the left door washer does not come out.
• Carry out the following troubleshooting when the left door wiper operates normally. (If the wiper does
not operate either, carry out troubleshooting in E-23 THE WIPER DOES NOT OPERATE first.
• Since the left door wiper switch and right door wiper switch use fuse (6) jointly, if fuse (6) is broken, both
wipers do not operate.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (Switch position: W/ )
Defective left door washer Wiring harness between 9 (female) (1) – ground Resistance Max. 1 z
1
motor
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between 9 (2) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective left door wiper
CN15 (female)
Position of switch
Resistance
2
switch
W/ or W/
Max. 1 z
Between (2) – (1)
OFF
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse (6) – CN15 (feResistance Max. 1 z
male) (2)
Disconnection or short
circuit with chassis ground in Wiring harness between fuse (6) – CN15 (fe- Resistance
Min. 1 Mz
wiring harness (Disconnec- male) (2) with ground
3
tion in wiring or defective
Wiring harness between CN15 (female) (1) –
Resistance Max. 1 z
contact in connector or
19 (1) – 13 (1) – 9 (female) (2)
contact with ground circuit) Wiring harness between CN15 (female) (1) –
Resistance Min. 1 Mz
19 (1) – 13 (1) – 9 (female) (2) and ground
Wiring harness between 9 (female) (1) –
Resistance Max. 1 z
ground
For the electric circuit diagram of each system, see Trouble (1).
D65EX, PX-15
20-651
(1)
TROUBLESHOOTING
Trouble (4)
Related
information
E-24
• Washing water of the right door washer does not come out.
• Carry out the following troubleshooting when the right door wiper operates normally. (If the wiper does
not operate either, carry out troubleshooting in E-23 THE WIPER DOES NOT OPERATE first.
• Since the right door wiper switch and left door wiper switch use fuse (6) jointly, if fuse (6) is broken, both
wipers do not operate.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (Switch position: W/ )
Defective right door washer Wiring harness between 10 (female) (1) – ground Resistance Max. 1 z
1
motor
aPrepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between 10 (2) – ground
Voltage 20 – 30 V
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective right door wiper
CN13 (female)
Position of switch
Resistance
2
switch
W/ or W/
Max. 1 z
Between (2) – (1)
OFF
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse (6) – CN13 (feResistance Max. 1 z
male) (2)
Disconnection or short
circuit with chassis ground in Wiring harness between fuse (6) – CN13 (fe- Resistance
Min. 1 Mz
wiring harness (Disconnec- male) (2) with ground
3
tion in wiring or defective
Wiring harness between CN13 (female) (1) –
Resistance Max. 1 z
contact in connector or
19 (2) – 13 (2) – 10 (female) (2)
contact with ground circuit) Wiring harness between CN13 (female) (6) –
Resistance Min. 1 Mz
19 (2) – 13 (2) – 10 (female) (2) and ground
Wiring harness between 10 (female) (1) –
Resistance Max. 1 z
ground
For the electric circuit diagram of each system, see Trouble (1).
20-652
(1)
D65EX, PX-15
TROUBLESHOOTING
E-25
E-25 THE AIR CONDITIONER DOES NOT OPERATE.
Trouble (1)
Related
information
• No air flow.
Cause
Defective circuit breaker
1
(CB2)
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
When the circuit breaker is cut off, a ground fault may have possibly occurred in the circuit.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective blower main relay
2
(coil side)
CN-R1 (male)
Resistance
Between (1) and (2)
240 ± 40 z
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective blower main relay
3
(contact side)
CN-R1 (male)
Voltage
Between (8C) and ground
20 – 30 V
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective blower Hi relay
4
(coil side)
CN-R2 (male)
Resistance
Between (1) and (2)
240 ± 40 z
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective blower Hi relay
5
(contact side)
The relay is in order when the motor rotates after the starting switch is
turned ON and the blower Hi switch is turned on.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective blower Mi1 relay
6
(coil side)
CN-R3 (male)
Resistance
Between (1) and (2)
240 ± 40 z
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective blower Mi1 relay
7
(contact side)
The relay is in order when the motor rotates after the starting switch is
turned ON and the blower Mi switch is turned on.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective blower Mi2 relay
6
(coil side)
CN-R4 (male)
Resistance
Between (1) and (2)
240 ± 40 z
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective blower Mi2 relay
7
(contact side)
The relay is in order when the motor rotates after the starting switch is
turned ON and the blower Mi switch is turned on.
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
8 Defective blower motor
The motor is in order when it rotates after the starting switch is turned
ON and the blower Lo switch is turned on.
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
8 Defective blower motor
The motor is in order when it rotates after the starting switch is turned
ON and the blower Lo switch is turned on.
D65EX, PX-15
20-653
(1)
TROUBLESHOOTING
E-25
Cause
Possible causes
and standard
value in normal
state
20-654
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring harness between CN-R4 (female)
(14C), AC1 (female) (14A), CN-R (female)
Resistance Max. 1 z
(S141) or CN-R2 (female) (14E) or CN-R3 (female) (14N) and ground
Wiring harness between CN-B (female) (11B)
Resistance Max. 1 z
and CN-R1 (female) (11A)
Wiring harness between CN-B (female) (12A)
Resistance Max. 1 z
and CN-R2 (female) (12B) or CN-R (female)
(11C)
Disconnection of wiring
harness (Disconnection in Wiring harness between CB2 outlet and AC1
9
Resistance Max. 1 z
wiring or defective contact in (female) (1A), CN-R1 (female) (1D), CN-R2
(female) (1E) or CN-R4 (female) (11)
connector)
Wiring harness between CN-R1 (female) (2B)
Resistance Max. 1 z
and AC1 (female) (2A)
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring harness between CN-R3 (female) (3B)
Resistance Max. 1 z
and AC1 (female) (3B)
Wiring harness between CN-R2 (female) (5B)
Resistance Max. 1 z
and AC1 (female) (5A)
Wiring harness between CN-R4 (female) (4B)
Resistance Max. 1 z
and AC1 (female) (4A)
When Causes 1 to 9 are not applicable, the control panel is supposed
10 Defective control panel
to be defective.
When any cause cannot be specified, failure phenomenon may have been
11 Different failure phenomenon
mistaken. Carry out the troubleshooting of “Cooling is not possible”.
D65EX, PX-15
TROUBLESHOOTING
Trouble (2)
Related
information
E-25
• Cooling is not possible.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
1 Defective pressure switch
CN-P
Blower switch
Voltage
Between (6B) and
ON
20 – 30 V
ground
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective compressor clutch
2
relay (coil side)
CN-R5 (male)
Resistance
Between (1) and (2)
240 ± 40 z
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective compressor clutch
3
relay (contact side)
CN-R5 (male)
Voltage
Between (18A) and ground
20 – 30 V
aPrepare with the starting switch OFF, then turn the starting switch
ON and carry out troubleshooting.
Defective condenser relay
4
(contact side)
CN-R6
Voltage
Between (23A) and ground
20 – 30 V
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
5 Defective thermistor
AC1 (male)
Resistance
Between (9A) and (13A)
Max. 3,500 z
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Defective condenser blower
6
resistor
Condenser blower resistor
Resistance
Between terminals
2.8 z ± 5%
aTurn the starting switch on and carry out the troubleshooting.
7 Defective condenser motor The motor is in order if it is rotating when the air conditioner is switched
ON.
aStart the engine and carry out the troubleshooting.
Defective compressor
8
The compressor magnet clutch is supposed to be out of order, so inmagnet clutch
spect it directly.
aStart the engine and carry out the troubleshooting.
9 Defective compressor
The compressor is supposed to be out of order, so inspect it directly.
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Wiring harness between CB2 outlet and
CN-R6 (female) (8B) or CN-R5 (female) (8D) Resistance Max. 1 z
Disconnection of wiring
or CN-R1 (female) (8C)
harness (Disconnection in
Wiring harness between CN-R5 (female)
10
Resistance Max. 1 z
wiring or defective contact in
(18A) and A/C (female) (1)
connector)
Wiring harness between CB2 outlet and
Resistance Max. 1 z
CN-R5 (female) (1K)
Wiring harness between CN-T (female) (9B)
Resistance Max. 1 z
and AC1 (female) (9A)
D65EX, PX-15
20-655
(1)
TROUBLESHOOTING
E-25
Cause
Possible causes
and standard
value in normal
state
20-656
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with the starting switch OFF, then carry out troubleshooting
without turning the starting switch ON.
Disconnection of wiring
harness (Disconnection in Wiring harness between CN-P (female) (7B)
Resistance Max. 1 z
10
wiring or defective contact in and CN-R5 (female) (7A)
connector)
Wiring harness between CN-P (female) (6B)
Resistance Max. 1 z
and AC1 (female) (6A)
When Causes 1 to 10 are not applicable, the control panel is supposed
11 Defective control panel
to be defective.
D65EX, PX-15
TROUBLESHOOTING
E-25
Circuit diagram related to air conditioner
D65EX, PX-15
20-657
(1)
TROUBLESHOOTING
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
(H-MODE)
Information described in troubleshooting list ........................................................................................... 20-702
H- 1 No travel power (no drawbar pull) .................................................................................................. 20-703
H- 2 Machine does not move (at 2nd or 3rd speed) .............................................................................. 20-704
H- 3 Machine does not move in any speed range ................................................................................. 20-705
H- 4 Machine travels only in one direction forward or in reverse ........................................................... 20-706
H- 5 When gear is shifted or travel direction is changed, large time lag is made .................................. 20-707
H- 6 Machine does not turn (not turned rightward or leftward) .............................................................. 20-708
H- 7 Steering speed or power is low ...................................................................................................... 20-708
H- 8 Brake does not work ...................................................................................................................... 20-709
H- 9 Overheat of power train oil temperature ......................................................................................... 20-709
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor ............ 20-710
H-11 All work equipment speeds are slow .............................................................................................. 20-710
H-12 Work equipment does not move .................................................................................................... 20-711
H-13 Blade lift speed is slow or lacks power ........................................................................................... 20-711
H-14 Blade tilt speed is slow or lacks power ........................................................................................... 20-712
H-15 Ripper lift speed is slow or lacks power ......................................................................................... 20-712
H-16 Excessive hydraulic drift of blade lift .............................................................................................. 20-713
H-17 Excessive hydraulic drift of blade tilt .............................................................................................. 20-713
H-18 Excessive hydraulic drift of ripper lift .............................................................................................. 20-714
D65EX, PX-15
20-701
(1)
TROUBLESHOOTING
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST
a Troubleshooting lists contain the following information all together. Understand the contents carefully and
troubleshoot the machine.
Trouble
Related
information
Problem that appears on the machine.
Information related to problems occurred or troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting
1
Possible causes
and standard
value in normal
state
2 Cause supposed to have
caused failure
<Contents>
(The sequence shows refer- • Standard values in normal state for judging possible causes
ence numbers and does not • Remarks for making judgment
3 mean priority.)
4
20-702
(1)
D65EX, PX-15
TROUBLESHOOTING
H-1
H-1 NO TRAVEL POWER (NO DRAWBAR PULL)
Trouble
Related
information
• There is no travel power. (No drawbar pull).
• Confirm that the oil quantity on the power train is normal before troubleshooting.
Cause
1
2
3
4
Possible causes
and standard
value in normal
state
5
6
7
8
D65EX, PX-15
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective engine
Measurement conditions
Number of engine rotations
F3 stall
1,650 rpm
Defective power train pump The power train pump is assumed to be defective; directly check it.
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Original pressure of
Torque converter
Internally defective torque
PCCS lever
torque converter
delivery pressure
converter
Max. 0.88 MPa
0.39 – 0.69 MPa
Full neutral
{Max. 9 kg/cm2}
{4 – 7 kg/cm2}
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
PCCS lever
Transmission main relief pressure
Full neutral
Min. 3.04 MPa {Min. 31 kg/cm2}
Defective set pressure of
aPrepare with the starting switch OFF, then carry out troubleshooting
transmission main relief
without turning the starting switch ON.
valve and internal defect
Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly.
• Free length of large spring: 128 mm
• Free length of small spring: 108 mm
• Number of shims: 6
aPrepare with starting switch OFF, then drive the engine in low idling
mode for troubleshooting.
Transmission clutch
Clutch pressure
FWD
Min. 2.84 MPa {Min. 29 kg/cm2}
Defective transmission valve
REV
Min. 2.84 MPa {Min. 29 kg/cm2}
(ECMV) function
1ST
Min. 2.84 MPa {Min. 29 kg/cm2}
2ND
Min. 2.84 MPa {Min. 29 kg/cm2}
3RD
Min. 2.84 MPa {Min. 29 kg/cm2}
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective brake valve
Parking lever
Brake pressure
Min. 2.55 MPa
Free
{Min. 26 kg/cm2}
If the result of the troubleshooting in cause 6 is abnormal, the parking
Defective parking lever or
lever or brake pedal linkage is not assumed to be adjusted normally.
brake pedal linkage
Directly check it.
Internally defective transThe transmission is assumed to be defective internally; directly check
mission
it.
20-703
(1)
TROUBLESHOOTING
H-2
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)
Trouble
Related
information
• Machine does not move. (At 2nd or 3rd speed)
• Confirm that the oil quantity on the power train is normal before troubleshooting.
• Confirm that the transmission main relief pressure is normal before troubleshooting. (See H-1.)
Cause
1
Possible causes
and standard
value in normal
state
2
3
4
5
6
20-704
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Original pressure of
Torque converter
Internally defective torque
PCCS lever
torque converter
delivery pressure
converter
Max. 0.88 MPa
0.39 – 0.69 MPa
Full neutral
{Max. 9 kg/cm2}
{4 – 7 kg/cm2}
aPrepare with starting switch OFF, then drive the engine in low idling
mode for troubleshooting.
Defective transmission valve
Transmission clutch
Clutch pressure
(ECMV) function
2ND
Min. 3.04 MPa {Min. 31 kg/cm2}
3RD
Min. 3.04 MPa {Min. 31 kg/cm2}
Internally defective transThe transmission clutch (2nd or 3rd speed) is assumed to be defective
mission clutch
internally; directly check it.
Defective parking brake
The parking brake function is assumed to be defective (dragged);
function (Drag)
check the linkage valves.
aMove to a flat place (a hard road), and start the engine for troubleshooting.
Defective brake function
(Drag)
If the machine does not run by low idling + F2 operation, brake drag occurs. (Carry out troubleshooting “Brake does not work”.)
Internally defective transThe transmission is assumed to be defective internally; directly check
mission
it.
D65EX, PX-15
TROUBLESHOOTING
H-3
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE
Trouble
Related
information
• Machine does not move in any speed range.
• Confirm that the oil quantity on the power train is normal before troubleshooting.
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective power train pump The power train pump is assumed to be defective; directly check it.
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
PCCS lever
Transmission main relief pressure
Full neutral
Min. 3.04 MPa {Min. 31 kg/cm2}
Defective and Internally de- aPrepare with the starting switch OFF, then carry out troubleshooting
2 fective set pressure of trans- without turning the starting switch ON.
mission main relief valve
Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly.
• Free length of large spring: 128 mm
• Free length of small spring: 108 mm
• Number of shims: 6
aPrepare with starting switch OFF, then drive the engine in low idling
mode for troubleshooting. (Before this, confirm that the transmission
main relief pressure is normal.)
Transmission clutch
Clutch pressure
Defective transmission valve
FWD
Min.
2.84
MPa {Min. 29 kg/cm2}
3
(ECMV) function
REV
Min. 2.84 MPa {Min. 29 kg/cm2}
1ST
Min. 2.84 MPa {Min. 29 kg/cm2}
2ND
Min. 2.84 MPa {Min. 29 kg/cm2}
3RD
Min. 2.84 MPa {Min. 29 kg/cm2}
Internally defective transThe transmission clutch is assumed to be defective internally; directly
4
mission clutch
check it.
aMove to a flat place, and drive the engine in high idling mode for troubleshooting. (Before this, confirm that the transmission main relief
pressure is normal.)
Brake hydraulic pressure
Brake pedal
(left/right)
5 Defective brake function
Release
Min. 2.55 MPa {Min. 26 kg/cm2}
Pedal
0 {0}
When the hydraulic pressure is abnormal, carry out troubleshooting
“Brake does not work”.
D65EX, PX-15
20-705
(1)
TROUBLESHOOTING
H-4
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE
Trouble
Related
information
Possible causes
and standard
value in normal
state
20-706
(1)
• Machine travels only in one direction Forward or in reverse.
• Confirm that the oil quantity on the power train is normal before troubleshooting.
Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective power train pump The power train pump is assumed to be defective; directly check it.
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
PCCS lever
Transmission main relief pressure
Full neutral
Min. 3.04 MPa {Min. 31 kg/cm2}
Defective set pressure of
aPrepare with the starting switch OFF, then carry out troubleshooting
2 transmission main relief
without turning the starting switch ON.
valve or internal defect
Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly.
• Free length of large spring: 128 mm
• Free length of small spring: 108 mm
• Number of shims: 6
aPrepare with starting switch OFF, then drive the engine in low idling
mode for troubleshooting. (Before this, confirm that the transmission
main relief pressures is normal.)
Defective transmission valve
3
Transmission clutch
Clutch pressure
(ECMV) function
FWD
Min. 2.84 MPa {Min. 29 kg/cm2}
REV
Min. 2.84 MPa {Min. 29 kg/cm2}
Defective transmission
When the troubleshooting in cause 3 is abnormal, the clutch seal is as4
clutch seal
sume to be defective; directly check it.
Internally defective transThe transmission clutch (forward or backward) is assumed to be defec5
mission clutch
tive internally; directly check it.
D65EX, PX-15
TROUBLESHOOTING
H-5
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME
LAG IS MADE
Trouble
Related
information
• Time lag is excessive when shifting gear or changing direction.
• Confirm that the oil quantity on the power train is normal before troubleshooting.
Possible causes
and standard
value in normal
state
Cause
Standard value in normal state/Remarks on troubleshooting
1 Defective power train pump The power train pump is assumed to be defective; directly check it.
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
PCCS lever
Transmission main relief pressure
Full neutral
Min. 3.04 MPa {Min. 31 kg/cm2}
Defective set pressure of
aPrepare with the starting switch OFF, then carry out troubleshooting
2 transmission main relief
without turning the starting switch ON.
valve or internal defect
Directly check that the spring length and the number of shims are normal and also that the spool rotates smoothly.
• Free length of large spring: 128 mm
• Free length of small spring: 108 mm
• Number of shims: 6
aPrepare with starting switch OFF, then drive the engine in low idling
mode for troubleshooting. (Before this, confirm that the transmission
main relief pressure is normal.)
Transmission clutch
Clutch pressure
Defective transmission valve
FWD
Min.
2.84
MPa {Min. 29 kg/cm2}
3
(ECMV) function
REV
Min. 2.84 MPa {Min. 29 kg/cm2}
1ST
Min. 2.84 MPa {Min. 29 kg/cm2}
2ND
Min. 2.84 MPa {Min. 29 kg/cm2}
3RD
Min. 2.84 MPa {Min. 29 kg/cm2}
Defective transmission
When the troubleshooting in cause 3 is abnormal, the clutch seal is as4
clutch seal
sume to be defective; directly check it.
Internally defective transThe transmission clutch is assumed to be defective internally; directly
5
mission clutch
check it.
aMove to a flat place (a hard road), then start the engine for troubleshooting.
Defective brake function
6
(Drag)
If the machine does not run by low idling + F2 operation, brake drag occurs. (Carry out troubleshooting “Brake does not work”.)
D65EX, PX-15
20-707
(1)
TROUBLESHOOTING
H-6, H-7
H-6
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD)
Trouble
Related
information
• Machine does not turn. (The machine does not turn leftward or rightward.)
• Confirm that the oil quantity for function is normal before troubleshooting.
Cause
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting the engine, then drive the engine in high idling
Defective set pressure or
mode for troubleshooting.
defective function of self1
PCCS lever
Original pressure of control circuit
pressure reducing valve
4.27 ± 0.25 MPa
(PPC source pressure)
Neutral
{43.5 ± 2.5 kg/cm2}
If an abnormal sound occurs in the HSS peripheral equipment, carry
Abnormal sound from HSS
2
out troubleshooting “Abnormal Sound around HSS and Work Equipperipheral equipment
ment Pump or HSS Motor”.
H-7 STEERING SPEED OR POWER IS LOW
Trouble
Related
information
• Steering speed or power is insufficient.
• Confirm that the oil quantity on the power train is normal before troubleshooting.
Cause
Possible causes
and standard
value in normal
state
20-708
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting the engine, then drive the engine in high idling
mode for troubleshooting.
Defective set pressure or
1 defective function of HSS
PCCS lever
HSS relief pressure
main relief valve
38.2 – 41.7 MPa
Left or right stroke end
{390 – 425 kg/cm2}
aPrepare with starting the engine, then drive the engine in high idling
Defective set pressure or
mode for troubleshooting.
defective function of self2
PCCS lever
Original pressure of control circuit
pressure reducing valve
4.27 ± 0.25 MPa
(PPC source pressure)
Neutral
{43.5 ± 2.5 kg/cm2}
If an abnormal sound occurs in the HSS peripheral equipment, carry
Abnormal sound from HSS
out troubleshooting “Abnormal Sound around HSS and Work Equip3
peripheral equipment
ment Pump or HSS Motor”.
D65EX, PX-15
TROUBLESHOOTING
H-8, H-9
H-8
H-8 BRAKE DOES NOT WORK
Trouble
Related
information
• Brake does not work.
• Confirm that the oil quantity on the power train is normal before troubleshooting.
• Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)
Cause
Possible causes
and standard
value in normal
state
1
Defective brake valve function
2
Defective adjustment of
brake pedal linkage
3 Defective brake seal
4
Slipped or abrasive brake
disk plate
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Brake pedal
Brake hydraulic pressure
Min. 2.55 MPa
At release
{Min. 26 kg/cm2}
At pedaling
0 {0}
If the troubleshooting in cause 1 is abnormal, the adjustment of the
brake pedal linkage is assumed to be abnormal; directly check it.
If the troubleshooting in cause 1 is abnormal, the brake seal is assumed to be defective; directly check it.
The brake disk plate is assumed to be slipped or abrasive; directly
check it.
H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE
Trouble
Related
information
• The oil temperature of the power train overheats.
• Confirm that the oil quantity on the power train is normal before troubleshooting.
• Confirm that the value of the oil temperature of the power train matches the actual oil temperature before troubleshooting. (If they do not match, carry out troubleshooting “Abnormal Power Train Oil temperature”.)
• Confirm that the main relief pressure for transmission is normal before troubleshooting. (See H-1.)
Cause
1
2
Possible causes
and standard
value in normal
state
3
4
5
D65EX, PX-15
Standard value in normal state/Remarks on troubleshooting
The engine cooling system is assumed to be defective or the engine
Defective engine system
output is assumed to be increased; see the Shop Manual: Engine.
Defective power train pump The power train pump is assumed to be defective or aired from the sucor air from suction circuit
tion circuit; directly check it.
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Original pressure of
Torque converter
Internally defective torque
PCCS lever
torque converter
delivery pressure
converter
0.39 – 0.69 MPa
Max. 0.88 MPa
Full neutral
{4 – 7 kg/cm2}
{Max. 9 kg/cm2}
Defective transmission
The transmission clutch is assumed to be defective internally (slipped);
clutch function (Slip)
directly check it.
aPrepare with starting the engine for troubleshooting.
1. Run the engine at low idling on a flat place (a hard road).
Defective brake function
2. Set the gearshift lever in F2.
(Drag)
3. See if the machine moves (travels). If it does not move, brake drag
occurs. (Carry out troubleshooting “Brake does not work”.)
20-709
(1)
TROUBLESHOOTING
H-10, H-11
H-10
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK
EQUIPMENT PUMP OR HSS MOTOR
Trouble
Related
information
Possible causes
and standard
value in normal
state
• Abnormal noise from around HSS and work equipment pump.
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
Cause
1 Inappropriate oil
Clogged hydraulic oil tank
2
strainer
Standard value in normal state/Remarks on troubleshooting
The oil used is assumed to be inappropriate; directly check it.
The strainer of the hydraulic oil tank is assumed to be clogged; directly
check it.
Air is assumed to be inhaled in the suction circuit of the HSS and work
3 Air inhaled in suction circuit
equipment pump; directly check the pipes.
Internally defective HSS
The HSS and work equipment pump is assumed to be defective inter4
pump
nally; directly check it.
Internally defective HSS mo5
The HSS motor is assumed to be defective internally; directly check it.
tor
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW
Trouble
Related
information
• All work equipment speeds are slow.
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
1
2
3
Possible causes
and standard
value in normal
state
4
5
6
20-710
(1)
Cause
Standard value in normal state/Remarks on troubleshooting
Defective PTO (pump drive
The PTO pump drive unit of the work equipment is assumed to be deunit of HSS and work equipfective; directly check it.
ment)
Defective HSS and work
The pump of the HSS and work equipment is assumed to be defective;
equipment pump
directly check it.
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective unload valve funcWork equipment lever
Unload pressure
tion
3.43 +1.37
MPa
0
Full neutral
2
{35 +14
0 kg/cm }
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective set pressure or
Work equipment lever
Main relief pressure
defective function of main
relief valve
Min. 19.6 MPa
Stroke end
{Min. 200 kg/cm2}
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective function of selfpressure reducing valve
Work equipment lever
Original pressure of control circuit
(PPC original pressure)
4.27 ± 0.25 MPa
Full neutral
{43.5 ± 2.5 kg/cm2}
Internally defective PPC
When the troubleshooting in cause 5 is abnormal, the PPC valve is asvalve
sumed to be defective internally; directly check it.
D65EX, PX-15
TROUBLESHOOTING
H-12, H-13
H-12
H-12 WORK EQUIPMENT DOES NOT MOVE
Trouble
Related
information
• Work equipment does not move.
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
1
2
3
Possible causes
and standard
value in normal
state
4
5
Cause
Standard value in normal state/Remarks on troubleshooting
Defective PTO (Pump drive
The PTO pump drive unit of the HSS and work equipment is assumed
unit of HSS and work equipto be defective; directly check it.
ment)
Defective HSS and work
The HSS and work equipment pump is assumed to be defective; directequipment pump
ly check it.
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective unload valve funcWork equipment lever
Unload pressure
tion
3.43 +1.37
MPa
0
Full neutral
2
{35 +14
0 kg/cm }
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective set pressure or
Work equipment lever
Main relief pressure
defective function of main
relief valve
Min. 19.6 MPa
Stroke end
{Min. 200 kg/cm2}
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Defective function of selfpressure reducing valve
Work equipment lever
Original pressure of control circuit
(PPC original pressure)
4.27 ± 0.25 MPa
Full neutral
{43.5 ± 2.5 kg/cm2}
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER
Trouble
Related
information
• Blade lift speed is slow or lacks power.
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
• Confirm whether the blade is remodeled.
• When the hydraulic drift rate of the blade lift is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Blade Lift”.
Cause
Possible causes
and standard
value in normal
state
1
Defective PPC valve function
2
Defective function of blade
lift operation valve (Spool)
3 Aired blade lift cylinder
D65EX, PX-15
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Blade lever
PPC valve output pressure
3.53 – 4.41 MPa
Lift stroke end
{36 – 45 kg/cm2}
The spool function of the blade lift operation valve is assumed to be defective; directly check it.
The blade lift cylinder is assumed to be aired; carry out the air bleed
and observe how the phenomenon changes.
20-711
(1)
TROUBLESHOOTING
H-14, H-15
H-14
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER
Trouble
Related
information
• Blade tilt speed is slow or lacks power.
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
• Confirm whether the blade is remodeled.
• When the hydraulic drift rate of the blade tilt is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Blade Tilt”.
Cause
Possible causes
and standard
value in normal
state
1
Defective PPC valve function
2
Defective function of blade
tilt operation valve (Spool)
3 Aired blade tilt cylinder
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Blade lever
PPC valve output pressure
3.53 – 4.41 MPa
Lift stroke end
{36 – 45 kg/cm2}
The spool function of the blade tilt operation valve is assumed to be defective; directly check it.
The blade tilt cylinder is assumed to be aired; carry out the air bleed
and observe how the phenomenon changes.
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER
Trouble
Related
information
• Ripper lift speed is slow or lacks power.
• Confirm that the oil quantity of the hydraulic oil tank is normal before troubleshooting.
• Confirm whether the ripper is remodeled.
• When the hydraulic drift rate of the ripper lift is also high, carry out troubleshooting “High Hydraulic Drift
Rate of Ripper Lift”.
Cause
Possible causes
and standard
value in normal
state
1
Defective PPC valve function
2
Defective function of ripper
lift operation valve (Spool)
Defective function of ripper
3 lift operation valve (suction
valve)
4 Aired ripper lift cylinder
20-712
(1)
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Ripper lever
PPC valve output pressure
3.53 – 4.41 MPa
Lift stroke end
{36 – 45 kg/cm2}
The spool function of the ripper lift operation valve is assumed to be defective; directly check it.
The suction valve of the ripper lift operation valve is assumed to be defective; directly check it.
aReplace the suction valve in the head with one at the bottom, and observe how the phenomenon changes.
The ripper lift cylinder is assumed to be aired; carry out the air bleed
and observe how the phenomenon changes.
D65EX, PX-15
TROUBLESHOOTING
H-16, H-17
H-16
H-16 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT
Trouble
Related
information
• Excessive hydraulic drift of blade lift.
• Confirm whether the blade is remodeled.
• Confirm that no oil leaks the circuits in the work equipment before troubleshooting.
Cause
Possible causes
and standard
value in normal
state
1
Defective seal of blade lift
operation valve (Spool)
2
Defective seal of blade lift
cylinder
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting the engine, then stop the engine for troubleshooting.
1. Raise the blade (about 800 mm).
2. Disconnect the hose on the cylinder head and block it.
3. Measure hydraulic drift of blade tip.
Blade lift
Hydraulic drift
Block blade lift circuit
100 mm/15 min
The seal of the blade lift cylinder is assumed to be defective; directly
check it.
H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT
Trouble
Related
information
• Excessive hydraulic drift of blade tilt.
• Confirm whether the blade is remodeled.
• Confirm that no oil leaks the circuits in the work equipment before troubleshooting.
Cause
Possible causes
and standard
value in normal
state
D65EX, PX-15
1
Defective seal of blade tilt
operation valve (Spool)
2
Defective seal of blade tilt
cylinder
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting the engine, then stop the engine for troubleshooting.
1. Fully extend the blade tilt cylinder.
2. Disconnect the hose on the cylinder head and block it.
3. Measure hydraulic drift of blade tip.
Blade tilt
Hydraulic drift
Block blade tilt circuit
200 mm/15 min
The seal of the blade tilt cylinder is assumed to be defective; directly
check it.
20-713
(1)
TROUBLESHOOTING
H-18
H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT
Trouble
Related
information
• Excessive hydraulic drift of ripper lift.
• Confirm whether the ripper is remodeled.
• Confirm that no oil leaks the circuits in the work equipment before troubleshooting.
Cause
Possible causes
and standard
value in normal
state
20-714
(1)
1
Defective seal of ripper lift
operation valve (Spool)
2
Defective seal of ripper lift
cylinder
Standard value in normal state/Remarks on troubleshooting
aPrepare with starting the engine, then stop the engine for troubleshooting.
1. Pull out the shank pin and raise the ripper to the maximum.
2. Disconnect the hose on the cylinder head side and block it.
Ripper lift
Hydraulic drift
Block ripper lift circuit
100 mm/15 min
The seal of the ripper lift cylinder is assumed to be defective; directly
check it.
D65EX, PX-15
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM
(S-MODE)
Method of using troubleshooting charts ................................................................................................... 20-802
S- 1 Starting performance is poor (starting always takes time) ............................................................. 20-806
S- 2 Engine does not start ..................................................................................................................... 20-807
S- 3 Engine does not pick up smoothly (follow-up is poor) .................................................................... 20-810
S- 4 Engine stops during operations ..................................................................................................... 20-811
S- 5 Engine does not rotate smoothly (hunting) .................................................................................... 20-812
S- 6 Engine lacks output (or lacks power) ............................................................................................. 20-813
S- 7 Exhaust smoke is black (incomplete combustion) ......................................................................... 20-814
S- 8 Oil consumption is excessive (or exhaust smoke is blue) .............................................................. 20-815
S- 9 Oil becomes contaminated quickly ................................................................................................ 20-816
S-10 Fuel consumption is excessive ...................................................................................................... 20-817
S-11 Oil is in cooling water (or water spurts back, or water level goes down) ........................................ 20-818
S-12 Oil pressure caution lamp lights up (drop in oil pressure) .............................................................. 20-819
S-13 Oil level rises (water, fuel in oil) ...................................................................................................... 20-820
S-14 Water temperature becomes too high (overheating) ...................................................................... 20-821
S-15 Abnormal noise is made ................................................................................................................ 20-822
S-16 Vibration is excessive ..................................................................................................................... 20-823
D65EX, PX-15
20-801
(1)
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corresponds 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 level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-802
(1)
D65EX, PX-15
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
The basic method of using the troubleshooting chart
is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high probability are marked with w.
Check each of the [Questions] and [Check items]
in turn, taking note of the Q or w marks in the chart
for the horizontal lines of symptoms applicable to the
machine. The vertical column (Causes) that has the
highest number of applicable Q or w marks is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For (Confirm recent repair history) in the
[Questions] Section, ask the user, and mark
the Cause column with E to use as reference for locating the cause of the fairure.
However, do not use this when marking caluculations to narrow down causes.
2. Use the E in the Cause column as reference
for [Degree of use (Operated for long period)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be included if necessary to determine the order
for troubleshooting.
1
2
D65EX, PX-15
20-803
(1)
TROUBLESHOOTING
•
METHOD OF USING TROUBLESHOOTING CHARTS
Example of troubleshooting when exhaust gas is black
Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have a causal relationship with this problem: [Exhaust gas gradually became black], [Power gradually became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black
• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because an error has occurred in the electrical
system.)
Legend
: Possible causes (judging from Questions and Check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
20-804
(1)
D65EX, PX-15
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
5 causes
Step 1
Clarify the relationship between the three symptoms in
the [Questions] and [Check items] section and the 5
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of
and
marked where the
horizontal limes for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cyl. head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element]. Follow
this column down to the troubleshooting area and carry
out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
D65EX, PX-15
20-805
(1)
TROUBLESHOOTING
S-1
S-1 Starting performance is poor (starting always takes time)
General causes why starting performance is poor
• Defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel
Causes
a With the common rail fuel injection system, the fuel injection timing is recognized electrically, so even when
the starting operation is carried out, the engine may not
start until the crankshaft has completed two rotations.
However, this does not indicate any abnormality.
Confirm recent repair history
Degree of use of machine
Ease of starting
Operated for long period
E
E E
Gradually became worse
E
Q w w
Q Q
w
Q Q Q Q
w w Q Q
w
Starts when warm
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation Manual
w
w
Engine oil must be added more frequently
w
Preheating indicator lamp does not light up during preheating or in low temperatures
w w
Charging caution lamp lights up while engine is running
w
Dust indicator lamp is red
w
Air breather hole in fuel tank cap is clogged
w
Q
w Q Q
Leakage of fuel from fuel piping
When fuel priming pump is operated, there is no response, or operation is too heavy
w
Starting motor cranks engine slowly
When engine is cranked with
starting motor
w w
No fuel comes out even when fuel filter air bleed plug is removed
When hose at collection portion for spill flow from fuel injector is
disconnected, spill flow is small (See error code “AD10L3”)
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w
Q w Q Q
There is hunting from engine (rotation is irregular)
w
Blow-by gas is excessive
q
Check air cleaner directly
q q
When compression pressure is measured, it is found to be low
q
When air is bled from fuel line, air comes out
q
Check fuel filter, strainer directly
q
Check fuel feed pump strainer directly
q
Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed”
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder
mode
q
q
Intake air heater mount does not become warm during operation of preheating
Is voltage 26 – 30 V between alternator terminal B and terminal E with engine at low
idling?
w
w
Q Q
Engine does not pick up smoothly add combustion is irregular
Yes
No
When specific gravity of electrolyte or voltage of battery is measured, it is found to be low
q
q
q
Remedy
20-806
(1)
D65EX, PX-15
TROUBLESHOOTING
S-2
S-2 Engine does not start
a) Engine does not turn
General causes why engine does not turn
• Internal parts of engine seized
a See “Engine stops during operations”.
• Defective electrical system
• Failure in power train
a Carry out troubleshooting of the machine.
Causes
Confirm recent repair history
Degree of use of machine
Operated for long period
Condition of horn when
starting switch is turned ON
Horn does not sound
E E
w
When battery is checked, battery electrolyte is found to be low
Q
Q
w
When starting switch is turned to ON, there is no actuation sound from battery relay
When starting switch is turned to START, pinion does not move out
Speed of rotation is low
Q
w
w
w
Makes grating noise
w
w
Q Q
Soon disengages again
Q
Makes rattling noise and does not turn
q
Check flywheel ring gear directly
q
When specific gravity of electrolyte or voltage of battery is measured, it is found to be low
q
There is no voltage (20 – 30 V) between battery relay terminal B and terminal E
Turn the starting switch OFF,
connect the cord, and carry
out troubleshooting at ON
w
w
Battery terminal is loose
When starting switch is
turned to START, pinion
moves out, but
Q
w
w
Horn volume is low
q
When terminal B and terminal C of starting switch are connected, engine starts
q
When terminal B and terminal C of starting motor are connected, engine starts
When terminal B and terminal C of safety relay are connected, engine starts
When terminal of safety switch and terminal B of starting motor are connected, engine starts
q
q
Remedy
D65EX, PX-15
20-807
(1)
TROUBLESHOOTING
S-2
b) Engine turns but no exhaust smoke comes out
General causes why engine turns but no exhaust smoke
comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
Causes
Confirm recent repair history
Degree of use of machine
E E E
Operated for long period
w Q w w w
Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to Operation Manual
E
Q Q Q
Q Q
E E
Q
w
Q w
Fuel tank is found to be empty
Air breather hole in fuel tank cap is clogged
Rust and water are found when fuel tank is drained
w
When fuel filter is removed, there is no fuel in filter
There is leakage from fuel piping
When fuel priming pump is operated, there is no response, or operation is too heavy
When engine is cranked with
starting motor
w w
No fuel comes out even when fuel filter air bleed plug is removed
When hose at collection portion for spill flow from fuel injector
is disconnected, spill flow is small (See error code “AD10L3”)
Q
w
w
w Q Q
Q
w Q
Q
w w w w
Q
q
When air is bled from fuel line, air comes out
q
Check fuel filter directly
q
Check fuel feed pump gauze filter directly
q
Check fuel feed pump directly
Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed”
Carry out troubleshooting “Abnormality in fuel supply pump solenoid” in troubleshooting for
monitor panel
q q
q
q
q
Check fuel overflow valve directly
q q
Possible to start in reduced cylinder mode
Remedy
20-808
(1)
D65EX, PX-15
TROUBLESHOOTING
S-2
c) Exhaust smoke comes out but engine does not
start (Fuel is being injected)
General causes why exhaust smoke comes out but engine does not start
• Lack of rotating force due to defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel
Causes
Confirm recent repair history
Degree of use of machine
E
Operated for long period
E E
w
Suddenly failed to start
w
Q Q
Non-specified fuel is being used
w
Replacement of filters has not been carried out according to Operation Manual
E
Q
w w
w
Engine oil must be added more frequently
w
Preheating indicator lamp dies not light up during preheating or in low temperatures
w
Dust indicator lamp is red
Q
Air breather hole in fuel tank cap is clogged
w w
Rust and water are found when fuel tank is drained
w
When fuel filter is removed, there is no fuel in filter
w
w Q Q
There is leakage from fuel piping
When fuel priming pump is operated, there is no response, or operation is too heavy
w
Starting motor cranks engine slowly
w
When engine is cranked, abnormal noise is heard from around cylinder head
When engine is cranked with
starting motor
Q
No fuel comes out even when fuel filter air bleed plug is removed
w w
When hose at collection portion for spill flow from fuel injector is
disconnected, spill flow is small (See error code “AD10L3”)
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w
w
q
Check air cleaner element directly
q
Remove head cover and check directly
q
When compression pressure is measured, it is found to be low
q
When air is bled from fuel line, air comes out
q
Check fuel filter, strainer directly
q
Check fuel feed pump strainer directly
q
Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed”
q
Spray condition is poor when fuel injector is tested as individual part
When specific gravity of electrolyte or voltage of battery is measured it is found to be low
q
q
Defective water temperature gauge display on machine
q
Intake air heater mount does not become warm during preheating
Remedy
D65EX, PX-15
20-809
(1)
TROUBLESHOOTING
S-3
S-3 Engine does not pick up smoothly (follow-up is poor)
General causes why engine does not pick up smoothly
• Insufficient intake of air
• Insufficient supply of fuel
• Abnormal fuel injection condition
• Improper selection of fuel
• Controller controlled by delayed mode
(The injection amount (output) is limited because an error has occurred in the electrical system.)
Causes
Confirm recent repair history
Degree of use of machine
E E
Operated for long period
E
w
Engine pick-up suddenly became poor
E E
Q Q
w w w
w w
Non-specified fuel is being used
w
Replacement of filters has not been carried out according to Operation Manual
w
Engine oil must be added more frequently
w
Dust indicator lamp is red
w
Air breather hole in fuel tank cap is clogged
w w
w
w Q Q
Rust and water are found when fuel is drained
There is leakage from fuel piping
When fuel priming pump is operated, there is no response, or operation is too heavy
Q
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Color of exhaust gas
Q
w
w
w
Blue under light load
w Q
Black
w
w
w
Abnormal noise is heard from around cylinder head when engine is run
w
Noise of interference is heard from around turbocharger
Q
Q
High idling speed is normal, but speed suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
w w
Q w
Q
w
Blow-by gas is excessive
q
Check air cleaner element directly
q
When compression pressure is measured, it is found to be low
q
q
Check valve clearance directly
q
When turbocharger is rotated by hand, it is found to be heavy
q
When air is bled from fuel line, air comes out
q
Check fuel filter, strainer directly
q
Check fuel feed pump strainer directly
q
Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed”
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode
q q
Remedy
20-810
(1)
D65EX, PX-15
TROUBLESHOOTING
S-4
S-4 Engine stops during operations
General causes why engine stops
• Internal part of engine seized
• Insufficient supply of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Failure in power train
a Carry out troubleshooting of the machine.
Causes
Confirm recent repair history
Degree of use of machine
E E
Operated for long period
Abnormal noise was heard and engine stopped suddenly
Condition when engine
stopped
Engine overheated and stopped
w w w w
w Q
Q w Q w w
Q
w
w Q
Engine stopped slowly
There was hunting and engine stopped
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation Manual
Q
w
w
Fuel level caution lamp lights up
Fuel tank is found to be empty
w
Air breather hole in fuel tank cap is clogged
w
w Q Q
w w
Q Q
There is leakage from fuel piping
When priming pump is operated, there is no response, or operation is too heavy
Rust and water are found when fuel tank is drained
w w
w w
Metal particles are found when oil is drained
Does not turn at all
When it is attempted to turn
engine by hand
Q Q
Q Q Q
Q Q Q
w w
w
Turns in opposite direction
w
Moves amount of backlash
w
w
Fuel supply pump shaft does not turn
w
Engine rotates, but stops when load is applied to machine
q
Check dynamic valve system directly
q
Check piston and connecting rod directly
q
Check crankshaft directly
q
Check gear train directly
q
Check fuel filter, strainer directly
q
Check fuel feed pump strainer directly
q
Check fuel feed pump directly
Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed”
q q
q
When auxiliary equipment (Hyd. pump, air compressor) is removed, engine turns
Remedy
D65EX, PX-15
20-811
(1)
TROUBLESHOOTING
S-5
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly
• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
Causes
Confirm recent repair history
Degree of use of machine
E E
Operated for long period
Q
w
Occurs at a certain speed range
Condition of hunting
Occurs at low idling
Occurs even when speed is raised
Occurs on slopes
Replacement of filters has not been carried out according to Operation Manual
Fuel tank is found to be empty
Air breather hole in fuel tank cap is clogged
Rust and water are found when fuel tank is drained
There is leakage from fuel piping
When fuel priming pump is operated, there is no response, or operation is too heavy
Q Q
Q Q Q Q Q Q Q
Q
Q Q
w
Q Q
w w
w
w
Q Q
w
w Q Q
q
When air is bled from fuel line, air comes out
q
Check fuel feed pump strainer directly
q
Check fuel filter, strainer directly
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode
q q
q
Carry out troubleshooting for error code “DLH1LC: Abnormality in Ne revolution sensor”
q
Carry out troubleshooting for error code “DLE3LC: Abnormality in G revolution sensor”
Remedy
20-812
(1)
D65EX, PX-15
TROUBLESHOOTING
S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output
• Insufficient intake of air
• Insufficient supply of fuel
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because an error has occurred in the electrical system.)
Causes
Confirm recent repair history
Degree of use of machine
Power was lost
E
Operated for long period
E
E
E E
Q
Q
Q Q
Q Q
Q
Suddenly
Q
Gradually
Replacement of filters has not been carried out according to Operation Manual
Q
Q Q Q
Q
w
Non-specified fuel is being used
Q Q Q
Engine oil must be added more frequently
w
Dust indicator lamp is red
w
Air breather hole in fuel tank cap is clogged
w
There is leakage from fuel piping
w
Power is lacking after short stop in operations
Color of exhaust gas
w w
Black
w
Blue under light load
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
w
w
Noise of interference is heard from around cylinder head when engine is run
w
Abnormal noise is heard from around cylinder head when engine is run
Q
High idling speed of engine is low
w w Q
High idling speed is normal, but speed suddenly drops when load is applied
w
Engine pickup is poor and combustion is irregular
Q Q
Q Q Q Q
There is hunting from engine (rotation is irregular)
w
w
Blow-by gas is excessive
When air cleaner element is inspected directly, it is found to be clogged
q
Check air intake piping directly
q
q q q
When boost pressure is measured, it is found to be low
q
When compression pressure is measured, it is found to be low
q
q
Check valve clearance directly
q
Check fuel filter, strainer directly
q
Check fuel feed pump gauze filter directly
Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed”
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode
q
q q
q
Check mounting of boost pressure sensor directly
Carry out troubleshooting for error code “DH30KX: Abnormality in boost pressure sensor”
q
q
Carry out troubleshooting for error code “DGE4KX: Abnormality in fuel temperature sensor”
Remedy
D65EX, PX-15
20-813
(1)
TROUBLESHOOTING
S-7
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black
• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because an error has occurred in the electrical system.)
Causes
Confirm recent repair history
Degree of use of machine
E
Operated for long period
Color of exhaust gas
E
E
w
Suddenly became black
w
Gradually became black
Q Q
Q Q
Q
w
Blue under light load
Q Q
Non-specified fuel is being used
w
Engine oil must be added more frequently
Power was lost
E
w
Suddenly
Q
w
Gradually
Dust indicator lamp is red
Q
Q
Q
Q Q
Q
w
Muffler is crushed
w
Leakage of air between turbocharger and cylinder head, loose damp
Q Q Q
Operates in low-temperature mode even at normal temperatures
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
Q w
w
Noise of interference is heard from around turbocharger when engine is run
w
Abnormal noise is heard from around cylinder head when engine is run
Q Q
Stall speed is too high (excessive injection of fuel)
Q
Q
Exhaust noise is abnormal
Engine pickup is poor and combustion is irregular
w
Q Q Q
Q
Q w
w
Blow-by gas is excessive
When hose from the injector to spill collection portion is disconnected, spill flow is found to
be abnormally high (See error code “AD10L3”)
w
q
Check air cleaner directly
q
When turbocharger is rotated by hand, it is found to be heavy
q
When compression pressure is measured, it is found to be low
q
q
Check valve clearance directly
q
When muffler is removed, exhaust color returns to normal
Carry out troubleshooting for error code “AD10L3: Fuel supply pump non-force feed”
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode
q
q
q
Check fuel spill piping directly
Carry out troubleshooting for error code “DGE3L6: Abnormality in water temperature sensor”
q
Remedy
20-814
(1)
D65EX, PX-15
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive
• Abnormal combustion of oil
• The engine has been run at low or high idling for a long
time continuously (more than 20 minutes continuous
operation is not allowed).
• External leakage of oil
• Wear of lubrication system
Causes
Confirm recent repair history
Degree of use of machine
E E E
Operated for long period
E
w
Oil consumption suddenly increased
Q
Q
w
Q Q w
Engine oil must be added more frequently
Engine oil becomes contaminated quickly
w w w w w
Outside of engine is dirty with oil
w
Loose piping clamp in air intake system
w
Inside of turbocharger air supply pipe is dirty with oil
Q w
Inside of exhaust pipe is dirty with oil
w
There is oil in engine cooling water
w
Oil level in clutch or damper chamber rises
w w
w w
Exhaust smoke is blue under light load
Amount of blow-by gas
Q
Excessive
Q
w
None
q
When intake manifold is removed, dust is found inside
q
When intake manifold is removed, inside is found to be extremely dirty
q q
Excessive play of turbocharger shaft
q
Check breather element directly
q q
When compression pressure is measured, it is found to be low
q
Check rear oil seal directly
q q
Pressure-tightness test of oil cooler shows there is leakage
q q q q
There is external leakage of oil from engine
Remedy
D65EX, PX-15
20-815
(1)
TROUBLESHOOTING
S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly
• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
Causes
Confirm recent repair history
Degree of use of machine
E E E
Operated for long period
Q
Non-specified fuel is being used
w
Engine oil must be added more frequently
w
Even when oil temperature rises, oil filter caution lamp lights up
Inside of exhaust pipe is dirty with oil
w
w
Engine oil temperature rises quickly
Color of exhaust gas
Amount of blow-by gas
Q
Q Q
w
When oil filter is inspected, metal particles are found
w
Blue under light load
w
Black
Q Q w
Excessive
Q
w
None
q
Excessive play of turbocharger shaft
q q
When compression pressure is measured, it is found to be low
q
Check breather, breather tube directly
q
Check oil cooler is inspected directly
q
Check oil filter directly
q
Spring of oil filter safety valve catching or broken
q
Check turbocharger drain tube directly
Remedy
20-816
(1)
D65EX, PX-15
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive
• Leakage of fuel
• Improper condition of fuel injection (injection pressure,
injection timing)
• Excessive injection of fuel
Causes
Confirm recent repair history
Degree of use of machine
E E
Operated for long period
Condition of fuel
consumption
E
Q
More than for other machines of same model
Q
Gradually increased
Q Q Q
Q
Q Q
w
Suddenly increased
There is external leakage of fuel from engine
w
There is irregular combustion
w
Engine oil level rises and smells of diesel fuel
w
w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Low idling speed is high
Q
Engine stall speed is high
Exhaust gas color
Q Q
Black
Q Q
Q
White
q
Remove head cover and check directly
q
Check fuel feed pump oil seal directly
q
Carry out troubleshooting for error code “DGE3L6: Fuel supply pump non-force feed”
q
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode
q
When flow of oil from fuel injector at spill return collection portion is measured, it is found to be excessive
q
Carry out troubleshooting for error code “AD10L3: Abnormality in water low-temperature sensor”
q
Check with monitoring function on machine
q
Remedy
D65EX, PX-15
20-817
(1)
TROUBLESHOOTING
S-11
S-11 Oil is in cooling water (or water spurts back, or water level goes down)
General causes why oil is in cooling water
• Internal leakage in lubrication system
• Internal leakage in cooling system
Causes
Confirm recent repair history
Degree of use of machine
Oil level
E
Operated for long period
E
Q
Suddenly increased
Q
Q Q
Q
Q Q
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
w
Excessive air bubbles inside radiator, spurts back
Q
Q
w
w
w
w
Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is found
q
Pressure-tightness test of cylinder head shows there is leakage
q q
Check cylinder block, liner directly
q
Check cylinder liner directly
q
Pressure-tightness test of oil cooler shows there is leakage
Remedy
20-818
(1)
D65EX, PX-15
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure drops
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Causes
Confirm recent repair history
Degree of use of machine
E
Operated for long period
E
Q
Non-specified oil is being used
Replacement of filters has not been carried out according to Operation Manual
w
Lights up at low idling
Condition when oil pressure
lamp light up
Q
w
Lights up at low idling and high idling
Lights up on slopes
E
Q w
Q
w
Q
w w w Q
Oil pressure caution lamp lights up
w
Sometimes lights up
Q Q
w
w
w
Oil temperature caution lamp lights up (machines equipped with lamp)
Oil level in oil pan is low
w
There is crushing, external leakage from hydraulic piping
w
Oil is cloudy white or smells of diesel oil
Metal particles are found when oil inside oil filter is drained
w
w
Metal particles are found in oil filter
q
Metal particles are found when oil is drained
Q
q q
Check oil pan strainer pipe directly
q
Oil pump rotation is heavy, there is play
q
Deterioration, damage of valve, spring in oil pump relief valve
q
Check oil filter directly
q
Carry out troubleshooting for error code “DDE2L6: Abnormality in oil pressure sensor”
q
When oil level sensor is replaces, oil pressure caution lamp goes out
Remedy
D65EX, PX-15
20-819
(1)
TROUBLESHOOTING
S-13
S-13 Oil level rises (water, fuel in oil)
General causes why oil level rises
• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
Causes
a If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”.
Confirm recent repair history
Degree of use of machine
E E
Operated for long period
E
E
w
Fuel consumption has increased
Q
Q
Water must be added more frequently
There is oil in engine cooling water
w
w
Q Q
w
w
Oil smells of diesel fuel
Q
When engine is started, drops of water come from muffler
Q
When radiator cap is left open and engine is run at idling, an abnormal number of bubbles appear, or water spurts back w
w
w
Oil is cloudy white
Q
Q
Exhaust smoke is white
Q
w
w
Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, water comes out
w
Oil level goes down in clutch chamber or damper chamber
w
Oil level goes down in hydraulic tank
q
When compression pressure is measured, it is found to be low
q
Remove head cover and check directly
q q
Check cylinder block, liner directly
q
Check rear oil seal directly
q
Pressure-tightness test of oil cooler shows there is leakage
q
Remove water pump and check directly
q
Remove thermostat cover and check directly
q
Remove fuel supply pump and check directly
q
Check auxiliary equipment seal directly
Remedy
20-820
(1)
D65EX, PX-15
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
a Carry out troubleshooting for machine.
Causes
Confirm recent repair history
Degree of use of machine
Condition of overheating
E E
Operated for long period
E E
Q w
Suddenly overheated
Q
Rises quickly
Water temperature gauge
Q
Q
Q w w
w
Always tends to overheat
w
Does not go down from red range
w
Radiator water level caution lamp lights up
w Q
Engine oil level has risen, oil is cloudy white
w
Fan belt tension is loose
w
There is play when fan pulley is rotated
w
Cloudy white oil is floating on cooling water
w
Excessive air bubbles inside radiator, water spurts back
w
w
When light bulb is held behind radiator, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud
w
w
Water is leaking because of cracks in hose or loose clamps
w
Cooling water flows out from radiator overflow hose
w
Fan belt whines under sudden acceleration
w
Power train oil temperature enters red range faster than engine water temperature
q
When compression pressure is measured, it is found to be low
q
Check cylinder liner directly
q
Check oil cooler directly
q
Temperature difference between top and bottom radiator tanks is excessive
When function test is carried out on thermostat, it does not open even at cracking temperature
q
q
Temperature difference between top and bottom radiator tanks is small
q
Check radiator core directly
q
When function test is carried out on radiator cap, cracking pressure is found to be low
Check fan belt, pulley directly
q
When water temperature is measured, it is found to be normal
Remedy
D65EX, PX-15
20-821
(1)
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made
General causes why abnormal noise is made
• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
Causes
a Judge if the noise is an internal noise or an external
noise.
a If the engine is not thoroughly warmed up, the engine
sound becomes slightly louder because it is operated in
the low temperature mode, but this is not an abnormality.
a When the engine is accelerated, it enters the acceleration mode and the engine noise is higher for 3 seconds,
but this is not an abnormality.
Confirm recent repair history
Degree of use of machine
Operated for long period
Condition of abnormal
noise
Gradually occurred
E
Q
Q
Q Q
Suddenly occurred
Q
Q
Non-specified fuel is being used
w
w
Engine oil must be added more frequently
Metal particles are found in oil drained from oil filter
w
w
Leakage of air between turbocharger and cylinder head
w
Noise of interference is heard from around turbocharger when engine is run
w
Abnormal noise is heard from around cylinder head when engine is run
w
w
Vibrating noise is heard from around muffler when engine is run
w Q
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Color of exhaust gas
w
Blue under light load
Q w
Black
Q
w
Q Q
Engine pickup is poor and combustion is abnormal
Q
Abnormal noise is loud when accelerating
Q
w
Blow-by gas is excessive
q
When turbocharger is rotated by hand, it is found to be heavy
q
Check dynamic valve system directly
q
When muffler is removed, abnormal noise disappears
q
Check valve clearance directly
q
When compression pressure is measured, it is found to be low
q q
Remove timing gear cover and check directly
q
Check fan, fan belt directly
Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode
Abnormal noise is made only when starting
q q
q
q
Check with monitoring function on machine
Remedy
20-822
(1)
D65EX, PX-15
TROUBLESHOOTING
S-16
S-16 Vibration is excessive
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
Causes
a If there is abnormal noise together with the vibration,
carry out troubleshooting also for “Abnormal noise is
made”.
Confirm recent repair history
Degree of use of machine
Condition of vibration
Operated for long period
E
E
E
E
Q
Q
w
w
Q
Q
Q
w
w
Q
Q
Q
Q
Suddenly increased
Gradually increased
Non-specified fuel is being used
Metal particles are found in oil drained from oil filter
Metal particles are found when oil pan is drained
Oil pressure is low at low idling
Q
Q
Q
Q Q Q Q
Vibration occurs at mid-range speed
Q
Vibration follows engine speed
Exhaust smoke is black
w
Check dynamic valve system directly
q
q
Check main bearing, connecting rod bearing directly
q
Check gear train directly
q
Check cam bushing directly
q
Check with monitoring function on machine
q
Check engine mounting bolts directly
q
When face runout and radial runout are inspected, they are found to be incorrect
q
Check support spigot joint portion directly
q
Check inside of output shaft (damper) directly
Remedy
D65EX, PX-15
20-823
(1)
DISASSEMBLY AND ASSEMBLY
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL ................. 30- 4
Removal and installation of assemblies .. 30- 4
Disassembly and assembly of assemblies . 30- 5
COATING MATERIALS LIST ...................... 30- 6
SPECIAL TOOL LIST ................................. 30- 8
SKETCHES OF SPECIAL TOOLS ............. 30- 12
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY ........... 30- 13
Special tool .............................................. 30- 13
Removal .................................................. 30- 13
Installation ............................................... 30- 14
REMOVAL AND INSTALLATION OF
ENGINE HOOD ASSEMBLY ...................... 30- 17
Removal .................................................. 30- 17
Installation ............................................... 30- 17
REMOVAL AND INSTALLATION OF
FUEL INJECTOR ASSEMBLY ................... 30- 18
Removal .................................................. 30- 18
Installation ............................................... 30- 19
REMOVAL AND INSTALLATION OF
NOZZLE TIP ............................................... 30- 22
Special tool .............................................. 30- 22
Removal .................................................. 30- 22
Installation ............................................... 30- 23
REMOVAL AND INSTALLATION OF
ENGINE FRONT SEAL .............................. 30- 24
Special tool .............................................. 30- 24
Removal .................................................. 30- 24
Installation ............................................... 30- 24
REMOVAL AND INSTALLATION OF
DAMPER ASSEMBLY ................................ 30- 25
Removal .................................................. 30- 25
Installation ............................................... 30- 25
REMOVAL AND INSTALLATION OF
ENGINE REAR SEAL ................................. 30- 26
Special tool .............................................. 30- 26
Removal .................................................. 30- 26
Installation ............................................... 30- 26
REMOVAL AND INSTALLATION OF
CYLINDER HEAD ASSEMBLY .................. 30- 29
Special tool .............................................. 30- 29
Removal .................................................. 30- 29
Installation ............................................... 30- 32
D65EX, PX-15
REMOVAL AND INSTALLATION OF
FUEL TANK ASSEMBLY ........................... 30- 34
Removal .................................................. 30- 34
Installation ............................................... 30- 35
REMOVAL AND INSTALLATION OF
RADIATOR ASSEMBLY ............................ 30- 36
Removal .................................................. 30- 36
Installation ............................................... 30- 37
REMOVAL AND INSTALLATION OF
ENGINE ASSEMBLY ................................. 30- 38
Special tool .............................................. 30- 38
Removal .................................................. 30- 38
Installation ............................................... 30- 41
REMOVAL AND INSTALLATION OF
POWER TRAIN UNIT ASSEMBLY ............ 30- 43
Removal .................................................. 30- 43
Installation ............................................... 30- 45
DISCONNECTION AND CONNECTION OF
POWER TRAIN UNIT ASSEMBLY ............ 30- 46
Disconnection ......................................... 30- 46
Connection .............................................. 30- 49
DISASSEMBLY AND ASSEMBLY OF
TORQFLOW TRANSMISSION
ASSEMBLY ................................................ 30- 50
Special tool .............................................. 30- 50
Disassembly ............................................ 30- 50
Assembly ................................................ 30- 57
DISASSEMBLY AND ASSEMBLY OF
HSS ASSEMBLY ....................................... 30- 68
Special tool .............................................. 30- 68
Disassembly ............................................ 30- 68
Assembly ................................................ 30- 75
DISASSEMBLY AND ASSEMBLY OF
PTO ASSEMBLY ....................................... 30- 86
Disassembly ............................................ 30- 86
Assembly ................................................ 30- 88
DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER ASSEMBLY ........ 30- 92
Disassembly ............................................ 30- 92
Assembly ................................................ 30- 94
REMOVAL AND INSTALLATION OF
SCAVENGING PUMP ASSEMBLY ........... 30- 97
Removal .................................................. 30- 97
Installation ............................................... 30- 97
30-1
(8)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
HSS PUMP ASSEMBLY ............................ 30- 98
Removal .................................................. 30- 98
Installation ............................................... 30- 98
REMOVAL AND INSTALLATION OF
COOLING FAN PUMP ASSEMBLY ........... 30- 99
Removal .................................................. 30- 99
Installation ............................................... 30-100
REMOVAL AND INSTALLATION OF
POWER TRAIN AND LUBRICATING
OIL PUMP ASSEMBLY .............................. 30-101
Removal .................................................. 30-101
Installation ............................................... 30-101
REMOVAL AND INSTALLATION OF
HSS MOTOR ASSEMBLY ......................... 30-102
Removal .................................................. 30-102
Installation ............................................... 30-102
REMOVAL AND INSTALLATION OF
FINAL DRIVE ASSEMBLY ......................... 30-103
Special tool ............................................. 30-103
Removal .................................................. 30-103
Installation ............................................... 30-104
DISASSEMBLY AND ASSEMBLY OF
FINAL DRIVE ASSEMBLY ......................... 30-105
Special tool ............................................. 30-105
Disassembly ............................................ 30-105
Assembly ................................................ 30-108
REMOVAL AND INSTALLATION OF
TRACK FRAME ASSEMBLY ..................... 30-112
Removal .................................................. 30-112
Installation ............................................... 30-113
REMOVAL AND INSTALLATION OF
IDLER ASSEMBLY .................................... 30-114
Removal .................................................. 30-114
Installation ............................................... 30-114
DISASSEMBLY AND ASSEMBLY OF
IDLER ASSEMBLY .................................... 30-115
Special tool ............................................. 30-115
Disassembly ............................................ 30-115
Assembly ................................................ 30-116
REMOVAL AND INSTALLATION OF
RECOIL SPRING ASSEMBLY ................... 30-119
Removal .................................................. 30-119
Installation ............................................... 30-119
DISASSEMBLY AND ASSEMBLY OF
RECOIL SPRING ASSEMBLY ................... 30-120
Special tool ............................................. 30-120
Disassembly ............................................ 30-120
Assembly ................................................ 30-122
REMOVAL AND INSTALLATION OF
TRACK ROLLER ASSEMBLY ................... 30-124
Removal .................................................. 30-124
Installation ............................................... 30-124
DISASSEMBLY AND ASSEMBLY OF
TRACK ROLLER ASSEMBLY ................... 30-125
Special tool ............................................. 30-125
Disassembly ............................................ 30-125
Assembly ................................................ 30-126
30-2
(2)
REMOVAL AND INSTALLATION OF
CARRIER ROLLER ASSEMBLY ................ 30-129
Removal .................................................. 30-129
Installation ............................................... 30-129
DISASSEMBLY AND ASSEMBLY OF
CARRIER ROLLER ASSEMBLY ................ 30-130
Special tool .............................................. 30-130
Disassembly ............................................ 30-130
Assembly ................................................. 30-131
EXPANSION AND INSTALLATION OF
TRACK SHOE ASSEMBLY ........................ 30-133
Check before expanding track
shoe assembly ......................................... 30-133
Expansion of track shoe assembly
(Ordinary) ................................................ 30-133
Expansion of track shoe assembly
(When track frame has internal trouble) .. 30-134
Installation ............................................... 30-135
WHOLE DISASSEMBLY AND WHOLE
ASSEMBLY OF TRACK SHOE
ASSEMBLY ................................................ 30-136
Special tool .............................................. 30-136
Whole disassembly .................................. 30-136
Whole assembly ...................................... 30-139
FIELD DISASSEMBLY AND ASSEMBLY
OF ONE LINK ............................................. 30-151
Special tool .............................................. 30-151
Disassembly ............................................ 30-151
Assembly ................................................. 30-152
REMOVAL AND INSTALLATION OF
PIVOT SHAFT ASSEMBLY ........................ 30-158
Special tool .............................................. 30-158
Removal .................................................. 30-158
Installation ............................................... 30-158
REMOVAL AND INSTALLATION OF
EQUALIZER BAR ASSEMBLY .................. 30-159
Special tool .............................................. 30-159
Removal .................................................. 30-159
Installation ............................................... 30-160
DISASSEMBLY AND ASSEMBLY OF
EQUALIZER BAR SIDE BUSHING ............ 30-161
Disassembly ............................................ 30-161
Assembly ................................................. 30-161
REMOVAL AND INSTALLATION OF
CONTROL VALVE ASSEMBLY ................. 30-162
Removal .................................................. 30-162
Installation ............................................... 30-163
DISASSEMBLY AND ASSEMBLY OF
CONTROL VALVE ASSEMBLY ................. 30-164
Assembly
............................................. 30-164
DISASSEMBLY AND ASSEMBLY OF
HYDRAULIC CYLINDER ASSEMBLY ....... 30-165
Special tool .............................................. 30-165
Disassembly ............................................ 30-165
Assembly ................................................. 30-167
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
BLADE ASSEMBLY .................................... 30-171
Removal .................................................. 30-171
Installation ............................................... 30-172
REMOVAL AND INSTALLATION OF
ROPS GUARD ........................................... 30-173
Removal .................................................. 30-173
Installation ............................................... 30-173
REMOVAL AND INSTALLATION OF
OPERATOR’S CAB ASSEMBLY ................ 30-174
Removal .................................................. 30-174
Installation ............................................... 30-176
REMOVAL AND INSTALLATION OF
OPERATOR’S CAB GLASS
(STUCK GLASS) ........................................ 30-179
Special tool .............................................. 30-180
Removal .................................................. 30-180
Installation ............................................... 30-181
REMOVAL AND INSTALLATION OF
FLOOR FRAME ASSEMBLY ..................... 30-187
Special tool .............................................. 30-187
Removal .................................................. 30-187
Installation ............................................... 30-191
D65EX, PX-15
REMOVAL AND INSTALLATION OF
STEERING AND TRANSMISSION
CONTROLLER ASSEMBLY ...................... 30-192
Removal .................................................. 30-192
Installation ............................................... 30-192
REMOVAL AND INSTALLATION OF
ENGINE CONTROLLER ASSEMBLY ....... 30-193
Removal .................................................. 30-193
Installation ............................................... 30-193
REMOVAL AND INSTALLATION OF
FAN DRIVE ASSEMBLY ............................ 30-194
Removal .................................................. 30-194
Installation ............................................... 30-194
REMOVAL AND INSTALLATION OF
FAN MOTOR ASSEMBLY ......................... 30-195
Removal .................................................. 30-195
Installation ............................................... 30-195
30-3
(2)
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL
1. Removal and installation of assemblies
Special tools
• Special tools which are deemed necessary
for removal or installation of parts are described as A1,•••X1 etc. and their part
names, part numbers and quantities are described in the special tool list.
• Also the following information is described in
the special tool list.
1) Necessity
t : Special tools that cannot be substituted
and should always be used (installed).
q : Special tools that will be useful if available and are substitutable with commercially available tools.
2) Distinction of new and existing special tools
N :
Tools newly developed for this
model. They respectively have a
new part number.
R :
Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
• The sketch of the special tool is presented in the section of “Sketches of special
tools”.
• This mark means part No. of special
tools starting with 79 Tand that they can not be supplied from
Komatsu in Japan (i.e. locally made
parts).
* *** ****
Removal
• The “Removal” section contains procedures
and precautions for implementing the work,
know-how and the amount of oil or coolant to
be drained.
• General tools that are necessary for removal
are described as [1], [2]•••etc. and their part
names, part numbers and quantities are not
described.
• Various symbols used in the “Removal” section
are explained and listed below.
k : This mark indicates safety-related precautions that must be followed when implementing the work.
a : Know-how or precautions for work
[*1] : This mark shows that there are instructions or
precautions for installing parts.
6 : This mark shows the amount of oil or coolant
to be drained.
4: Weight of part or component
Installation
• Except where otherwise instructed, installation
of parts is done in the reverse order of removal.
• Instructions and precautions for installing parts
are shown with [*1] mark in the “Installation”
section, identifying which step the instructions
are intended for.
• General tools that are necessary for installation
are described as [1], [2]•••etc. and their part
names, part numbers and quantities are not
described.
• Marks shown in the “Installation” section stand
for the following.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions when
doing the procedure.
2: Type of coating material
3: Tightening torque
5: Quantity of oil or coolant to be added
Sketches of special tools
• Various special tools are illustrated for the convenience of local manufacture.
30-4
(8)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
2. Disassembly and assembly of assemblies
Special tools
• Special tools which are deemed necessary
for disassembly or assembly of parts are described as A1,•••X1 etc. and their part
names, part numbers and quantities are described in the special tool list.
• Also the following information is described in
the special tool list.
1) Necessity
t : Special tools that cannot be substituted
and should always be used (installed).
q : Special tools that will be useful if available and are substitutable with commercially available tools.
2) Distinction of new and existing special tools
N :
Tools newly developed for this
model. They respectively have a
new part number.
R :
Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
• The sketch of the special tool is presented in the section of “Sketches of special
tools”.
• This mark means part No. of special
tools starting with 79 Tand that they can not be supplied from
Komatsu in Japan (i.e. locally made
parts).
* *** ****
Disassembly
• In “Disassembly” section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
• General tools that are necessary for disassembly are described as [1], [2]•••etc. and their part
names, part numbers and quantities are not
described.
• The meanings of the symbols used in “Disassembly” section are as follows.
k : This mark indicates safety-related precautions that must be followed when implementing the work.
a : Know-how or precautions for work
6: Quantity of oil or coolant drained
Assembly
• In “Assembly” section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant added are described.
• General tools that are necessary for assembly
are described as [1], [2]•••etc. and their part
names, part numbers and quantities are not
described.
• The meanings of the symbols used in “Assembly” section are as follows.
k : Precautions related to safety in execution
of work
a :This mark gives guidance or precautions when
doing the procedure.
2 : Type of coating material
3 : Tightening torque
5
: Quantity of oil or coolant to be added
Sketches of special tools
• Various special tools are illustrated for the convenience of local manufacture.
D65EX, PX-15
30-5
(8)
DISASSEMBLY AND ASSEMBLY
COATING MATERIALS LIST
COATING MATERIALS LIST
(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene • Features: Resistance to heat and chemicals.
container • Used to fix and seal bolts and plugs.
LT-3
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond
1735
Gasket sealant
Polyethylene
• Used to seal plugs.
container
Tube
• Heat-resistant seal used to repair engines.
50 g
• Quick-setting adhesive.
Polyethylene • Setting time: Within 5 sec. to 3 min.
container • Used mainly to stick metals, rubbers, plastics,
and woods.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
• Features: Resistance to heat and chemicals.
Polyethylene
• Used for fitted portions used at high temperacontainer
tures.
LG-1
790-129-9010
200 g
790-129-9080
Tube
• Used to stick or seal gaskets and packings of
power train case, etc.
1 kg
• Used to seal various threaded portions, pipe
Polyethylene
joints, and flanges.
container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-6
790-129-9020
200 g
Tube
• Features: Silicon-based heat and cold-resistant sealant.
• Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
LG-7
790-129-9070
1 kg
Tube
• Features: Silicon-based quick-setting sealant.
• Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.
• Used to seal transfer case, etc.
LG-8
ThreeBond
1207B
(8)
• Used to stick and seal metal, glass, and plastics.
• Quick-setting adhesive.
• Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
• Used mainly to stick rubbers, plastics, and
metals.
LG-5
30-6
790-129-9140
Can
419-15-18131
100 g
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
Grease
Seizure
prevention
compound
Molybdenum
disulfide
lubricant
Gasket sealant
CateKomatsu code
gory
Part number
COATING MATERIALS LIST
Q'ty
Container
Main features and applications
LG-9
ThreeBond
1206D
790-129-9310
200 g
Tube
• Used for rough surfaces such as the circle gear top
seal which does not need to be clamped, water
resistance of the clearance at the welded area, etc.
• Can be coated with paint.
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
• Used as lubricant/sealant when the radiator hoses
are inserted.
• Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
• Feature: Can be used together with gaskets.
• Used for covers of the transmission case and steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
• Gasket sealant used to repair engine.
Tube
• Used to prevent scuffing and seizure of press-fitted
portions, shrink-fitted portions, and threaded portions.
• Used to lubricate linkages, bearings, etc.
—
Can
• Feature: Seizure and scuffing prevention compound
with metallic super-fine-grain, etc.
• Used for the mounting bolt in the high temperature
area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Various
Various
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
• Used for parts under heavy load.
Caution:
400 g x 10 Bellows-type • Do not apply grease to rolling bearings like swing
circle bearings, etc. and spline.
400 g x 20 container
• The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for greasing
afterwards.
LM-P
LC-G
NEVER-SEEZ
09940-00040
—
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
G2-S
ThreeBond
1855
G2-U-S
ENS grease
D65EX, PX-15
—
427-12-11871
200 g
400 g
16 kg
400 g
16 kg
200 g
2 kg
• Feature: Lithium grease with extreme pressure
lubrication performance.
• General purpose type.
Bellows-type • Seizure resistance, heat resistance and water resiscontainer
tance higher than molybdenum disulfide grease.
Can
• Not conspicuous on machine since color is white.
Bellows-type • Since this grease is decomposed by natural bactecontainer
ria in short period, it has less effects on microorganCan
isms, animals, and plants.
Tube
• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of
rubber and plastic parts.
• Used for oil seals of the transmission, etc.
Can
• Feature: Urea (organic system) grease with heat
resistance and long life. Enclosed type.
• Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
30-7
(8)
DISASSEMBLY AND ASSEMBLY
Part number
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
Main features and applications
20 ml
Glass
container
• Used as primer for cab side.
(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
• Used as primer for glass side.
(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
417-926-3910
22M-54-27230
• Used as primer for painted surface on cab
side.
(Using limit: 4 months after date of manufacture)
• Used as primer for black ceramic-coated surface on glass side and for hard polycarbonatecoated surface.
(Using limit: 4 months after date of manufacture)
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
• Used as primer for sash (Almite).
(Using limit: 4 months after date of manufacture)
SUNSTAR
PENGUINE
SEAL 580
SUPER “S” or
“W”
417-926-3910
320 ml
Polyethylene
container
• “S” is used for high-temperature season and
“W” for low-temperature season as adhesive
for glass.
(Using limit: 4 months after date of manufacture)
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
• Used as adhesive for glass.
(Using limit: 6 months after date of manufacture)
SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
• Used to seal front window.
(Using limit: 6 months after date of manufacture)
Cartridge
• Used to seal joint of glasses.
Translucent white seal.
(Using limit: 12 months after date of manufacture)
GE TOSHIBA
SILICONES
TOSSEAL 381
30-7-1
(8)
Container
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
Q'ty
Adhesive for cab glass
CateKomatsu code
gory
COATING MATERIALS LIST
• Used as adhesive for glass.
(Using limit: 6 months after date of manufacture)
• Used to seal joints of glass parts.
(Using limit: 4 months after date of manufacture)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST
795-471-1800
Removal and installation of fuel
A1
supply pump assembly
Removal and installation of
engine front seal
A2
Removal and installation of
nozzle tip
A3
A4
Removal and installation of
engine rear seal
A5
Part name
Remover
t
1
1 795-471-1810
• Plate
1
2 795-471-1820
• Bolt
1
3 795-471-1830
• Bracket
1
4 01435-01035
• Bolt
3
5 01435-01025
• Bolt
1
795T-521-1140 Push tool
t
1
01010-31640
t
3
795T-471-1550 Wrench
t
1
795-931-1210
t
1
t
3
Bolt
Push tool
• 01050-31625 • Bolt
• 01050-31645 • Bolt
t
3
795-931-1220
t
1
• 01050-31645 • Bolt
t
3
Push tool
Sketch
Part No.
Q’ty
Symbol
New/
remodel
Item
Necessity
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t: Cannot be substituted, should always be installed (used).
q: Extremely useful if available, can be substituted with commercially available part.
a New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: Tools already available for other models, used without any modification.
a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).
Nature of work, remarks
Removal, installation of fuel supply
pump drive gear
Q
Press fitting of engine front seal
Q Fixing of injector assembly
Press fitting of standard seal
Press fitting of sleeved seal
Removal and installation of
cylinder head assembly
A6
790-331-1110
Wrench
q
1
Tightening of cylinder head bolt
Disassembly and assembly of
TORQFLOW transmission
assembly
D1
799-301-1600
Oil leak tester
t
1
Check of operation of piston
1 791T-422-1320 Hanger
q
1
2 790-302-1500
Wrench kit
q
1
3 796-730-2300
Wrench assembly
q
1
Commercially
4 available or
795-630-1810
Torque wrench
q
1
790-337-1032
Lifting tool
t
1
791-427-1090
Plate
t
1
01010-51635
Bolt
t
2
791-427-1100
Remover assembly
t
1
2 790-101-2102
Puller
t
1
790-101-1102
Pump
t
1
Disassembly and assembly of
HSS assembly
E
Removal and installation of final
drive assembly
Disassembly and assembly of
final drive assembly
J1
J
Installer
t
1
Installer assembly
t
1
4 790-101-2102
Puller
t
1
790-101-1102
Pump
t
1
3 792-520-2121
791-427-1200
30-8
(6)
Q
Removal, installation of brake and
carrier assembly
Removal, installation of bevel pinion
nut
Adjustment of preload on bevel gear
shaft and bevel gear assembly
Lifting up of final drive assembly
Separation of sprocket hub assembly
and bearing
Installation of floating seal
Press fitting of sprocket hub bearing
D65EX, PX-15
1 791-515-1520
Installer
t
1
Disassembly and assembly of
track roller assembly
2 791-530-1520
Installer
t
1
3 796-230-1110
Installer
t
1
4 791-601-1000
Oil pump
t
1
791-685-8005
Compressor of type B t
1
791-635-3160
Extension
t
1
790-201-2780
Spacer
t
1
790-201-2790
Spacer
t
1
790-101-1102
Pump
t
1
790-101-1600
Cylinder
t
1
791-450-1100
Remover assembly
t
1
790-101-2102
Puller
t
1
Disassembly and assembly of
carrier roller assembly
Symbol
L
Disassembly and assembly of
idler assembly and track roller
assembly
Disassembly and assembly of
recoil spring assembly
M
Removal and installation of
equalizer bar assembly
N
Removal and installation of
pivot shaft assembly
P
Part No.
Pulling out of center pin
t
1
t
1
790-101-2102
Puller
t
1
790-101-1102
Pump
t
1
1 790-646-7531
Remover
t
1
Removal of pin plug of track link
2 791-660-7460
Brush
t
1
Cleaning of pin of track link
Push tool
t
1
Bar
t
1
791-646-7560
Guide
t
1
791-932-1110
Push tool
t
1
Bar
t
1
Guide
t
1
5 790-701-3000
Checker
t
1
Check of track link for airtightness
6 791-432-1120
Installer
t
1
Installation of seal of track link
7 791-601-1000
Oil pump
t
1
Supply of track link oil
791-432-1110
Push tool
t
1
Bar
t
1
791-646-7560
Guide
t
1
791-932-1110
Push tool
t
1
Bar
t
1
3 791-646-7550
4 791-646-7523
Press fit ring
Installation pin plug of track link
(for large plug)
Installation pin plug of track link
(for small plug)
Installation of pin plug of track link
(for large plug)
Installation of pin plug of track link
(for small plug)
Guide
t
1
6 791-432-1120
Installer
t
1
Installation of seal of track link
7 791-601-1000
Oil pump
t
1
Supply of track link oil
Frame
t
1
791-635-3160
Extension
t
1
791-635-3170
Nut
t
4
8 791-635-3180
Screw
t
2
791-635-3190
Screw
t
1
791-645-3510
Adapter
t
1
791-646-3260
Pusher
t
1
791-646-7590
791-635-3110
D65EX, PX-15
Disassembly, assembly of recoil spring
assembly
Pump
4 791-646-7523
R
Supply of oil
Installer assembly
791-646-7590
Field disassembly and
assembly of one link
Installation of floating seal
790-101-1102
3 791-646-7550
R
Nature of work, remarks
791-430-1200
791-432-1110
Whole disassembly and whole
assembly of track shoe
assembly
Part name
Sketch
Q’ty
Disassembly and assembly of
idler assembly
Item
New/
remodel
SPECIAL TOOL LIST
Necessity
DISASSEMBLY AND ASSEMBLY
Pulling out of pin
30-9
(5)
9
10
t
1
790-101-1300
Cylinder
t
1
790-105-2300
Jack
t
1
790-101-1102
Pump
t
1
Adapter
t
1
Spacer
t
1
12 791-645-3540
Guide
t
1
791-635-3110
Frame
t
1
791-635-3160
Extension
t
1
791-635-3170
Nut
t
4
791-635-3180
Screw
t
2
791-635-3190
Screw
t
1
791-645-3510
Adapter
t
1
791-645-3520
Adapter
t
1
791-645-3530
Pusher
t
1
791-432-1210
Spacer
t
1
791-432-1220
Spacer
t
1
R
14
791-635-3110
Frame
t
1
791-635-3160
Extension
t
1
791-635-3170
Nut
t
4
791-635-3180
Screw
t
2
791-635-3190
Screw
t
1
791-645-3520
Adapter
t
1
791-645-3540
Guide
t
1
Pulling out of pin
Connection of link
Press fitting of bushing
Press fitting of pin
Press fitting of bushing
791-645-3550
Pusher
t
1
Guide
t
1
791-635-3110
Frame
t
1
791-635-3160
Extension
t
1
791-635-3170
Nut
t
4
791-635-3180
Screw
t
2
791-635-3190
Screw
t
1
791-645-3510
Adapter
t
1
790-502-1003
Repair stand
t
1
790-101-1102
Pump
t
1
Disassembly, assembly of hydraulic
cylinder assembly
2 790-330-1100
Wrench
t
1
Removal, installation of cylinder head
790-302-1270
Socket
t
1
3 790-302-1280
Socket
t
1
1
U
5
Connection of link
Press fitting of pin
Removal, installation of nut
Socket
t
2
Expander
t
1
Installation of piston ring
796-720-1650
Ring
t
1
07281-01029
Clamp
t
1
Installation of piston ring
(for blade lift cylinder)
796-720-1680
Ring
t
1
07281-01589
Clamp
t
1
790-302-1340
4 790-720-1000
(4)
Nature of work, remarks
15 791-646-3270
16
30-10
Sketch
Pump
Part name
791-645-3520
13
Disassembly and assembly of
hydraulic cylinder assembly
790-101-1102
Part No.
791-432-1210
11
Field disassembly and
assembly of one link
Q’ty
Symbol
New/
remodel
Item
SPECIAL TOOL LIST
Necessity
DISASSEMBLY AND ASSEMBLY
Installation of piston ring
(for blade tilt cylinder)
D65EX, PX-15
790-201-1791
Push tool
t
1
Press fitting of bushing
(for blade lift cylinder)
790-201-1811
Push tool
t
1
Press fitting of bushing
(for blade tilt cylinder)
790-101-5021
Grip
t
1
Press fitting of dust seal
01010-50816
Bolt
t
1
790-201-1620
Plate
t
1
(for blade tilt cylinder)
790-201-1610
Plate
t
1
(for blade lift cylinder)
793-498-1210
Lifter (Suction cup)
t
2
Installation of window glass
Part No.
Part name
6
Disassembly and assembly of
hydraulic cylinder assembly
U
7
Removal and installation of
operator’s cab glass
(Stuck glass)
D65EX, PX-15
X1
Sketch
Q’ty
Symbol
New/
remodel
Item
SPECIAL TOOL LIST
Necessity
DISASSEMBLY AND ASSEMBLY
Nature of work, remarks
30-11
(8)
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS
Note: We will not be liable for any result caused by a special tool made according to this drawing.
A2 Push tool
A3 Wrench
30-12
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS
Note: We will not be liable for any result caused by a special tool made according to this drawing.
E1 Hanger
CWD10332
30-12-1
(6)
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP
ASSEMBLY
795-471-1800
A1
Remover
t
Sketch
Part name
Q’ty
Part No.
New/
remodel
Symbol
Necessity
SPECIAL TOOL
7. Disconnect fuel supply pump wiring connectors
PCV1 (5), PCV2 (6), and G (7).
1
1 795-471-1810
• Plate
1
2 795-471-1820
• Bolt
1
3 795-471-1830
• Bracket
1
4 01435-01035
• Bolt
3
5 01435-01025
• Bolt
1
REMOVAL
k Disconnect the cable from the negative (–) termi-
nal of the battery.
1. Release the residual pressure from the fuel system. For details, see TESTING AND ADJUSTING, Releasing residual pressure from fuel
system.
2. Close the fuel supply valve of the fuel tank.
8. Remove fuel hoses (8) and (9).
*1
9. Remove the 2 clamps and fuel tubes (10) and
(11).
*2
10. Remove covers (12) and (13).
*3
3. Remove the engine undercover.
4. Open engine left cover (1).
5. Remove covers (2) and (3).
11. Remove high-pressure pipe clamps (14), (15),
(16), and (17).
*4
a Clamp (15) is on the back side of the oil feed
pipe.
6. Remove the clamp and move hose (4).
D65EX, PX-15
12. Remove high-pressure pipes (18) and (19).
*5
13. Remove lubrication tube (20).
*6
30-13
(5)
DISASSEMBLY AND ASSEMBLY
14. Removal of fuel supply pump.
1) Remove cover (22).
2) Remove gear mounting nut (23) and washer
(24).
a Take great care not to drop the nut and
washer in the case.
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
4) Install plate A1-1 with its shouldered side toward the gear and tighten bolt A1-4 with your
fingers.
a Install the plate with tap hole "f" up.
5) Install bracket A1-3.
• Rotate the crankshaft to match tap hole
"f" of plate A1-1 and secure bracket A13 with bolt A1-5.
6) Install bolt A1-2.
• Tighten the bolt with your fingers until it
touches the pump shaft.
3) Rotate the crankshaft forward to bring supply
pump key position "e" up.
a Use the damper mounting bolt to rotate
the crankshaft.
30-14
(4)
D65EX, PX-15
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
DISASSEMBLY AND ASSEMBLY
7) Remove bracket (26) and 4 mounting bolts
(32) of fuel supply pump (27).
• Tighten 1 mounting bolt on the upper
side temporarily as a guide bolt.
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
3 Fuel hoses (8) and (9):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
2
3 Eyebolts of fuel tubes (10) and (11)
(Both on filter side and fuel supply
pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3
8) Tighten bolt A1-2 and remove the gear and
fuel supply pump (27).
3 Tightning torque of bolt:
Approx. 196 – 294 Nm
{20 – 30 kgm}
a Install cover (12) with its slit on the cylinder
block side. Install cover (13) with its face
down.
4
5
k Do
8
not correct the high-pressure pipe by
bending before installing it.
k Be sure to use the genuine high-pressure
pipe clamp and observe the tightening
torque.
k Install the high-pressure pipe and wiring harness at least 10 mm apart from each other.
a When installing each high-pressure pipe,
check the taper seal of its joint (Part "a": Part
of 2 mm from the end) for visible lengthwise
slit "b" and spot "c" and check part "d" (End
of taper seal: Part of 2 mm from the end) for
stepped-type wear caused by fatigue which
your nail can feel. If there is any of those defects, it can cause fuel leakage. In this case,
replace the high-pressure pipe.
a Take care not to drop the woodruff key of
the supply pump shaft.
a Do not remove bracket A1-3 until you will
install the supply pump assembly again.
D65EX, PX-15
30-15
(4)
DISASSEMBLY AND ASSEMBLY
a Install the fuel supply pump and the parts between it and common rail according to the
following procedure.
1) Installation of fuel supply pump assembly.
i) Remove bolt A1-2 from plate A1-1.
ii) Insert supply pump (27) with key (33) up
and matched to the key way of the gear,
and then secure it temporarily.
iii) Tighten supply pump drive gear mounting nut (23) and washer (24) temporarily.
iv) Remove bracket A1-3 and plate A1-1.
v) Tighten supply pump drive gear mounting nut (23).
3 Mounting nut:
127 – 147 Nm {13 – 15 kgm}
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
3 Mounting nut:
vi) Install gear cover (22).
14.7 – 17.6 Nm {1.5 – 1.8 kgm}
2) Installation of high-pressure pipe.
i) Tighten brackets (26) and (28) and highpressure pipes (18) and (19) with your
fingers.
ii) Tighten high-pressure pipes (18) and
(19) permanently.
3 Sleeve nut on common rail side:
39.2 – 58.8 Nm {4 – 6 kgm}
3 Sleeve nut on supply pump side:
39.2 – 49 Nm {4 – 5 kgm}
2 4 supply pump mounting bolts:
iii) Tighten supply pump (27) permanently.
Adhesive (LT-2)
iv) Tighten bracket (26) and (28) permanently.
v) Install high-pressure pipe clamp (14) and
brackets (29) and (30) with your fingers.
vi) Tighten high-pressure clamp (16) permanently.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
vii) Tighten bracket (29), and then tighten
bracket (30) permanently.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
30-16
(4)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
FUEL SUPPLY PUMP ASSEMBLY
viii) Install clamps (16) and (17) and bracket
(31) with your fingers.
iv) Tighten clamps (16) and (17) permanently.
x) Tighten bracket (31) permanently.
xi) Install clamp (15).
6
3 Lubrication tube (20)
Joint bolt on supply pump side:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Joint bolt on engine side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
•
Checking for fuel leakage
Check for fuel leakage. For details, see
TESTING AND ADJUSTING, Checking
fuel system for leakage.
•
Bleeding air
Bleed air from the fuel circuit. For details, see TESTING AND ADJUSTING,
Bleeding air from fuel circuit.
D65EX, PX-15
30-16-1
(4)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
REMOVAL
INSTALLATION
1. Remove right and left covers (1).
•
2. Open cover (2).
Carry out installation in the reverse order to removal.
3. Loosen the clamp and disconnect air conditioner
duct hose (3).
4. Lift off engine hood assembly (4).
4 Engine hood assembly: 160 kg
D65EX, PX-15
30-17
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR
ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) termi-
nal of the battery.
1. Open the right and left engine side covers.
2. Remove cap assembly (1) and cover (2).
8. Remove 6 injector-side covers (10) and common
rail-side cover (11) from the high-pressure pipe
junction.
5
3. Remove air cleaner assembly (3) and bracket
(4).
1
a Rotate the air cleaner assembly in the circumferential direction and remove it, letting
the tube at the end through the hole of the
hood.
4. Remove eyebolt (5) and fuel filter and bracket
assembly (6) (when removing and installing the
No. 1 cylinder injector).
2
5. Remove oil filter and bracket assembly (7).
6. Remove air intake connector (8).
3
7. Remove common rail cover (9).
4
9. Remove high-pressure pipe clamp (12) and
gate-type frame (25).
6
10. Remove high-pressure pipe clamps (13), (14),
and (15) and plates (23) and (24) according to
the fuel injectors to be removed and installed.
7
11. Remove common rail-side sleeve nut (17) and
fuel injector-side sleeve nut (18) of high-pressure pipe (16).
8
12. Remove head cover (19).
30-18
(2)
9
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
4
6
7
8
k Do not bend the high-pressure pipes before
using them.
k Be sure to use the genuine high-pressure
13. Remove wiring harness (20) from the fuel injector.
10
14. Remove holder mounting bolts (21), and then remove the holder and fuel injector assembly (22)
together.
11
a Do not grip the solenoid valve at the top of
the injector with pliers, etc.
a Install high-pressure pipes (16) between the
common rail and fuel injector according to
the following procedure.
1) Tighten sleeve nuts (17) and (18) of 6 highpressure pipes (16).
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
3 Air cleaner band:
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
2
3 Eyebolt:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
3
pipe clamps and tighten them to the specified torque.
k Install the high-pressure pipes and wiring
harness at least 10 mm apart.
a When installing each high-pressure pipe,
check the taper seal of its joint (Part “a”: Part
of 2 mm from the end) for visible lengthwise
slit “b” and spot “c” and check part “d” (End
of taper seal: Part of 2 mm from the end) for
stepped-type wear (fatigue) which your nail
can feel. If there is any of those defects, it
can cause fuel leakage. In this case, replace
the high-pressure pipe.
3 Hose clamp between air intake connector and turbocharger:
6.8 ± 0.49 Nm {69 ± 5 kgcm}
3 High-pressure pipe sleeve nut:
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
2) Tighten high-pressure pipe clamps (13),
(14), and (15) and plates (23) and (24) temporarily with the fingers.
3) Tighten high-pressure clamps (13), (14), and
(15) permanently.
3 Clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
4) Tighten plates (23) and (24) permanently.
5) Install the common rail cover, high-pressure
pipe clamp (12), and gate-type frame (25)
temporarily.
6) Tighten common rail cover and high-pressure pipe clamp (12) permanently first, then
tighten gate-type frame (25) permanently.
3 Clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
D65EX, PX-15
30-19
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
5
11
a Turn the slit of the cover on the common rail
side to face the cylinder block.
a Turn the slit of cover (10) on the fuel injector
side to face “a” position in the figure.
a Install the fuel injector assembly in the following manner.
1) Fit gasket (b) and O-ring (c) to fuel injector
(a).
2) Put holder (d) in injector (a) and install to the
rocker housing temporarily.
a Align the injector key with the rocker
housing keyway, and push in until the injector seal face comes into contact with
the seal face on the cylinder head side.
3) Coat the face of spherical washer (e) with
engine oil.
4) Tighten bolt (f) for the holder.
3 Injector holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
9
3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3 Wiring harness mounting nut:
10
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
30-20
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
•
Check for fuel leak
Check for fuel leak, referring to the section of
“CHECKING FOR LEAKAGE IN FUEL CIRCUIT” in INSPECTION AND MAINTENANCE.
•
Air bleeding
Bleed air from the fuel circuit, referring to the
section of “BLEEDING AIR FROM FUEL CIRCUIT” in INSPECTION AND MAINTENANCE.
D65EX, PX-15
30-21
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF NOZZLE TIP
REMOVAL AND INSTALLATION OF NOZZLE TIP
a [EPA regulations]
For countries subject to EPA regulations, the entire nozzle assembly of the common rail engine
shall be replaced if any of its components needs
to be replaced. For other countries, the following
procedure may be applied for replacing the nozzle tip.
3. Loosen retaining nut (4) with 19 mm deep socket
[3].
SPECIAL TOOL
Symbol
Part No.
A3
795T-471-1550
Part name
Wrench
t
1
Q
REMOVAL
1. Fix tool A3 in vice [1].
a Do not pinch the injector directly in the vice.
4. Remove retaining nut (4) from injector assembly
(3).
5. Lift nozzle assembly (5) perpendicularly upward
to remove it.
a Do not remove tip guide (6). (Disassembling
the portion after the tip guide is not allowed.)
a Be careful not to get the assembly dirty.
2. Set injector assembly (3) on tool A3.
30-22
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF NOZZLE TIP
INSTALLATION
5. Mount nozzle assembly (3) and manually tighten
retaining nut (2).
1. Fit tool A3 in vice [1].
a Do not pinch the injector directly in the vice.
2. Set injector assembly (1) on tool A3.
3. Completely clean the lower body and screw sections of retaining nut (2) with parts cleaner, and
apply air blow.
6. Set 19 mm deep socket [2] in the torque wrench,
then tighten the retaining nut by following the
steps below.
a Apply rust prevention oil on the nozzle body.
1) Tighten with torque of 88.3 Nm {9.0 kgm}.
2) Attach identification mark (6) to retaining nut
(2) and lower body (5).
3) Tighten at an angle of 45º (angle tightening).
4. Mount new nozzle assembly (3) so that the assembly fits the knock pin of tip guide (4).
a Be careful not to drop the tip.
D65EX, PX-15
30-23
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
SPECIAL TOOL
Symbol
A2
INSTALLATION
Part No.
•
Part name
795T-521-1140
Push tool
t
1
01010-31640
Bolt
t
3
Carry out installation in the reverse order to removal.
Q
1
1. Using guide bolt [1], set the crank pulley.
REMOVAL
k Disconnect the cable from the negative (–) termi-
nal of the battery.
1. Remove the undercover.
2. Remove air conditioner compressor belt (1) and
alternator belt (2). For details, see TESTING
AND ADJUSTING, Testing adjusting air conditioner compressor belt tension and TESTING
AND ADJUSTING, Testing and adjusting alternator belt tension.
3. Remove 6 mounting bolts (3) and crank pulley
(4).
1
a One of the mounting bolts has a smaller diameter than the others.
3 Mounting bolt:
2. Tighten the mounting bolts.
(M14): 157 – 196 Nm {16 – 20 kgm}
(M16): 245 – 308.7 Nm {25 – 31 kgm}
2
a Tighten the bolts of tool A2 evenly until the
end of tool A2 touches the end of crankshaft
(6) to press fit engine front seal (5).
a Fill the space between the seal lips with lithium grease up to 50 – 80%.
a Fitting dimension “a”: 16 +10 mm
4. Remove engine front seal (5).
30-24
(2)
2
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
REMOVAL
6. Remove damper assembly (3).
3
1. Remove the floor frame assembly. For details,
s ee RE M OVA L A N D IN S TA L L AT I O N O F
FLOOR FRAME ASSEMBLY.
2. Remove the power train and lubricating oil pump
assembly. For details, see REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY.
3. Remove universal joint (1).
4 Universal joint: 25 kg
1
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
2 Mounting bolt:
3 Mounting bolt:
Liquefied adhesive (LT-2)
98.1 – 122.6 Nm {10 – 12.5 kgm}
2
4. Drain oil from the damper case.
6 Damper case: 1.7 l
3 Mounting bolt:
5. Using guide bolt [1], remove damper cover (2).
4 Damper cover: 35 kg
2 Cover mounting face:
2
Gasket sealant (LG-6)
98.1 – 122.6 Nm {10 – 12.5 kgm}
3
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
•
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil. Then, stop the
engine and check the oil level again.
5 Damper case: 1.7 l (TO30)
3 Drain plug: 58.8 – 78.5 Nm {6 – 8 kgm}
D65EX, PX-15
30-25
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
SPECIAL TOOL
Symbol
Part No.
INSTALLATION
•
Part name
Push tool
t
1
4 • 01050-31625
• Bolt
t
3
• 01050-31645
• Bolt
t
3
795-931-1220
Push tool
t
1
• 01050-31645
• Bolt
t
3
795-931-1210
A
5
Carry out installation in the reverse order to removal.
1
a Apply sufficient amount of clean lubricating
oil (EO30-CD) to the threads, seats, and
washers of the bolts.
a Tighten the 6 flywheel mounting bolts in the order of 1 – 6 as shown in the following figure.
a Tighten each mounting bolt twice.
REMOVAL
4 Mounting bolt:
1st tightening torque:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd tightening torque:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
1. Remove the damper assembly. For details, see
REMOVAL AND INSTALLATION OF DAMPER
ASSEMBLY.
2. Using guide bolt [1], remove flywheel assembly
(1).
1
4 Flywheel assembly: 60 kg
2
3. Remove engine rear seal (2).
30-26
(2)
•
2
Procedure for installing engine rear seal (2)
a Before installing the Teflon seal (lay-down lip
seal) 6151-21-4160 check the shaft for wear.
Then, install “standard seal A” or “sleeved
seal B” according to the check result.
a If the shaft is still glossy (If the wear depth felt
with a finger cushion is 10 µm or less) and it
does not have a flaw, install “standard seal
A”. In other cases, install “sleeved seal B”.
a Part (3) is the internal plastic cylinder which
is also used as a installation guide.
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
•
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
Procedure for installing standard seal A
a Before installing the seal, check the rims of
the crankshaft end, sliding surfaces of the lip,
and housing for flaw, burr, sharp fin, rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thoroughly
from the shaft.
a Never remove internal plastic cylinder (3) of
the spare seal before installing the seal.
1) Put large inside diameter side “b” of internal
plastic cylinder (3) to the end of crankshaft
(4).
a Take care not to mistake the direction of
the plastic internal cylinder.
2) Evenly push in the metallic ring of seal (2)
with both hands, getting over the large diameter side of the internal plastic cylinder.
3) After pushing in seal (2), remove internal
plastic cylinder (3).
a When removing, take care not to damage the seal lip.
4) Tighten the bolt of tool A4 evenly until the
end of tool A4 touches the end of crankshaft
(4) to press fit seal (2).
a When press fitting the seal, take care not
to damage the lip on the damper side
with the tool, etc.
a After press fitting the seal, remove the
red sealant layer on its periphery.
D65EX, PX-15
30-27
(2)
DISASSEMBLY AND ASSEMBLY
•
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
Procedure for installing sleeved seal B
a Before installing the seal, check the rims of
the crankshaft end, sliding faces of the lip,
and housing for flaw, burr, sharp fin, rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thoroughly
from the shaft.
a Handle the seal and sleeve as an assembly.
Never separate them from each other.
1) Set sleeved seal (2) to tool A5.
a Take care not to mistake the direction of
the seal.
2 Internal cylinder (C) of sleeve:
2) Put the sleeve of the seal to the end of the
crankshaft and tighten the bolt of tool A5
evenly until the end of tool A5 touches the
end of crankshaft (4) to press fit sleeved seal
(2).
3) Remove tool A5 and install tool A4.
4) Tighten the bolt of tool A4 evenly until the
end of tool A4 touches the end of crankshaft
(4) to press fit sleeved seal (2).
a After press fitting the seal, remove the
red sealant layer on its periphery.
Gasket sealant (LG-7)
30-28
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD
ASSEMBLY
SPECIAL TOOL
Symbol
A6
11. Disconnect 6 wiring connectors of the injector
and move the wiring harness.
Part No.
790-331-1110
Part name
Wrench
12. Remove tube (11).
q
5
13. Remove high-pressure pipe clamps (12), (13),
and (14), 2 pieces each.
6
1
REMOVAL
14. Remove bracket (15).
k Disconnect the cable from the negative (–) termi-
15. Remove filler tube (16).
nal of the battery.
1. Drain cooling water.
1
2. Close the fuel feed valve.
3. Remove the engine hood assembly. For details,
see REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY.
4. Remove the right and left side covers.
5. Remove air cleaner assembly (1) and bracket
(2).
2
6. Remove tube (3) and oil filter and bracket assembly (4).
7. Remove tube (5) and fuel filter and bracket assembly (6).
3
8. Remove corrosion resistor (7) and bracket together and fix them on the chassis side.
9. Remove air intake connector (8).
4
10. Disconnect wiring connectors E21 (9) and E22
(10) and remove bracket.
D65EX, PX-15
30-29
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
16. Remove tubes (17) and (18) on the front and rear
sides of the air intake connector.
18. Disconnect hose (20) and remove the bracket
and reservoir tank (21) together.
19. Remove heat insulation panels (22), (23), and
(24).
20. Remove muffler assembly (25).
21. Remove tube (26).
17. Remove air intake manifold assembly (19).
4 Air intake manifold assembly: 40 kg
a Take care not to drop the ribbon heater on
the mounting face.
22. Remove exhaust manifold and turbocharger assembly (27).
7
4 Exhaust manifold and turbocharger
assembly:
50 kg
30-30
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
23. Remove high-pressure pipe (28).
8
29. Remove push rod (40).
24. Remove spill tubes (29) and (30).
9
25. Remove head cover (31).
10
30. Remove mounting bolt (41) and fuel injector assembly (42).
15
26. Remove wiring harness (32) from the injector.
11
27. Loosen locknut (33), and then loosen adjustment
screw (34) by 2 – 3 turns.
12
31. Remove 6 mounting bolts (43) and rocker housing (44).
16
32. Remove 6 cylinder head bolts (45), 1 auxiliary bolt
(46), and cylinder head assembly (47).
17
28. Remove rocker shaft mounting bolt (35) and rocker
arm and rocker shaft assembly (36).
13
a If cross head (37) needs to be replaced,
loosen locknut (38), and then loosen adjustment screw (39) by 2 – 3 turns and remove
the cross head.
14
a The cylinder head assembly can be removed
and installed without removing the cross
head.
D65EX, PX-15
30-31
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
3 Drain plug:
11.8 – 17.6 Nm {1.2 – 1.8 kgm}
2
3 Air cleaner band:
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
3
3 Tube eyebolt (at each end):
34.3 – 44.1 Nm {3.5 – 4.5 kgm}
4
3 Hose clamp between air intake connector and turbocharger:
6.8 ± 0.49 Nm {69 ± 5 kgcm}
5
3 Eyebolt on cylinder block side:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
6
8
a For the procedure for installing the highpressure pipe and clamp, see REMOVAL
AND INSTALLATION OF FUEL INJECTOR
ASSEMBLY.
7
a Tighten the exhaust manifold mounting bolts
in the following numerical order, and then
tighten the other bolts from the central one to
the outside ones.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
9
3 Mounting bolt:
10
3 Spill tubes (29) (5 pieces from front
of engine):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Spill tubes (30) (on both ends):
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3 Injector wiring harness mounting nut:
11
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
12
a Adjust the valve clearance. For details, see
ADJUSTING VALVE CLEARANCE.
3 Rocker shaft mounting bolt:
13
58.8 – 73.5 Nm {6 – 7.5 kgm}
14
a Install the cross head according to the following
procedure.
1) Loosen locknut (38) and adjustment screw
(39) and install the cross head on the valve
stem.
a Loosen adjustment screw (39) until it
does not touch the valve stem.
2) Lightly hold the rocker arm contact face of
cross head (37) with the finger to keep the
cross head in contact with valve stem (a) on
the push rod side.
3) Under the above condition, tighten adjustment screw (39) until it touches the valve
stem.
4) Tighten the adjustment screw 20º more (Angle tightening).
5) While fixing adjustment screw (39) with a
flat-head screwdriver, etc., tighten locknut
(38).
3 Locknut: 58.8 – 73.5 Nm {6 – 7.5 kgm}
15
a For the installation procedure, see REMOVAL AND INSTALLATION OF FUEL INEJCTOR ASSEMBLY.
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
30-32
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
3 Rocker housing mounting bolt:
2. Make a punch mark (g).
16
3 Bolt 7 (Auxiliary bolt):
3. Tighten bolt 7 to the following torque.
58.8 – 73.5 Nm {6 – 7.5 kgm}
66.2 ± 7.4 Nm {6.8 ± 0.8 kgm}
17
a Clean the underside of the head, top of the
block, and liner with a dry cloth or a cloth
soaked in solvent.
a If there are 5 or more punch marks (g) on a
bolt head, do not use that bolt again but replace it. (See the procedure for tightening
the head bolts, Step 2, in this section.)
a Before tightening each cylinder head bolt,
measure its stem length “a” and make sure
that the result is less than the using limit. If
the stem is longer than the using limit, do not
use it again but replace it.
• Using limit length “a”: Max. 171.4 mm
a Tighten each cylinder head bolt more than 2
turns with the fingers.
2 Threads of bolt and underside of
bolt head:
Lubricant containing molybdenum
disulfide (LM-P) or engine oil
(EO30-CD)
•
Refilling with water
Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
5 Cooling system (including sub tank): 59 l
a Tighten the cylinder head bolts and auxiliary
bolts in the following order.
1. Tighten the bolts in the numerical order of 1
to 6:
1st time:
Tighten to 88.3 – 108 Nm {9 – 11 kgm}.
2nd time:
Tighten to 157 – 167 Nm {16 – 17 kgm}.
3rd time:
Using tool A6, tighten by 90º +30º
0
(Angle tightening).
a You may tighten each bolt by the following method at the 3rd time.
1) Make marks (f) on the bolt and cylinder head with a marker.
2) Tighten the bolt by 90º +30º
by using
0
a protractor and a wrench.
D65EX, PX-15
30-33
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL
3. Disconnect hose (3).
k Disconnect the cable from the negative (–) termi-
4. Remove bolt (4) and move valve (5) down.
nal of the battery.
a Drain fuel, if necessary.
5. Disconnect wiring connector CN-244 (6) and remove 2 wiring harness clamps.
1. Remove cover (1).
6. Remove support (16).
2. Close fuel feed valve (2).
a The closed valve is shown in the following
figure.
7. Remove plate and backup buzzer assembly (7).
30-34
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
8. Disconnect wiring connectors CN-247 (8) and
CN-224 (9) of the rear lamp and remove the wiring harness clamp.
9. Remove cover (10) in the rear of the operator’s
seat.
12. Sling the fuel tank assembly temporarily.
13. Remove 4 right and left covers (14) and mounting bolts.
14. Lift off fuel tank assembly (15).
4 Fuel tank assembly (excluding fuel):
200 kg
10. Disconnect wiring connector CN-423 (11).
11. Disconnect hoses (12) and (13) and remove the
hose clamp under them.
INSTALLATION
•
D65EX, PX-15
Carry out installation in the reverse order to removal.
30-35
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL
k Lower the work equipment to the ground and
loosen the oil filler cap of the hydraulic tank to release the internal pressure of the hydraulic tank.
1. Drain cooling water.
1
2. Remove the engine hood assembly. For details,
see REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY.
3. Remove cover (1) and bracket (2).
4. Disconnect hoses (3), (4), and (5).
2
5. Remove the mounting bolts of air conditioner
condenser (6) and move the air conditioner condenser aside.
a Take care not to damage the air conditioner
condenser.
8. Remove the clamp and move wiring harness
(13).
9. Sling the radiator assembly temporarily and remove 4 mounting bolts of bracket (14).
4
10. Lift off radiator assembly (15).
4 Radiator assembly: 150 kg
6. Disconnect hoses (7), (8), and (9) under the radiator and hydraulic oil cooler hoses (10) and
(11).
3
7. Remove 2 right and left mounting bolts (12).
30-36
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
3 Drain plug:
11.8 – 17.6 Nm {1.2 – 1.8 kgm}
2
3 Clamp of hose (4) and (7):
3
8.8 ± 0.5 Nm {90 ± 5 kgcm}
4
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
•
Refilling with water
Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
5 Cooling system (including sub tank): 59 l
•
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
D65EX, PX-15
30-37
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
REMOVAL
k Lower the work equipment to the ground and
loosen the oil filler cap of the hydraulic tank to release the internal pressure of the hydraulic tank.
k Disconnect the cable from the negative (–) terminal of the battery.
k In the case that you do not drain the coolant, if
you disconnect the heater hose when the coolant temperature in the radiator is high, you may
be scalded. In this case, wait until the coolant
temperature lowers and then disconnect the
heater hose.
k Collect the air conditioner refrigerant (R134a)
from air conditioner circuit in advance.
a Ask professional traders for collecting and filling
operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you
•
4. Close the fuel feed valve.
5. Drain cooling water.
1
6. Move the air conditioner hoses and disconnect
fuel hoses (4) and (5).
7. Disconnect hoses (6) and (7) and remove the
bracket and receiver tank (8) together.
2
may lose your sight. Accordingly, put on protective goggles while you are collecting the refrigerant (R134a) or filling the air conditioner circuit
with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
For the method of fuel injection amount adjustment after replacement of the engine assembly
or engine controller, ask your Komatsu distributor.
1. Remove right and left covers (1).
2. Remove the engine hood assembly. For details,
see REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY.
8. Disconnect hose (9).
3. Remove right and left covers (3).
30-38
(8)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
9. Disconnect wiring connectors E21 (10) and E22
(11).
15. Disconnect heater hoses (19) and (20) and remove the clamp.
10. Disconnect hose (12).
16. Remove heat insulation panel (21).
3
11. Remove duct (13) and cover (14).
12. Disconnect hose (15) and remove the bracket
and reservoir tank (16) together.
17. Remove the radiator assembly. For details, see
REMOVAL AND INSTALLATION OF RADIATOR
ASSEMBLY.
18. Remove the mounting bolts and open fan guard
(22).
13. Loosen the alternator belt and tilt alternator (17)
toward the engine.
4
14. Remove water connector (18) and hose together.
D65EX, PX-15
19. Remove fan guard (23).
30-39
(8)
DISASSEMBLY AND ASSEMBLY
20. Disconnect wiring connector FAR (24).
21. Remove plate (25).
22. Disconnect hoses (26), (27), and (28).
23. Remove plate (29).
24. Lift off fan drive assembly (30).
4 Fan drive assembly: 110 kg
30-40
(8)
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
25. Remove the mounting bolt and clamp of tube
(31) under the right side of the engine and lower
the tube.
26. Remove universal joint (32).
5
27. Loosen the elbow of the breather pipe at the
damper and direct breather pipe (33) straight
down.
6
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
28. Sling the engine assembly temporarily.
a Pass sling wires through the mounting
bracket on the rear side.
INSTALLATION
•
Carry out installation in the reverse order to removal.
29. Remove 8 engine mounting bolts (34).
1
3 Drain plug:
11.8 – 17.6 Nm {1.2 – 1.8 kgm}
2
3
a Install each hose so that it will not be twisted.
a When installing the air conditioner hoses,
take care that dirt, dust, water, etc. will not
enter them.
a When tightening each joint of the air conditioner hose, check that O-ring (46) is fitted to
it.
a Apply sufficient compressor oil (Showa-Shell
Suniso 4G or 5G) to each O-ring.
30. Lift off engine assembly (35).
a Check that all the wires and pipes are disconnected, and then sling the engine assembly, taking care that the engine assembly will
not interfere with the chassis.
4 Engine assembly: 1,300 kg
3 Tightening torque of air conditioner refrigerant piping:
Thread size
Tightening torque
16 x 1.5
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 x 1.5
19.6 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4
a Adjust the tension of the alternator belt. For
details, see TESTING AND ADJUSTING,
Testing and adjusting alternator belt tension.
5
2 Mounting bolt:
3 Mounting bolt:
Liquefied adhesive (LT-2)
98.1 – 122.6 Nm {10 – 12.5 kgm}
6
2 Threads of elbow:
3 Elbow: 13.7 – 21.6 Nm {1.4 – 2.2 kgm}
Gasket sealant (LG-1)
D65EX, PX-15
30-41
(8)
DISASSEMBLY AND ASSEMBLY
•
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
Refilling with water
Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then, check the water level
again.
5 Cooling system (including sub tank): 59 l
•
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
•
Filling air conditioner circuit with refrigerant
(R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
30-42
(8)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
POWER TRAIN UNIT ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT
ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) termi-
6. Disconnect hoses (6), (7), and (8).
7. Remove suction tube (9).
nal of the battery.
1. Drain oil.
6 Hydraulic tank: 55 l
6 Power train case: 48 l
2. Remove the floor frame assembly. For details,
s ee RE M OVA L A N D IN S TA L L AT I O N O F
FLOOR FRAME ASSEMBLY.
3. Remove the fuel tank assembly. For details, see
REMOVAL AND INSTALLATION OF FUEL
TANK ASSEMBLY.
4. Disconnect hoses (1) and (2) and remove clamp
(3).
8. Disconnect hoses (10) and (11) on the control
valve side.
9. Remove oil level gauge guide (12).
5. Disconnect hoses (4) and (5).
10. Disconnect hoses (13) and (14) from the HSS
motor.
D65EX, PX-15
30-43
(2)
DISASSEMBLY AND ASSEMBLY
11. Disconnect tube (15) from the HSS pump assembly.
12. Disconnect hoses (16), (17), and (18) from the
cooling fan pump.
REMOVAL AND INSTALLATION OF
POWER TRAIN UNIT ASSEMBLY
15. Remove universal joint (24).
2
16. Remove right and left final drive shaft covers
(25).
13. Disconnect the suction tube and hose (19) together from the rear.
1
14. Remove the cover and disconnect hoses (20),
(21), (22), and (23) from the pressure pickup
ports.
30-44
(2)
17. Using forcing screw [1], pull out right and left
drive shafts (26) until the spline on the steering
case side comes off.
a If the shafts cannot be pulled out, raise the
shoe grouser with a jack to a position where
the shafts can be pulled out.
D65EX, PX-15
REMOVAL AND INSTALLATION OF
POWER TRAIN UNIT ASSEMBLY
DISASSEMBLY AND ASSEMBLY
18. Remove covers (27) of the right and left steering
case bevel gear shafts.
21. Lift off power train unit assembly (32).
4
a When lifting off the power train unit assembly, check that all the wires and pipes are disconnected.
4 Power train unit assembly: 1,650 kg
19. Remove right and left caps (28). Loosen clamp
(29) and move seal (30) to the outside.
3
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
3 Hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
2
2 Mounting bolt:
3 Mounting bolt:
Liquefied adhesive (LT-2)
20. Remove 4 right and left mounting bolts (31).
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
3
a Apply the clamp all round the seal of the coupling securely.
4
a When installing, take extreme care not to
damage right and left bevel gear shaft seals
(31).
•
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank: 55 l (EO10-DH)
5 Power train case: 48 l (TO30)
D65EX, PX-15
30-45
(2)
DISASSEMBLY AND ASSEMBLY
DISCONNECTION AND CONNECTION OF
POWER TRAIN UNIT ASSEMBLY
DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT
ASSEMBLY
DISCONNECTION
1. Drain oil from the power train case.
6 Power train case: 48 l
2. Disconnect wiring connector TM1 (1) above the
HSS case.
3. Disconnect wiring connector TMV (2) on the
right side of the transmission case.
4. Remove the mounting bolt of bracket (3).
1
5. Remove all the wiring harness clamps from each
part and disconnect wiring harness assembly
(4).
6. Remove parking brake cable (5).
2
a Do not loosen the mounting nut but remove
it together with the bracket.
7. Remove all the pipes and hoses from each part.
3
a Put tags to the disconnected pipes hoses to
prevent a mistake in re-connecting them.
8. Remove power train and lubricating oil pump assembly (6).
4
4 Power train and lubricating oil pump
assembly:
20 kg
30-46
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISCONNECTION AND CONNECTION OF
POWER TRAIN UNIT ASSEMBLY
9. Remove HSS pump assembly (7).
12. Remove HSS motor assembly (10).
10. Remove cooling fan pump assembly (8).
13. Remove 13 mounting bolts and HSS assembly
(11).
5
4 HSS pump assembly: 75 kg
4 Cooling fan pump assembly: 30 kg
4 HSS motor assembly: 45 kg
4 HSS assembly: 750 kg
11. Remove scavenging pump assembly (9).
14. Sling the PTO, torque converter, and transmission assembly and remove right and left mount
assemblies (12).
D65EX, PX-15
30-47
(2)
DISCONNECTION AND CONNECTION OF
POWER TRAIN UNIT ASSEMBLY
DISASSEMBLY AND ASSEMBLY
15. Set the PTO, torque converter, and transmission
assembly on block [1] with PTO assembly (13)
up.
16. Remove coupling (14).
6
19. Remove 12 mounting bolts and sling PTO assembly (13) and disconnect it from transmission
assembly (18).
8
a The torque converter assembly is left on the
transmission side.
4 PTO assembly: 150 kg
17. Using forcing screw [2], remove retainer (15)
from the PTO case.
7
20. Remove 8 mounting bolts. Using eyebolt [3], remove torque converter assembly (19).
4 Torque converter assembly: 150 kg
18. Remove sleeves (16) and (17).
30-48
(2)
D65EX, PX-15
DISCONNECTION AND CONNECTION OF
POWER TRAIN UNIT ASSEMBLY
DISASSEMBLY AND ASSEMBLY
CONNECTION
•
7
a Using push tool [4], install oil seal (22) to retainer (15).
Carry out connection in the reverse order to disconnection.
1
2 Lip of oil seal: Grease (G2-LI)
2 Periphery of press fitting surface of
3 Mounting bolt of bracket (3):
oil seal and inside wall of hole of
retainer: Gasket sealant (LG-5)
a Wipe off the projected gasket sealant.
98 – 123 Nm {10.0 – 12.5 kgm}
2
a If the cable nut was loosened, adjust it. For
details, see TESTING AND ADJUSTING,
Adjusting parking brake lever.
3
a Apply gasket sealant (LG-6) to the threads of
only 1 mounting bolt (21) of tube (20).
8
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
•
4
3 Mounting bolt:
Refilling with oil
5 Power train case: 48 l (TO30)
98 – 123 Nm {10.0 – 12.5 kgm}
5
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
6
2 O-ring between coupling and shaft:
2 Mounting bolt:
Grease (G2-LI)
3 Mounting bolt:
Liquefied adhesive (LT-2)
245.1 – 309.0 Nm {25.0 – 31.5 kgm}
D65EX, PX-15
30-49
(2)
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
SPECIAL TOOL
Symbol
D1
Part No.
Part name
799-301-1600
Oil leak tester
4) Disconnect 10 connectors (6) of the ECMV.
5) Remove cover (7) and wiring harness (8) together.
q
1
DISASSEMBLY
a Keep the removed discs and plates on a flat
place so that they will not be warped.
1. Relief valve assembly
Remove relief valve assembly (1).
2. Sleeve
Remove sleeve (2).
3. Control valve assembly
1) Remove cover (3).
2) Remove flange (4).
3) Using eyebolt [1], remove sleeve (5).
30-50
(2)
6) Remove control valve assembly (9).
4. Transmission case
1) Set the transmission assembly on the block
securely with the torque converter side up.
2) Remove 11 tie bolts (10) (used to secure the
transmission case).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
3) Using eyebolts [2], remove transmission case
(11).
a Hang the transmission case vertically by
using a lever block.
4) Remove snap ring (21).
5) Drive out the input shaft (22) from the torque
converter side and remove front plate assembly (23).
5. Input shaft/Front plate/No. 1 carrier assembly
1) Remove remaining 3 tie bolts (12).
2) Using eyebolts [3], remove input shaft/front
plate/No. 1 carrier assembly (13).
6) Remove snap ring (24), then remove input
shaft (22) by driving it out to the torque converter side.
6. Disassemble the Input shaft/Front plate/No. 1
carrier assembly
1) Remove snap ring (14), No. 2 sun gear (15),
and snap ring (16).
2) Remove snap ring (17) and No. 1 sun gear
(18).
3) Remove snap rings (19) and (20).
D65EX, PX-15
7) Remove snap ring (25) and No. 1 ring gear
(26).
8) Pull out shaft (27) and remove thrust washer
(28), gear (29), bearing (30), and ball (31).
a Take care not to lose the ball (31).
30-51
(2)
DISASSEMBLY AND ASSEMBLY
7. No. 1 discs, plates, and springs
1) Remove 5 springs (32).
2) Remove 6 plate (33) and 5 discs (34).
8. No. 1 housing assembly
1) Using eyebolts [4], remove No. 1 housing assembly (35).
2) Remove No. 1 piston (36) from the housing.
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
12. No. 2 housing and No. 2 carrier assembly
1) Push up the output shaft lightly from underside.
2) Remove snap ring (42).
3) Using eyebolts [5], remove No. 2 housing
and No. 2 carrier assembly (43).
13. Disassembly No. 2 housing and No. 2 carrier
assembly
1) Remove snap ring (44) and pull No. 2 carrier
assembly (45) out of No. 2 housing (46).
9. No. 2 piston
Remove No. 2 piston (37).
10. Guide pin
Remove 5 guide pin (38).
11. No. 2 discs, plates, and springs
1) Remove 5 No. 2 clutch springs (39).
2) Remove 7 discs (40) and 6 plates (41).
30-52
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
2) Remove spacer (47) from No. 2 carrier assembly (45).
3) Remove No. 2 ring gear (48).
4) Pull out shaft (49) and remove thrust washer
(50), gear (51), bearing (52), and ball (53).
a Take care not to lose the ball (53).
5) Remove snap ring (54).
6) Remove snap ring (55) and ring gear (56).
a Contract snap ring (55) by inserting
round rods [6] with a diameter of less
than 3 mm in 2 diagonal holes of 4 on the
ring gear and pull out ring gear (56).
14. No. 3 discs, plate, and springs
1) Remove 5 No. 3 springs (57).
2) Remove 4 No. 3 discs (58) and 3 plates (59).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
15. No. 3 ring gear
Remove No. 3 ring gear (60).
16. No. 3 and No. 4 carriers and output shaft assembly
Using eyebolts [7], remove No. 3 and No. 4 carriers and output shaft assembly (61).
17. Disassemble No. 3 and No. 4 carriers and output shaft assembly
1) Remove snap ring (62), then remove output
shaft assembly (63) from No. 3 and No. 4
carriers (64) with push tool [8].
2) Remove seal ring (65).
3) Drive pin (66) into shaft (67).
4) Drive out shaft (67) from No. 3 carrier side.
30-53
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
5) Remove thrust washer (68), No. 4 planetary
gear (69), and bearing (70).
a Pull the pin (66) out of the shaft (67).
18. No. 3 housing
1) Using eyebolt [9], remove housing (83).
2) Remove No. 3 piston (84).
6) Drive out shaft (71) and remove thrust washer (72), No. 3 planetary gear (73), bearing
(74), and ball (75).
a Take care not to lose the ball (75).
19. No. 4 discs, plates, and springs
1) Remove 5 springs (85).
2) Remove 4 discs (86) and 3 plates (87).
7) Remove snap ring (76), then remove No. 4
sun gear (77) from output shaft (78).
8) Remove snap rings (79) and (80), then remove No. 5 sun gear (81) from the output
shaft (78).
9) Remove inner race (82) from the bearing.
30-54
(2)
20. No. 5 carrier and No. 4 ring gear assembly
1) Remove 4 mounting bolts (88).
2) Remove No. 5 carrier and No. 4 ring gear assembly (89).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
21. Disassemble No. 5 carrier and No. 4 ring gear
assembly
1) Drive out shaft (90) and remove thrust washer (91), gear (92), bearing (93), and ball (94).
a Take care not to lose the ball (94).
2) Remove snap ring (95), then remove No. 4
ring gear (96) from carrier (97).
22. No. 4 housing assembly
1) Remove No. 4 housing assembly (98).
2) Remove No. 4 piston (99).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
23. Guide pin and No. 5 piston
Remove 5 guide pin (100) and No. 5 piston
(101).
24. No. 5 discs, plates, and springs
Remove 5 springs (102), 3 discs (103), and 2
plates (104).
25. No. 5 ring gear
Remove No. 5 ring gear (105).
30-55
(2)
DISASSEMBLY AND ASSEMBLY
26. Cage (For fixing No. 5 carrier)
1) Remove snap ring (106).
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
27. Output shaft bearing
1) Remove snap ring (110).
2) Remove bearing (111) from housing (112).
2) Using forcing screws [10], remove cage
(107) and bearing (108) as a unit.
3) Remove seal ring (109) and bearing (108) to
cage (107).
30-56
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
•
Precautions for assembly
a Clean the all parts and check them for dirt or
damage before installing.
a Coat the sliding surfaces of each part with
engine oil before installing.
a Install seal ring (a) for the piston and piston
housing with power receiving side (b) to
housing (c) as shown in the figure.
a Apply grease (G2-LI) to each seal ring and
install it evenly.
a Before cooling the bearing in dry ice, etc. for
expansion fit, drop about 6 cc of engine oil
(EO10-CD or EO30-CD) onto it and revolve
it 10 turns.
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
2. Cage (For fixing No. 5 carrier)
1) Install bearing (108) to cage (107) with the
push tool.
2) Install seal ring (109) to cage (107).
3) Install cage (107) to housing (112) with push
tool [12].
a Press fit the inner race side of bearing
(108).
4) Install snap ring (106).
1. Output shaft bearing
1) Using push tool [11], install bearing (111) to
housing (112).
2) Install snap ring (110).
3. No. 5 ring gear
Install No. 5 ring gear (105).
D65EX, PX-15
30-57
(2)
DISASSEMBLY AND ASSEMBLY
4. Guide pin
Install 5 guide pin (100).
5. No. 5 discs, plates, and springs
1) Install discs (103) and plates (104) alternately in order from the bottom.
a Discs: 3 pieces, Plates: 2 pieces
2) Install 5 springs (102).
a Free length of spring: 59 mm
6. No. 5 piston
1) Install seal ring (113) to No. 5 piston (101).
a When installing the seal ring, check the
direction of the pressure receiving side.
2) Install No. 5 piston (101), matching it to
springs (102).
a Check that the springs are fitted securely
in the grooves of the piston.
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
7. No. 4 housing
1) Install seal ring (114) to No. 4 housing (98).
a When installing the seal ring, check the
direction of the pressure receiving side.
2) Install seal ring (115) to No. 4 piston (99).
a When installing the seal ring, check the
direction of the pressure receiving side.
3) Install No. 4 piston (99) to No. 4 housing (98).
4) Install No. 4 housing (98), matching it to No. 5
piston.
8. Assembly of No. 5 carrier and No. 4 ring gear
assembly
1) Set No. 4 ring gear (96) to carrier (97) and install snap ring (95).
30-58
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
2) Install gear (92) to bearing (93) and fit thrust
washers (91) to both sides, then set them to
the carrier.
3) Install ball (94) and shaft (90).
9. No. 5 carrier and No. 4 ring gear assembly
Using a guide bolt, install No. 5 carrier and No. 4
ring gear assembly (89) and tighten bolts (88).
2 Mounting bolt:
3 Mounting bolt:
Liquefied adhesive (LT-2)
27 – 34 Nm {2.8 – 3.5 kgm}
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
10. No. 4 discs, plates, and springs
1) Install discs (86) and plates (87) alternately
in order from the bottom.
a Discs: 4 pieces, Plates: 3 pieces
2) Install 5 springs (85).
a Free length of spring: 59 mm
11. No. 3 housing
1) Install the seal ring to No. 3 housing (83) and
No. 3 piston (84).
a When installing the seal ring, check the
direction of the pressure receiving side.
2) Install the No. 3 piston to the No. 3 housing.
3) Using eyebolts [9], install No. 3 housing (83).
a Check that the springs are fitted securely
in the grooves.
30-59
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
4) Using 2 forcing screws [13], tighten No. 3
housing (83) and insert dowel pin in the
housing securely.
a Keep 2 forcing screws [13] installed until
step 13.
12. Assembly of No. 3 and No. 4 carrier and output shaft assembly
1) Install inner race (82) to output shaft (78).
2) Install No. 5 sun gear (81) and snap rings
(80) and (79).
3) Install No. 4 sun gear (77) and snap ring
(76).
7) Install bearing (70) to No. 4 planetary gear
(69) and fit thrust washers (68) to both sides,
then set them to the carrier.
8) Install shaft (67), matching the pin hole of the
shaft to the pin hole of the carrier.
9) Check that the pin holes are matched to
each other and drive in pin (66).
10) Install seal ring (65).
a Before driving in pin (66), check that
there are no burrs in the pin hole of carrier (64). If there is any burr, remove it with
sandpaper, and then drive in pin (66).
9JS02171
4) Press fit bearing (116) to No. 3 carrier and install snap ring (117).
11) Set No. 3 and No. 4 carrier assemblies (64)
to output shaft (78).
12) Set jig [14] on the inner race side of bearing
(116) and tighten bolt [15] to press fit bearing
(116) to output shaft (78).
a Dimensions of tap hole: M10 x 1.5,
Depth: 32 mm
5) Install bearing (74) to No. 3 planetary gear
(73) and fit thrust washers (72) to both sides,
then set them to the carrier.
6) Install ball (75) and shaft (71).
30-60
(6)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
13) Install snap ring (62).
13. No. 3 and No. 4 carrier assemblies, output shaft
assembly
1) Using eyebolts [7], install No. 3 and No. 4
carriers and output shaft assembly (61).
2) Remove 2 forcing screws [13].
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
17. No. 2 housing and No. 2 carrier assembly
1) Press fit bearing (118) to No. 2 housing (46)
and install snap ring (44).
2) Set ring gear (56) to No. 2 carrier (45) and install snap ring (55).
14. No. 3 ring gear
Install No. 3 ring gear (60).
a Direct the notched side of the outside teeth
down.
15. Guide pin
Install guide pin (38).
3) Install bearing (52) to gear (51) and fit thrust
washers (50) to both sides, then set them to
the carrier.
4) Install ball (53) and shaft (49).
a After assembling 2 gear sets, install snap
ring (42).
16. No. 3 discs and plates
Install discs (58) and plates (59) alternately in order from the bottom.
a Dises: 4 pieces, Plates: 5 pieces
D65EX, PX-15
30-61
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
5) Install the seal ring to No. 2 housing.
6) Install No. 2 ring gear (48).
7) Install spacer (47).
a Install the spacer with the cut inside end
directed to the carrier.
2) Clamp No. 2 housing with tie bolts (10) and
a pipe [17] and push the dowel pin in the
housing securely.
3) Push up output shaft (63) lightly from underside and install snap ring (42).
8) Install No. 2 housing (46) to carrier assembly
(45).
a Press fit the inner race side of the housing bearing.
9) Install snap ring (44).
4) Install sleeve (119).
a If the sleeve has been removed, install it
to the bolt hole marked
in the figure
with the slit side (d) down.
18. No. 2 housing and No. 2 carrier assembly
1) Using eyebolts [16], install No. 2 housing and
No. 2 carrier assembly (43).
30-62
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
5) Install spring (120) and valve (121).
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
22. No. 1 housing assembly
1) Install the seal ring to the No. 1 housing and
No. 1 piston.
a When installing the seal ring, check the
direction of the pressure receiving side.
2) Install No. 1 piston (36) to housing.
3) Using eyebolts [4], install No. 1 housing assembly (35), matching it to No. 2 piston.
a Press the housing and hit the dowel pin.
19. No. 2 discs and plates
Install discs (40) and plates (41) alternately in order from the bottom.
a Discs: 7 pieces, Plates: 6 pieces
23. Assembly of input shaft and No. 1 carrier assembly
1) Install bearing (30) to gear (29) and fit thrust
washers (28) to both sides, then set them to
the carrier.
2) Install ball (31) and shaft (27).
20. Springs for No. 3 and No. 2 housings
Install 5 springs (39).
a Free length of spring: 77.0 mm
21. No. 2 piston
1) Install the seal ring to the No. 2 piston.
a When installing the seal ring, check the
direction of the pressure receiving side.
2) Install No. 2 piston (37).
a Set spring (39) in the spring groove of
the piston.
D65EX, PX-15
30-63
(2)
DISASSEMBLY AND ASSEMBLY
3) Set No. 1 ring gear (26) to No. 1 carrier and
install snap ring (25).
4) Press fit bearing (122) to input shaft (22).
5) Install snap rings (20) and (19) to the input
shaft.
6) Install input shaft (22) to No. 1 carrier assembly (123), and then install snap ring (24).
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
8) Install snap rings (17) and (16).
9) Install No. 2 sun gear (15) and snap ring
(14).
24. Input shaft and No. 1 carrier assembly
Using eyebolt [3], sling and install input shaft and
No. 1 carrier assembly (124). At this time, engage the No. 2 sun gear with the No. 1 planetary
gear.
7) Install No. 1 sun gear (18).
25. No. 1 discs, plates, and springs
1) Install plates (33) and discs (34) alternately
in order from the bottom.
a Discs: 5 pieces, Plates: 6 pieces
a Free length of spring: 69.5 mm
2) Install 5 springs (32).
30-64
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
26. Front plate assembly
1) Press fit bearing (126) to front plate (125).
2) Install seal ring (127).
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
27. Tie bolts
Install 3 tie bolts (12).
3 Tie bolt:
156.9 – 176.5 Nm {16.0 – 18.0 kgm}
28. Operation check of piston
3) Install collar (128) to No. 1 carrier (129).
Using tool D1, check the operating condition and
stroke of each piston.
Piston
Standard stroke (mm)
No. 1
5
No. 2
7
No. 3
4
No. 4
4
No. 5
3
4) Using eyebolts [18], install front plate assembly (23), matching it to the guide pin and
spring.
5) Press fit the inner race side of bearing (126)
to input shaft (22) and install snap ring (21).
a Check that the spring is fitted to the cover securely.
D65EX, PX-15
30-65
(2)
DISASSEMBLY AND ASSEMBLY
29. Transmission case
1) Fit the O-ring and install transmission case
(11), using eyebolts [2].
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
3) Install cover (7) and wiring harness (8) together.
2 Cover: Gasket sealant (LG-6)
2 1 bolt marked with :
Gasket sealant (LG-6)
4) Connect 10 ECMV connectors (6).
2) Tighten 11 tie bolts (10) (to secure the transmission).
3 Tie bolt:
156.9 – 176.5 Nm {16.0 – 18.0 kgm}
30. Control valve
1) Set the transmission assembly on its side.
2) Fit the O-ring and install control valve assembly (9).
3 Mounting bolt:
44.1 – 53.9 Nm {4.4 – 5.5 kgm}
30-66
(2)
5) Using eyebolt [1], fit the O-ring and install
sleeve (5).
6) Install flange (4).
2 Cover: Gasket sealant (LG-6)
7) Install cover (3).
31. Sleeve
Install sleeve (2).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
32. Relief valve assembly
Install relief valve assembly (2).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
D65EX, PX-15
30-67
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
Hanger
q
1
Wrench kit
q
E
1
3 796-730-2300
Commercially
4 available or
795-630-1810
Wrench
q
1
Torque wrench
q
1
Part No.
Part name
Sketch
Q’ty
1 791-422-1320
2 790-302-1500
Symbol
New/
remodel
Necessity
SPECIAL TOOL
3. Cover assembly
1) Using eyebolt [1], remove cover assembly
(5).
DISASSEMBLY
1. Transmission speed sensor
Remove transmission speed sensor cover (1),
and then pull out and remove transmission
speed sensor (2).
2) Remove 5 sleeves (24) and 2 pieces of (25)
from the HSS case.
2. Brake valve assembly
Remove brake valve assembly (4).
4. Disassembly of cover assembly
1) Input gear assembly
i) Remove snap ring (12).
30-68
(5)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
ii) Using puller [2], pull out gear assembly
(6) and cage (7) together, and then remove gear assembly (6) from cage (7).
a Take care not to lose ball (8).
ii) Remove the bolt and holder (13).
iii) Drive out shaft (14) from the bolt side
and remove gear (15).
a Take care not to lose the ball.
iii) Remove bearing (10) from gear (9).
iv) Remove bearing (17) and spacer (17a)
from gear (15).
2) Intermediate gear
i) Remove tube (11).
D65EX, PX-15
3) Left carrier driver gear
i) Remove bolt (19) and holder (20).
ii) Remove gear (22).
30-69
(2)
DISASSEMBLY AND ASSEMBLY
iii) Using gear puller [3], push out shaft (21).
iv) Remove snap ring (23), then remove
bearing (28) from cover (32).
v) Remove outer race (29) from cover (32).
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
4) Remove the plug, spring (30), and valve
(31).
5. Remove brake and carrier assembly
Remove the mounting bolt, then remove brake
and carrier assembly (34) with tool E1.
a Do not remove 4 hexagon socket head bolts.
vi) Remove bearing (26) from shaft (21).
6. Disassembly of brake assembly
1) Remove flange (36).
2) Remove snap ring (37) and space (38).
30-70
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
3) Set puller [4] and loosen 4 hexagon socket
head bolts and remove cover (41).
a The inner race side of the bearing comes
out.
a Do not remove bolts (40) until cover (41)
comes off.
7) Push up and remove cage (51), taking care
not to damage the disc.
8) Remove seal rings (53) and (27) from cage
(51).
9) Using eyebolts [7], remove drum (45), discs,
and plates as a unit.
4) Remove bearing (60) from cover (41).
10) Remove discs (46), plates (47), and springs
(48) from drum (45).
5) Remove spring (42).
6) Using eyebolts [5], remove piston (43).
D65EX, PX-15
11) Remove snap ring (59) and bearing (57).
a Pry up the bearing from the cut of the
hub.
30-71
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
12) Remove 18 mounting bolts, then remove hub
(39) from hub (54).
2) Remove hub (92) from carrier assembly (64),
then remove snap ring (50) and gear (52).
13) Remove bushing (60) from hub (39).
14) Remove snap ring (58), then remove stopper
(56) from the hub.
3) Drive roll pin (65) into the shaft.
4) Pull out shaft (66) and remove gear (52),
thrust washer (67), and bearing (69).
a Pull roll pin (65) out of the shaft.
7. Disassembly of carrier assembly
1) Turn over the hub and carrier assembly and
remove bolts (89), then remove carrier assembly (64) from hub (54).
30-72
(2)
5) Remove bushing (91) from carrier (90).
8. Sun gear
1) Remove snap ring (70) and collar (73).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
2) Using gear puller [8], remove sun gear (72)
and bearing (98).
3) Using the bearing race puller, remove bearing (74).
4) Remove collar (71).
5) Remove snap ring (93).
a Only the right side of the machine.
9. Bevel pinion assembly
1) Remove the mounting bolts.
2) Using guide bolts [9] and forcing screws [10],
remove bevel pinion assembly (95) and shim
(96).
a Check the quantity and thickness of the
shims and store them.
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
3) Disassembly of bevel pinion assembly
i) Remove the bolt (97), plate (99), and pin
(100).
ii) Secure the pinion with a press and remove nut (101) with tool E2.
iii) Using push tools [11], remove bevel pinion (102) from cage (103).
iv) Remove bearing (104).
v) Remove outer races (105) and (107)
from cage (103).
30-73
(2)
DISASSEMBLY AND ASSEMBLY
vi) Remove bearing (106) and spacer (108)
from bevel pinion (102).
10. Bevel gear shaft and bevel gear
1) Sling bevel gear and shaft assembly (75)
temporarily.
2) Remove cage assemblies (76) and (86).
a Check the thickness, quantity, and positions of shims (77).
a Since both cages are different from each
other, make marks on them.
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
4) Sling bevel gear (79) and remove mounting
nut (80) and pull out bevel gear shaft assembly (81) to the right side of the machine.
5) Remove bearing (78) from bevel gear shaft
(82).
6) Remove bolts (83).
7) Remove outer race (84) from cage (76).
8) Remove seal ring (85) from bevel gear shaft
(81).
3) Move bevel gear and shaft assembly (75) to
the left end and remove bearing (78) with
puller [12].
a Remove only the bearing on the left side
of the machine.
30-74
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
•
Precautions for assembly
a Clean the all parts and check them for dirt or
damage before installing.
a Drop engine oil onto the rotating parts of
each bearing and rotate it several turns.
a Coat the sliding parts with engine oil before
installing.
a Apply grease (G2-LI) to each piston seal ring
and install it evenly with the pressure receiving side directed to the housing.
2 Rotary seal ring:
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
2) Heat bearing (78) with a bearing heater, etc.
and install it to the right side of the bevel gear
shaft by shrink fit.
a If the bearing temperature is raised too
high, the hardness of the heat-treated
part lowers. Accordingly, do not raise the
bearing temperature more than 120ºC.
a After installing the bearing, drop engine
oil onto its rotating parts and rotate it
several turns.
a Check that the clearance at the bearing
end is 0.03 mm or less.
3) Install outer race (84) to cages (76) and (86).
Fix each seal ring with grease (G2LI) and install it very carefully not to
catch it in the parts.
a Check that the snap rings are fitted securely
in the grooves.
4) Install seal ring (85) to bevel gear shaft (81).
1. Suction tube
Install suction tube (55).
5) Insert bevel gear shaft (81) in bevel gear (79)
slung at the center of the case from the right
side of the machine.
a Tighten mounting nut (80) temporarily in
advance.
2. Bevel gear shaft and bevel gear assembly
1) Install bolt (83) to bevel gear shaft (82).
D65EX, PX-15
30-75
(2)
DISASSEMBLY AND ASSEMBLY
6) Heat bearing (78) with a bearing heater, etc.
and install it to the left side of the bevel gear
shaft by shrink fit.
a If the bearing temperature is raised too
high, the hardness of the heat-treated
part lowers. Accordingly, do not raise the
bearing temperature more than 120ºC.
a After installing the bearing, drop engine
oil onto its rotating parts and rotate it
several turns.
a Check that the clearance at the bearing
end is 0.03 mm or less.
7) Install cages (76) and (86) to bevel gear and
shaft assembly (75).
a Since both cages are different from each
other, take care not to mistake them.
a Install shims (77) of the thickness and
quantity recorded when removed.
• Standard shim thickness: 1.5 mm
• Varieties of shim thickness:
0.2 mm, 0.3 mm, 0.5 mm
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
9) Adjusting pre-load
a Adjust the pre-load with the bevel pinion
assembly removed.
i) Rotate the bevel gear and shaft assembly several turns to fit the bearing.
ii) Install too E3 to the end of bevel gear
shaft (81) and measure the rotation
torque with a torque wrench E4.
• Standard rotation torque:
10.3 – 14.7 Nm {1.05 – 1.5 kgm}
a If the rotation torque is lower than the
standard value, reduce the quantity of
shims (77) in step 7. If the former is higher, increase the latter.
3. Bevel pinion assembly
1) Assembly of bevel pinion
i) Using push tool, press fit bearing (106)
to bevel pinion (102) and install spacer
(108).
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
8) Tighten the bevel gear mounting nut securely.
a Place a plastic hammer, etc. between
the bevel.
3 Mounting nut:
245 – 309 Nm {25 – 31.5 kgm}
30-76
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
ii) Using the push tool, press fit outer races
(105) and (107) to cage (103).
iii) Place bevel pinion (102) on the press
stand and set cage (103).
vii) Install pin (100), plate (99), then tighten
the bolt (97).
iv) Press fit bearing (104) to cage (103) with
the press.
v) Secure the pinion with the press and
tighten locknut (101) with tool E2.
2) Using guide bolt [9], install shims (96) and
bevel pinion assembly (95).
a Install shims of the thickness and quantity recorded when removed.
• Standard shim thickness: 2 mm
• Varieties of shim thickness:
0.2 mm, 0.3 mm, 1.0 mm
2 Locknut:
3 Locknut:
Liquefied adhesive (LT-2)
3 Bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
392 – 441 Nm {40 – 45 kgm}
vi) After tightening the nut, return it until 1 of
its pin holes (8 places) is matched to 1 of
the pin holes of the pinion shaft (5 places).
a Return the nut by 0 – 9º.
a Tighten the nut, turning the cage.
a After tightening the nut, check that
the bevel pinion rotates smoothly.
4. Adjusting backlash and tooth contact
1) Adjusting backlash
Apply the probe of dial gauge [13] to the
tooth tip at the end of the bevel gear at right
angles. Fix the bevel pinion and move the
bevel gear forward and backward, and read
the value at this time.
a Standard backlash: 0.2 – 0.28 mm
a Measure the backlash diagonally at 3 or
more places.
D65EX, PX-15
30-77
(2)
DISASSEMBLY AND ASSEMBLY
•
If the measured backlash is out of the
standard range, adjust it according to the
following procedure.
a Adjust the backlash by increasing or decreasing the thickness of both shims. Do
not change the total thickness of both
shims so that the pre-load will not
change. (If the thickness of the shim on
one side is increased, decrease the
thickness of the other side, and vice versa.)
• When backlash is insufficient
Decrease the thickness of the shim on
the right side of the machine body and
increase the thickness on the left side by
the same quantity. (Move the bevel gear
in direction A.)
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
•
When backlash is too large
Decrease the thickness of the shim on
the left side of the machine body and increase the thickness on the right side by
the same quantity. (Move the bevel gear
in direction B.)
2) Adjusting tooth contact
Testing
i)
Apply red lead thinly to the tooth surfaces of the bevel gear and turn the bevel
gear in the forward and reverse directions, then check the tooth contact pattern on the bevel gear.
ii) The tooth contact must be as follows
(The standard distance is measured
from the tooth tip of the bevel pinion.)
a) Center of tooth contact:
20 – 40% of face width
(from small end)
b) Width of tooth contact:
30 – 50% of face width
c) Center of tooth contact:
35 – 65% of tooth depth
(from bottom)
d) Width of tooth contact:
60 – 80% of tooth depth
Check that tooth tip A, bottom B, small
end C, and large end D of the teeth do
not have any strong tooth contact.
30-78
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
a If the level gear and bevel pinion are adjusted in this way, their teeth come in
contact with each other correctly when
they are loaded.
Adjusting
If the tooth contact pattern is not proper adjust the tooth contact according to the following procedure.
i)
•
If the bevel pinion is too far from the center line of the bevel gear, the contact is at
the small end of the bevel gear tooth faces curved outward and at the large end
of the bevel gear tooth faces curved inward.
In this case, adjust the tooth contact according to the following procedure.
Adjust the thickness of the shims on the
bevel pinion side to move the bevel pinion in direction A. Move the bevel gear in
direction B, then check the tooth contact
pattern and backlash again.
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
ii) If the bevel pinion is too close to the center line of the bevel gear, contact is at the
large end of the bevel gear tooth faces
curved outward and the small end of the
bevel gear tooth faces curved inward.
• In this case, adjust the tooth contact according to the following procedure.
Adjust the thickness of the shims on the
bevel pinion side to move the bevel pinion in direction A. Move the bevel gear in
direction B, then check the tooth contact
pattern and backlash again.
a Do not change the total thickness of the
shims on both sides.
iii) When adjustment is finished, tighten the
mounting bolts of the cage and bevel pinion assembly to the specified torque.
3 Mounting bolts of cage and
bevel pinion assembly:
98 – 123 Nm {10 – 12.5 kgm}
5. Sun gear
1) Install snap ring (93) to the shaft.
a Perform this work for only right side of
the machine.
2) Install collar (71).
3) Install bearing (74) with the push tool.
30-79
(2)
DISASSEMBLY AND ASSEMBLY
4) Install sun gear (72).
5) Install bearing (98) with the push tool.
a Press fit the inner race and outer race simultaneously.
6) Install collar (73) and snap ring (70).
6. Assembly of carrier assembly
1) Install bushing (91) to carrier (90).
2) Install bearing (69) to gear (52). Fit thrust
washers (67) to top and bottom of the bearing, then set them to the carrier.
3) Install shaft (66), matching the inside of the
thrust washers and bearing to the shaft hole
of the carrier.
a Match the roll pin hole accurately.
4) Install roll pin (65).
30-80
(2)
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
5) Set hub (92) to ring gear (52) and install
snap ring (50).
6) Install hub (92) to carrier assembly (64).
7) Install hub and carrier assembly (64) to hub
(54) and tighten bolts (89).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
7. Assembly of brake assembly
1) Install stopper (56) to the hub, then install
snap ring (58).
2) Install bushing (60) to hub (39).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
3) Install hub (39) to hub (54) with 18 mounting
bolts.
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
4) Install bearing (57) to hub (39).
5) Install snap ring (59).
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
8) Install seal rings (27) and (53) and cage (51).
a Roughly match the oil holes on the cage
to the 4 oil holes on the drum.
a Press fit the cage to the outer race side
of the bearing.
9) Install the seal ring to piston (43).
10) Install piston (43), matching the center of the
spot-face (b) having the match mark (a) to
the drilled hole (c) “13.5 in diameter” (on the
opposite side (d) of the side hole).
6) Set brake drum (45) to hub (39).
7) Install discs (46), plates (47), and springs
(48).
D65EX, PX-15
30-81
(2)
DISASSEMBLY AND ASSEMBLY
11) Install spring (42).
12) Install guide bolt [14] to cage (51).
13) Install bearing (60) to cover (41).
14) Using eyebolts [15] and matching to the guide
bolt, set cover (41).
a Check that the spring is fitted securely to
both of the piston and case.
15) Compressing the spring with forcing screws
[17] and nuts [16], press fit the inner race
side of the bearing to the hub assembly.
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
18) Remove the bolts and nuts used to compress the spring, then install 4 bolts (40).
8. Installation of brake and carrier assembly
1) Equalize the projection of the seal rings from
the shaft on the carrier side.
2) Using tool E1, install brake and carrier assembly (34).
9. Assembly of cover assembly
1) Install valve (31) and spring (30) to the cover,
then install the plug.
16) Install spacer (38) and snap ring (37).
17) Install flange (36).
30-82
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
2) Left carrier drive gear
i) Press fit bearing (26) to shaft (21).
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
v) Install gear (22).
vi) Install holder (20) and tighten bolt (19).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
ii) Install outer race (29) to cover (32).
iii) Press fit bearing (28) to cover (32), then
install snap ring (23).
iv) Using puller [18], press fit shaft (21) to
the inner race side of bearing (28).
a Replace the bolt with one having different length.
D65EX, PX-15
3) Intermediate gear assembly
i) Install bearings (17) and spacer (17a) to
gear (15).
ii) Press fit shaft (14) to the inner race side
of bearing (17). Fit ball (16) halfway and
press fit completely.
a Before the shaft enters the cover position the ball accurately.
30-83
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
3 Mounting bolt:
ii) Install gear assembly (6).
iii) Install cage (7) and ball (8), matching
them to the hole for ball (8).
iv) Install snap ring (12).
iii) Install holder (13) and tighten bolt (12).
98 – 123 Nm {10 – 12.5 kgm}
iv) Install tube (11).
10. Installation of cover assembly
1) Install 2 sleeves (25) and 5 sleeves (24) to
the HSS case.
4) Input gear assembly
i) Install bearings (10) to gear (9).
2 Mating face of cover:
2) Using eyebolts [1], install cover assembly (5).
Gasket sealant (LG-6)
a Apply gasket sealant to both mating faces of the case and cover.
a Apply gasket sealant to each mating face
without breakage.
30-84
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY
11. Brake valve assembly
Install brake valve assembly (4).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
12. Transmission speed sensor
Install transmission speed sensor (2) and cover
(1). For details, see TESTING AND ADJUSTING, Adjusting transmission speed sensor (Replacement procedure).
D65EX, PX-15
30-85
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
DISASSEMBLY
1. Lubrication tubes
Remove lubrication tubes (1) and (2).
2. Cover assembly (right)
1) Remove mounting bolts, then using forcing
screw [1], remove cover assembly (3).
3. Cover assembly (left)
1) Remove mounting bolts, then using forcing
screw [2], remove cover assembly (8).
2) Knock out gear assembly (9) from cover
(10).
3) Remove bearing (11) from gear (12).
2) Knock out gear assembly (4) from cover (5)
and remove.
3) Remove bearings (6) from gear (7).
30-86
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
4. Idler gear
1) Remove mounting bolts, then remove plate
(13).
2) Remove mounting bolts, and using forcing
screws [3], remove shaft (14).
3) Remove bearing (16) and spacer (17) from
gear (15).
a If these parts are to be used again, do
not change the sets. Put them in sets
with the outer race and keep them in a
safe place.
4) Remove outer race (18) from gear (15).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
5. Cover
Remove cover (19).
6. Scavenging pump drive gear
1) Remove snap ring (20) and (21).
2) Knock out gear (22) from snap ring side.
3) Remove bearing (23).
30-87
(2)
DISASSEMBLY AND ASSEMBLY
7. Input shaft bearing
Remove snap ring (24), then remove bearing
(25).
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
ASSEMBLY
a Clean all parts, and check for dirt or damage before installing.
a Put a drop of engine oil on the rotating portion of
the bearing, then rotate it several times.
a Check that the snap ring is fitted securely in the
groove.
1. Input shaft bearing
Press fit bearing (25), and install snap ring (24).
2. Scavenging pump drive gear
1) Install bearing (23).
30-88
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
2) Hold the inner race side of bearing (23) with
push tool [4] and install gear (22) to the bearing.
3) Install snap ring (20) and (21).
3. Idler gear
1) Fit the O-ring to shaft (14) and install them to
the case.
2 O-ring: Grease (G2-LI)
2) Install bearing (16).
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
3) Install spacer (17).
4) Install outer race (18) to gear (15).
5) Install gear (15).
6) Install bearing (16).
a Press fit inner race side.
2 Mounting bolt:
7) Fit plate (13) and tighten bolts.
3 Mounting bolt:
Liquefied adhesive (LT-2)
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
D65EX, PX-15
30-89
(2)
DISASSEMBLY AND ASSEMBLY
4. Cover assembly (left)
1) Install bearings (11) to gear (12).
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
5. Cover assembly (right)
1) Install bearing (6) to gear (7).
2) Install gear assembly (4) to cover (5).
3) Install O-ring to cover (5).
2 O-ring: Grease (G2-LI)
2 O-ring: Grease (G2-LI)
3) Install gear assembly (9) to cover (10).
2) Install O-ring to cover (10).
4) Mesh idler gear, install cover assembly (3).
4) Mesh idler gear, and install cover assembly
(8).
30-90
(2)
6. Cover
Install cover (19).
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
7. Lubrication tubes
Install lubrication tubes (2) and (1).
D65EX, PX-15
30-91
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER
ASSEMBLY
DISASSEMBLY
1. Case, turbine assembly
Remove 24 bolts from below, then use eyebolts
[1], and remove case and turbine assembly (1).
3. Case
1) Remove snap ring (8).
2) Remove spacer (9).
3) Using puller [2], disconnect case assembly
(10) and turbine (11).
2. Gear and input shaft
1) Remove 14 bolts (3), then remove gear (4)
and input shaft (5).
4) Remove bearing (13) from case (12).
2) Remove collar (6) and inner race (7) from input shaft (5).
30-92
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER ASSEMBLY
4. Stator
Remove snap ring (14), then remove stator (15).
3) Remove 12 bolts (20), then remove cage assembly (21) from pump (22).
5. Pump assembly
1) Using forcing screws [3] from stator shaft
end, remove pump assembly (16) from stator
shaft (17).
4) Remove snap ring (23), then remove bearing
(25) from cage (24).
2) Remove seal ring (18) and flange (19) from
stator shaft (17).
D65EX, PX-15
30-93
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER ASSEMBLY
ASSEMBLY
a Clean all parts, and check for dirt or damage.
a Check that the snap ring is fitted securely in the
groove.
1. Pump assembly
1) Press fit bearing (25) to cage (24), and install
snap ring (23).
4) Using push tool [4], install pump assembly
(16) to stator shaft (17).
a Push the inner race of the bearing to
press fit.
a After press fitting the bearing, apply 6 cc
of EO10-CD or EO30-CD in drops, then
rotate 10 times.
2 Mounting bolt (20):
2) Install cage assembly (21) to pump (22).
3 Mounting bolt:
Liquefied adhesive (LT-2)
58.9 – 73.6 Nm {6 – 7.5 kgm}
2. Stator
1) Install stator (15).
2) Install snap ring (14).
3) Install seal ring (18) and flange (19) to stator
shaft (17).
a Coat the seal ring with grease (G2-LI)
and align the end gaps.
a Take care not to open the abutment joint
of the seal ring too much.
30-94
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
3. Case
1) Install bearing (13) to case (12).
2) Using push tool [5], push inner race end of
bearing, then install case assembly (10) to
boss portion of turbine (11).
DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER ASSEMBLY
4. Gear and input shaft
1) Press fit collar (6) and inner race (7) to input
shaft (5).
2 Mounting bolt:
2) Install input shaft (5) and gear (4).
3 Mounting bolt:
Liquefied adhesive (LT-2)
58.9 – 73.6 Nm {6 – 7.5 kgm}
3) Install spacer (9).
4) Install snap ring (8).
D65EX, PX-15
30-95
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER ASSEMBLY
5. Case, turbine assembly
1) Using eyebolt [1] and matching the groove of
the case to the drain plug, install case and
turbine assembly (1) and tighten bolt (2).
2 Mounting bolt:
3 Mounting bolt:
Liquefied adhesive (LT-2)
49.0 – 58.8 Nm {5.0 – 6.0 kgm}
2) Install drain plug.
3 Drain plug:
5.9 – 8.8 Nm {0.6 – 0.9 kgm}
30-96
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
SCAVENGING PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF SCAVENGING PUMP
ASSEMBLY
REMOVAL
1. Remove the undercover.
2. Drain the power train oil.
6 Power train case: 48 l
3. Disconnect hose (1).
4. Remove scavenging pump assembly (2).
INSTALLATION
•
Carry out installation in the reverse order to removal.
•
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Power train case: 48 l (TO30)
D65EX, PX-15
30-97
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY
REMOVAL
8. Lift off HSS pump assembly (7).
4 HSS pump assembly: 75 kg
k Disconnect the cable from the negative (–) termi-
nal of the battery.
1. Drain the hydraulic oil.
6 Hydraulic tank: 55 l
2. Remove the floor frame assembly. For details,
s e e RE M OVA L A N D IN S TA L L AT I O N O F
FLOOR FRAME ASSEMBLY.
3. Remove the undercover.
4. Disconnect wiring connector SDS (1) under the
HSS pump assembly.
5. Disconnect tube (2).
INSTALLATION
•
Carry out installation in the reverse order to removal.
•
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank: 55 l (EO10-DH)
6. Disconnect hoses (3), (4), and (5) and remove
the clamp.
7. Disconnect tube (6).
30-98
(2)
D65EX, PX-15
REMOVAL AND INSTALLATION OF
COOLING FAN PUMP ASSEMBLY
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF COOLING FAN PUMP
ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) termi-
8. Remove 4 tube mounting bolts (8) under the
HSS pump assembly.
nal of the battery.
1. Drain the hydraulic oil.
6 Hydraulic tank: 55 l
2. Remove the floor frame assembly. For details,
s ee RE M OVA L A N D IN S TA L L AT I O N O F
FLOOR FRAME ASSEMBLY.
3. Remove the undercover.
4. Disconnect hoses (1) and (2).
9. Remove bracket (9). While raising tube (10), disconnect hose (11).
a Tube (10) cannot be removed completely.
5. Disconnect hoses (3), (4), and (5).
6. Disconnect wiring connector FAC (6).
7. Disconnect hose and tube (7).
1
10. Remove cooling fan pump assembly (12).
4 Cooling fan pump assembly: 30 kg
D65EX, PX-15
30-99
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF
COOLING FAN PUMP ASSEMBLY
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
3 Hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
•
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank: 55 l (EO10-DH)
30-100
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN AND
LUBRICATING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN AND
LUBRICATING OIL PUMP ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) termi-
5. Lift off power train and lubricating oil pump assembly (4).
1
4 Power train and lubricating oil pump
assembly:
15 kg
nal of the battery.
1. Remove the floor frame assembly. For details,
s ee RE M OVA L A N D IN S TA L L AT I O N O F
FLOOR FRAME ASSEMBLY.
2. Remove the undercover.
3. Disconnect tube (1) under the power train and lubricating oil pump assembly.
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
4. Disconnect tubes (2) and (3).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
•
D65EX, PX-15
Refilling with oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
30-101
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY
REMOVAL
k Disconnect the cable from the negative (–) termi-
nal of the battery.
INSTALLATION
•
Carry out installation in the reverse order to removal.
1. Remove the fuel tank assembly. For details, see
REMOVAL AND INSTALLATION OF FUEL
TANK ASSEMBLY.
2. Disconnect hoses (1), (2), and (3).
3. Lift off HSS motor assembly (4).
4 HSS motor assembly: 45 kg
30-102
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
SPECIAL TOOL
Symbol
J1
5. Remove cover (2).
Part No.
6. Use bolt [3] to pull drive shaft (3) out to a position
where spline portion comes out.
a If the shaft will not come out, move the
sprocket (use a jack to push up the shoe
grouser from the ground), and adjust to a position where the shaft can be removed. Then
pull the shaft out.
Part name
790-337-1032
Lifting tool
t
1
791-427-1090
Plate
t
1
01010-51635
Bolt
t
2
2
REMOVAL
1. Remove track shoe assembly. For details, REMOVAL OF TRACK SHOE ASSEMBLY.
7. Leave 2 or 3 of 11 inside mounting bolts (4) and
9 outside mounting bolts in position at top, and
remove remaining mounting bolts.
3
2. Using jack, jack up chassis, then set stands [1]
and [2] under front frame and steering case.
k Set the stands in position securely.
8. Remove 2 cover mounting bolts from final drive
case, then set tool J1 and lever block in position,
and sling final drive assembly (5).
4
3. Drain oil from final drive case.
6 Final drive case: D65EX: 24 l
D65PX: 27 l
4. Remove bracket (1).
1
9. Remove the remaining bolts and move the final
drive assembly outward to remove it from the
case.
a While operating the lever block and keeping
the clearance between the final drive case
assembly and the case even, pry off the final
drive assembly with a bar, etc.
4 Final drive assembly: 850 kg
10. Remove sprocket (6).
D65EX, PX-15
30-103
(2)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
INSTALLATION
•
Carry out installation in the reverse order to removal.
1
2 Thread of bracket mounting bolt:
Liquefied adhesive (LT-2)
2
a Be careful not to damage the seal when installing.
3 Cover mounting bolt:
98 – 122.6 Nm {10 – 12.5 kgm}
3
3 Final drive assembly mounting bolt:
490.3 – 608 Nm {50 – 62 kgm}
4
3 Cover mounting bolt:
245.2 – 308.9 Nm {25 – 31.5 kgm}
•
Refilling with oil
5 Final drive case: Power train oil (TO30)
D65EX: 24 l
D65PX: 27 l
30-104
(2)
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
t
1
Puller
t
1
790-101-1102
Pump
t
1
Installer
t
1
Part No.
791-427-1100
J
3 792-520-2121
Part name
Installer assembly
t
1
4 790-101-2102
Puller
t
1
790-101-1102
Pump
t
1
791-427-1200
Sketch
Q’ty
Remover assembly
2 790-101-2102
Symbol
New/
remodel
Necessity
SPECIAL TOOL
a If gear assembly (4) remains in position
when the plate is remains, use puller [3]
to remove it.
DISASSEMBLY
1. Carrier assembly
1) Remove cover.
2) Remove mounting bolts, and using eyebolts
[1], remove carrier assembly (1).
2. Disassembly of carrier assembly
1) Remove lock plate (2).
2) Using forcing screw [2], remove plate (3) together with gear assembly (4).
3) Remove gear assembly (4) from plate (3).
D65EX, PX-15
4) Support dear (5), then push shaft (6) and remove bearing (7).
5) Remove bearing (7) from shaft (6).
6) Remove outer race (8) from gear (5).
30-105
(5)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
3. Shaft
Using eyebolts [4], remove shaft (9).
4. Ring gear, housing assembly
1) Remove holder (10).
2) Using eyebolts [5], remove ring gear and hub
assembly (11).
3) Remove snap ring (12), then remove ring
gear (14) from hub (13).
5. Sprocket, hub assembly
1) Fit eyebolts, pull out sprocket and hub assembly (15) with tool J2, and remove.
a Bearing (19) will come out at the same
time.
30-106
(2)
2) Remove floating seal (16).
a If it is to be used again, be careful not to
damage the seal surface and keep it in a
safe place.
3) Remove outer race (18).
6. Cover assembly
1) Tighten forcing screw [6] to pull cover assembly (21) out of case (22). Then, using
eyebolts [7], remove cover assembly (21).
a Although the cover assemblies of D65EX15 and D65PX-15 have different shapes,
they can be removed similarly.
D65EX, PX-15
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
2) Remove floating seal (16).
a If it is to be used again, be careful not to
damage the seal surface and keep it in a
safe place.
3) Using forcing screw [8], remove spacer (20)
and bearing (19) from cover.
2) Remove pinion assembly (29).
3) Remove bearing (31) from pinion (30).
4) Remove outer rave (32) and oil seal (33)
from cage (28).
5) Remove outer race (34) from case.
7. Gear assembly
1) Using eyebolts [9], remove gear assembly
(24) from case.
2) Using puller [10], remove bearing (26) from
gear assembly (25).
8. Output shaft
Remove output shaft (27).
9. Pinion assembly
1) Using forcing screws [11], remove cage (28).
a Check the number and thickness of the
shims, and keep in a safe place.
D65EX, PX-15
30-107
(2)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
ASSEMBLY
6) Assemble shim, the install cage (28).
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Pinion assembly
1) Using push tool [12], install oil seal (33) to
cage (28).
2 Lip of oil seal: Grease (G2-LI)
2) Install outer race (32) to cage (28).
3) Install outer race (34) to case.
a Select the shim thickness to be assembled as follows.
i) Install pinion without fitting O-ring to
cage.
ii) Hold cage down by hand, and use a
thickness gauge to measure clearance between gauge and case at 2
places on the circumf