D65ex-15 67000 Up

SEBM029508
Machine model D65EX-15 D65PX-15 D65WX-15
Serial number 67001 and up 67001 and up 67001 and up
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. D65-15 mount the SA6D125E-3 engine. For details of the engine, see the 125-3 Series Engine Shop Manual.
2008 All Rights Reserved Printed in Japan 02-08 (01)
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CONTENTS
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GENERAL ......................................................................................... 01-1 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1 TESTING AND ADJUSTING ............................................................ 20-1 DISASSEMBLY AND ASSEMBLY .................................................. 30-1 OTHERS ........................................................................................... 90-1
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D65EX, PX-15
FOREWORD
SAFETY NOTICE
SAFETY NOTICE
(Rev. 2007/03)
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. D65EX, PX-15 8) Before starting work, warm up your body thoroughly to start work under good condition. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Precautions against work which you are not used to or you are used to too much
6 Safety check before starting work 7 8
9 Good physical condition and preparation 10
2. Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
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FOREWORD
SAFETY NOTICE
3. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative () terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated.
11) When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are correctly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
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D65EX, PX-15
FOREWORD
SAFETY NOTICE
4. Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. Do not stand under the load. Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. Do not lift up the load slantingly.
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FOREWORD
SAFETY NOTICE
13) When lifting down a load, observe the following. When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. Check that the load is stable, and then remove the sling. Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. 5. Precautions for using mobile crane Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency. 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation.
15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard Z twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
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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.
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FOREWORD
HOW TO READ THE SHOP MANUAL

Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the engine volume of the engine model mounted on the machine.
1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. FOREWORD This section explains the safety and basic information. 01. GENERAL This section explains the specifications of the machine. 10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. TESTING AND ADJUSTING Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The S mode of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 30. DISASSEMBLY AND ASSEMBLY This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume) Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. Engine volume This section explains the method of reproducing, repairing, and replacing parts. 2. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most upto-date information before you start any work.
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3. Filing method See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function, Maintenance Standard) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5 Revised edition mark When a manual is revised, an edition mark ((1) (2) (3)....) is recorded on the bottom of the pages. Revisions Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
4. Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol k a 4 3 2 5 6 Item Safety Caution Weight Tightening torque Coat Oil, coolant Drain Remarks Special safety precautions are necessary when performing work. Special technical precautions or other precautions for preserving standards are necessary when performing work. Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
5. Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. The above size set temporarily is called the standard size and the range of difference from the standard size is called the tolerance. The tolerance with the symbols of + or is indicated on the right side of the standard size. Example: Standard size 120
Tolerance 0.022 0.126
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (0.022/0.126) Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them Example: Standard size 60 Tolerance Shaft 0.030 0.076 Hole +0.046 +0
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2. Standard clearance and standard value The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. When some parts are repaired, the clearance is generally adjusted to the standard clearance. A value of performance and function of new products or equivalent is called the standard value, which is indicated by a range or a target value. When some parts are repaired, the value of performance/function is set to the standard value. 3. Standard interference When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the interference. The range (A B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the standard interference. After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. 4. Repair limit and allowable value The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the repair limit. If a part is worn to the repair limit must be replaced or repaired. The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the allowable value. If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
5. Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the clearance limit. If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. 6. Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit. The interference limit shows the repair limit of the part of smaller tolerance. If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
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FOREWORD
HOW TO READ ELECTRIC WIRE CODE

The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Symbol AV Conductor Insulator Conductor Insulator Conductor Insulator Material Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Using temperature range (C) Example of use General wiring (Nominal No. 5 and above) 30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely 50 to +110 cold district, wiring at high-temperature place
AVS
Heat-resistant low-voltAEX age wire for automobile
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2.
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 CovAV Standard 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8 50/0.45 7.95 3.7 5.5 5.3
15 84/0.45 13.36 4.8 7.0 7.0
20 41/0.80 20.61 6.0 8.2 8.2
30 70/0.80 35.19 8.0 10.8 10.8
40 85/0.80 42.73 8.6 11.4 11.4
50
60
85
100
108/0.80 127/0.80 169/0.80 217/0.80 54.29 9.8 13.0 13.0 63.84 10.4 13.6 13.6 84.96 12.0 16.0 16.0 109.1 13.6 17.6 17.6
f of nominal No. denotes flexible.
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FOREWORD
3.
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: GW means that the background is Green and marking is White. 4. Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch WG

AEX R B R D Y G L

RB YR GW LW BrW LgR

RY YB GR LR BrR LgY

RG YG GY LY BrY LgB

RL YL GB LB BrB LgW

YW GL

Gr Br

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FOREWORD
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) Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234 Sleeve nut (elbow end) 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500
3)
If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D d L 6 5 8 8 6.5 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 22.5 34
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FOREWORD
2.
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.
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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.
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FOREWORD
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 release 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.
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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)
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FOREWORD
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)
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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
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
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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 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} Width across flats mm
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 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}
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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 02 03 04 05 06 (10) (12) (14) Width across flats 19 22 24 27 32 36 41 46 55 Range 34 54 { 3.5 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 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
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}
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. Thread size mm 6 8 10 12 14 Nm 10 2 24 4 43 6 77 12 Tightening torque Bolts and nuts 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 Tightening torque Nm 82 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
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FOREWORD
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 Tightening torque Nm 31 82 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
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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. 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.
2.
Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
(B) 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 2.205 2.598 2.992 3.386 3.780 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 2.244 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
0 10 20 30 40 (A) 50 60 70 80 90
D65EX, PX-15
00-25
(8)
FOREWORD
CONVERSION TABLE
Millimeters to inches 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 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
0 10 20 30 40 50 60 70 80 90
Kilogram to pound 0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42 1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62 2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83 3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03 4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24 5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44 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 85.98 101.41 103.62 105.82 108.03 123.46 145.51 167.55 189.60 211.64 125.66 147.71 169.76 191.80 213.85 127.87 149.91 171.96 194.01 216.05 130.07 152.12 174.17 196.21 218.26
0 10 20 30 40 50 60 70 80 90
Liters to U.S. Gallons 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 13.209 15.850 18.492 21.134 23.775 13.473 16.115 18.756 21.398 24.040 13.737 16.379 19.020 21.662 24.304 3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568 4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832 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 14.529 17.171 19.813 22.455 25.096 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
0 10 20 30 40 50 60 70 80 90
00-26
(8)
D65EX, PX-15
FOREWORD
CONVERSION TABLE
Liters to U.K. Gallons 0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797 1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017 2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237 3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457 4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677 5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897 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 12.318 14.518 16.718 18.917 21.117 12.528 14.738 16.938 19.137 21.337 12.758 14.958 17.158 19.357 21.557 12.978 15.178 17.378 19.577 21.777
0 10 20 30 40 50 60 70 80 90
kgm to ft.lb 0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 491.8 564.2 636.5 708.8 426.8 499.1 571.4 643.7 716.1
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
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 1084.9 1157.3 1129.6 1301.9 1374.3 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 1142.8 1215.1 1287.5 1359.8 1432.1 1150.0 1222.4 1294.7 1367.0 1439.4
D65EX, PX-15
00-27
(8)
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414 1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428 2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442 3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456 4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470 5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485 6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499 1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 953.0 1,095 1,237 1,380 1,522 1,664 1,806 1,949 2,091 2,233 2,375 2,518 2,660 2,802 2,944 3,086 3,229 3,371 3,513 825.0 967.2 1,109 1,252 1,394 1,536 1,678 1,821 1,963 2,105 2,247 2,389 2,532 2,674 2,816 2,958 3,101 3,243 3,385 3,527 839.2 981.4 1,124 1,266 1,408 1,550 1,693 1,835 1,977 2,119 2,262 2,404 2,546 2,688 2,830 2,973 3,115 3,257 3,399 3,542
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
00-28
(8)
D65EX, 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. 1C = 33.8F F 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
C 40.4 37.2 34.4 31.7 28.9 28.3 27.8 27.2 26.7 26.1 25.6 25.0 24.4 23.9 23.3 22.8 22.2 21.7 21.1 20.6 20.0 19.4 18.9 18.3 17.8 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 40 35 30 25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10
F 40.0 31.0 22.0 13.0 4.0 2.2 0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
C 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4
D65EX, PX-15
00-29
(8)
GENERAL
01 GENERAL
Specification dimensions ........................................................................................................................... Specifications ............................................................................................................................................. Weight table ............................................................................................................................................... Table of fuel, coolant and lubricant ............................................................................................................ 01- 2 01- 3 01- 8 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
Item Machine weight Engine name Rated engine output A Overall length B Overall height (excluding antenna) C Overall width Travel speed (1st/2nd/3rd gear speed) Forward Reverse
Unit kg kW {HP}/rpm mm mm mm km/h km/h
D65EX-15 20,000
D65PX-15 20,770 142 {190}/1,950
D65WX-15 20,860
Komatsu SA6D125E-3 diesel engine 5,440 3,220 3,455 5,550 3,255 3,970 3.9/6.8/10.6 5.0/8.6/13.4 5,440 3,220 3,640
01-2
(7)
D65EX, PX-15
GENERAL
SPECIFICATIONS
SPECIFICATIONS
D65EX-15 Machine name and type Serial No. Machine mass Tractor unit Mass With work equipment With work equipment and ROPS cab With work equipment, ripper, and ROPS cab Min. swing radius Gradeability Stability (Front, rear, left, right) Forward 1st Gear speed Forward 2nd Forward 3rd Reverse 1st Reverse 2nd Reverse 3rd Tractor unit Ground pressure With work equipment With work equipment and ROPS cab kg kg kg kg m deg. deg. km/h km/h km/h km/h km/h km/h kPa {kg/cm2} kPa {kg/cm2} kPa {kg/cm2} 16,270 19,270 20,000 (21,680)
[Pivot turn] Semi-U dozer Semi-U dozer with wide gauge Semi-U dozer with long track
D65PX-15
Power tilt dozer
D65WX-15
Semi-U dozer
67001 and up
67001 and up 67001 and up
17,050 20,130 20,860 (22,540)

[Pivot turn]
17,010 20,010 20,740 (22,420)

[Pivot turn]
17,300 20,040 20,770

[Pivot turn]
17,050 20,130 20,860 (22,540)

[Pivot turn]
30 35 3.9 6.8 10.6 5.0 8.6 13.4 58.8 {0.60} 69.6 {0.71} 71.6 {0.73} (77.5) ({0.79}) 4,335 5,440 2,390 3,455 2,990 2,315 3,220 3,220 3,080 1,880 2,675 510 405
30 35 3.9 6.8 10.6 5.0 8.6 13.4 38.2 {0.39} 45.1 {0.46} 47.1 {0.48} (51.0) ({0.52}) 4,335 5,440 2,890 3,640 2,990 2,315 3,220 3,220 3,080 2,050 2,675 810 405
30 35 3.9 6.8 10.6 5.0 8.6 13.4 50.0 {0.51} 58.8 {0.60} 60.8 {0.62} (65.7) ({0.67}) 4,520 5,845 2,390 2,990 2,990 2,315 3,220 3,220 3,080 1,880 3,285 510 405
30 35 3.9 6.8 10.6 5.0 8.6 13.4 27.5 {0.28} 31.4 {0.32} 32.4 {0.33} 4,520 5,550 3,000 3,970 3,025 2,350 3,255 3,255 3,115 2,050 3,285 950 510
30 35 3.9 6.8 10.6 5.0 8.6 13.4 38.2 {0.39} 45.1 {0.46} 47.1 {0.48} (51.0) ({0.52}) 4,335 5,440 2,890 3,640 2,990 2,315 3,220 3,220 3,080 2,050 2,675 810 405
Performance
With work equipment, ripper, kPa and ROPS cab {kg/cm2} Tractor unit With work equipment Tractor unit With work equipment Up to exhaust pipe Up to top of operators seat When ROPS cab is installed (excluding antenna) When ROPS canopy is installed When cab is installed (excluding antenna) mm mm mm mm mm mm mm mm mm mm mm mm mm
Track gauge Length of track on ground Track width (Standard track shoe) Minimum ground clearance
aValues in ( ) are shown for reference.
Overall height
Dimensions
Overall Overall width length
D65EX, PX-15
01-3
(7)
GENERAL
SPECIFICATIONS
D65EX-15 Machine name and type Serial No. Name Type Number of cyl. Bore x Stroke Total displacement Rated output Performance mm l {cc} kW/rpm {HP/ rpm} Nm/rpm {kgm/ rpm} rpm rpm g/kWh {g/HPh}
Semi-U dozer Semi-U dozer with wide gauge Semi-U dozer with long track
D65PX-15
Power tilt dozer
D65WX-15
Semi-U dozer
67001 and up
SA6D125E-3 4-cycle, water-cooled, in-line, direct-injection diesel engine with turbocharger and aftercooler 6 125 x 150 11.04 {11,040} 142/1,950 {190/1,950}
Engine
Max. torque High idling speed under no load Low idling speed under no load Min. fuel consumption ratio
941/1,400 {96/1,400} 2,100 50 825 25 222 {163} 24 V, 7.5 kW 24 V, 50 A 12 V, 112 Ah, 2 units D-6 3-element, 1-stage, 1-phase type Planetary gear, multiple disc, hydraulic, gear pump forced lubrication, 3 forward/reverse gear speeds, manual electronic type Spiral bevel gear, gear pump forced lubrication type Differential planetary gear, hydraulic motor drive, manual electronic, hydraulic type Wet multiple disc, spring-boosted, foot-operated, hydraulic type 1-stage spur gear/1-stage planetary gear reduction, splash lubrication type Semi-hard, equalizing beam type 2 pieces on each side 7 pieces on each side
Width: 510 mm Width: 810 mm 39 pieces on 39 pieces on each side each side Pitch: 203.2 mm Pitch: 203.2 mm
Starting motor Alternator Battery (*1) Type of radiator core Torque converter Transmission Power train Bevel gear shaft HSS unit HSS Brake
Final drive Type of suspension Carrier roller Track roller Undercarriage Track shoe Assembly type single grouser shoe
8 pieces on each side

Width: 510 mm 45 pieces on each side Pitch: 203.2 mm
7 pieces on each side
Assembly type special swamp shoe
*1 : The battery capacity (Ah) is on 5-hours rate.
01-4
(7)
D65EX, PX-15
GENERAL
SPECIFICATIONS
D65EX-15 Machine name and type Serial No. HSS pump Type Theoretical capacity Cooling fan pump Hydraulic pump Type Theoretical capacity Power train and lubricating oil pump Type Theoretical capacity Scavenging pump Hydraulic system Type Theoretical capacity HSS motor Hydraulic motor Type Motor capacity Cooling fan motor Type Motor capacity Control valve Type and quantity Control method cm3/rev cm3/rev cm3/rev Gear type 61.2 cm3/rev cm3/rev cm3/rev
D65PX-15
Power tilt dozer
D65WX-15
Semi-U dozer
67001 and up
HPV95, variable-capacity piston, load sensing type 112
LPV30, variable-capacity piston type 30
SAL (2) 45 + 45, gear type (Tandem) 43.7 x 2
HMF95, fixed-capacity piston type with brake valve 96
LMF28, fixed-capacity piston type 28 3-spool type, 1 piece 4-spool type, 1 piece (Machine with ripper: Optional) Hydraulic assist type Box type (External control valve type) Return side of tank Air-cooled type (3A-CS)
Hydraulic tank Hydraulic oil filter Oil cooler
D65EX, PX-15
01-5
(7)
GENERAL
SPECIFICATIONS
D65EX-15 Machine name and type Serial No. Type Lift cylinder Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins Tilt and pitch cylinder Type Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins Type Ripper cylinder Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins Type Blade supporting method Performance Max. lift (above ground) Max. drop (below ground) Max. tilting distance Blade angle range Blade width Blade height Blade angle mm mm mm deg. mm mm deg. 1,105 440 870 7 3,415 1,225 55 mm mm mm mm mm 140 70 330 1,080 750 mm mm mm mm mm mm mm mm mm mm 95 65 1,165 1,685 520 140 70 145 1,222 1,077
D65PX-15
Power tilt dozer
D65WX-15
Semi-U dozer
67001 and up 95 65
67001 and up 67001 and up 95 65 1,165 1,685 520
Double-acting piston type
1,105 1,905 800 Double-acting piston type
Work equipment hydraulic system
Double-acting piston type 140 70 330 1,080 750
Power tilt dozer Left: Brace, Right: Tilt cylinder 1,170 470 870 7 3,415 1,110 55 1,205 440 890 7 3,970 1,110 57
Work equipment
Type Blade supporting method Performance Max. lift (above ground) Max. drop (below ground) Max. tilting distance Blade angle range Blade width Blade height Blade angle mm mm mm deg. mm mm deg. 1,105 440 855 7 3,455 1,480 55 440 820 7
Dimensions
Semi-U dozer Left: Brace, Right: Tilt cylinder 1,105 1,180 565 680 7 3,460 1,480 55 1,105 440 820 7 3,640 1,410 55
Dimensions
3,640 1,410 55
01-6
(7)
D65EX, PX-15
GENERAL
SPECIFICATIONS
D65EX-15 Machine name and type Serial No. Type Blade supporting method Performance Max. lift (above ground) Max. drop (below ground) Max. tilting distance Max. angle Blade width Blade height Blade angle mm mm mm deg. mm mm deg. 1,180 460 400 25 3,970 1,120 55
D65PX-15
Power tilt dozer
D65WX-15
Semi-U dozer
67001 and up Angledozer Both sides: Brace
Work equipment
Dimensions
Type Blade supporting method Performance Max. lift (above ground) Max. drop (below ground) Max. tilting distance Blade angle range Blade width Blade height Blade angle mm mm mm deg. mm mm deg.
Power tilt, power pitch dozer Left: Tilt cylinder, Right: Pitch cylinder 1,200 445 890 +9/7 3,970 1,110 57 Parallelogram mm piece deg. 2,170 3 55/45 Changeable to 3 levels mm mm mm 595 640 950/950 Parallelogram 2,170 3 55/45 Changeable to 3 levels 595 640 950/950
Type Beam length Number of shanks Ripper Digging angle (A/B) Performance Digging depth Max. digging depth Max. lift Shank position (Left/Right)
Dimensions
D65EX, PX-15
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 Serial No. D65EX-15 Standard Wide gauge 67001 and up 1,300 1,200 25 2 22 145 125 12 28 13 200 1,435 290 340 13 6 710 6 45 65 20 5 75 1,300 1,200 25 2 22 145 125 12 28 13 200 1,435 290 340 13 6 710 6 45 65 20 5 75 1,300 1,200 25 2 22 145 125 12 28 13 200 1,435 290 340 13 6 710 6 45 65 20 5 75 Long track D65PX-15 Standard D65WX-15 Wide gauge
67001 and up 67001 and up 1,300 1,200 25 2 22 145 125 12 28 13 200 1,435 290 340 13 6 710 6 45 65 20 5 75 1,300 1,200 25 2 22 145 125 12 28 13 200 1,435 290 340 13 6 710 6 45 65 20 5 75
Engine and damper assembly (Excluding coolant and oil) Engine assembly Damper assembly Engine-related parts (Wiring) Universal joint Cooling assembly (Excluding coolant and oil) Radiator assembly Hydraulic oil cooler Cooling fan pump Cooling fan motor Fuel tank (Excluding fuel) Power train unit assembly (Excluding oil) Torque converter and PTO assembly Transmission assembly Transmission ECMV assembly Main relief valve assembly HSS unit assembly Brake valve assembly HSS motor HSS pump Power train and lubricating oil pump Scavenging pump Hydraulic tank (Excluding oil) Control valve 3-spool valve 4-spool valve (Machine with ripper: Optional) Final drive assembly (Each side) Sprocket (Each side) Frame assembly Engine underguard Transmission underguard
84 95 765 8.3 x 9 2,140 105 30
84 95 790 8.3 x 9 2,140 105 30
84 95 765 8.3 x 9 2,140 105 30
84 95 790 8.3 x 9 2,140 105 30
84 95 790 8.3 x 9 2,140 105 30
01-8
(7)
D65EX, PX-15
GENERAL
WEIGHT TABLE
Unit: kg
Machine name and type Serial No. Track group assembly (Each side) Track frame Idler assembly (Each side) Recoil spring assembly (Each side) Single flange track roller assembly (Each side) Double flange track roller assembly (Each side) Carrier roller assembly (Each side) Track shoe assembly (Each side) Single grouser shoe (510 mm) Single grouser shoe (810 mm) Swamp shoe (950 mm) Pivot shaft (Each side) Equalizer bar Floor frame assembly Operators seat Cab assembly ROPS guard assembly (for cab) ROPS canopy assembly Semi-U dozer Power tilt dozer assembly Blade Straight frame (Each side) Tilt cylinder assembly Lift cylinder assembly Ripper assembly Ripper cylinder assembly 1,310 90 125 300 59 410 220 410 2,280 1,355 285 75 95 x 2 1,530 75 1,735 100 145 300 59 410 220 410 2,360 1,325 285 75 95 x 2 1,530 75 1,580 90 125 300 59 410 220 410 2,280 1,355 285 75 95 x 2 1,530 75 2,110 100 145 300 59 410 220 410 2,030 1,190 285 75 95 x 2 1,735 100 145 300 59 410 220 410 2,360 1,325 285 75 95 x 2 1,530 75 1,495 590 200 250 54 x 5 61 x 2 30 x 2 D65EX-15 Standard Wide gauge 67001 and up 1,495 590 200 250 54 x 5 61 x 2 30 x 2 1,695 700 200 250 54 x 6 61 x 2 30 x 2 Long track D65PX-15 Standard D65WX-15 Wide gauge
67001 and up 67001 and up 1,695 700 200 250 54 x 6 61 x 2 30 x 2 1,495 590 200 250 54 x 5 61 x 2 30 x 2
D65EX, PX-15
01-9
(7)
GENERAL
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 SAE 30 SAE 10W Engine oil pan SAE 10W-30 SAE 15W-40 SAE 5W-30 Power train case including torque converter, transmission and bevel gear case Final drive case (each side) Damper case Idler (each) Pivot shaft case (each side) SAE 10W Hydraulic oil SAE 10W-30 SAE 15W-40 Track roller (each) Carrier roller (each) Grease fitting 0.32 GO 140 0.24 NLGI No.2 0.24 0.32 95 55 SAE 30 44 38 Specified Refilled oil amount oil amount 104F 122F (l) (l) 40C 50C
SAE 30 Engine oil SAE 10W
68
48
EX: 24 EX: 24 PX,WX: 27 PX,WX: 27 1.7 0.15 0.25 1.7 0.15 0.25
Gear oil
Grease
Fuel tank
Diesel fuel
ASTM D975 No.2 415
*1
Add antifreeze 59
Cooling system (Incl. reservoir tank)
Coolant
*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
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 0C (32F), be sure to use engine oil of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10C (50F) 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 0.5 to 1.0% Above 1.0% Change interval of oil in engine oil pan 1/2 of regular interval 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 ........................................... Engine mount ............................................. Power train .................................................. Overall drawing of power train unit ............. Hydraulic piping of power train ................... Damper, universal joint ............................... Transmission, steering, brake control ......... Torque converter, PTO ................................ Transmission ............................................... Transmission ECMV ................................... Main relief valve .......................................... Lubrication relief valve ................................ Scavenging pump ....................................... Power train pump, lubrication pump ........... HSS system ................................................ Hydraulic, HSS pump ................................. HSS motor .................................................. Bevel gear shaft, HSS, brake ...................... Brake valve ................................................. Final drive ................................................... Frame assembly ......................................... Suspension ................................................. Track frame, recoil spring ............................ Idler ............................................................. Track roller .................................................. Carrier roller ................................................ Sprocket ...................................................... Track shoe .................................................. Work equipment hydraulic piping diagram .. 10- 2 10- 4 10- 5 10- 7 10- 9 10- 10 10- 12 10- 14 10- 19 10- 30 10- 36 10- 38 10- 39 10- 40 10- 41 10- 43 10- 61 10- 68 10- 83 10- 88 10- 93 10- 95 10-101 10-105 10-107 10-108 10-109 10-113 10-118 Work equipment control ............................. Hydraulic tank ............................................ Accumulator ............................................... PPC lock valve ........................................... Hydraulic cylinder ....................................... Piston valve ................................................ Quick drop valve ........................................ Cooling fan pump ....................................... Cooling fan motor ....................................... PPC valve .................................................. PCCS lever ................................................ Control valve .............................................. Self pressure reducing valve ...................... Work equipment ......................................... Cutting edge, end bit .................................. Ripper ........................................................ Cab mount ................................................. Cab ............................................................ Air conditioner piping ................................. Engine control ............................................ Engine control system ................................ CRI engine control system ......................... Cooling system control system .................. Palm command control system .................. System components .................................. Engine controller ........................................ Transmission and steering controller ......... Monitor system ........................................... Monitor panel ............................................. Sensors ...................................................... 10-120 10-122 10-124 10-125 10-126 10-128 10-129 10-131 10-139 10-145 10-155 10-158 10-190 10-197 10-201 10-202 10-203 10-204 10-206 10-207 10-208 10-210 10-212 10-214 10-216 10-218 10-220 10-222 10-224 10-228
D65EX, PX-15
10-1
COOLING SYSTEM
COOLING SYSTEM
Engine-related parts
10-2
D65EX, PX-15
COOLING SYSTEM
A: B: C: D: 1. 2. 3. 4. 5. 6. 7. 8. 9.
Power train oil cooler inlet Power train oil cooler outlet Hydraulic oil cooler inlet Hydraulic oil cooler outlet
Cooling fan motor Radiator Radiator inlet hose Hydraulic oil cooler Reservoir tank Radiator outlet hose Radiator cap Cooling fan Power train oil cooler (built in radiator lower tank) 10. Drain plug
Specifications
Radiator Core type Fin pitch (mm) Total heat dissipation surface (m2) Pressure valve cracking pressure (kPa {kg/cm2}) Vacuum valve cracking pressure (kPa {kg/cm2}) D-6 4.0 52.627 88.3 14.7 {0.9 0.15} 0 4.9 {0 0.05} Power train oil cooler PTO-OL 1.722 Hydraulic oil cooler 3A-CS 3.5 1.860
D65EX, PX-15
10-3
ENGINE MOUNT
ENGINE MOUNT
Unit: mm No. Check item Standard size 60 2 Free height of mount rubber Criteria Tolerance Shaft 0.100 0.300 Standard size 90 Hole +0.046 0 Standard clearance 0.100 0.346 Repair limit 88 Clearance limit 0.4 Replace Remedy
Clearance between bracket and 1 cushion
10-4
D65EX, PX-15
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. 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).
D65EX, PX-15
10-5
POWER TRAIN
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Engine Damper Universal joint HSS pump PTO Cooling fan pump Torque converter Transmission Bevel gear HSS unit
11. 12. 13. 14. 15. 16. 17. 18. 19.
HSS motor Brake Final drive Sprocket Track shoe Power train pump Lubricating oil pump Scavenging pump Cooling fan motor
10-6
D65EX, PX-15
OVERALL DRAWING OF POWER TRAIN UNIT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
HSS pump Cooling fan pump HSS motor Lubricating oil pump Power train pump Torque converter and PTO Main relief valve Transmission ECMV Transmission Brake valve HSS unit Scavenging pump Power train oil strainer
Outline The power train unit consists of the main components of torque converter and PTO (6), 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.
D65EX, PX-15
10-7
Unit: mm No. Check item Standard size 60 2 Clearance between steering case cover and bushing 204 Criteria Tolerance Shaft 0.100 0.300 +0.096 +0.050 Standard size 3 Free height of front mount rubber 90 43 Hole +0.046 0 +0.046 0 Standard clearance 0.100 0.346 0.096 0.004 Repair limit 88 41 Clearance limit 0.4 Max. 0 Replace Remedy
Clearance between bracket and 1 cushion
4 Free height of rear mount rubber
10-8
D65EX, PX-15
HYDRAULIC PIPING OF POWER TRAIN
HYDRAULIC PIPING OF POWER TRAIN
A: B: C: D: E: F:
Load sensing oil pressure pickup port Main pump discharge oil pressure pickup port Transmission oil pressure pickup port Torque converter outlet oil pressure pickup port Torque converter inlet oil pressure pickup port Brake oil pressure pickup port
1. 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)
D65EX, PX-15
10-9
DAMPER, UNIVERSAL JOINT
10-10
D65EX, PX-15
Unit: mm No. Check item Inside diameter of contact surfaces of coupling and oil seal Facial and radial runout of coupling Standard size 85 Criteria Tolerance 0 0.087 Repair limit 84.8
Plate with hard chromium or replace
Remedy
Facial runout: Max. 1.0 (at 148.38), Radial runout: Max. 1.5
(when damper shaft and transmission input shaft are rotated simultaneously)
Adjust
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Breather Oil filler plug Inspection plug Drain plug Damper case Coupling Spider Yoke Shaft Bearing Drive plate Torsion spring Stopper pin Friction plate Friction spring Hub Cover
Outline The damper is a wet friction spring type. Stopper angle: 4 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.
D65EX, PX-15
10-11
TRANSMISSION, STEERING, BRAKE CONTROL

a PCCS: Abbreviation for Palm Command Control System
10-12
D65EX, PX-15
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Brake pedal Decelerator pedal Brake valve Transmission ECMV Fuel control dial Steering/directional/gear shift lever (PCCS lever) Neutral safety limit switch Transmission and steering controller Rod Brake potentiometer Cable Packing brake lever
Outline The transmission, 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)
TORQUE CONVERTER, PTO

a PTO: Abbreviation for Power Take Off
10-14
D65EX, PX-15
D65EX, PX-15
10-15
A: From transmission case (To torque converter) B: To oil cooler C: From traffic accident (To scavenging pump) D: From transmission case (To power train and lubricating oil pump) E: To transmission case (Drain)
Outline The torque converter is a 3-element, 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).
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
D65EX, PX-15
D65EX, PX-15
10-17
Unit: mm No. Check item Outside diameter of oil seal contact surface of input coupling Inside diameter of seal ring contact surface of retainer Backlash between PTO drive gear and PTO idler gear Standard size 110 105 Criteria Tolerance 0 0.087 +0.035 0 0.17 0.46 0.16 0.42 Repair limit 109.8 105.5
Plate with hard chromium or replace
Remedy
1 2 3
Backlash between PTO idler gear and 4 HSS pump and cooling fan pump drive gear Backlash between PTO idler gear and 5 power train and lubricating oil pump drive gear 6 Backlash between PTO drive gear and scavenging pump drive gear Standard size Fit tolerance of PTO 7 idler gear bearing
Outside diameter Inside diameter Outside diameter (Cover side)
0.16 0.42 0.17 0.46 Tolerance Shaft 0 0.015 0 0.019 0 0.015 +0.021 +0.002 0 0.015 +0.021 +0.002 0 0.013 +0.011 0.005 Hole 0.010 0.035 0 0.015 +0.035 0 +0.022 0.013 0 0.015 +0.035 0 +0.022 0.013 0 0.015 +0.030 0 0 0.010 Replace
110 60
Fit tolerance of HSS pump and cooling fan 8 pump drive gear bearing
120
Outside diameter (Case side) Inside diameter Outside diameter (Cover side)
55
Fit tolerance of power train and lubricating oil 9 pump drive gear bearing
120
Outside diameter (Case side) Inside diameter Outside diameter Inside diameter
55 72 35
Fit tolerance of 10 scavenging pump drive gear bearing
10-18
D65EX, PX-15
TRANSMISSION
TRANSMISSION
D65EX, PX-15
10-19
TRANSMISSION
A: B: C: D: E: F: G: H: J: K: L: M: N: P: R: S: T:
1st clutch oil pressure pickup port 3rd clutch oil pressure pickup port R clutch oil pressure pickup port 2nd clutch oil pressure pickup port F clutch oil pressure pickup port From power train pump (To brake valve) To PTO case (To torque converter) From oil cooler To PTO case (To scavenging pump) From PTO case (Drain) To PTO case (To power train and lubricating oil pump) From steering case From transmission ECMV (For R clutch) From transmission ECMV (For 3rd clutch) From transmission ECMV (For 1st clutch) From transmission ECMV (For 2nd clutch) From transmission ECMV (For F clutch)
10-20
D65EX, PX-15
TRANSMISSION
*1. D65EX-15 Serial No. : 67137 and up D65PX-15 Serial No. : 67136 and up D65WX-15 Serial No. : 67001 and up 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Main relief valve Transmission ECMV cover Transmission case Transmission ECMV Lubricating oil relief valve Transmission input shaft R sun gear (Number of teeth: 26) R planetary pinion (Number of teeth: 22) R ring gear (Number of teeth: 70) Disc Plate Piston F planetary pinion (Number of teeth: 23) 3rd planetary pinion (Number of teeth: 30) 3rd ring gear (Number of internal teeth: 76) 2nd sun gear (Number of teeth: 33) 1st planetary pinion (Number of teeth: 18) 1st sun gear (Number of teeth: 39) 19. 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
D65EX, PX-15
10-21
(7)
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 Number of plates 6 Number of discs 5 7 4 4 3
*1 *2 *1 *2 *1 *2 *1 *2
6 8 3 5 3 5 2 4
*1. D65EX-15 D65PX-15 *2. D65EX-15 D65PX-15 D65WX-15
Serial No. : 67001- 67136 Serial No. : 67001- 67135 Serial No. : 67137 and up Serial No. : 67136 and up Serial No. : 67001 and up
Gear speeds and operated clutches

Gear speed Forward 1st Forward 2nd Forward 3rd Neutral Reverse 1st Reverse 2nd Reverse 3rd Operated clutches F x 1st F x 2nd F x 3rd Reduction ratio 1.948 1.096 0.656 1.462 0.823 0.492
*
R x 1st R x 2nd R x 3rd
*:
The 1st, 2nd, or 3rd clutch is filled with low-pressure oil.
10-22
(7)
D65EX, PX-15
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)
TRANSMISSION
Unit: mm No. Check item

Standard size
Criteria
Repair limit Free length 65.3 72.4 55.5 55.5 55.5
Installed load
Remedy
1 R clutch spring (5 pcs.)
Free length Installed length Installed load 69.5 58.7 63.6 44.1 44.5 44.3 233.2 N {23.8 kg} 95.2 N {9.7 kg} 146.0 N {14.9 kg} 142.1 N {14.5 kg} 144.1 N {14.7 kg} Tolerance 0.33 0.36 0.39 0.26 0.30 0.26 0.30 0.22 0.26 0.1 0.1 0.01 0.03 0.10 0.11 0.30 0.11 0.29 0.12 0.33 0.14 0.44 0.14 0.38 0.14 0.39
198 N {20.2 kg} 81 N {8.2 kg} 125 N {12.7 kg} 121 N {12.3 kg} 123 N {12.5 kg}
2 F clutch spring (5 pcs.) 3 3rd clutch spring (5 pcs.) 4 2nd clutch spring (5 pcs.) 5 1st clutch spring (5 pcs.)
of 6 Total thicknessandassembled 5 R clutch discs 6 plates
77.0 59.0 59.0 59.0 Standard size 36.2
Repair limit 32.2 37.4 43.8 20.0 26.4 20.0 26.4 14.2 20.6 2.6 2.9 2.70 2.15
of assembled 7 Total thicknessand 6 plates 7 F clutch discs
*1 *2 *1 *2 *1 *2 *1 *2
43.0 49.4 23.2 29.6 23.2 29.6 16.6 23.0 3.4 3.2
8 Total thickness of assembled 4 3rd clutch discs and 3 plates
thickness of assembled 9 Totalclutch discs and 3 plates4 2nd
Replace
10 Total thickness of assembled 3 1st clutch discs and 2 plates 11 Thickness of clutch disc 12 Thickness of clutch plate 13 Wear of seal ring of transmission input shaft
between R/F/2nd/1st 14 Backlash and planetary pinion sun gear
Width Thickness
3.0 2.3
15 Backlash between 3rd sun gear and planetary pinion 16 Backlash between planetary pinion and internal teeth of ring gear
carrier 17 Backlash between Rgear and internal teeth of ring carrier 18 Backlash between F gear and internal teeth of ring
19 Backlash between 1st carrier and internal teeth of ring gear
*1. D65EX-15 D65PX-15 *2. D65EX-15 D65PX-15 D65WX-15
Serial No. : 67001- 67136 Serial No. : 67001- 67135 Serial No. : 67137 and up Serial No. : 67136 and up Serial No. : 67001 and up
10-24
(7)
D65EX, PX-15
TRANSMISSION
Disc clutch Structure 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). Clutch OFF (Released) 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) 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. Oil passage in speed clutch 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.
D65EX, PX-15
10-25
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).
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).
10-26
D65EX, PX-15
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).
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).
D65EX, PX-15
10-27
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).
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).
10-28
D65EX, PX-15
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).
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
10-29
TRANSMISSION ECMV
TRANSMISSION ECMV
a ECMV: Abbreviation for Electronic Control Modulation Valve
10-30
D65EX, PX-15
TRANSMISSION ECMV
P: PF: PR: P1: P2: P3: CF: CR: C1: C2: C3: SDF: SDR: SD1: SD2: SD3: Dr:
From power train pump F clutch oil pressure pickup port R clutch oil pressure pickup port 1st clutch oil pressure pickup port 2nd clutch oil pressure pickup port 3rd clutch oil pressure pickup port To F clutch To R clutch To 1st clutch To 2nd clutch To 3rd clutch F fill switch drain R fill switch drain 1st fill switch drain 2nd fill switch drain 3rd fill switch drain Drain
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Fill switch (For 1st clutch) Fill switch (For R clutch) Fill switch (For F clutch) Fill switch (For 3rd clutch) Fill switch (For 2nd clutch) Proportional solenoid (For 3rd clutch) Proportional solenoid (For 1st clutch) Proportional solenoid (For R clutch) Proportional solenoid (For F clutch) Proportional solenoid (For 2nd clutch) Fill switch connector (For 1st clutch) Fill switch connector (For R clutch) Fill switch connector (For F clutch) Fill switch connector (For 3rd clutch) Fill switch connector (For 2nd clutch) Proportional solenoid connector (For 1st clutch) Proportional solenoid connector (For 3rd clutch) Proportional solenoid connector (For R clutch) Proportional solenoid connector (For 2nd clutch) Proportional solenoid connector (For F clutch) Filter
D65EX, PX-15
10-31
TRANSMISSION ECMV
1. 2. 3. 4. 5. 6. 7.
Fill switch Valve body (Upper) Pressure control valve Valve body (Lower) Proportional solenoid Oil pressure detection valve Plug
10-32
D65EX, PX-15
TRANSMISSION ECMV
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
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).
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.
D65EX, PX-15
10-33
(7)
TRANSMISSION ECMV
ECMV operation The ECMV is controlled with the command current sent from the controller to the proportional solenoid and the output signal of the fill switch. 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
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
TRANSMISSION ECMV
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".
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).
D65EX, PX-15
10-35
(7)
MAIN RELIEF VALVE
MAIN RELIEF VALVE

Main relief, torque converter relief valve
PP: TC: drT: dr1: dr2: P1: P8:
From pump To torque converter Drain port (for torque converter relief) Drain port Drain port Main relief oil pressure detection port Torque converter relief oil pressure detection port
1. 2. 3. 4. 5.
Body Piston Torque converter relief valve Piston Main relief valve
Unit: mm No. Check item Standard size 28 22 Criteria Tolerance Shaft 0.035 0.045 0.035 0.045 Standard size 8 Main relief valve spring (outer) Free length 128 9 Main relief valve spring (inner) 10 Torque converter relief valve spring 108 50
Installed length Installed load
Remedy Standard clearance 0.035 0.058 0.035 0.058 Free length 124.2 104.8 48.5 Clearance limit 0.078 0.078 Replace
Clearance between main relief 6 valve and valve body Clearance between torque converter relief valve and valve body
Hole +0.013 0 +0.013 0
Repair limit
Installed load
75.3 75.3 42
508.6 N {51.9 kg} 401.8 N {41.0 kg} 153.0 N {15.6 kg}
483.2 N {49.3 kg} 382.5 N {39.0 kg} 145.1 N {14.8 kg}
10-36
D65EX, PX-15
MAIN RELIEF VALVE
Outline Torque converter relief valve The torque converter relief valve protects the torque converter from abnormally high pressure by keeping the oil pressure in the torque converter inlet port circuit below the set pressure. Set pressure: 0.83 MPa {8.5 kg/cm2} (Cracking pressure) Main relief valve The main relief valve holds the oil pressure in the transmission and brake at the set pressure. Set pressure: 3.31 MPa {33.8 kg/cm2} (Engine at rated speed)
Operation of main relief valve The oil from the hydraulic pump passes through the filter and enters port A of the relief valve. 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.
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)
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)
D65EX, PX-15
10-37
LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
2. Piston 3. Spring 4. Forward clutch housing A: From oil cooler B: Drain C: Drain
Outline The oil leaving the torque converter passes through the oil cooler built in the radiator lower tank. 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 Normal pressure (MPa {kg/cm }) Cracking pressure (MPa {kg/cm2})
2
0.05 0.15 {0.5 1.5} 0.29 {3.0} Unit: mm
No.
Check item Standard size
Criteria Repair limit

Installed load
Remedy
1 Lubrication relief valve spring
Free length 26
Installed length
Free length 25.2
Installed load
Replace
23.7
12.0 N {1.22 kg}
11.4 N {1.16 kg}
10-38
D65EX, PX-15
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) Gear pump 61.2 0.29 {3.0} 2,500
D65EX, PX-15
10-39
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 Type 3 Side clearance Clearance between inside of plain bearing and outside of gear shaft SAL (2) 45 SAL (2) 45 Type 5 Driving depth of pin 6 Rotating torque of spline Discharge Oil: SAE10W Oil temperature: 45 55C Type SAL (2) 45 SAL (2) 45 Criteria Standard clearance 0.10 0.15 0.060 0.125 Standard size 12 Tolerance 0 0.5 Clearance limit 0.19 0.20 Repair limit Replace Remedy
5.8 13.8 Nm {0.6 1.4 kgm} Speed (rpm) 3,000

Discharge pressure (MPa {kg/cm2}) Standard discharge (l/min) Allowable discharge (l/min)
2.94 {30}
126
115
10-40
D65EX, PX-15
HSS SYSTEM
HSS SYSTEM
a HSS: Abbreviation for Hydrostatic Steering System
D65EX, PX-15
10-41
HSS SYSTEM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Steering/directional/gear shift lever (PCCS lever) Transmission and steering controller Engine controller Control valve EPC valve HSS pump Servo valve HSS motor HSS circuit Engine Final drive Sprocket Hydraulic tank
Outline The HSS system consists of control valve (4), HSS 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).
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
D65EX, PX-15
HYDRAULIC, HSS PUMP
HYDRAULIC, HSS PUMP

HPV95
Outline This pump consists of a variable displacement swash plate type piston pump and LS valve.
PA: PS: PD1: PD2: PLS1: PEN12:
Pump discharge port Pump suction port Pump drain plug Pump drain Load pressure inlet port Control pressure detection plug
Specification Model: Theoretical displacement capacity: Rated speed: Max. cut off pressure: HPV95 (112 cm3/rev) 112 1 cm3/rev 2,280 rpm 41.2 MPa {420 kg/cm2}
1. Piston pump 2. Servo valve
D65EX, PX-15
10-43
HYDRAULIC, HSS PUMP
PISTON PUMP
PA: PS: PA1: PD2: PNC1:
Pump discharge port Pump suction port Pump pressure signal port Pump drain Control pressure port
10-44
D65EX, PX-15
HYDRAULIC, HSS PUMP
1. 2. 3. 4. 5. 6. 7.
Shaft Case Cradle Rocker cam Shoe Servo piston Rod
8. 9. 10. 11. 12. 13.
Piston Cylinder block Valve plate End cap Impeller Spline
D65EX, PX-15
10-45
HYDRAULIC, HSS PUMP
Outline The engine rotation and torque transmitted to the pump shaft is converted to hydraulic energy and pressurized oil is discharged according to the load. 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.
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.
10-46
D65EX, PX-15
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 pumpings 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
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
HYDRAULIC, HSS PUMP
SERVO VALVE
PT: PA1: PLS1: PEN11: PEN12:
Drain port Pump self pressure port Load pressure input port Control pressure port Control pressure detection port
D65EX, PX-15
10-49
HYDRAULIC, HSS PUMP
LS VALVE 1. 2. 3. 4. 5. 6. 7. Locknut Plug Spring Spool Sleeve Piston Plug
TCC VALVE 8. 9. 10. 11. 12. 13. 14. 15. Plate Piston Sleeve Spring Spring Piston Lever Valve body
VARIABLE THROTTLE VALVE 16. 17. 18. 19. 20. 21. 22. Screw Locknut Spring Seat Spool Block Plug
10-50
D65EX, PX-15
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.
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.
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
10-51
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.
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).
10-52
D65EX, PX-15
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.)
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.
D65EX, PX-15
10-53
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.
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.
10-54
D65EX, PX-15
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.)
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}.
D65EX, PX-15
10-55
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).
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.
10-56
D65EX, PX-15
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
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.
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.
10-58
D65EX, PX-15
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
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.
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.
10-60
D65EX, PX-15
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
Specifications Model: Theoretical displacement: Rated output pressure: Rated speed: HMF95 96.0 cc/rev 38.2 MPa {390 kg/cm2} 2,430 rpm
PA: From control valve PB: From control valve T2: To hydraulic tank
D65EX, PX-15
10-61
HSS MOTOR
1. 2. 3. 4. 5. 6. 7. 8. 9.
Output shaft Motor case Swash plate Piston Cylinde Valve plate End cover Brake valve assembly Spool return spring
10. 11. 12. 13. 14. 15. 16. 17.
Counterbalance valve Safety valve Check valve Check valve spring Sub bearing Spline Shoe Main bearing
Unit: mm No. Check item Standard size 18 Spool return spring

Free length x OD Installed length Installed load
Criteria Repair limit Free length

Installed load
Remedy
42.7 x 30.0 19 Check valve spring 43 x 13.8
40.5 32.9
192 N {19.6 kg} 1.27 N {0.13 kg}
154 N {15.7 kg} 0.98 N {0.10 kg}
Replace spring if damaged or deformed
10-62
D65EX, PX-15
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
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. 19. 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
HSS MOTOR
OPERATION OF BRAKE VALVE 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.
1. Counterbalance valve, check valve Function When operation the steering on slopes, the weight on the machine produces a force in the downward direction which makes the machine try to turn faster than the speed of the HSS motor. 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 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.
D65EX, PX-15
10-65
HSS MOTOR
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.
Action of brakes when oprating steering on downhill slopes 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.
10-66
D65EX, PX-15
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
BEVEL GEAR SHAFT, HSS, BRAKE

a HSS: Abbreviation for Hydrostatic Steering System
10-68
D65EX, PX-15
D65EX, PX-15
10-69
10-70
D65EX, PX-15
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
Brake valve HSS motor Output shaft Brake spring (Large) Brake spring (Small) Spacer Hub Cage Piston Cover Plate (4 pieces on 1 side) Disc (5 pieces on 1 side) Brake drum Brake hub Gear A (Number of teeth: 38/55 Cage Gear B (Number of teeth: 32) Bevel gear shaft Bevel gear (Number of teeth: 35) Bearing Shaft Gear C (Number of teeth: 32) Planetary pinion (Number of teeth: 26) Ring gear (Number of teeth: 91) Pinion shaft Hub Carrier Gear D shaft Gear D (Number of teeth: 48) HSS motor drive gear (Number of teeth: 25) Bevel pinion (Number of teeth: 23) Cage
D65EX, PX-15
10-71
10-72
D65EX, PX-15
Unit: mm No. Check item Standard size 1 Brake plate

Thickness
Criteria Tolerance 0.1 Max. 0.15 0.1 Max. 0.25 0.3 Repair limit 4.7 0.3 4.7 0.4 43.3 Clearance limit
Remedy
5.0 5.2 46.0 Standard clearance
Replace
Distortion
Repair or replace Replace Repair or replace
Thickness
2 Brake disc
Distortion
Total thickness of assembled 4 brake plates and 5 discs
4 Backlash between gear A and gear B Backlash between gear A and 5 planetary pinion 6 7 Backlash between planetary pinion and ring gear Preload on bevel gear shaft tapered roller bearing
0.06 0.65 0.14 0.35 0.15 0.38
Replace
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}.
Adjust
D65EX, PX-15
10-73
10-74
D65EX, PX-15
Unit: mm No. Check item Backlash between gear A and gear D Backlash between gear C and gear D Backlash between gear D and HSS motor drive gear Backlash between bevel pinion and bevel gear Standard clearance 0.09 0.64 0.15 0.49 0.10 0.40 0.20 0.28 Criteria Clearance limit Adjust Replace Remedy
2 3 4
D65EX, PX-15
10-75
Outline Bevel gear shaft 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). Brake 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.
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
D65EX, PX-15
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 Direction changing operation of PCCS lever Turning direction of HSS motor seen from left of chassis
Neutral
Turning to right
Turning to left
Any
Neutral
Forward Reverse
Neutral
Forward Reverse
Stopped
Left
Left
Right
Right
Right
Left
: Pivot turn
D65EX, PX-15
10-77
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.
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.
10-78
D65EX, PX-15
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.
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.
D65EX, PX-15
10-79
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.
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.
10-80
D65EX, PX-15
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.
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.
D65EX, PX-15
10-81
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.
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.
10-82
D65EX, PX-15
BRAKE VALVE
BRAKE VALVE
P: T1: T2: Br (R): Br (L): 1. 2. 3. 4. 5. 6.
From power train pump To steering case To steering case To right brake To left brake
Outline The brake valve is in the circuit between the power train pump and the brake piston in the HSS unit and installed to the top of the HSS unit. 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.
Parking brake valve Body Main brake valve Piston Shaft Guide
D65EX, PX-15
10-83
BRAKE VALVE
Unit: mm No. Check item Standard size 19 2 3 Clearance between brake valve and piston Clearance between parking brake valve and body 9 19 Criteria Tolerance Shaft 0.020 0.030 0.030 0.040 0.034 0.043 Standard size 4 Brake modulating spring Free length 48 5 Brake valve return spring 6 Parking brake valve return spring 52 36.5
Remedy Standard clearance 0.020 0.043 0.030 0.055 0.034 0.056 Free length 46.6 50.4 35.4 Clearance limit 0.07 0.08 0.08 Replace
Clearance between brake valve 1 and body
Hole +0.013 0 +0.015 0 +0.013 0
Repair limit
Installed load
36 38 28.5
75.3 N {7.68 kg} 157.9 N {16.11 kg} 16.7 N {1.7 kg}
71.6 N {7.3 kg} 150 N {15.3 kg} 15.7 N {1.6 kg}
10-84
D65EX, PX-15
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
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.
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.
10-86
D65EX, PX-15
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
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
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
9. 10. 11. 12. 13. 14. 15.
1st pinion (Number of teeth: 21) 1st pinion (Number of teeth: 78) Sprocket hub Sprocket teeth Hub Planetary pinion (Number of teeth: 27) Pinion shaft
D65EX, PX-15
10-89
FINAL DRIVE
a The following drawing shows D65EX-15.
10-90
D65EX, PX-15
FINAL DRIVE
Unit: mm No. Check item Backlash between 1st pinion and 1st gear Backlash between pinion and planetary pinion Backlash between planetary pinion and ring gear Outside diameter of oil seal contact surface of 1st pinion (Large) Outside diameter of oil seal contact surface of 1st pinion (Small) Standard clearance 0.23 0.61 0.18 0.45 0.23 0.67 Standard size 80 70 Standard size 56 7 8 Axial clearance of 1st pinion bearing Standard shim thickness of 1st pinion bearing cage Projection of ball from 1st pinion cover
Standard bushing type Rotary bushing type
Criteria Clearance limit 1.0 1.0 1.0 Tolerance 0 0.074 0 0.074 Tolerance Shaft +0.051 +0.032 Hole +0.030 0 0 0.1 Repair limit 79.9 69.9 Standard interference 0.002 0.051
Interference limit
Remedy
2 3 4 5
Replace
Interference between pinion shaft 6 and carrier
0.002
Adjust 1.5 Standard size 5.2 317 317 Repair limit 1.5 299 301 Replace
Wear of sprocket 10 tooth surface
Repair by buildup welding or replace
D65EX, PX-15
10-91
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).
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).
10-92
D65EX, PX-15
FRAME ASSEMBLY
FRAME ASSEMBLY
D65EX, PX-15
10-93
FRAME ASSEMBLY
Unit: mm No. Check item Standard size 85 2 Clearance between cylinder yoke and bushing (Small) 65 Criteria Tolerance Shaft 0.036 0.090 0.030 0.076 Hole +0.207 +0.120 +0.174 +0.100 Standard clearance 0.156 0.297 0.130 0.250 Clearance limit 0.5 0.5 Replace bushing Remedy
Clearance between cylinder yoke 1 and bushing (Large)
3. 4. 5. 6.
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
SUSPENSION
SUSPENSION
D65EX-15 D65EX-15 (Long track specification)
D65EX, PX-15
10-95
(7)
SUSPENSION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Equalizer bar Center pin Side pin Pivot shaft Bushing Seal Seal Bushing Bushing (Large) Plug (Oil filler) Bushing (Small) Cover Seal
Outline The track frame moves the front part of the track frame up and down around pivot shaft (4) in its rear. 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 Downward 72.6 72.6
10-96
(7)
D65EX, PX-15
SUSPENSION
Unit: mm No. Check item Standard size 148 105 70 60 Criteria Tolerance Shaft 0.045 0.208 0.120 0.174 0.100 0.146 0.100 0.146 Hole +0.063 0 +0.054 0 +0.174 +0.100 +0.010 0.020 Standard clearance 0.145 0.271 0.120 0.228 0.200 0.320 0.080 0.156 Clearance limit 1.0 1.0 0.5 0.5 Replace bushing Remedy
Clearance between pivot shaft 14 and bushing (Large) Clearance between pivot shaft and bushing (Small) Clearance between center pin and bushing Clearance between side pin and bushing Press fitting force of pivot shaft bushing (Large) Press fitting force of pivot shaft bushing (Small) Quantity of oil in pivot shaft section
15 16 17 18 19
0.98 22.6 kN {0.1 2.3 ton} 0.98 36.3 kN {0.1 3.7 ton} 4.5 l (Engine oil: SAE30)
D65EX, PX-15
10-97
SUSPENSION
D65PX-15 D65EX-15 (Wide gauge specification) D65WX-15
10-98
(7)
D65EX, PX-15
SUSPENSION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Equalizer bar Center pin Side pin Pivot shaft Bushing Seal Seal Bushing Bushing (Large) Plug (Oil filler) Bushing (Small) Cover Seal
Outline The track frame moves the front part of the track frame up and down around pivot shaft (4) in its rear. 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 Downward 81.9 81.9
D65EX, PX-15
10-99
(7)
SUSPENSION
Unit: mm No. Check item Standard size 148 105 70 60 Criteria Tolerance Shaft 0.045 0.208 0.120 0.174 0.100 0.146 0.100 0.146 Hole +0.063 0 +0.054 0 +0.174 +0.100 +0.010 0.020 Standard clearance 0.145 0.271 0.120 0.228 0.200 0.320 0.080 0.156 Clearance limit 1.0 1.0 0.5 0.5 Replace bushing Remedy
Clearance between pivot shaft 14 and bushing (Large) Clearance between pivot shaft and bushing (Small) Clearance between center pin and bushing Clearance between side pin and bushing Press fitting force of pivot shaft bushing (Large) Press fitting force of pivot shaft bushing (Small) Quantity of oil in pivot shaft section
15 16 17 18 19
0.98 22.6 kN {0.1 2.3 ton} 0.98 36.3 kN {0.1 3.7 ton} 4.5 l (Engine oil: SAE30)
10-100
D65EX, PX-15
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
10. 11. 12. 13. 14. 15. 16. 17. 18.
Recoil spring Wear ring U-packing Cabin Nut Lubricator Cylinder Bushing Holder
D65EX, PX-15
10-101
(7)
Unit: mm No. Check item Item 19 Deformation of track frame Bend Twist Opening of idler Standard size 20 Recoil spring
Free length x Outside diameter
Criteria Repair limit 7 (in length of 3,000) 3 (in length of 300) 5 Repair limit
Installed load
Remedy
Repair
Installed length
Free length 772 Standard clearance 0.100 0.360
Installed load
Replace
791.5 x 239
634
189.5 kN {19,320 kg} Hole +0.270 +0.061
168.6 kN {17,195 kg} Clearance limit 1.0 Adjust
Clearance between piston and 21 bushing
Standard size 90
Tolerance Shaft 0.039 0.090
Replace bushing
22 Press fitting force of idler yoke Quantity of grease
392 kN {40 ton} 140 cc (Grease: G2-LI)
Outline Recoil spring (10) is used to adjust the track shoe tension by supplying grease through lubricator (15) or discharge existing grease and moving piston (9) forward or in reverse. It also damps sudden shocks applied to idler (1).
Qty on each side D65EX-15 D65EX-15 (Wide gauge specification) D65WX-15 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
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
10. 11. 12. 13. 14. 15. 16. 17. 18.
Recoil spring Wear ring U-packing Cabin Nut Lubricator Cylinder Bushing Holder
D65EX, PX-15
10-103
Unit: mm No. Check item Item 19 Deformation of track frame Bend Twist Opening of idler Standard size 20 Recoil spring
Criteria Repair limit 7 (in length of 3,000) 3 (in length of 300) 5 Repair limit
Installed load
Remedy
Repair
Installed length
Free length 772 Standard clearance 0.100 0.360
Installed load
Replace
791.5 x 239
634
189.5 kN {19,320 kg} Hole +0.270 +0.061
168.6 kN {17,195 kg} Clearance limit 1.0 Adjust
Clearance between piston and 21 bushing
Standard size 90
Tolerance Shaft 0.039 0.090
Replace bushing
22 Press fitting force of idler yoke Quantity of grease
392 kN {40 ton} 140 cc (Grease: G2-LI)
Outline Recoil spring (10) is used to adjust the track shoe tension by supplying grease through lubricator (15) or discharge existing grease and moving piston (9) forward or in reverse. It also damps sudden shocks applied to idler (1).
Qty on each side D65PX-15 D65EX-15 (Long track specification)
Flange type and arrangement S, S, D, S, S, D, S, S
8 pcs.
S: Single flange W: Double flange
10-104
D65EX, PX-15
IDLER
IDLER
D65EX, PX-15
10-105
IDLER
Unit: mm No. Check item Standard size 1 Outside diameter of projection 630 590 20 15 44.5 190 Standard size 65 8 Clearance between shaft and support 64.7 Tolerance Shaft 0.250 0.350 0.250 0.350 Hole +0.142 0.008 +0.090 0 Standard clearance 0.242 0.492 0.250 0.440 Criteria Repair limit 570 30 5 48.5 Clearance limit Replace Repair by buildup welding or replace Remedy
2 Outside diameter of tread 3 Depth of tread 4 Thickness of tread 5 Width of tread 6 Overall width
Clearance between shaft and 7 bushing
Standard clearance 9 Axial play of shaft Clearance between guide plate and support Clearance between guide plate and side plate 0.26 0.66 2.0 1.0 4.0
Clearance limit Repair by buildup welding or replace Adjust shim or replace plate
10 11
Standard shim thickness at side 12 plate fitting part
10-106
D65EX, PX-15
TRACK ROLLER
TRACK ROLLER
a The following drawing shows the double-flange type.
Unit: mm No. Check item Outside diameter of flange (outside) Outside diameter of flange (inside) Standard size 240 236 210 69 19.5 19.5 47 47.7 235 Standard size 65 11 Clearance between shaft and collar 64.7 Tolerance Shaft 0.250 0.350 0.250 0.350 Hole +0.143 0.007 0.100 0.150 Standard clearance 0.243 0.493 0.100 0.250 Criteria Repair limit 174 51 13.5 13.5 Clearance limit Replace Remedy
3 Outside diameter of tread 4 Thickness of tread 5 Width of flange (outside) 6 Width of flange (inside) 7 8 Width of tread (Single-flange type) Width of tread (Double-flange type)
Repair by buildup welding or replace
9 Overall width
Clearance between shaft and 10 bushing
Standard clearance 12 Axial play of roller 0.26 0.66
Clearance limit
D65EX, PX-15
10-107
CARRIER ROLLER
CARRIER ROLLER
Unit: mm No. Check item Standard size 1 Outside diameter of flange 215 185 37.5 49.5 21 Standard size 61 Standard size 61.5 8 Play in axial direction of shaft Tolerance Shaft 0.100 0.200 Shaft +0.150 +0.130 Hole +0.300 0 Hole +0.030 0 Standard clearance 0.100 0.500 Standard interference 0.100 0.150 Criteria Repair limit 163 26.5 55.5 15 Clearance limit
Interference limit
Remedy
2 Outside diameter of tread 3 Thickness of tread 4 Width of tread 5 Width of flange
Rebuild or replace
Clearance between shaft and 6 support
Tolerance
Interference between shaft and 7 seal guard
Replace
Standard clearance 0 0.22
Clearance limit
10-108
D65EX, PX-15
SPROCKET
SPROCKET
Unit: mm No. Check item Standard size 1 Wear of tooth root 2 Thickness of tooth root 87 26 Criteria Repair limit 77 17 Rebuild or replace Remedy
D65EX, PX-15
10-109
(7)
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
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)
TRACK SHOE
Unit: mm No. 1 Link pitch Check item Standard size 203.45 Standard size 2 Outside diameter of bushing 73 3 Thickness of bushing 4 Height of link 5 Thickness of link (Bushing fitting part) a. Regular link 6 Shoe bolt b. Master link 13.9 Standard size 132 44.8 Tightening torque (Nm {kgm}) 539 49 {55 5} Tightening torque (Nm {kgm}) 343 39 {35 4} Standard size 66.5 44.4 Standard size 44.6
Retightening angle (deg.)
Criteria Repair limit 206.45 Turning over Light load 62.8 3.7 Repair limit 119.5 32.3 Retightening angle (deg.) 120 10 Lower limit of torque (Nm {kgm}) 784 {80} Standard interference 0.230 0.404 0.199 0.411 Standard clearance 0.180 0.830 Heavy load 65.4 6.3
Remedy
Turn over or replace
Repair or replace Replace
Retighten
180 (0/20) Tolerance Shaft +0.404 +0.304 +0.435 +0.285 Shaft +0.235 +0.085 Hole +0.074 0 +0.086 +0.024 Hole +0.915 +0.415
Interference between bushing 7 and link Interference between regular pin and link
Adjust or replace
Tolerance
Interference between regular pin 9 and bushing
10-114
D65EX, PX-15
TRACK SHOE
Single shoe
Unit: mm No. Check item Standard size 1 Height of grouser 2 Thickness of grouser 65 77 Criteria Repair limit 25 37 Repair by buildup welding or replace Remedy
Swamp shoe
Unit: mm No. Check item Standard size 1 Height of grouser 2 Thickness of grouser 109.5 20 Criteria Repair limit 94.5 5 Repair by buildup welding or replace Remedy
D65EX, PX-15
10-117
(5)
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
10-118
D65EX, PX-15
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
WORK EQUIPMENT CONTROL
10-120
D65EX, PX-15
1. 2. 3. 4. 5. 6.
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)
HYDRAULIC TANK
HYDRAULIC TANK
10-122
D65EX, PX-15
HYDRAULIC TANK
1. 2. 3. 4. 5. 6. 7.
Oil filler cap Hydraulic tank Element Bypass valve Strainer Drain plug Sight gauge
Specifications
Tank capacity (l) Quantity of oil in tank (l) Set pressure of bypass valve (MPa {kg/cm2}) Cracking pressure of pressure valve (kPa {kg/cm2}) Actuating pressure of vacuum valve (kPa {kg/cm2}) 80 55 0.15 0.03 {1.5 0.3} 38 14 {0.39 0.15} 0 4.5 {0 0.046}
D65EX, PX-15
10-123
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: Quantity of gas: Charged gas pressure: Max. using pressure: Nitrogen gas 300 cc 1.18 MPa {12 kg/cm2} (at 80C) 6.86 MPa {70 kg/cm2}
10-124
D65EX, PX-15
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 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.
D65EX, PX-15
10-125
(7)
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
HYDRAULIC CYLINDER
RIPPER LIFT CYLINDER

D65EX-15 D65WX-15
*1. D65EX-15 (Serial No. : 67001- 67322)

Unit: mm No. Check item
Cylinder name
Criteria Standard size 65 70 70 S 85

S 90 (Shaft) S 91 (Hole)
Remedy Standard clearance 0.097 0.366 0.105 0.375 0.105 0.375 0.2 0.5 0.2 0.5 0.130 0.250 0.100 0.290 0.280 0.542 0.130 0.250 Clearance limit 0.666 0.675 0.675 1.0 2.0 1.0 1.0 1.0 1.0 Replace bushing Adjust shim or replace Replace bushing
Tolerance Shaft 0.030 0.104 0.025 0.064 0.025 0.087 0.2 0.3 0.1 0.3 0.030 0.076 0.100 0.174 0.200 0.400 0.030 0.076 Hole +0.262 +0.067 +0.271 +0.075 +0.271 +0.075 +0.3 0 +1.0 0 +0.174 +0.100 +0.116 0 +0.142 +0.080 +0.174 +0.100
Clearance between piston rod 1 and bushing
Lift Tilt Pitch Ripper
Spherical clearance between piston rod and trunnion Spherical clearance between 2 piston rod and bracket Clearance between piston rod support shaft and bushing Clearance between cylinder boss and bushing 3 Clearance between cylinder bottom support shaft and bushing Tightening torque of cylinder head 4 Tightening torque of cylinder head mounting bolt
Lift Tilt Pitch Ripper Lift Tilt Pitch Ripper Lift Tilt Pitch Ripper Lift
75 55 50 75
735 74.0 Nm {75.0 7.5 kgm} 162 14.7 Nm {16.5 1.5 kgm} 162 14.7 Nm {16.5 1.5 kgm} Retighten 1.08 0.11 kNm {110 11.0 kgm} (Width across flats: 50 mm) 3.97 0.40 kNm {405 40.5 kgm} (Width across flats: 80 mm) 3.97 0.40 kNm {405 40.5 kgm} (Width across flats: 80 mm)
Tightening torque of cylinder piston clamping nut
Tilt Pitch Ripper
D65EX, PX-15
10-127
(7)
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.
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.
10-128
D65EX, PX-15
QUICK DROP VALVE
QUICK DROP VALVE

(Blade lift cylinder)
Unit: mm No. Check item Standard size 33 2 Clearance between piston and plug 25 Criteria Tolerance Shaft 0.034 0.050 0.039 0.054 Standard size 3 Valve spring Free length 108.3 4 Piston spring 27.3
Remedy Standard clearance 0.034 0.075 0.039 0.075 Free length 97.5 24.6 Clearance limit 0.080 0.080 Replace
Clearance between valve and 1 body
Hole +0.025 0 +0.021 0
Repair limit
Installed load
26 26
88.2 N {9.0 kg} 4.6 N {0.47 kg}
79.4 N {8.1 kg} 4.1 N {0.42 kg}
5. 6. 7. 8.
Body Valve Piston Plug
VH: VB: CH2: CB1: CB2:
From control valve, blade LOWER From control valve, blade RAISE To both blade lift cylinder heads To left blade lift cylinder bottom To right blade lift cylinder bottom
D65EX, PX-15
10-129
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.
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.
10-130
D65EX, PX-15
COOLING FAN PUMP
COOLING FAN PUMP

LPV30
P1: Pump discharge pressure PS: Pump suction TO: Drain
T1: Drain plug PEPC: EPC valve main pressure PCEPC: EPC valve output pressure detection plug
D65EX, PX-15
10-131
COOLING FAN PUMP
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Shaft Oil seal Case Rocker cam Shoe Piston Cylinder block Valve plate Spring Servo piston
10-132
D65EX, PX-15
COOLING FAN PUMP
Function The rotation and torque of the engine are transmitted to the shaft of this pump and converted into hydraulic energy in this pump. 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.
Structure Cylinder block (7) is supported on shaft (1) through spline a. Shaft (1) is supported by the front and rear bearings.
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).
D65EX, PX-15
10-133
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.) 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.
10-134
D65EX, PX-15
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
COOLING FAN PUMP
SERBO VALVE
P: T: PE: PH: 1. 2. 3. 4. 5. 6. 7.
EPC valve main pressure Drain Control piston pressure Pump discharge pressure Plug Lever Retainer Seat Spool Piston Sleeve
10-136
D65EX, PX-15
COOLING FAN PUMP
A: Drain side B: Pump discharge pressure input side
C: EPC output pressure received D: EPC output pressure
D65EX, PX-15
10-137
COOLING FAN PUMP
Function The servo valve controls the current input to the EPC valve and the swash plate angle of the pump so that they will be related as shown in the figure.
Operation The output pressure of the EPC valve is applied to the piston chamber to push the piston. Piston (6) pushes spool (5) until it is balanced with the spring. 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.
The relationship between the input current to the EPC valve and the output pressure of the EPC valve is as follows.
10-138
D65EX, PX-15
COOLING FAN MOTOR
COOLING FAN MOTOR

LMF28
P: From fan pump T: From oil cooler to hydraulic tank TC: To hydraulic tank
Specifications Model: LMF28 Capacity: 28 cc/rev Rated speed: 1,850 rpm Rated flow rate: 51.8 l/min Cracking pressure of check valve: 44.1 kPa {0.45 kg/cm2}
D65EX, PX-15
10-139
COOLING FAN MOTOR
1. 2. 3. 4. 5. 6. 7.
Output shaft Case Thrust plate Piston assembly Cylinder block Valve plate End cover
8. 9. 10. 11. 12. 13. 14.
Center spring Check valve spring Check valve Pilot valve Reversible valve spool Reversible valve spring Safety valve
Unit: mm
No.
Criteria Repair limit Installed load 3.43 N {0.35 kg} Free length Installed load 2.55 N {0.26 kg}
Remedy
9 Check valve spring
Installed length 7.0
If damaged or deformed, replace spring
13.0 x 6.5
10-140
D65EX, PX-15
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)
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. (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.
Operation (1) When pump is started If the hydraulic oil from the pump is supplied to port P and the pressure on the MA side rises and starting torque is generated in the motor, 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
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). (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).
D65EX, PX-15
10-143
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
PPC VALVE
PPC VALVE
FOR BLADE LIFT, BLADE TILT
a PPC: Abbreviation for Proportional Pressure Control
P: From self pressure reducing valve T: To hydraulic tank
P1: P2: P3: P4:
To blade lift valve port PA3 To blade lift valve port PB3 To blade tilt valve port PA2 To blade tilt valve port PB2
D65EX, PX-15
10-145
PPC VALVE
1. Disc 2. Plate 3. Body
10-146
D65EX, PX-15
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). 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).
D65EX, PX-15
10-147
PPC VALVE
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.
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.
10-148
D65EX, PX-15
PPC VALVE
4. When lever is operated fully 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.
5. When blade is operated to FLOAT 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.
D65EX, PX-15
10-149
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
PPC VALVE
FOR RIPPER
T: P: P1: P2:
To hydraulic tank From self pressure reducing valve To ripper spool (To control valve port PB4) To ripper spool (To control valve port PA4)
1. 2. 3. 4. 5. 6. 7. 8.
Spool Metering spring Centering spring Piston Lever Plate Retainer Body
D65EX, PX-15
10-151
PPC VALVE
Unit: mm No. Check item Standard size 9 Centering spring

Criteria Repair limit Installed load 125 N {12.7 kg} 16.7 N {1.70 kg} Free length Installed load 100 N {10.2 kg} 13.3 N {1.36 kg}
Remedy
Installed length 28.4 22.0
33.9 x 15.3 10 Metering spring 22.7 x 8.10
10-152
D65EX, PX-15
PPC VALVE
Operation 1. At neutral 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). 2. During fine control (Neutral o fine control) 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.
D65EX, PX-15
10-153
PPC VALVE
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.
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.
10-154
D65EX, PX-15
PCCS LEVER
PCCS LEVER
FOR STEERING
1. 2. 3. 4.
Boot Bracket Plate Bolt
5. Screw 6. Lever 7. Connector
D65EX, PX-15
10-155
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). (2) Operation for steering Free return (Operating effort characteristics chart B).
10-156
D65EX, PX-15
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
CONTROL VALVE
CONTROL VALVE
Outline This manual explains the 3-spool valve (Blade lift + Tilt + Steering) and 4-spool valve (Ripper + Blade lift + Tilt + Steering).
1. 3-spool valve P: T: A1: A2: A3: B1: B2: B3: LS: PC: PI: TS: PA1: PA2: PA3: PB1: PB2: PB3: PLSC: From pump To hydraulic tank To HSS motor To tilt cylinder bottom To lift cylinder head To HSS motor To tilt cylinder head To lift cylinder bottom To pump LS valve Pump pressure plug From self-pressure reducing valve To hydraulic tank Connector (From controller) From PPC valve From PPC valve Connector (From controller) From PPC valve From PPC valve LS pressure plug
1. EPC valve
10-158
D65EX, PX-15
CONTROL VALVE
D65EX, PX-15
10-159
CONTROL VALVE
1. 2. 3. 4. 5. 6. 7.
Cover Lift spool Tilt spool Steering spool Valve body Steering priority valve Load check valve
8. 9. 10. 11. 12. 13. 14.
Pressure compensation valve Main relief valve LS relief valve (for steering valve) Unload valve LS relief valve (for work equipment valve) LS check valve (for work equipment valve) LS check valve (for steering valve)
10-160
D65EX, PX-15
CONTROL VALVE
Unit: mm No. Check item Basic dimension 15 Spool return spring (for lift)
Criteria Allowable limit Installed load 224 N {22.8 kg} 140 N {14.3 kg} 217 N {22.1 kg} 12.7 N {1.3 kg} 216 N {22 kg} 216 N {22 kg} 216 N {22 kg} 235 N {24 kg} Free length Installed load 178 N {18.2 kg} 112 N {11.4 kg} 173 N {17.6 kg} 9.81 N {1.0 kg} 173 N {17.6 kg} 173 N {17.6 kg} 173 N {17.6 kg} 188 N {19.2 kg}
Remedy
Installed length 68.5 50 33.5 13.5 61.8 61.8 61.8 69.5
73.4 x 31 16 17 Spool return spring (tilt, steering) Spool return spring (for lift FLOAT) 51.7 x 31.3 54.7 x 36.5 20.8 x 10.2 70 x 26.5 70 x 26.5 70 x 26.5 94.8 x 30
18 Road check valve spring 19 20 21 Pressure compensation valve spring (steering valve) Pressure compensation valve spring (tilt valve) Pressure compensation valve spring (lift valve)
22 Unload valve spring
D65EX, PX-15
10-161
CONTROL VALVE
1. Suction valve 2. Preset check valve 3. LS bypass valve

Unit: mm No. Check item Standard size 4 Suction valve spring
Remedy
Installed length 56
64.9 x 12.5
10-162
D65EX, PX-15
CONTROL VALVE
2. 4-spool valve P: T: A1: A2: A3: A4: B1: B2: B3: B4: LS: PC: PI: TS: PA1: PA2: PA3: PA4: PB1: PB2: PB3: PB4: PLSC: From pump To hydraulic tank To HSS motor To tilt cylinder bottom To lift cylinder head To ripper cylinder bottom To HSS motor To tilt cylinder head To lift cylinder bottom To ripper cylinder head To pump LS valve Pump pressure plug From self-pressure reducing valve To hydraulic tank Connector (From controller) From PPC valve From PPC valve From PPC valve Connector (From controller) From PPC valve From PPC valve From PPC valve LS pressure plug
1. EPC valve
D65EX, PX-15
10-163
CONTROL VALVE
10-164
D65EX, PX-15
CONTROL VALVE
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
9. 10. 11. 12. 13. 14. 15.
Pressure compensation valve Main relief valve LS relief valve (for steering valve) Unload valve LS relief valve (for work equipment valve) LS check valve (for work equipment valve) LS check valve (for steering valve)
D65EX, PX-15
10-165
CONTROL VALVE
Unit: mm No. Check item Standard size 16 Spool return spring (For lift)
Criteria Repair limit Installed load 224 N {22.8 kg} 140 N {14.3 kg} 217 N {22.1 kg} 12.7 N {1.3 kg} 216 N {22 kg} 216 N {22 kg} 216 N {22 kg} 216 N {22 kg} 235 N {24 kg} Free length Installed load 178 N {18.2 kg} 112 N {11.4 kg} 173 N {17.6 kg} 9.81 N {1.0 kg} 173 N {17.6 kg} 173 N {17.6 kg} 173 N {17.6 kg} 173 N {17.6 kg} 188 N {19.2 kg}
Remedy
Installed length 68.5 50 33.5 13.5 61.8 61.8 61.8 61.8 69.5
73.4 x 31 17 18 Spool return spring 51.7 x 31.3 (For tilt and steering) Spool return spring (For lift FLOAT) 54.7 x 36.5 20.8 x 10.2 70 x 26.5 70 x 26.5 70 x 26.5 70 x 26.5 94.8 x 30
19 Load check valve spring 20 21 22 23 Pressure compensation valve spring (Steering valve) Pressure compensation valve spring (Tilt valve) Pressure compensation valve spring (Lift valve) Pressure compensation valve spring (Ripper valve)
24 Unload spring
10-166
D65EX, PX-15
CONTROL VALVE
1. Suction valve 2. Preset check valve
3. LS bypass valve 4. Safety-suction valve

Unit: mm
No.
Remedy
5 Suction valve spring
Installed length 56
64.9 x 12.5
D65EX, PX-15
10-167
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.
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).
10-168
D65EX, PX-15
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. 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.
D65EX, PX-15
10-169
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
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
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
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
CONTROL VALVE
(3) Meter-out control when blade moves down under its own weight
10-174
D65EX, PX-15
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
CONTROL VALVE
(4) Meter-out control when blade moves down under its own weight (work equipment lever at FLOAT)
10-176
D65EX, PX-15
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
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
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
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
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
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
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
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
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. 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.
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.
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
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
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
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
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
SELF PRESSURE REDUCING VALVE
T: P1: P2: PR:
To hydraulic tank From pump To fan motor Supply to PPC valve and EPC valve
10-190
D65EX, PX-15
1. 2. 3. 4. 5.
Valve (sequence valve) Spring Screw Poppet Spring (pressure reducing valve pilot)
6. 7. 8. 9. 10.
Spring (pressure reducing valve main) Valve (pressure reducing valve) Spring (safety valve) Ball Filter
D65EX, PX-15
10-191
Unit: mm No. Check item Standard size 11 Spring (pressure reduction main)
Free length x O.D. Installed length Installed load
Criteria Repair limit Free length

Installed load
Remedy
19.2 x 7.20 12 Spring 17.8 x 7.20 (pressure reduction valve pilot) 71.0 x 18.0 16.1 x 7.80
16.1 12.1 59.0 13.4
19.6 N {2.0 kg} 31.4 N {3.20 kg} 200 N {20.4 kg} 61.7 N {6.30 kg}
17.7 N {1.80 kg} 28.4 N {2.90 kg} 186 N {19.0 kg} 58.8 N {6.0 kg}
Replace spring if any damages or deformations are found
13 Spring 14 Spring (safety valve)
Function The self pressure reducing valves reduces the discharge pressure of the fan pump and supplies it to the PPC valve, the EPC valve, etc. as the control pressure.
10-192
D65EX, PX-15
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
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.
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.
10-194
D65EX, PX-15
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.
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.
D65EX, PX-15
10-195
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
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
WORK EQUIPMENT
Unit: mm No. Check item Standard size S 140 2 3 4 5 6 7 8 9 10 Clearance between brace mounting pin and bracket Clearance between brace mounting pin and brace Spherical clearance between bracket and brace Spherical clearance between bearing and bushing Clearance between frame mounting pin and bracket Clearance between frame mounting pin and bearing Clearance between center brace mounting pin and bracket Clearance between center brace mounting pin and brace Spherical clearance between bracket and center brace 50 50
Criteria Tolerance Shaft 0.1 0.5 0.2 0.4 0.2 0.4 0.1 0.3 0.1 0.5 0 0.3 0 0.3 0.2 0.4 0.2 0.4 0.1 0.3 Hole +1.5 0 +0.2 0 +0.2 0 +1.0 0 +0.5 0 +0.6 +0.2 +0.5 +0.2 +0.2 0 +0.2 0 +1.0 0 Standard clearance 0.3 0.7 0.2 0.6 0.2 0.6 0.3 0.7 0.1 1.0 0.2 0.9 0.2 0.8 0.2 0.6 0.2 0.6 0.3 0.7 Clearance limit 5.0 2.0
Remedy
Spherical clearance between 1 trunnion and cap
Adjust shim or replace
Replace 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 Adjust shim or replace Replace Adjust shim or replace
S 90 55 55 50 50
10-198
D65EX, PX-15
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
WORK EQUIPMENT
Unit: mm No. Check item Standard size S 140 2 3 4 5 6 7 8 9 10 11 12 Clearance between arm mounting pin and bracket (Large) Clearance between arm mounting pin and bracket (Small) Clearance between brace mounting pin and arm bracket Clearance between brace mounting pin and brace Clearance between brace mounting pin and joint Clearance between brace mounting pin and bearing Clearance between joint mounting pin and bracket Clearance between joint mounting pin and joint Clearance between center shaft and frame Clearance between center shaft mounting pin and bracket Clearance between center shaft mounting pin and center shaft 100 80 50 50 50 50 50 50
79.5 (Shaft) 80 (Hole)
Criteria Tolerance Shaft 0.1 0.5 0.6 1.0 0.6 1.0 0.3 0.6 0.3 0.6 0 0.3 0 0.3 0.1 0.3 0.1 0.3 0.2 0.5 0.1 0.3 0.1 0.3 Hole +1.5 0 +1.5 +1.0 +1.5 +1.0 +0.7 0 +0.2 0 +0.2 0 +0.5 0 +0.3 0 +0.2 0 +0.5 0.5 +0.3 0 +0.5 +0.1 Standard clearance 0.1 2.0 1.6 2.5 1.6 2.5 0.3 1.3 0.3 0.8 0 0.5 0 0.8 0.1 0.6 0.1 0.5 0.2 1.5 0.1 0.6 5.2 5.8 Clearance limit 8.0 3.5 3.5 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 7.0
Remedy
Spherical clearance between 1 trunnion and cap
Replace
55
55 (Shaft) 60 (Hole)
10-200
D65EX, PX-15
CUTTING EDGE, END BIT
CUTTING EDGE, END BIT
Unit: mm No. Check item Standard size PT (EX) 1 PT (PX) Height of end bit (outside) PTP (PX) SEMI-U (EX,WX) A (EX) PT (EX) 2 Width of end bit PT (PX) PTP (PX) SEMI-U (EX,WX) A (EX) PT (EX) PT (PX) PTP (PX) Height of end bit 3 (inside) SEMI-U (EX,WX) A (EX) PT (EX) Height of cutting edge PT (PX) PTP (PX) 4 (From center of bolt SEMI-U hole to end face) (EX,WX) A (EX) PT (EX) Tightening torque of 5 end bit and cutting edge PT (PX) PTP (PX) SEMI-U (EX,WX) A (EX) 242 204 315 242 330 325 540 330 204 204 254 204 102 102 102 102 Criteria Repair limit 187 187 237 187 300 300 515 300 187 187 237 187 85 85 85 85 Replace Remedy
392.2 529.2 Nm {40 54 kgm} 392.2 529.2 Nm {40 54 kgm} Cutting edge: 392.2 529.2 Nm {40 54 kgm} End bit: 637 852.6 Nm {65 87 kgm} 392.2 490.3 Nm {40 50 kgm} Retighten
PT: For power tilt dozer, PTP: For power tilt, power pitch dozer, SEMI-U: semi-U dozer, A: For angledozer
D65EX, PX-15
10-201
(7)
RIPPER
RIPPER
D65EX-15 D65WX-15 (If equipped)
Unit: mm No. Check item Standard size 56 Criteria Tolerance Shaft 0.030 0.076 Standard size 2 Wear of point 222 Hole +0.299 +0.169 Standard clearance 0.199 0.375 Repair limit 152 Clearance limit 1.0 Replace Remedy
Clearance between pin and 1 bushing
3. 4. 5. 6. 7. 8. 9.
Bracket Upper link Ripper cylinder Beam Shank Point Lower link
A: Pin hole A (Point digging angle: 55 deg.) B: Pin hole B (Point digging angle: 45 deg.)
10-202
(7)
D65EX, PX-15
CAB MOUNT
CAB MOUNT
1. Support 2. Damper mount (front) 3. Damper mount (rear)
Outline Viscous damper mounts (2) and (3) are installed at two places at the front and two places at the rear to secure the floor frame and cab. An oil-filled damper mount is used to absorb the vibration.
D65EX, PX-15
10-203
CAB
CAB
1. 2. 3. 4.
Front wiper Front glass Rear wiper Door
10-204
D65EX, PX-15
CAB
ROPS GUARD
a ROPS: Abbreviation for ROllover Protective Structure
1. ROPS guard
D65EX, PX-15
10-205
AIR CONDITIONER PIPING
AIR CONDITIONER PIPING
1. 2. 3. 4. 5. 6. 7. 8.
Condenser Valve (hot water outlet) Hot water pick-up piping Refrigerant piping Receiver tank Hot water return piping Air conditioner compressor Valve (hot water inlet)
9. 10. 11. 12. 13.
Front window defroster Air conditioner unit Vent Blower motor Side window defroster
A. Fresh air B. Recirculated air C. Hot air/cold air
10-206
D65EX, PX-15
ENGINE CONTROL
ENGINE CONTROL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Battery Starting switch Engine Starting motor Engine controller Transmission and steering controller Neutral safety relay Limit switch Parking brake lever Electric lever Steering/directional/gear shift lever (PCCS lever)
Function A limit switch is installed to the linkage of the parking brake. The transmission and steering controller permits the engine to start only when the parking brake is in the LOCK position and the steering/directional/gear shift lever is in the N (Neutral) position.
Input and output signals a. b. c. d. e. Battery power source Engine start signal Starting switch ACC signal Parking brake signal Neutral signal
D65EX, PX-15
10-207
(7)
ENGINE CONTROL SYSTEM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Battery Starting switch Neutral safety relay Fuel supply pump power relay Engine controller Transmission and steering controller Monitor panel Fuel control dial Decelerator pedal Engine Engine speed sensor Coolant temperature sensor Engine oil pressure sensor Injector Fuel supply pump valve
Input and output signals a. b. c. d. e. f. g. h. i. j. 1st throttle signal (Fuel control dial signal) 2nd throttle signal (Decelerator pedal signal) 3rd throttle signal (Controller control signal) Starting switch ACC signal Controller power source Engine speed signal Coolant temperature signal Engine oil pressure signal Sensor signal Monitor display signal
10-208
D65EX, PX-15
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)
CRI ENGINE CONTROL SYSTEM

a CRI: Abbreviation for Common Rail Injection
SYSTEM DIAGRAM
1. Fuel tank 2. Fuel supply pump assembly 2a. PCV (Discharge control valve) 2b. High pressure pump 2c. Priming pump 2d. Feed pump 2e. Bypass valve 2f. G speed sensor 3. Fuel filter 4. Overflow valve 5. Common rail
6. Pressure limiter 7. Flow damper 8. Injector assembly 8a. Orifice 8b. Control chamber 8c. Hydraulic piston 8d. Injector 8e. Nozzle 9. Engine controller 10. NE speed sensor
10-210
D65EX, PX-15
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
COOLING SYSTEM CONTROL SYSTEM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Battery Battery relay Transmission and steering controller Engine controller Monitor panel Cooling fan motor Cooling fan pump Fan rotation selector switch Power train oil temperature sensor Hydraulic oil temperature sensor Engine Engine speed sensor Coolant temperature sensor
Input and output signals a. b. c. d. e. f. g. h. i. Controller power source Fan rotation selector signal Power train oil temperature signal Hydraulic oil temperature signal Engine speed signal Coolant temperature signal CAN signal Pump control signal Fan reverse signal
10-212
(7)
D65EX, PX-15
Outline The transmission and steering controller monitors the coolant, power train oil, and hydraulic oil temperatures and controls the fan speed according to those temperatures.
Selection of fan rotation mode While the starting switch is in the ON position and the engine is stopped, one of the following fan rotation modes can be selected with the fan rotation selector switch. 1) Forward rotation mode 2) Reverse rotation mode 3) Cleaning mode The transmission and steering controller operates the reverse solenoid valve of the cooling fan motor to change the rotation direction of the fan according to the selected mode. 1) Forward rotation mode In this mode, the reverse solenoid valve does not operate and the fan rotates forward. The fan speed varies with the temperature sensor signal. This mode is selected normally. 2) Reverse rotation mode In this mode, the reverse solenoid valve operates and the fan rotates in reverse. The fan can warm the operators cab as a substitute for a reversible fan. Since the cooling efficiency is low in this mode, the engine overheats easily. Accordingly, this mode shall be used only in cold weather. 3) Cleaning mode In this mode, the fan rotates in reverse at high speed to blow off dirt from the radiator fins, regardless of the temperature sensor signals. If this mode is used periodically, the cleaning interval of the radiator fins can be expanded. Interlock for changing rotation mode If the rotation direction of the fan is changed while the fan is rotating, the fan drive circuit is broken. To prevent this, the fan rotation selector switch signal is ignored while the engine is running. In this case, the fan operation pilot lamp on the monitor panel flashes.
Function Fan speed control The transmission and steering controller controls the discharge of the cooling fan to set the fan speed properly according to the information from the coolant, power train oil, and hydraulic oil temperature sensors. The transmission and steering controller selects the maximum target fan speed obtained from the coolant, power train oil, and hydraulic oil temperatures and outputs it as the pump control signal to the cooling fan pump. The cooling fan pump changes its swash plate angle to controls its oil discharge for the cooling fan motor.
D65EX, PX-15
10-213
(7)
PALM COMMAND CONTROL SYSTEM
1. 2. 3. 4. 5. 6. 7. 8.
Monitor panel Automatic shift-down switch Preset mode switch Steering/directional/gear shift lever (PCCS lever) Engine controller Transmission and steering controller Engine speed sensor Engine
9. 10. 11. 12. 13. 14.
Torque converter Transmission Transmission control valve Transmission output shaft speed sensor HSS unit Control valve 14a. Steering control valve 15. HSS motor
10-214
D65EX, PX-15
Preset mode function The gear speed applied for forward travel and reverse travel can be set in advance. Preset mode 1: F1-R1 Preset mode 2: F1-R2 Preset mode 3: F2-R2 Preset mode 4: F2-R3
Automatic shift-down function If the travel speed lowers because of the loading condition, the transmission gear is shifted down automatically. 1) The traction force (load on the chassis) is calculated from the engine speed, transmission output shaft speed, and the throttle information sent from the transmission and steering controller, and then the transmission gear is shifted down automatically according to the load and travel speed. 2) Once the transmission gear is shifted automatically, it is not shifted up again automatically. (It can be shifted up with the UP switch of the PCCS lever, however.) 3) This function is applicable to both forward and reverse travels.
1. How to use 1) Set the PCCS lever in the N (Neutral) position. 2) Set the preset mode switch (1) to the ON position. 3) Press the UP/DOWN switch of the PCCS lever to select a mode.
1. How to use 1) Set the automatic shift-down switch (2) to the ON position.
2. Display The selected mode is displayed on display panel B of the monitor panel.
D65EX, PX-15
10-215
SYSTEM COMPONENTS
SYSTEM COMPONENTS
Fuel control dial
1. 2. 3. 4. 5. 6.
Knob Dial Spring Ball Potentiometer Connector
Function The fuel control dial is installed to the left side of the operators 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.
10-216
(7)
D65EX, PX-15
SYSTEM COMPONENTS
Decelerator pedal potentiometer
1. 2. 3. 4. 5. 6. 7.
Lever Shaft Coupling Body Potentiometer Stopper Connector
Function The decelerator pedal potentiometer is installed under the front part of the floor and connected to the decelerator pedal by the linkage. 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.
D65EX, PX-15
10-217
ENGINE CONTROLLER
ENGINE CONTROLLER
10-218
D65EX, PX-15
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 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
D65EX, PX-15
10-219
TRANSMISSION AND STEERING CONTROLLER
10-220
D65EX, PX-15
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) 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
D65EX, PX-15
10-221
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)
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.
10-222
D65EX, PX-15
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 Flow of signals Each sensor O Controller O Monitor panel
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
a For details of the operating method, see TESTING AND ADJUSTING, Special functions of monitor panel (EMMS). Other items
Contents and conditions of processing 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 Method Flow of signals
a For details of the operating method, see TESTING AND ADJUSTING, Special functions of monitor panel (EMMS).
D65EX, PX-15
10-223
MONITOR PANEL
MONITOR PANEL
Outline The monitor panel consists of the monitor section which outputs an alarm when the machine has any trouble and the gauge section and display panel which display the machine condition constantly. 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.
Check before starting After the operation performed when the power is turned ON, if there is any abnormal one in the check-before-starting items, the lamp of that item flashes or the contents of the abnormality are displayed on display panel B.
Caution items The caution items are checked constantly while the engine is running. If any item is abnormal, it and alarm lamp flash synchronously. The alarm buzzer may sound at this time.
Operation When power is turned ON (When starting switch is turned to ON position) All the LC segments and lamps of the monitor panel light up for 2 seconds and the alarm buzzer sounds for 2 seconds.
10-224
D65EX, PX-15
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 10C). 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 Input/Output signal Input Input Input Input Input Input Input Input Output
AMP070-12P [CN-S04]
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
D65EX, PX-15
10-225
MONITOR PANEL
Monitor panel display
10-226
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D65EX, PX-15
MONITOR PANEL
No.
Display section Gauge
Display item
Display range See diagram at left
Display method Corresponding segment (1 place) All light up OFF Flashing Flashing Corresponding segment (1 place) All light up OFF Flashing Flashing Corresponding segment (1 place) All light up OFF Flashing Flashing At corresponding segment or lower all light up
P: Parking brake lever in "Lock" and PCCS lever in Neutral: lamp is ON N: PCCS lever in "Neutral": lamp is ON F: PCCS lever in "Forward": lamp is ON R: PCCS lever in "Reverse": lamp is ON
Caution lamp Output
Alarm buzzer Output
Display color
Remarks
1a 1b 2a 2b 3a 3b 4
OFF
Flashing Flashing
OFF OFF ON OFF OFF ON OFF OFF ON -
Black Red Black Red Black Red
LCD LED LCD LED LCD LED
Coolant temperature
Caution Gauge Caution Gauge Caution Gauge Hydraulic oil temperature Power train oil level
102C or lower 102C - 108C 108C or higher See diagram at left 120C or lower 120C - 130C 130C or higher See diagram at left 100C or lower 100C - 110C 110C or higher See diagram at left
OFF
Flashing Flashing
OFF
Flashing Flashing
Fuel level
Travel direction (P,N,F,R) [*1] Display panel A Indicator (travel direction, gear speed, engine tachometer)
OFF
OFF LCD
1: PCCS lever gear speed Black switch in "1st" 2: PCCS lever gear speed Gear speed switch in "2nd" (1,2,3) 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).
LED
D65EX, PX-15
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(7)
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 Engine oil pressure Coolant temperature Power train oil temperature Hydraulic oil temperature Fuel level Engine speed Transmission output shaft speed Pitch angle Type of sensor Contact Resistance Resistance Resistance Resistance Electromagnetic Electromagnetic Capacitor When normal OFF When abnormal ON
ENGINE OIL PRESSURE SENSOR
1. Plug 2. Contact ring Function
3. Contact 4. Diaphragm
5. Spring 6. Terminal
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.
10-228
D65EX, PX-15
SENSORS
COOLANT TEMPERATURE SENSOR (FOR MONITOR) Power train oil temperature sensor Hydraulic oil temperature sensor
1. Connector Function
2. Plug
3. Thermistor
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
2. Plug
3. Thermistor
The coolant temperature sensor (for preheating) is installed to the engine coolant piping and the fuel temperature sensor is installed to the engine fuel piping. These sensors sense the change of the temperature by the change of resistance of the thermistors in them.
D65EX, PX-15
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SENSORS
FUEL LEVEL SENSOR
1. 2. 3. 4.
Connector Float Arm Body
5. Spring 6. Contact 7. Spacer
Function The fuel level sensor is installed to the side of the fuel tank. Its float moves up and down according to the fuel level. The movement of the float operates the variable resistor through the arm. As a result, signals of change in resistance are generated.
10-230
D65EX, PX-15
SENSORS
ENGINE SPEED SENSOR
2. O-ring
3. Sensor
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 Function
3. Housing 4. Terminal
5. Boots 6. Connector
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)
SENSORS
PITCH ANGLE SENSOR
1. Body 2. Tube Function
3. Wire 4. Connector
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.
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D65EX, PX-15
TESTING AND ADJUSTING
20 TESTING AND ADJUSTING

STANDARD VALUE TABLE Standard value table for engine ............................................................................................................ Standard value table for chassis ........................................................................................................... TESTING AND ADJUSTING ................................................................................................................... TROUBLESHOOTING ............................................................................................................................
20- 2 20- 4 20-101 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)
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Machine model Engine Item Measurement conditions High idling Engine speed Low idling Rated speed Air supply Exhaust gas color Exhaust temperature (Torbocharger inlet temperature) Valve clearance Compression pressure (SAE30 or SAE15W-40) Blow-by pressure (SAE30 or SAE15W-40) At rated output At sudden acceleration At high idling Whole speed range (Ambient temperature 20C) Intake valve Exhaust valve Oil temperature: 40 60C (Engine speed) (Water temperature: Operating range) At rated output (Water temperature: Operating range) At high idling (SAE30 or SAE15W-40) Oil pressure At high idling (SAE10W) At low idling (SAE30 or SAE15W-40) At low idling (SAE10W) Oil temperature Whole speed range (Inside oil pan) Deflection when pressed with a finger force of approx. 58.8 N {approx. 6 kg} Deflection when pressed with a finger force of approx. 98 N {approx. 10 kg} C kPa {kg/cm2} 392 690 {4.0 7.0} 343 640 {3.5 6.5} Min. 147 {Min. 1.5} Min. 98 {Min. 1.0} 90 120 206 {2.1} 176 {1.8} 69 {0.7} 69 {0.7} Min. 120 kPa {mmHg} Bosch index C mm MPa {kg/cm2} (rpm) kPa {mmH2O} rpm Unit D65EX, PX, WX-15 SA6D125E-3 Standard value for Service limit value new machine 2,100 50 825 50 1,950 Min. 79.8 {Min. 600} Max. 4.5 Max. 1.0 Max. 650 0.33 0.71 Min. 2.9 {Min. 30} (150 200) Max. 0.98 {Max. 100} 2,100 50 825 50 60 {450} 6.5 2.0 700 1.96 {200}
Alternatorcrankshaft pulley mm Air conditionercrankshaft pulley
13
Belt tension
15 18
20-2
(7)
D65EX, PX-15
STANDARD VALUE TABLE FOR CHASSIS

Machine model Category Item Measurement conditions Unit D65EX, WX-15 Standard value for new machine 1,000 25 rpm 1,770 100 1,650 Service limit value 1,000 25
Engine water temperature: Decelerator pedal Within operating range speed Power train oil temperature: Within operating range Hydraulic oil temperature: Within operating range Torque converter Decelerator pedal speed: Press pedal. 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 55C Lower Set lever knob to center. Neutral o Left/Right tilt Engine: Low idling Neutral o Ripper lever Hydraulic oil temperature: (If equipped) 45 55C 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 55C 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 55C Neutral o Set lever knob to center. Lower PCCS lever PCCS lever
Engine speed
30 10 30 10 40 15 (Play: Max. 3) 40 15 (Play: Max. 3) 52 9 mm 79 12 72 11 52 9 54 8
30 10 30 10 40 15 (Play: Max. 3) 40 15 (Play: Max. 3) 52 9 79 12 72 11 52 9 54 8
Stroke of control lever/pedal
54 8
54 8
56.9 19.6 {5.8 2.0}
56.9 19.6 {5.8 2.0}
Operating effort of control lever/pedal
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}
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} 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}
N {kg}
20-4
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D65EX, PX-15
D65PX-15 Standard value for new machine 1,000 25 Service limit value 1,000 25
1,770 100
1,650
30 10 30 10 40 15 (Play: Max. 3) 40 15 (Play: Max. 3) 52 9 79 12 72 11 52 9 54 8
30 10 30 10 40 15 (Play: Max. 3) 40 15 (Play: Max. 3) 52 9 79 12 72 11 52 9 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} 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}
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} 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)
Machine model Category Item Torque converter inlet pressure Measurement conditions Unit
D65EX, PX, WX-15 Standard value for new machine 0.1 0.5 {1 5} Max. 0.88 {Max. 9} 0.05 0.29 {0.5 3} 0.39 0.69 {4 7} 3.13 0.1 {32 1.0} 3.33 0.1 {34.0 1.0} 3.13 0.1 {32 1.0} 3.33 0.1 {34.0 1.0} 3.13 0.1 {32 1.0} 3.33 0.1 {34.0 1.0} 3.13 0.1 MPa {32 1.0} {kg/cm2} 3.33 0.1 {34.0 1.0} 3.13 0.1 {32 1.0} 3.33 0.1 {34.0 1.0} 3.13 0.1 {32 1.0} 3.33 0.1 {34.0 1.0} 0.1 0.25 {1.0 2.5} 2.75 2.94 {28 30} 2.75 2.94 {28 30} 36.8 2.0 {375 20} 34.8 2.0 {355 20} 3.5 0.2 6.2 0.3 9.9 0.5 km/h R1 R2 R3 4.7 0.3 8.0 0.4 12.4 0.6 4.7 0.3 8.0 0.4 12.4 0.6 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} 3.5 0.2 6.2 0.3 9.9 0.5
Engine: Low idling Engine: High idling Engine: Low idling Torque converter outlet pressure Engine: High idling Engine: Transmission Low idling main relief Engine: pressure High idling Engine: Low idling Transmission F clutch pressure Engine: High idling Engine: Low idling Transmission R clutch pressure Engine: Power train oil temperature: High idling 70 80C Engine: Low idling Transmission 1st clutch pressure Engine: High idling Engine: Low idling Transmission 2nd clutch pressure Engine: High idling Engine: Low idling Transmission 3rd clutch pressure Engine: High idling Transmission lubricating oil Engine: pressure High idling (For reference) Engine: Low idling Brake pressure Engine: High idling Relief pressure LS pressure
(Load sensing pressure)
HSS pressure
Power train oil pressure
Hydraulic oil temperature: 45 55C Engine: High idling F1 Flat road Engine water temperature: Within operating range Power train oil temperature: 70 80C Engine: High idling Run up distance: 10 30 m Measuring distance: 20 m F2 F3
Performance of power train
Travel speed
20-6
(7)
D65EX, PX-15
Machine model Category Item Unload pressure Measurement conditions Engine: High idling Blade tilt relief pressure Engine: Low idling Hydraulic oil temperature: Engine: 45 55C 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 Unit
D65EX-15 Standard value for new machine 3.43 {35 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} 4.27 0.25 {43.5 2.5} 3.53 4.41 {36 45} 2.6
+0.2 0.5 +1.37 0 +14 0 }
Service limit value 3.43 {35 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} 3.53 4.41 {36 45} 3.1
+1.37 0 +14 0 }
Blade lift relief pressure Work equipment oil pressure
Ripper lift relief pressure LS pressure (Load sensing pressure) Control circuit main pressure (HSS, PPC, fan) PPC valve output pressure
Hydraulic oil temperature: 45 55C Engine: High idling aSee the figure A Hydraulic oil temperature: 45 55C Apply no load to blade. Between ground level and rising end of blade Engine: High idling aSee the figure B Hydraulic oil temperature: 45 55C Apply no load to blade. Between left tilt end and right tilt end Engine: High idling aSee the figure C Hydraulic oil temperature: 45 55C Apply no load to ripper. Between ground level and rising end of blade aSee the figure D Hydraulic oil temperature: 45 55C Apply no load to blade. Pitch in pitch back Engine: High idling Left tilt
Raise
Blade lift
Lower Straight tilt Power tilt Straight tilt Power tilt Low idling High idling Low idling High idling Pitch in sec
1.7 0.2 2.5 0.3 2.3 0.3 2.4 0.2 1.4 0.2 1.9 0.2 1.1 0.2
2.0 3.0 2.8 2.9 1.9 2.4 1.6
Work equipment speed
Blade tilt
Work equipment
Ripper lift (If equipped)
Pitch speed (If equipped)
Lower
Raise
Right tilt
Pitch back
20-8
(1)
D65EX, PX-15
D65PX, WX-15 Standard value for new machine 3.43 {35 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} 4.27 0.25 {43.5 2.5} 3.53 4.41 {36 45} 2.4
+0.2 0.5 +1.37 0 +14 0 }
Service limit value 3.43 {35 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} 3.53 4.41 {36 45} 2.9
+1.37 0 +14 0 }
1.4 0.2 2.5 0.3 2.5 0.3 2.3 0.3 2.3 0.3 3.5 0.5
1.7 3.0 3.0 2.8 2.8 4.2
3.5 0.5
4.2
D65EX, PX-15
20-9
(7)
Machine model Category Item Measurement conditions Hydraulic oil temperature: 45 55C 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 55C Engine: Stopped Measure reduction of blade bottom height h (for 15 minutes). Left aSee the figure F tilt Hydraulic oil temperature: 45 55C Engine: Stopped Right Reduction of blade tip height tilt aSee the figure G Hydraulic oil temperature: 45 55C Engine: Stopped Measure reduction of shank bottom height h (for 15 minutes). Engine: High idling Hydraulic oil temperature: 45 55C Relieve cylinder and measure leakage for 1 minute. Unit
D65EX-15 Standard value for new machine Service limit value
Time lag
Blade
sec
Max. 1.3
Max. 1.6
Hydraulic drift of lifted blade Work equipment Hydraulic drift Hydraulic drift of tilted blade Hydraulic drift of lifted ripper Leakage from cylinder Blade tilt cylinder Ripper lift cylinder
Max. 100
Max. 100
mm/ 15 min
Max. 200 Max. 200
Max. 200 Max. 200
Max. 50
4 cc/min 4
16
16
Leakage
Fan speed Cooling fan
Fan pump pressure
Hydraulic oil temperature: 45 55C 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. 80C 45 55C 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 55C {200 230} MPa Fan forward 2 {kg/cm } 15.7 18.6 Fan 100% speed mode For EU spec. {160 190} Engine: High idling Min. speed Max. speed
HSS motor
30
700
1,750 1,500 18.6 {190} 13.7 {140}
20-10
(7)
D65EX, PX-15
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
16
16
Max. 15
30
800 50
700
1,850 1,600
+100 0 +100 0
1,750 1,500 18.6 {190} 13.7 {140}
19.6 22.5 {200 230} 15.7 18.6 {160 190}
D65EX, PX-15
20-11
(7)
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

Tools for testing, adjusting, and troubleshooting ..................................................................................... Measuring engine speed ......................................................................................................................... Measuring intake air pressure (boost pressure) ...................................................................................... Measuring exhaust temperature .............................................................................................................. Measuring exhaust gas color ................................................................................................................... Adjusting valve clearance ........................................................................................................................ Measuring compression pressure ........................................................................................................... Measuring blow-by pressure ................................................................................................................... Measuring engine oil pressure ................................................................................................................ Handling of fuel system devices .............................................................................................................. Releasing residual pressure from fuel system ............................................................................................ Measuring fuel pressure .......................................................................................................................... Bleeding air from fuel circuit .................................................................................................................... Inspection of fuel circuit for leakage ........................................................................................................ Reduced cylinder mode operation for engine .......................................................................................... Testing and adjusting alternator belt tension ........................................................................................... Testing and adjusting air conditioner compressor belt tension ................................................................ Adjusting fuel control dial and decelerator pedal ..................................................................................... Measuring power train oil pressure ......................................................................................................... Adjusting transmission speed sensor (replacement procedure) ............................................................... Simple method of testing brake performance .......................................................................................... Adjusting brake pedal .............................................................................................................................. Emergency escape method when power train has trouble ...................................................................... Adjusting clearance of idler ..................................................................................................................... Inspecting wear of sprocket ..................................................................................................................... Testing and adjusting track shoe tension ................................................................................................. Testing and adjusting work equipment and HSS oil pressure ................................................................. Testing control circuit main pressure ....................................................................................................... Measuring PPC valve output pressure .................................................................................................... Adjusting play of work equipment PPC valve .......................................................................................... Measuring internal leakage of work equipment cylinder .......................................................................... Bleeding air from work equipment cylinder .............................................................................................. Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed) .................... Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed) .............. Adjusting work equipment lock lever ....................................................................................................... Measuring fan motor speed ..................................................................................................................... Measuring fan pump circuit pressure ...................................................................................................... Bleeding air from fan pump ..................................................................................................................... Adjusting straight tiltdozer ....................................................................................................................... Testing and adjusting operators cab ....................................................................................................... Special functions of monitor panel (EMMS) ............................................................................................. Handling of high-voltage circuit of engine controller ................................................................................ Adjustment method of replaced controller ............................................................................................... Preparation work for troubleshooting for electric system ......................................................................... Pm clinic service ...................................................................................................................................... Undercarriage troubleshooting report ...................................................................................................... D65EX, PX-15 20-103 20-105 20-107 20-109 20- 110 20- 112 20- 114 20- 116 20- 117 20- 118 20- 118 20- 119 20-120 20-123 20-124 20-125 20-125 20-126 20-128 20-133 20-134 20-135 20-138 20-141 20-141 20-142 20-143 20-146 20-147 20-149 20-150 20-150 20-151 20-151 20-152 20-153 20-154 20-155 20-156 20-158 20-162 20-199 20-199 20-201 20-203 20-210
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k k k k
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety pins and blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. 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. Be careful not to get caught in the fan, fan belt, or other rotating parts. D65EX, PX-15
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TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Check or measurement item Boost pressure Water temperature, Oil temperature, Exhaust temperature Exhaust color Valve clearance Compression pressure Blow-by pressure Engine oil pressure, Fuel pressure, Power train pressure, HST pressure, Work equipment pressure E F C D Symbol A B Part No. Part name Boost gauge kit Elbow Digital temperature gauge Handy smoke checker Smoke meter Filler gauge Compression gauge Adapter Blow-by checker Hydraulic tester Digital hydraulic tester Hydraulic gauge 0 5 kPa {0 500 mmH2O} Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Pressure gauge: 1 MPa {10 kg/cm2} Intake valve: 0.33 mm, Exhaust valve: 0.71 mm 0 7 MPa {0 70 kg/cm2} Kit part No.: 795-502-1205 99.9 1,299C Bosch index: Level 0 9 Remarks 101 200 kPa {760 1,500 mmHg}
1 799-201-2202 2 790-301-1530 799-101-1502 1 799-201-9001 2 Commercially available Commercially available 1 795-502-1590 2 795-471-1410 799-201-1504 799-101-5002 1
790-261-1204 2 799-401-2320 1
19M-06-32820 Switch assembly 17M-06-41530 Wiring harness Pump assembly Elbow (R 3/8 x M18) Hydraulic tester Digital hydraulic tester Adapter O-ring Hydraulic tester Digital hydraulic tester Adapter O-ring Measuring cylinder Tachometer kit 100 cc Digital display : 6 99999.9 rpm Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Face seal type (#02) Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Face seal type (#03)
Emergency escape when power train has trouble
2 790-190-1600 3 144-865-6260 799-101-5002 1
Control circuit main pressure J 2
790-261-1204 799-401-3200 02896-11009 799-101-5002 1
PPC valve outlet pressure
K 2
790-261-1204 799-401-3100 02896-11008 Commercially available 799-205-1100
Oil leakage of work equipment cylinder Fan motor speed
L M
D65EX, PX-15
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Check or measurement item
Symbol
Part No. 799-101-5002
Part name Hydraulic tester Digital hydraulic tester Adapter O-ring Push-pull scale Push-pull scale Scale Stopwatch Tester T-adapter kits Adapter T-adapter kits T-adapter kits Socket Adapter Socket
Remarks Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Face seal type (#05) 0 294 N {0 30 kg} 0 490 N {0 50 kg}
1 Fan pump circuit oil pressure P 2 Operating effort Stroke, hydraulic drift Work equipment speed Measuring voltage, resistance value Q R S T 1 790-261-1204 799-401-3400 02896-11015 79A-264-0021 79A-264-0091 Commercially available Commercially available Commercially available 799-601-7400 799-601-7360
For relay (5-pin) For DT connector For DT connector (24-pin, 40-pin) For NE sensor, G sensor For boost pressure sensor, Fuel pressure sensor For PCV solenoid
2 799-601-9000 Troubleshooting of wiring harness, sensor U 3 799-601-9300 799-601-9410 4 799-601-9420 799-601-9430
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D65EX, PX-15
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)
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)
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.
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.
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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.
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.
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D65EX, PX-15
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

a Measuring instruments for intake air pressure (boost pressure)
Symbol A
k
Part No. 799-201-2202 790-301-1530
Name Boost gauge kit Elbow
1 2
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.
When installing and removing the measuring instrument, 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 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.
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a The boost pressure can be measured in the Pm Clinic auxiliary mode of the monitor panel.
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D65EX, PX-15
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

a Measuring instrument for exhaust temperature
Symbol B
k
Part No. 799-101-1502
Name Digital thermometer
Install and remove the measuring instrument after 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 1. Open the right side cover of the engine and remove turbocharger heat insulation cover (1).
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 [C] = Measured value + 2 x (20 Outside air temperature)
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.
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 650C 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.
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MEASURING EXHAUST GAS COLOR
2) Stop only relieving the ripper and lower the exhaust temperature by only stalling the torque converter (Condition b in the figure). 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.

a Measuring instrument for exhaust gas color
Symbol C
k
Part No. 799-201-9001 Purchased
Name Handy smoke checker Smoke meter
1 2
When installing and removing the measuring instrument, 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 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.
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D65EX, PX-15
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.
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.
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ADJUSTING VALVE CLEARANCE

a Adjusting instrument for valve clearance
Symbol D Part No. Purchased Filler gauge Name
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.
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).
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.
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D65EX, PX-15
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. 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.
3 Locknut:
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} 6.8 0.49 Nm {69 5 kgcm}
3 Air cleaner air intake hose clamp bolt: 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
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MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pressure
Symbol E
k
6) Remove air intake connector (12).
Part No. 795-502-1590 795-471-1410
Name Compression gauge Adapter
1 2
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 60C) 1. Open both engine side covers. 2. Air cleaner 1) Remove cap assembly (1) and cover (2).
3. Remove all of 6 fuel high-pressure tubes (3), and then remove the all clamps so that the tubes can be moved.
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).
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D65EX, PX-15
5. Remove wiring harness (5) and injector assembly (6).
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: 3 Cylinder head cover mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm} 39.2 49.0 Nm {4.0 5.0 kgm} 9.8 1.0 Nm {1.0 0.1 kgm} 6.8 0.49 Nm {69 5 kgcm}
3 Air intake connector hose clamp bolt:
3 Air cleaner air intake hose clamp bolt: 3 Air cleaner band bolt:
8.8 0.5 Nm {0.9 0.05 kgm}
9.8 11.76 Nm {1.0 1.2 kgm}
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MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measuring instrument for blow-by pressure
Symbol F Part No. 799-201-1504 Name Blow-by checker
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.
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.
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D65EX, PX-15
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

a Measuring instruments for engine oil pressure
Symbol 1 G 2 Part No. 799-101-5002 790-261-1204 799-401-2320 Name Hydraulic tester Digital hydraulic tester Hydraulic tester (1 MPa {10 kg/cm2})
3. Run the engine at low idling and high idling and measure the engine oil pressure in each speed.
a Measure the engine oil pressure under the following condition. Engine water temperature: Within operating range 1. Open the left side cover of the engine and remove plug (1) RC 1/8.
4. After finishing measurement, remove the measuring instruments and return the removed parts.
2. Install nipple [1] of hydraulic tester G1 and connect them to hydraulic tester G2.
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HANDLING OF FUEL SYSTEM DEVICES RELEASING RESIDUAL PRESSURE FROM FUELDEVICES HANDLING OF FUEL SYSTEM SYSTEM
HANDLING OF FUEL SYSTEM DEVICES

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

a Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump Fuel filter Fuel supply pump High-pressure circuit: Fuel supply pump Common rail Fuel injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. k Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
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D65EX, PX-15
MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE

a Measuring instrument for fuel pressure
Symbol 1 G 2 Part No. 799-101-5002 790-261-1204 799-401-2320 Name Hydraulic tester Digital hydraulic tester Hydraulic tester (1 MPa {10 kg/cm2})
3. Run the engine at high idling and measure the fuel pressure. a For the standard value, see Troubleshooting when error code is displayed (Error code AD10L3).
a Measure only the fuel pressure in the low-pressure circuit from the feed pump to the fuel filter and fuel supply pump. k Since the pressure in the high-pressure circuit from the fuel supply pump to the common rail and fuel injector is very high, it cannot be measured. 1. Open the left side cover of the engine and remove fuel pressure pick-up plug (1).
2. Install nipple [1] of hydraulic tester G1 and connect them to hydraulic tester G2.
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BLEEDING AIR FROM FUEL CIRCUIT
a Bleeding the air as follows if the engine has run out of fuel or the fuel circut equipment has been removed and installed. 1. Remove fuel filter (1), fill with fuel, then install again. a When filling, use clean fuel and be careful not to let dirt get in. a Add fuel through inlet port portion a (8 places) of the filter. Portion b is the outlet port (clean side) after the fuel has been filtered, so never add fuel from here. a If clean fuel is not available, do not remove the filter. Operate the priming pump to fill the filter with fuel.
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2. Remove air bleed plug (2) of the fuel filter and operate priming pump (4). a Continue operating the priming pump until flow out from the plug hole. When fuel comes out, install the plug.
3 Air bleed plug:
Air bleeding steps i) Remove air bleeding plug (2) of fuel filter (1) and operate priming pump (4). Continue to operate the priming pump until fuel is confirmed to flow out of the air bleeding plug hole and then tighten it.
7.8 9.8 Nm {0.8 1.0 Nm} 3. There are the following two cases that the engine does not start up easily after bleeding air from CRI, (Common Rail Injection System), i.e. even after carrying out the Items 1 and 2 above. a If air has not been removed completely, leaving some in the system, cranking up the engine with the engine starting motor cannot get rid of the remaining air in a short span of time. Thus the engine start-up becomes difficult. 1) In the cases that the fuel has run out, that the fuel filter has been replaced or that some fuel device has been removed and installed. Most of the fuel is left in the fuel circuit, so the engine may be started after bleeding air with the air bleeding methods introduced in the Item 1 and 2 above. 2) In the case that a number of fuel devices have been removed and installed in course of engine overhauling. Little fuel is left in the fuel circuit, so air cannot be get rid of completely with the air bleeding methods introduced in the Item 1 and 2 above (i.e. ordinary method). In that case, bleed air in the following manner.
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm} ii) Remove fuel pressure measuring plug (3) for the fuel filter and operate priming pump (4). Continue to operate the priming pump until fuel is confirmed to flow out of the air bleeding plug hole and then tighten it.
3 Fuel pressure measuring plug:
3.9 6.9 Nm {0.4 0.7 kgm} iii) Loosen air bleeder (5) of the fuel supply pump (only after loosening the lock nut) and operate priming (4) 90 to 100 times. Continue to operate the priming pump until fuel is confirmed to flow out of air bleeder (5) and then tighten it.
3 Air bleeder:
4.9 6.9 Nm {0.5 0.7 kgm} Still continue to operate the priming pump until it becomes harder to operate and a relief sound of overflow valve (6) in the fuel supply pump is heard. (A high pitch sound) it requires approx. 50 times of operation to reach that stage.
iv) Push in the knob of priming pump (4) to tighten it. v) Crank up the engine with the engine starting motor for start-up. a Do not keep the engine starting motor running idly for more than 20 seconds. Moreover try to start up the engine only after two minute pause. a If the engine does not start up even after repeating to crank for 20 seconds 4 times, insufficient air bleeding is suspected of. In that case, start the air bleeding steps once again from the beginning.
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4. Loosen air bleeder (5) of the fuel supply pump and operate priming pump (4) 90 to 100 times. a Continue operating the priming pump until fuel flow out from the bleeder. When fuel comes out, tighten the bleeder, then operate several times until the priming pump becomes stiff.
3 Air bleeder:
4.9 6.9 Nm {0.5 0.7 kgm} 5. Crank the engine with the starting motor and start the engine. a When the engine is cranked, the air in the high-pressure circuit is automatically bled. a If the engine does not start, the air has probably been not properly bled from the lowpressure circuit, so repeat the procedure from Step 2.
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D65EX, PX-15
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE

Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its parts, inspect it for fuel leakage according to the following procedure. a Clean and degrease the engine and the parts around it in advance so that you can inspect it easily for fuel leakage. 1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping. 2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized. 3. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 4. Run the engine at low idling. 5. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. 6. Run the engine at high idling. 7. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2.
k
8. Run the engine at high idling and apply a load to it. a Relieve the oil by tilting the blade or raising the ripper. 9. Inspect the fuel piping and devices for fuel leakage. a Inspect around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 2. a If any fuel leakage is not detected, inspection is completed.
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REDUCED CYLINDER MODE OPERATION FOR ENGINE
REDUCED CYLINDER MODE OPERATION FOR ENGINE

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

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

Testing Press the intermediate point between air conditioner compressor pulley and drive pulley with a finger and measure deflection a of the belt. a Pressing force: Approx. 98 N {Approx. 10 kg}
Adjusting a If the deflection is abnormal, adjust it according to the following procedure. 1. Loosen the 2 alternator mounting bolts and the 1 adjustment rod set bolt. 2. Loosen locknut (1) and turn adjustment nut (2) to move alternator (3) and adjust the belt tension. 3. Tighten the 2 alternator mounting bolts and the 1 adjustment rod set bolt.
Adjusting a If the deflection is abnormal, adjust it according to the following procedure. 1. Loosen the 2 compressor bracket mounting bolts (1). 2. Loosen locknut (2) and turn adjustment nut (3) and adjust the belt tension. 3. Tighten the 2 compressor bracket mounting bolts (1).
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ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL

1. Outline of fuel control system The following signals are input as rotation command signals to the engine controller. Fuel control dial potentiometer signal Decelerator pedal potentiometer signal 3rd throttle signal The engine controller controls the fuel control system of the engine (CRI system) according to the one of the above input signals having the lowest engine speed. Adjust the deceleration slow rotation by adjusting the decelerator pedal linkage.
2. Preparation work 1) Start the engine, set the monitor panel in the Adjustment mode, and prepare for measuring the engine speed. a For the method of operation, see Special functions of monitor panel (EMMS). Adjustment code: 0007 (Engine deceleration cut mode) a The engine speed is displayed in 1 rpm.
[1] [2] [3] [4] [5] [6] [7] [8]
Fuel control dial Engine controller Steering and transmission controller Decelerator pedal Decelerator pedal potentiometer Engine (CRI system) 3rd throttle signal Rod
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3. Adjusting decelerator pedal engine speed With the fuel control dial in the high idling position, press decelerator pedal (1) to stopper bolt (2) and check that the decelerator pedal engine speed is normal. Decelerator pedal engine speed: 975 1,025 rpm Potentiometer output: 3.8 0.1 V a If the decelerator pedal engine speed is abnormal, adjust installed dimension a of stopper bolt (2). Standard installed dimension a of stopper bolt: 23 mm 4. High idling engine speed Set the fuel control dial in the high idling position and check that the high idling engine speed is normal. High idling engine speed: 2,050 2,150 rpm Potentiometer output: 0.8 0.1 V Standard installed dimension b of stopper bolt: 24 mm a If the engine speed is abnormal, perform the following. When the engine speed is above 2,150 rpm: Lower the engine speed below 2,050 rpm temporarily with stopper bolt (3) to eliminate the play of the decelerator pedal, and then adjust the engine speed to the high idling speed. When the engine speed is below 2,050 rpm: Adjust the engine speed to the high idling speed with stopper bolt (3).
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MEASURING POWER TRAIN OIL PRESSURE

a Measuring instruments for power train pressure
Symbol 1 G 2
k
Part No. 799-101-5002 790-261-1204 799-401-2320
Name Hydraulic tester Digital hydraulic tester Hydraulic tester (1 MPa {10 kg/cm2})
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and safety lock lever in the LOCK position. a Measure the power train oil pressure under the following condition. Power train oil temperature: 70 80C a The centralized power train pressure pickup ports are installed inside the inspection cover (1) on the right outside of the operators cab.
1. Measuring brake pressure 1) Remove oil pressure pickup plug (1) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/ cm2}.
a List of oil pressure measuring points and gauges to be used

No. 1 2 3 4 Measured oil pressure Steering brake pressure Torque converter inlet pressure Torque converter outlet pressure Transmission main relief pressure Gauge (MPa {kg/cm2}) 6 {60} 2.5 {25} 1 {10} 6 {60}
2) Run the engine and set the parking brake lever in the FREE position. 3) Measure the oil pressure while the engine is running at low idling and high idling. a Check that the oil pressure lowers to 0 when the brake pedal is pressed or the parking brake lever is set in the LOCK position.
4) After finishing measurement, remove the measuring instrument and return the removed parts.
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2. Measuring torque converter inlet pressure 1) Remove oil pressure pickup plug (2) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.
3. Measuring torque converter outlet pressure 1) Remove oil pressure pickup plug (3) and connect hydraulic tester G2. a Use an oil pressure gauge of 1 MPa {10 kg/ cm2}.
2) Start the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling. 4) After finishing measurement, remove the measuring instrument and return the removed parts. a For the oil pressure gauge, see BPD11546.
2) Start the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling.
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4. Measuring transmission main relief pressure 1) Remove oil pressure pickup plug (4) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/ cm2}.
5. Measuring clutch pressure Remove the operators seat assembly and measure the clutch pressure from the top of the floor frame. a List of oil pressure measuring points and necessary gauges
No. 5 6 7 8 9 Measuring point Transmission forward clutch pressure Transmission reverse clutch pressure Transmission 1st clutch pressure Transmission 2nd clutch pressure Transmission 3rd clutch pressure Gauge (MPa {kg/cm2}) 6 {60} 6 {60} 6 {60} 6 {60} 6 {60}
2) Start the engine and set the PCCS lever in the full neutral position. 3) Measure the oil pressure while the engine is running at low idling and high idling. 4) After finishing measurement, remove the measuring instrument and return the removed parts. a For the oil pressure gauge, see BPD11546.
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1) Measuring transmission forward clutch pressure i) Remove oil pressure pickup plug (5) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the FORWARD and 3rd gear speed position. iv) Measure the oil pressure while the engine is running at high idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. v) After finishing measurement, remove the measuring instrument and return the removed parts. 2) Measuring transmission reverse clutch pressure i) Remove oil pressure pickup plug (6) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the REVERSE and 3rd gear speed position. iv) Measure the oil pressure while the engine is running at high idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. v) After finishing measurement, remove the measuring instrument and return the removed parts.
3) Measuring transmission 1st clutch pressure i) Remove oil pressure pickup plug (7) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the FORWARD and 1st gear speed position. iv) Measure the oil pressure while the engine is running at low idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. k Do not run the engine at high idling while measuring. v) After finishing measurement, remove the measuring instrument and return the removed parts. 4) Measuring transmission 2nd clutch pressure i) Remove oil pressure pickup plug (8) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the FORWARD and 2nd gear speed position. iv) Measure the oil pressure while the engine is running at low idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. k Do not run the engine at high idling while measuring. v) After finishing measurement, remove the measuring instrument and return the removed parts.
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5) Measuring transmission 3rd clutch pressure i) Remove oil pressure pickup plug (9) and connect oil pressure gauge [1] of hydraulic tester G1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. ii) Run the engine and set the parking brake lever in the FREE position. iii) Press the brake pedal and set the PCCS lever in the FORWARD and 3rd gear speed position. iv) Measure the oil pressure while the engine is running at low idling. k Since the torque converter will be stalled, keep pressing the brake pedal securely. k Do not run the engine at high idling while measuring. v) After finishing measurement, remove the measuring instrument and return the removed parts.
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ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)
ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)

1. Remove the undercover of the fuel tank, and then remove transmission speed sensor assembly (1) from steering case (2).
2) Pull the connector of sensor (3) out of the flange hole of tube (6) and insert it in connector assembly (7) (securely until it clicks).
3) Install connector assembly (7) to tube (6). 4.9 6.9 Nm {0.5 0.7 kgm} 4) Insert sensor (3) in the boss of tube (6) and secure it with nuts (4) and (5). a Installed dimension of sensor: Dimension L measured when removed 0.2 mm
3 Mounting bolt:
2. Measure dimension L of removed sensor (3). a When replacing the sensor, be sure to measure dimension L.
3 Locknut: 49 68.7 Nm {5 7 kgm} 2 Threads of sensor: Adhesive (LT-2)
4. Install sensor assembly (1) to steering case (2). Standard clearance between bevel gear and sensor tip: 0.65 1.65 mm 5. After finishing adjustment, set the monitor panel in the Monitoring display mode and check that it displays the transmission speed normally. a For the operating method, see Special functions of monitor panel (EMMS). a Monitoring code: 31400 (Transmission speed)
3. Assembly procedure for sensor assembly 1) Remove only nut (4) from sensor (3) and insert sensor (3) in the opening at the end of tube (6) from the connector side.
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SIMPLE METHOD OF TESTING BRAKE PERFORMANCE
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE

a Carry out the simple test of brake performance under the following condition. Power train oil temperature: Within operating range 1. Set the blade and ripper (if equipped) in the travel position on a level place.
2. Run the engine and set the parking brake lever in the FREE position. 3. Run the engine at low idling and press the brake pedal and set the PCCS lever in the FORWARD and 2nd gear speed position. k If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd gear speed. a Set the steering unit in neutral. 4. Press the decelerator pedal and set the fuel control dial in the high idling position. 5. Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idling level. k Since the torque converter will be stalled, press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
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ADJUSTING BRAKE PEDAL
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}
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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} Brake OFF Brake ON Min. 2.55 {Min. 26} 0 Remarks Engine at full throttle
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).
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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
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)
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EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE

a Devices used for emergency escape
Symbol 1 H 2 3 Part No. Name
19M-06-32820 Switch assembly 17M-06-41530 Wiring harness 790-190-1600 144-865-6260 Pump assembly Elbow (R 3/8 x M18)
2) Remove the cover on the left of the toe board and connect wiring harness [2] to connectors PL1 (1) and PL2 (2). 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.
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.
3) Open the battery cover on the left of the cab and remove the cover of relay box (3).
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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.
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 operators 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.
3) Remove the fuel tank undercover and plug (5) (R 3/8) of the brake release pressure supply port of brake valve (4).
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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.
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ADJUSTING CLEARANCE OF IDLER ADJUSTING CLEARANCE OF IDLER INSPECTING WEAR OF SPROCKET
ADJUSTING CLEARANCE OF IDLER

a If the lateral guide of the idler are so worn that the idler runs out or slants, adjust the clearance of the idler according to the following procedure. 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
INSPECTING WEAR OF SPROCKET

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.
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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.
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TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE

a Testing and adjusting instruments for work equipment and HSS oil pressure
Symbol G1
k
1. 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}.
Part No. 795-101-5002 790-261-1204
Name Hydraulic tester Digital hydraulic tester
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 operators cab.
2) Running the engine at high idling, set the blade lever and ripper lever in neutral and measure the oil pressure.
a Oil pressure measuring points (2): Main pump pressure (3): Load sensing pressure (LS pressure)
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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}
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.
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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}.
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:
3 Locknut:
29.4 39.2 Nm {3 4 kgm} After adjusting, check the relief pressure and LS pressure of work equipment again.
68.6 78.5 Nm {7 8 kgm} After adjusting, check the relief pressure and LS pressure of work equipment again.
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TESTING CONTROL CIRCUIT MAIN PRESSURE
TESTING CONTROL CIRCUIT MAIN PRESSURE

a Testing and adjusting instruments for control circuit main pressure
Symbol 1 J 2 Part No. 799-101-5002 790-261-1204 799-401-3200 02896-11009 Name Hydraulic tester Digital hydraulic tester Oil pressure pickup adapter (Size 03) O-ring
4. 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 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 1. Open the main control valve cover on the right of the operators cab. 2. Disconnect hose (1).
5. Run the engine at high idling and set the blade lever and ripper lever in neutral and measure the oil pressure.
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.
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MEASURING PPC VALVE OUTPUT PRESSURE

a Measuring instruments for PPC valve output pressure
Symbol 1 K 2
k
4. Install nipple [1] of hydraulic tester K1 and connect oil pressure gauge [2].
Part No. 799-101-5002 790-261-1204 799-401-3100 02896-11008
Name Hydraulic tester Digital hydraulic tester Oil pressure pickup adapter (Size 02) O-ring
Stop the machine on a level place, 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 operators 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.
3. Install oil pressure pickup adapter K2 and connect the disconnected hose again.
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1. 2. 3. 4. 5.
Main valve Self-pressure reducing valve PPC lock valve Blade PPC valve Ripper PPC valve (If equipped)
A. B. C. D. E. F.
Blade LEFT TILT Blade LOWER Ripper RAISE Ripper LOWER Blade RAISE Blade RIGHT TILT
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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. Fix disc (3) and tighten locknut (2).
3 Locknut: 98 127 Nm {10 13 kgm}
4. Install boot (1).
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MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER BLEEDING AIR FROM
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER

a Measuring instruments for internal leakage of work equipment cylinder
Symbol L Part No. Purchased Name 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. 5. After finishing measurement, return the removed parts.
a Measure the internal leakage of work equipment cylinder under the following condition. Hydraulic oil temperature: 45 55C a Since the blade lift cylinder is equipped with a piston valve, its internal leakage cannot be measured. 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. 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.
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER

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. 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.
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RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (If PPC accumulator is installed) RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (If PPC accumulator is not installed)
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER

(If PPC accumulator is installed)
a When disconnecting the piping between the control valve and work equipment cylinder, 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. 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.
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER

(If PPC accumulator is not installed)
a When disconnecting the piping between the control valve and work equipment cylinder, release the residual pressure in the circuit according to the following procedure. 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. 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. <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.
4. Repeat above steps 2 and 3 by 2 - 3 times.
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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.
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MEASURING FAN MOTOR SPEED
MEASURING FAN MOTOR SPEED

a Measuring instruments for fan motor speed
Symbol M Part No. 799-205-1100 Name Tachometer kit
6. 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.
1. Open the radiator mask. 2. Remove fan guard (1).
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)
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MEASURING FAN PUMP CIRCUIT PRESSURE
MEASURING FAN PUMP CIRCUIT PRESSURE

a Measuring instruments for fun pump circuit pressure
Symbol 1 P 2 Part No. 799-101-5002 790-261-1204 799-401-3400 02896-11015 Name Hydraulic tester Digital hydraulic tester Oil pressure pickup adapter (Size 05) O-ring
4. 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}.
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).
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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 operators 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).
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ADJUSTING STRAIGHT TILTDOZER

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
PX A (mm) 1147 EX 1151
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.
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 Item Tilt section (3) Center section (4) Lift section (5)
Unit: mm
Trunnion section (6)
2) Measure right and left tilting distances B1 and B2.

PX Right tilting distance B1 (mm) Left tilting distance B2 (mm) Approx. 450 EX Approx. 440
Clearance Standard clearance (Note) Standard thickness of shim
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.
Approx. 450
Approx. 440
2 Adjustment sections (3), (4), (5):
Grease (G1-T)
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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:

PX C (mm) 991.5 EX 995
a Adjust center brace (10) so that clearances e between the track and frame on both sides will be the same.
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TESTING AND ADJUSTING OPERATORS CAB

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.
a [a] side: Inside of cab (Pressurized) [b] side: Out of cab (Atmospheric pressure)
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})
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3. Testing door lock Close the door and check the relationship between the operators 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 operators 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.
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.
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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 operators 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.
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.
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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.
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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
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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 Normal display (Default) 1 2 Travel direction/Gear speed + Shift mode/Service meter [U] ( ) [T] (Automatic) Action code display function [T] 3 4 1 Oil, filter maintenance mode [>] [>] [>] [>] [<] Auxiliary menu: 4 items [<] [<] Adjustment menu: 4 items [<] Pm clinic auxiliary mode Error code display mode Adjustment mode Oil, filter maintenance mode Maintenance item: 12 items
[ON] & [U](
Service mode Maintenance interval change mode [>] 6 [<] Electric system error code display mode [>] 7 [<] Mechanical system error code display mode [>] 8 9 [>] [>] [>] [>] 5 [<] Adjustment menu: 16 items Display menu: 3 items [<] [<] [<] [<] [ON]: [U]: [ T ]: [ > ]: [ < ]: ( ): Service switch Buzzer cancel switch (Left) Buzzer cancel switch (Right) Information switch (Right) Information switch (Left) Min. 2.5 sec Adjustment mode Load memory display mode
Maintenance item: 12 items
10 Real-time monitoring mode 11 Dual display monitoring mode Maintenance interval change mode
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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 (PNFR) Rear side: Gear speed (123) Graphics: Engine speed Multi-information section (2): a Information is displayed in 2 lines of 16 characters each. Front side: Gear shift mode (F1-R1F1-R2F2-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. 01 02 03 04 05 06 07 08 09 10 11 12 Engine oil Engine oil filter Fuel filter Hydraulic oil filter Corrosion resistor Bypass filter a Damper oil Final drive oil Hydraulic oil Power train oil Power train oil filter HSS charge filter (HSS specification) a Maintenance item
The items marked with a are displayed but not used for this machine.
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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. 01 02 03 04 Pm clinic auxiliary item Engine speed Boost pressure Work equipment pressure a Battery voltage
Although the items marked with a are displayed, 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.
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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. 01 02 03 Adjustment item Brightness of LCD Brightness of display Contrast of display
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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 Indication method of fault Contents of fault Remedy Automatic function stops or normal function stops partially but machine can work. Call your Komatsu distributor for repair. 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.
E01
Only action code is displayed.
Backup alarm does not sound. Fan speed is kept at maximum.
E02
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. Engine water temperature is defective. Usable gear speeds are limited. Engine speed does not rise fully. Gear shifting shocks become large. Steering performance lowers. Engine cannot be controlled. Machine cannot travel. Machine stops.
CALL E03
Move machine to safe place. Call your Komatsu distributor for repair.
CALL E04
Stop machine immediately. Call your Komatsu distributor for repair.
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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.
No. 5 6 7 8 9 10 11
Gear speed display section
Service mode item

Maintenance interval change mode Electric system error code display mode Mechanical system error code display mode Adjustment mode Load memory display mode Real-time monitoring mode Dual display monitoring mode
1C EE bE Cb Ld 5R dR
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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).
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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.
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Maintenance items table

Replacement interval time Code 01 02 03 04 05 06 07 08 09 10 11 12 ENG OIL ENG FILT FUEL FILT HYD FILT CORR RES BYPS FILT DAMP OIL FNL OIL HYD OIL POWL OIL POWL FILT HSS FILT Maintenance item Engine oil Engine oil filter Fuel filter Hydraulic oil filter Corrosion resistor Bypass filter Damper oil Final drive oil Hydraulic oil Power train oil Power train oil filter HSS charge filter (HSS specification) 1st time (Cannot be changed) 0500h 0500h 0500h 2000h 1000h 2000h 1000h 2000h 1000h 0500h 2nd time and after (Can be changed) 0500h 0500h 0500h 2000h 1000h 2000h 1000h 2000h 1000h 0500h
a The first replacement interval is the same as the second and after replacement intervals, and the former cannot be changed.
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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.
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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.
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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.
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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.
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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.
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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.
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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. [1] a[2] a[3] a[4] a[5] [6] a[7] a[8] a[9] [10] [11] [12] [13] [14] [15]
k
Code 0001 INP TEL NO. 0002 S/T S.CODE 0004 BODY TYPE 0005 BRAKE BASE 0007 ENG.FULL CH 0008 INJ->123456 0009 PITCH SENS.
Adjustment item Phone No. input mode Steering and transmission controller specification set Machine specification set Brake potentiometer zero point adjustment Engine deceleration-cut mode Common rail reduced cylinder mode Pitch angle sensor initial set
Related information Figure/Symbol Code Code Voltage Speed Speed Voltage Adjustment data Adjustment data Voltage Voltage Voltage Current Speed Symbol
Disassembly/ Assembly q q q
0010 FAN 70%MODE Fan 70% speed mode 1005 FAN100%MODE Fan 100% speed mode 1012 S/T N-SET 1013 S/T M.L-SET 1014 S/T M.R-SET 2222 HSS ADJUST 9997 HI IDLE SET 9998 SFT INHIBIT Steering lever neutral set Steering lever left set Steering lever right set HSS lever initial current set High idling limit mode Gear speed limit mode
Items marked with q in the Disassembly/Assembly column of the above table must be adjusted after the machine is assembled or any controller is replaced. (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.
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[ 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.
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(1)
[ 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.
Code 000 008 080 088 010 018 090 098 Standard For EU district For cold
Specification
For EU district + For cold district Pitch specification For EU district + Pitch specification For cold district + Pitch specification For EU district + For cold district + Pitch specification
[ 4 ] 0005: Brake potentiometer zero point adjustment This code is used to adjust the zero point of the potentiometer of the brake pedal. 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.
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(1)
D65EX, PX-15
[ 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.
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(1)
[ 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
[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.
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(6)
[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.
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(6)
D65EX, PX-15
[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.
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20-185
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[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.
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D65EX, PX-15
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. 01 02 03
Displayed information 1,000 rpm service meter Forward odometer 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.
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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.
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D65EX, PX-15
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.
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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.
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D65EX, PX-15
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.
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Monitoring mode table

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

Character
0 150 0 5000
(See detailed information)
0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 0 1000 30 30 0 150 30.0 30.0 0 200 0 300 0 100
mm3/st 30 600
Character 0123456789abcdef Character 0123456789abcdef
km/h Bit Bit
0 100
(See detailed information) (See detailed information)
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D65EX, PX-15
No. Code 47 40905 T/M-SW1 48 40906 T/M-SW2 49 40909 T/M SOL.2 50 40910 S/T-SW1 51 40911 S/T-SW2 52 40913 S/T-SW5 53 40914 S/T SOL.1 55 50100 SSC 56 50101 SSC ORDER 57 50200 T/M LEVER 1 58 50201 T/M LEVER 2 59 50300 S/T LEVER 1 60 50301 S/T LEVER 2 61 50400 BRAKE PEDL 62 50600 HSS L.H.F 63 50601 HSS R.H.F 64 50602 HSS L.H.O 65 50603 HSS R.H.O 66 50900 N-SAFETY 67 51000 SSC ORDER 68 60000 TRACTION 69 60100 BODY ANGLE 70 60600 BR HOLD 71 60700 S/T MODE 72 60800 FILL MODE 73 60909 MOD. MODE 74 70000 CHG. P. MODE 75 70300 B.KNOB SW 76 70304 T/M SOL.1 77 70400 BACK ALARM 78 70500 Regulation
Monitored item Transmission-related controller input signal 1 Transmission-related controller input signal 2 Transmission-related controller output signal Steering-related controller input signal 1 Steering-related controller input signal 2 Steering-related controller input signal 5 Output signal of steering controller 3rd throttle 3rd throttle command voltage Voltage of forward-reverse potentiometer 1 Voltage of forward-reverse potentiometer 2 Voltage of steering potentiometer 1 Voltage of steering potentiometer 2 Voltage of brake potentiometer Output FB current of left HSS solenoid Output FB current of right HSS solenoid Output command current of left HSS solenoid Output command current of right HSS solenoid Drive current of neutral safety relay 3rd throttle command speed Traction force (Theoretical value) Machine pitch angle sensor voltage Drive voltage of battery relay Steering state code Variable for setting fill condition Setting of modulation condition Variable for setting condition of gear shift point Input signal of work equipment-related controller Output signal of work equipment-related controller Drive voltage of back-up alarm relay Reguration speed
Unit Bit Bit Bit Bit Bit Bit Bit % % mV mV mV mV mV mV mA mA mA mA mV rpm W mV mV

Character Character Character Character
Display range
(See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information) (See detailed information)
54 50000 DESEL PEDAL Deceleration ratio
0 100 0 100 0 5000 0 5000 0 5000 0 5000 0 5000 0 5000 0 1000 0 1000 0 1000 0 1000 0 30000 0 3000 00 0 5000 0 30000
Bit Bit mV rpm
(See detailed information) (See detailed information)
0 30000 0 2200
The numbers marked with tion.
can be displayed in order by setting the information switch in the > or < posi-
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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)
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D65EX, PX-15
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)
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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)
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D65EX, PX-15
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)
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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.
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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.
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D65EX, PX-15
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER HANDLING OF HIGH-VOLTAGE CIRCUIT REPLACED CONTROLLER ADJUSTMENT METHOD OF OF ENGINE
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
ADJUSTMENT METHOD OF REPLACED CONTROLLER

a After the machine is assembled or steering and transmission controller is replaced, 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.
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. 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.
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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.
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.
5. Adjusting brake potentiometer Select Brake potentiometer initial set (0005) and adjust the brake potentiometer.
6. Adjusting pitch angle sensor Select and adjust the initial setting (0009) of the pitch angle sensor.
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D65EX, PX-15
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM

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. Engine controller 1) Remove left console box inspection cover (3).
2) Insert or connect T-adapters in or to connectors S03 and S04 on the back side of monitor panel (2).
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}
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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}
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D65EX, PX-15
PM CLINIC SERVICE
Pm CLINIC SERVICE
Model Serial No. Service meter h Date of clinic Serviceman
D65EX, PX, WX-15

User name
Blade
Semi-U blade Angle blade Straight tilt blade
Specifications Attachment
Multi-shank ripper Towing winch CAB ROPS 510 mm 560 mm 610 mm 660 mm
Shoe width
810 mm 915 mm 950 mm
Operating conditions
Quarry, 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 Power train Final drive

Power train oil temperature Max. range
Damper case (
Ambient temperature
Max. Min.
Height above sea level m Operator's opinion
Visual check results
Service code history

E Content: E Content: h h E Content: E Content: h h
D65EX, PX-15
20-203
(7)
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
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)
PM CLINIC SERVICE
Pm CLINIC CHECK SHEET

Work order No. / Date /
D65EX, PX, WX-15

Service meter h
Serial No.
Serviceman
Item
Measurement conditions Low idling
Unit
Standard value for Service limit value Measurement results Pass new machine
Fail
800 850
Deceleration pedal depressed
800 850 975 1025 2050 2150 1650 Max. 1.96 <Max. 200> 0.07 <0.7> 0.18 <1.8> 0.07 <0.7> 0.21 <2.1> 60 <450> 700
Engine speed
High idling High idling
rpm
975 1025 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
Torque converter stall Blow-by pressure Torque converter stall Engine at low idling Engine at high idling Engine at low idling Engine at high idling Engine kPa <mmAq>
SAE10W MPa <kg/cm2> SAE15W-40 SAE30 kPa <mmHg> C
Engine oil pressure
Boost pressure
Torque converter stall
Exhaust temperature Torque converter stall
Item Torque converter Inlet oil pressure Outlet oil pressure Inlet oil pressure Outlet oil pressure
Measurement conditions
Unit
Fail
Transmission: Neutral Oil temperature: 70 90C
Engine at low idling MPa <kg/cm2> Engine at high idling
0.1 0.5 <1 5> 0.05 0.29 <0.5 3> Max. 0.88 <Max. 9> 0.39 0.69 <4 7>
0.1 0.5 <1 5> 0.05 0.29 <0.5 3> Max. 0.88 <Max. 9> 0.39 0.69 <4 7>
Item Transmission
Measurement conditions Engine at low idling Engine at high idling

Engine: Low idling Coolant temperature: Power train oil temperature: Max. 80C
Standard
Unit
Fail
Main relief pressure
Transmission: Neutral
MPa <kg/cm2>
3.03 3.23 <31 33> 3.23 3.43 <33 35>
Min. 2.84 <Min. 29> Min. 3.04 <Min. 31>
Min. speed
rpm
800 50
700
Cooling fan
Fan speed
idling Fan 100% speed mode
Max. speed
Hydraulic oil temperature: 45 55C Fan forward Engine: High
1,850 0 1,600 0
+100
1,750 1,500 18.6 {190} 13.7 {140}
For EU spec.
+100
Fan pump pressure
Hydraulic oil temperature: 45 55C Fan forward Fan 100% speed mode Engine: High idling
Standard
For EU spec.
MPa {kg/cm2}
19.6 22.5 {200 230} 15.7 18.6 {160 190}
20-206
(7)
D65EX, PX-15
PM CLINIC SERVICE
Pm CLINIC CHECK SHEET

D65EX, PX, WX-15

Service meter h
Serial No.
Serviceman
Item Steering Steering load sensing pressure
Unit
Fail
Engine at high idling Steering relief pressure Brake actuating pressure Brake performance Engine at high idling
MPa <kg/cm2>
Brake
32.8 36.8 <335 375> 34.8 38.8 <355 395> 2.75 2.94 <28 30>
Min. 30.9 <Min. 315> Min. 32.8 <Min. 335> Min. 2.55 <Min. 26.0>
Apply brake and run engine at full throttle with transmission gear in F2. Measurement conditions Engine at high idling Ripper lift relief Engine at low idling
Unit
Machine must not move

Item Work equipment load sensing pressure
Fail
19.6 23.6 <200 240> 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. 17.6 <Min. 180> 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> Fail
Hydraulic components
HSS and work equipment pump
Blade tilt relief Ripper lift relief Blade tilt relief Engine at high idling
MPa <kg/cm2>
PPC valve output Blade tilt relief pressure Item Work equipment speed Blade RAISE Single tilt (left o right) Ripper RAISE Measurement conditions Engine at high idling Sec. Engine at high idling Engine at high idling
Unit
EX: 2.1 2.8 PX: 1.9 2.6 2.0 2.6 1.2 1.6
Max. 3.1 Max. 2.9 Max. 2.8 Max. 1.9
Item Hydraulic drift Hydraulic oil temperature Blade lift cylinder Ripper tilt cylinder
Unit
Fail
C Engine stopped mm/15 min.
45 55 Max. 100 Max. 200
Max. 100 Max. 200
Item
Unit
Fail
Visual inspection of final drive drain plug Engine stopped
There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
D65EX, PX-15
20-207
(7)
PM CLINIC SERVICE
Pm CLINIC UNDERCARRIAGE CHECK SHEET

D65EX , WX-15
Service meter h
Serial No.
Serviceman
Measure the bushing temperature immediately after operations Left side of machine
Measurement results
Pas Fail s
Right side of machine

Measurement results
Pas Fail s
Opening of track link
Left track
A: Clearance between links
Pin No.
1.4
Right track
Pin No.
1.4
20-208
(7)
D65EX, PX-15
PM CLINIC SERVICE
Pm CLINIC UNDERCARRIAGE CHECK SHEET

D65PX-15
Service meter h
Serial No.
Serviceman
Measure the bushing temperature immediately after operations Left side of machine
Measurement results
Pas Fail s
Right side of machine

Measurement results
Pas Fail s
Opening of track link
Left track
Pin No.
1.4
Right track
Pin No.
1.4
D65EX, PX-15
20-209
(1)
UNDERCARRIAGE TROUBLESHOOTING REPORT
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)

(Program form No.: SELA195001)
Y
Komatsu Undercarriage Inspection
Customer name: Address:
Model Location
D65EX, PX, WX-15
Serial No SMR Dealer Inspector
Equip No
Work Order No Wet,AR,HD or Dry Shoe width (mm) Shoe type

(yyyy/m/d)
Wet SINGLE
Soil condition Working condition
LINK PITCH
M L
LH R
Insp.Date(yy/mm/dd) New 100% Measured Wear mm 813.8 825.8 813.8 825.8 203.45 206.45
Wear %
New
SMR Hours on Rebuilt Parts:
Wear type NORMAL Comments/Observation
L=l/4
l
RH LH M
master pin
master i
1.3
RH 203.45 206.45 LH
132.0 132.0 73.0 73.0 65.0 65.0 185.0 185.0 185.0 185.0 20.0 20.0 20.0 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 0.0
119.5 119.5 New Turned Turned 62.8 New 62.8 25.0 25.0 163.0 163.0 163.0 163.0 30.0 30.0 30.0 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 9.0
LINK HEIGHT 1.3 BUSHIN G

d D is the smallest ofd1,,d2 and,d3 d1
RH
LH RH
1
LH
GROUSER HIGHT
H
0
CARRIER CARRIER Front
RH LH RH
D
Rear
LH RH LH Front RH LH Rear
1.3
IDLER IDLER
H
1.3
1 2 3 4 5 6 7
RH LH LH LH LH LH LH LH LH LH LH RH RH RH RH RH RH RH RH RH RH LH
TRACK ROLLER
8 9 10
D h2 h1
1 2 3 4 5 6 7 8 9
D=2(h1-h2)
1.3
SPROCKET
H is the smallest of h3 h1,h2,h3 h1 h2
10
1.3
RH
Remarks:
20-210
(7)
D65EX, PX-15
UNDERCARRIAGE TROUBLESHOOTING REPORT
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)

(Program form No.: SELA195001)
Y
Komatsu Undercarriage Inspection
Customer name: Address:
Model Location
D65EX, PX, WX-15
Serial No SMR Dealer Inspector
Equip No
Work Order No Wet,AR,HD or Dry Shoe width (mm) Shoe type

(yyyy/m/d)
Wet SINGLE
Soil condition Working condition
LINK PITCH
M L
LH R
Insp.Date(yy/mm/dd) New 100% Measured Wear mm 813.8 825.8 813.8 825.8 203.45 206.45
Wear %
New
SMR Hours on Rebuilt Parts:
Wear type IMPACT Comments/Observation
L=l/4
l
RH LH M
master pin
master i
1.3
RH 203.45 206.45 LH
132.0 132.0 73.0 73.0 65.0 65.0 185.0 185.0 185.0 185.0 20.0 20.0 20.0 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 0.0
119.5 119.5 New Turned Turned 65.4 New 65.4 25.0 25.0 163.0 163.0 163.0 163.0 30.0 30.0 30.0 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 9.0
LINK HEIGHT 1.3 BUSHIN G

d D is the smallest ofd1,,d2 and,d3 d1
RH
LH RH
1
LH
GROUSER HIGHT
H
0
CARRIER CARRIER Front
RH LH RH
D
Rear
LH RH LH Front RH LH Rear
1.3
IDLER IDLER
H
1.3
1 2 3 4 5 6 7
RH LH LH LH LH LH LH LH LH LH LH RH RH RH RH RH RH RH RH RH RH LH
TRACK ROLLER
8 9 10
D h2 h1
1 2 3 4 5 6 7 8 9
D=2(h1-h2)
1.3
SPROCKET
H is the smallest of h3 h1,h2,h3 h1 h2
10
1.3
RH
Remarks:
D65EX, PX-15
20-211
(7)
TROUBLESHOOTING
TROUBLESHOOTING
Points to remember when troubleshooting .............................................................................................. Sequence of events in troubleshooting ................................................................................................... Handling of electric equipment and hydraulic component ....................................................................... Checks before troubleshooting ................................................................................................................ Classification and procedures of troubleshooting .................................................................................... Types and locations of connectors (D65EX, PX-15) ............................................................................... Connector arrangement drawing ............................................................................................................. Circuit drawing for engine controller system (E circuit) ........................................................................... Circuit drawing for steering and transmission controller system (ST TM circuit) ................................... Circuit drawing for monitor panel system (M circuit) ................................................................................ Connection table for connector pin numbers ........................................................................................... T-branch box and T-branch adapter table ............................................................................................... Troubleshooting when error code is displayed (Error code) .................................................................... Troubleshooting of electrical system (E-mode) ....................................................................................... Troubleshooting of hydraulic and mechanical system (H-mode) ............................................................. Troubleshooting of engine system (S-mode) ........................................................................................... 20-302 20-303 20-304 20-312 20-313 20-316 20-322 20-328 20-330 20-332 20-334 20-370 20-401 20-601 20-701 20-801
D65EX, PX-15
20-301
(8)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k k k k k k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. 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. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative () terminal of the battery first. 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.
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.
20-302
(8)
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

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
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. 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.
5)
D65EX, PX-15
20-305
(8)
TROUBLESHOOTING
3.
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)
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
Disconnection
Connection (Example of incomplete setting of (a))
20-308
(8)
D65EX, PX-15
TROUBLESHOOTING
4)
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
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
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. 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. 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. 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.
2.
3.
4.
D65EX, PX-15
20-311
(8)
TROUBLESHOOTING
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. 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.
6.
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. 2. 3. 4. 5. 6. 7. 8. 9. Check fuel level Check for impurities in fuel Check hydraulic oil level Check oil level in damper case Check power train oil level Check engine oil level (engine oil pan level) Check coolant level Check dust indicator for clogging Check travel of brake pedal Judgement Value 20 30 V
After running for several minutes: 27.5 29.5 V
Action Add fuel Clean, drain Add oil Add oil Add oil Add oil Add water Clean or replace Adjust Tighten or replace Tighten or replace Tighten or replace Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace Replace
10. Check for looseness, corrosion of battery terminal, wiring 11. Check for looseness, corrosion of alternator terminal, wiring 12. Check for looseness, corrosion of starting motor terminal, wiring 13. Check for abnormal noise, smell 14. Check for oil leakage 15. Carry out air bleeding 16. Check battery voltage (engine stopped) 17. Check battery electrolyte level 18. Check for discolored, burnt, exposed wiring 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 22. Check alternator voltage (engine running at 1/2 throttle or above) 23. Check operating sound of battery relay (starting switch ON, OFF)
20-312
(1)
D65EX, PX-15
TROUBLESHOOTING
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING

Classification of Troubleshooting
Mode Error code E Mode H Mode S Mode Explanation Troubleshooting when a service code is displayed Troubleshooting of the electrical system Troubleshooting of the hydraulic and mechanical systems Troubleshooting of the engine body
Troubleshooting Procedures
When any phenomenon supposed to be a failure appeared on the machine, 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
Phenomena supposed to be Failures and Troubleshooting No.

Troubleshooting No. Phenomenon suppose to be Failure Phenomenon related to action code/error code 1 2 3 4 5 6 7 8 9 An action code is displayed on the monitor panel. A error code is displayed in the error code display mode. Phenomenon related to engine The engine does not start smoothly. (Engine starting takes a time all the time.) The engine does not rotate. The engine does not start. The engine rotates but does not exhaust gas. The engine exhausts gas but does not rotate. The engine does not pick-up smoothly. (Poor follow-up performance) The engine stops during operation. The engine rotates abnormally. (Hunting) E-1 S-1 S-2 a) S-2 b) S-2 c) S-3 S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 E-2 Phenomenon related to power train 22 The power train has no power (no drawbar pull). 23 The power train does not travel (in case of 2-spool or 3-spool). 24 The power train does not start at all gear speeds. 25 The power train travel forward or in reverse only 26 Large time lag at any gear speed or at forward-reverse shifting 27 Steering is not possible. (Left turn or right turn is impossible.) 28 The steering speed is slow or the steering system has no power. 29 The brake does not work. 30 The power train oil is overheated. 31 Abnormal noise around the HSS and work equipment pump or the HSS motor Phenomenon related to work equipment 32 All the work equipment operates slowly. 33 All the work equipment does not operate. 34 The blade lift moves slowly or has no power. 35 The blade tilt moves slowly or has no power. 36 The ripper lift moves slowly or has no power. 37 Large hydraulic drift of the blade lift 38 Large hydraulic drift of the blade tilt 39 Large hydraulic drift of the ripper lift H-11 H-12 H-13 H-14 H-15 H-16 H-17 H-18 H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 S-6 q Check the error code. Error E Mode H Mode S Mode Code
10 Insufficient output or no power 11 Black exhaust (Imperfect combustion) 12 Large oil consumption or blue exhaust 13 Oil is contaminated fast. 14 Large fuel consumption 15 Oil mixes in coolant, spurts or water reduces. 16 Engine oil pressure drops. 17 Oil increases. 18 Water temperature rises too high. (Overheat) 19 An abnormal noise occurs. 20 Large vibration 21 The preheater does not work.
20-314
(1)
D65EX, PX-15
TROUBLESHOOTING
Troubleshooting No. Phenomenon suppose to be Failure Error E Mode H Mode S Mode Code E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19
Phenomenon related to monitor panel (Operator mode: Normal screen) 40 When the starting switch is set to ON, no light on the monitor panel comes on. 41 When the starting switch is set to ON, all the lights on the monitor panel do not go out. 42 While the engine is operating, the battery charge caution items flash. 43 While the engine is operating, the emergency warning items flash. 44 While the preheater is operating, the preheating pilot lamp does not come on. 45 Indication of the engine water temperature gauge is abnormal. 46 Indication of the power train oil temperature gauge is abnormal. 47 Indication of the hydraulic oil temperature gauge is abnormal. 48 Indication of the fuel gauge is abnormal. 49 Indications of gear speed and engine speed are abnormal. 50 Indication of the preset mode service meter is abnormal. 51 The warning lamp does not flash or does not go out. 52 The alarm buzzer does not sound or does not stop. 53 Auto shift down is not possible or is not released. 54 The buzzer cancel switch does not work. 55 The information switch does not work. 56 The preset mode does not be operated or cancelled.
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. 59 The head lamp, rear lamp, and ripper point lamp on the panel do not come on. 60 The wiper malfunctions. 61 Washing water does not come out. 62 The air conditioner does not operate. E-21 E-22 E-23 E-24 E-25
D65EX, PX-15
20-315
(1)
TROUBLESHOOTING
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
Location
Arrange- Engine ST MON ment system system system drawing diagram diagram diagram
1 2 4 6 7 8 9 9 10 10 11 11 12 12 13 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33
DT KES1 KES1
One-pin connector
4 2 2 1 9 2 3 2 2 2 2 2 6 2 6 6 6 6 2 4 4 4 1 1 6 4 4 6 5 6 5 6 5 6 5
Intermediate connector [Cab specification] Rear speaker (Left) [Cab specification] Rear speaker (Right) [Cab specification] Heater wire glass [Cab specification] Radio [Cab specification] Accessory (12 V) [Cab specification] Heater wire glass switch [Cab specification] Washer motor (Left) Additional light switch [Cab specification] Washer motor (Right) Wiper intermittent switch [Cab specification] Washer motor (Front) Rear wiper switch [Cab specification] Washer motor (Rear) Right door wiper switch [Cab specification] Intermediate connector (Washer motor) Front wiper switch [Cab specification] Left door wiper switch [Cab specification] Room lamp [Cab specification] Right door wiper [Cab specification] Intermediate connector [Cab specification] Intermediate connector (Windshield washer motor) [Cab specification] Cab power supply [Cab specification] Cab power supply (Battery direct) [Cab specification] Front wiper [Cab specification] Left door wiper [Cab specification] For light [Cab specification] Left wiper intermittent relay [Cab specification] Left wiper intermittent selector relay [Cab specification] Front wiper intermittent relay [Cab specification] Front wiper intermittent selector relay [Cab specification] Right wiper intermittent relay [Cab specification] Right wiper intermittent selector relay [Cab specification] Rear wiper intermittent relay [Cab specification] Rear wiper intermittent selector relay [Cab specification]
I9 I8 H9 H9 B9 B9 B8 D7 B8 D7 B9 D7 A9 E7 A9 E8 A9 A9 B7 B7 F8 C5, W2 C5, W2 C6, V2 E8 C5 C8 C8 C7 C8 C7 C8 C7 C8 D8
PA DT YAZAKI M M M M M KES1 M KES1 SWP KES1 KES1 KES1 DT DT DT DTHD#12 DTHD#8 DT DT

Relay (YAZAKI) Relay (YAZAKI)
Relay
Relay (YAZAKI)
Relay
Relay (YAZAKI)
Relay
Relay (YAZAKI)
Relay
20-316
(1)
D65EX, PX-15
TROUBLESHOOTING
Address
Connector No.
Type
Relay (YAZAKI)
Number of pins
Location
34 35 36 37 53 101 203 204 205 214 215 217 218 224 228 244 247 250 255 260 262 270 280 423 453 800 1SOL 2SOL 3SOL 1SW 2SW 3SW A/C AL/B AL/E
4 4 1 4 2 8 2 2 1 12 12 2 12 2 2 2 2 1 1 1 2 1 1 2 2 1 2 2 2 2 2 2 2 1 1
Heater wire glass relay [Cab specification] Converter [Cab specification] Heater wire glass [Cab specification] Rear wiper [Cab specification] Intermediate connector (Pitch selector solenoid) (If equipped) Intermediate connector Right head lamp Left head lamp Horn Intermediate connector [Dashboard] Intermediate connector [Dashboard] Caution buzzer Intermediate connector [Air conditioner] Intermediate connector Rear lamp (If equipped) Backup alarm Rear lamp (Rear left) Starting switch (Terminal B) Starting switch (Terminal R1) Starting switch (Terminal BR) Horn switch Starting switch (Terminal ACC) Starting switch (Terminal C) Fuel level sensor Torque converter oil temperature sensor Service power supply 1st clutch ECMV solenoid 2nd clutch ECMV solenoid 3rd clutch ECMV solenoid 1st clutch ECMV fill switch 2nd clutch ECMV fill switch 3rd clutch ECMV fill switch Air conditioner compressor Alternator terminal B Alternator terminal E
C8 C8 J8 I9 O5 B5 B4 B3 B3 O2 O2 O4 O2 J8 K7 K7 J8 N5 N4 M4 S9 M5 N5 K8 AI2 U1 AF6 AI3 AG6 AH7 AI3 AG6 Y2 Y6 Y6 K3 K3 K2 K3 K3 K2 J6 J9 J9 D9 D9 D1 D1 H8 H8 I9 J9 J9 C9 C9 A1 G8 D1 D1 D1 G8 G8 B7 D7 C8 B6 E6 B2 J7 J8 J8
M
One-pin connector
KES1 DT DT (Gr) DT DT Terminal DT (B) DT (G) DT DT (Br) DT DT DT DT Terminal Terminal Terminal DT Terminal Terminal DT DT DTHD#12 DT DT DT DT DT DT DT Terminal Terminal
D65EX, PX-15
20-317
(1)
TROUBLESHOOTING
Address
Connector No.
Type
Number of pins
Location
AL/R AC1 AC2 AC3 ACC ASD BKA BRK BUZ C CA2 CA2 ( 1) CAN CB1 CIG CN-1 CN-2 CN-3 CN-4 CN-5 CN-6 CUR DCL DIAL E21 E22 E29 EN1 EN2 EN3 FAC FAM FAR FFC FL FL1 FLS FR
Terminal MIC AMP AMP YAZAKI KES1 Relay DT KES1 Terminal DT DT DT (Gr)
One-pin connector
1 17 16 12 2 4 5 3 3 1 3 3 12 2 2 2 2 2 2 2 2 3 3 3 31 31 1 24 40 40 2 4 2 6 2 2 4 2
Alternator terminal R Air conditioner unit Auto air conditioner controller Auto air conditioner controller Accessory socket [Cab specification] Auto shift-down switch Backup alarm relay Brake pedal potentiometer Buzzer cancel switch Battery relay power supply outlet CAN terminating resistor CAN terminating resistor Intermediate connector [KOMTRAX] Circuit breaker (20 A) (Starting switch) Cigarette lighter Engine No. 1 injector Engine No. 2 injector Engine No. 3 injector Engine No. 4 injector Engine No. 5 injector Engine No. 6 injector Information switch Decelerator pedal potentiometer Fuel control dial potentiometer Intermediate connector (Engine) Intermediate connector (Engine) Engine oil pressure sensor (High pressure) Engine controller Engine controller Engine controller Fan pump TVC solenoid Fan reverse mode switch Fan reverse solenoid Intermediate connector Front additional light (Left) Fusible link Software writing connector (Engine controller) Front additional light (Right)
Y6 O6 P1 P1 D6 N7 V1 R1 P8 W4 X1 I1 L2 I9 Q9 M7 D6 AB2 AC2 AC3 AD5 AD6 AD6 O7 Q1 V8 C1, AC9 D1, AD9 Z1 V1 W1 W1 AF6 O7 B2 K5 G9 W2 W1 F8 B3 K2 K1 J8 J8 C3 C7 E9 A7 A6 A4 J7 D8 A2 B1 G7 H1 H1 I2 K6 L8 K1 K1 A3 A2 A2 A1 A2 A2 E8 E8 J8 E8 F8 A2 F8 E1 A8 A8 C1 C9 D8 B2 C9 E8
YAZAKI DT DT DT DT DT DT KES1 DT M HD-24 HD-24 Terminal DRC-26 DRC-26 DRC-26 DT KES1 DT DT (Gr) DT L X DT
1. For KOMTRAX use.
20-318
(1)
D65EX, PX-15
TROUBLESHOOTING
Address
Connector No.
Type
Number of pins
Location
FS1 FS2 FSOL FSW FUSE1 FUSE2 FWL G ( 1) G01 ( 1) G02 ( 1) G03 ( 1) G04 ( 1) G05 GND GND1 GND1 GND2 GND2 GND3 GND3 GND4 GND01 GND03 GND04 H HSA HSB HT/A HT/B HT/S KEY ( 1) KOM2 ( 1) KOM3 ( 1) KOM4 M26 MAM NE NSF
DT DT Terminal Terminal KES1 090 DRC-26 x x x x Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT DT Terminal Terminal Terminal DT GT5 BNC ML M KES1 090 Relay 2 2 1 1 4 2 40 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 6 1 1 1 6 4 2 5
Fuse box Fuse box Forward clutch ECMV solenoid Forward clutch ECMV (Fill switch) Fusible link (Battery side) Fusible link (Alternator side) Head lamp switch Engine speed G sensor KOMTRAX control Check connector (KOMTRAX) Check connector (KOMTRAX) Check connector (KOMTRAX) Check connector (KOMTRAX) Intermediate connector (Intermediate connector to ground) Ground [Cab specification] Ground (In cab) Ground (In cab) Ground [Engine] Ground [Cab specification] Ground [Engine] Ground Ground [Floor] Ground [Fender] Ground [Flame] Battery relay power supply inlet HSS-EPC (Left swing) HSS-EPC (Right swing) Intake air heater relay (Terminal A) Intake air heater relay (Terminal B) Intake air heater relay (Terminal coil) Intermediate connector (Starting switch) [Canopy specification] KOMTRAX controller KOMTRAX controller KOMTRAX controller (Antenna) Air conditioner unit Manual mode switch Engine speed NE sensor Neutral safety relay
W4 W3 AJ3 AI7 AA9 AA9 O7 AB2 R9 P8 P8 P9 P9 AA9 B9 B9 B9 A5 D7 Y2 H9 T1 K5 B5 W4 AG8 AE6 AC9 AB9 AB9 O9 Q9 Q9 H9 O6 O7 AD3 U1
G2 G1
D2 D2 K4 K4
A1 A1
D8 E8 L8
B7
I1
K1 B7 I1
K1
F1 F1 F1 I1 E1 K7 K6 B8 B8 B8
F1
J5
I1 I1 I1
E8 E9 L7 F8 L8 F6
1. For KOMTRAX use. D65EX, PX-15
20-319
(1)
TROUBLESHOOTING
Address
Connector No.
Type
Number of pins
Location
NSW P03 P04 PCV1 PCV2 PFUEL PIM PL1 PL2 PPR PSL PT1 R1 R2 R3 R4 RHR RL RR RSOL RSW RWL S03 S04 S13 S24 SDS SFTD SFTU ST ST/B ST1 ST2 ST3 STA STB STF SW
DT DT DT 090 090 AMP 090 HD-24 HD-24 Relay Terminal DT

Relay (YAZAKI) Relay (YAZAKI) Relay (YAZAKI) Relay (YAZAKI)
2 6 6 2 2 3 3 23 31 5 1 3 4 4 4 4 5 2 2 2 2 4 20 12 12 4 2 3 3 2 1 24 40 40 6 6 4 1
Safety lock switch Intermediate connector (Pitch selector switch) (If equipped) Intermediate connector (Pitch selector switch) (If equipped) Fuel supply pump Fuel supply pump Common rail fuel pressure switch Boost pressure sensor Intermediate connector [Power train] Intermediate connector [Power train] Supply pump power relay Engine oil pressure sensor (Low pressure) Pitch angle sensor Air conditioner relay Air conditioner relay Air conditioner relay Air conditioner relay Pre-heater relay Rear additional light (Left) [Cab specification] Rear additional light (Right) [Cab specification] Reverse clutch ECMV solenoid Reverse clutch ECMV fill switch Rear lamp switch Monitor panel Monitor panel Intermediate connector Service switch Hydraulic oil temperature sensor Shift-down switch Shift-up switch Starting motor Starting motor (Terminal B) Steering and transmission controller Steering and transmission controller Steering and transmission controller Intermediate connector (HSS-EPC) Intermediate connector (HSS-EPC) Software writing connector (Steering and transmission controller) Battery relay terminal BR
W7 S9 S9 AB2 AB2 AD3 AO7 S1, AH2 S1, AH2 V2 Z1 Q9 O5 O4 O4 O4 U1 I8 G9 AG7 AI7 O7 N9 N9 O3 M7 AE2 U9 U9 Y7 Y8 W3 X3 X3 AG1 AF9 X1 W5 J1 K2 H8 I7 K7 K7 E9 A8 A9
A2
A2
I4 I7
K8 D1
Relay DT DT DT DT KES1 AMP070 AMP070 DT (Gr) Terminal DT C C DT Terminal DRC-26 DRC-26 DRC-26 DT DT X Terminal
E6
K4 K4 E8 A8 B8 C7 D9 J6 K8 K8 H2 D6 D9
A7 A6 A4 J7 J7 B8 E1
A4 A3 A3
20-320
(1)
D65EX, PX-15
TROUBLESHOOTING
Address
Connector No.
Type
Number of pins
Location
SWG THL TL1 TL2 TL3 TM1 TMV TWH TWL
Terminal DT HD-24 DT (B) DT DT HD-24 DT DT
1 3 23 8 6 2 23 2 2
Battery relay ground Fuel temperature sensor Intermediate connector [Console] Travel lever Intermediate connector [Shift switch] Transmission bevel speed sensor Intermediate connector [Transmission ECMV] Engine water temperature sensor (High temperature) Engine water temperature sensor (Low temperature)
W5 AD3 V8 V8 V8 AJ6 AG7 Y6 AB9
J1 E8 J7
E1
I9 J9 J8 J6 J4
B9 B9
K8 K8
The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles) and (DT-12 poles) are as follows. (Gr) = Gray, (B) = Black, (G) = Green, (Br) = Brown
Type of connector AMP AMP070 BNC C DRC-26 DT DTHD GT5 HD30 KES1 L M MIC ML PA SUMITOMO SWP X YAZAKI One-pin connector Terminal Relay Relay (YAZAKI)
Detail Connector manufactured by NIPPON AMP Connector of type 070 manufactured by NIPPON AMP Connector of type BNC for coaxial cable Connector of type C manufactured by CALSONIC KANSEI DRC type connector DT type connector (08192-XXXXX) DTHD type connector (08192-XXXXX) Connector of type GT5 for coaxial cable of GPS antenna HD30 type connector (08191-XXXXX) Connector of KES1 type (08027-1XXXX) Connector of type L manufactured by YAZAKI (08056-2XXXX) Connector of type M manufactured by YAZAKI (08056-0XXXX) Connector of MIC type manufactured by NIPPON AMP L-connector of M type for coaxial cable Connector of PA type manufactured by YAZAKI Connector manufactured by SUMITOMO DENSO Connector of SWP type manufactured by YAZAKI (08055-1XXXX) Connector of X type manufactured by YAZAKI (08055-0XXXX) YAZAKI type connector 1-pole connector of pin type Round terminal or ordinary terminal Connector of PH166-05020 type manufactured by SHINAGAWA JIDOSHA DENSEN Connector manufactured by YAZAKI (For relay)
D65EX, PX-15
20-321
(1)
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
20-322
(1)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-323
(1)
TROUBLESHOOTING
20-324
(1)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-325
(1)
TROUBLESHOOTING
20-326
(1)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-327
(1)
TROUBLESHOOTING
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
20-328
(1)
D65EX, PX-15
TROUBLESHOOTING
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)
20-330
(1)
D65EX, PX-15
TROUBLESHOOTING
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)
20-332
(1)
D65EX, PX-15
TROUBLESHOOTING
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
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
20-335
(8)
TROUBLESHOOTING
20-336
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-337
(8)
TROUBLESHOOTING
20-338
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-339
(8)
TROUBLESHOOTING
20-340
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-341
(8)
TROUBLESHOOTING
20-342
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-343
(8)
TROUBLESHOOTING
20-344
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-345
(8)
TROUBLESHOOTING
20-346
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-347
(8)
TROUBLESHOOTING
20-348
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-349
(8)
TROUBLESHOOTING
20-350
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-351
(8)
TROUBLESHOOTING
20-352
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-353
(8)
TROUBLESHOOTING
20-354
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-355
(8)
TROUBLESHOOTING
20-356
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-357
(8)
TROUBLESHOOTING
20-358
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-359
(8)
TROUBLESHOOTING
20-360
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-361
(8)
TROUBLESHOOTING
20-362
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-363
(8)
TROUBLESHOOTING
20-364
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-365
(8)
TROUBLESHOOTING
20-366
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-367
(8)
TROUBLESHOOTING
20-368
(8)
D65EX, PX-15
TROUBLESHOOTING
D65EX, PX-15
20-369
(8)
TROUBLESHOOTING
T- BRANCH BOX AND T- BRANCH ADAPTER TABLE

(Rev. 2007.12) a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
Number of pins T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4101 q q 1 2 3 4 6 8 12 14 16 1 2 3 M2P M3P X2P X3P X4P SW6P SW8P SW12P SW14P SW16P q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q 799-601-4201 Identification symbol Out of kit q q q 24 24 17 17 5 10 5 17 19 14 5 13 17 21 9 2 3 4 8 8 12 16 MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P MIC-5P MIC-13P MIC-17P MIC-21P MIC-9P ECONO2P ECONO3P ECONO4P ECONO8P DLI-8P DLI-12P DLI-16P q q q q q q q q q q q q q q q q 60 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-2600 T-box (for ECONO) 799-601-3100 T-box (for MS) 799-601-3200 T-box (for MS) 799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS) 799-601-3420 Adapter for BENDIX (MS) 799-601-3430 Adapter for BENDIX (MS) 799-601-3440 Adapter for BENDIX (MS) 799-601-3450 Adapter for BENDIX (MS) 799-601-3460 Adapter for BENDIX (MS) 799-601-3510 Adapter for BENDIX (MS) 799-601-3520 Adapter for BENDIX (MS) 799-601-3530 Adapter for BENDIX (MS) 799-601-2910 Adapter for BENDIX (MS) 799-601-3470 Case 799-601-2710 Adapter for MIC 799-601-2720 Adapter for MIC 799-601-2730 Adapter for MIC 799-601-2740 Adapter for MIC 799-601-2950 Adapter for MIC 799-601-2750 Adapter for ECONO 799-601-2760 Adapter for ECONO 799-601-2770 Adapter for ECONO 799-601-2780 Adapter for ECONO 799-601-2790 Adapter for ECONO 799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI 799-601-2840 Extension cable (ECONO type) 799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO) 799-601-4360 Case 799-601-7010 Adapter for X (T-adapter) 799-601-7020 Adapter for X 799-601-7030 Adapter for X 799-601-7040 Adapter for X 799-601-7050 Adapter for SWP 799-601-7060 Adapter for SWP 799-601-7310 Adapter for SWP 799-601-7070 Adapter for SWP 799-601-7320 Adapter for SWP 799-601-7080 Adapter for M (T-adapter) 799-601-7090 Adapter for M 799-601-7110 Adapter for M
21 37 37
q q
12 ECONO12P q q
12 ECONO12P q q
20-370
(8)
D65EX, PX-15
TROUBLESHOOTING
Number of pins
T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4101 799-601-4201 Identification symbol Out of kit q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-7120 Adapter for M 799-601-7130 Adapter for M 799-601-7340 Adapter for M 799-601-7140 Adapter for S 799-601-7150 Adapter for S (White) 799-601-7160 Adapter for S (Blue) 799-601-7170 Adapter for S (Blue) 799-601-7330 Adapter for S (White) 799-601-7350 Adapter for S (White) 799-601-7180 Adapter for AMP040 799-601-7190 Adapter for AMP040 799-601-7210 Adapter for AMP040 799-601-7220 Adapter for AMP040 799-601-7230 Short connector for X 799-601-7240 Case 799-601-7270 Case 799-601-7510 Adapter for 070 799-601-7520 Adapter for 070 799-601-7530 Adapter for 070 799-601-7540 Adapter for 070 799-601-7550 Adapter for 070 799-601-7360 Adapter for relay 799-601-7370 Adapter for relay 799-601-7380 Adapter for JFC 799-601-9010 Adapter for DTM 799-601-9020 Adapter for DT 799-601-9030 Adapter for DT 799-601-9040 Adapter for DT 799-601-9050 Adapter for DT 799-601-9060 Adapter for DT (Gray) 799-601-9070 Adapter for DT (Black) 799-601-9080 Adapter for DT (Green) 799-601-9090 Adapter for DT (Brown) 799-601-9110 Adapter for DT (Gray) 799-601-9120 Adapter for DT (Black) 799-601-9130 Adapter for DT (Green) 799-601-9140 Adapter for DT (Brown) 799-601-9210 Adapter for HD30-18 799-601-9220 Adapter for HD30-18 799-601-9230 Adapter for HD30-18 799-601-9240 Adapter for HD30-18 799-601-9250 Adapter for HD30-24 799-601-9260 Adapter for HD30-24 799-601-9270 Adapter for HD30-24 799-601-9280 Adapter for HD30-24 799-601-9290 Adapter for HD30-24 799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO) 799-601-9330 Case
4 6 8 8 10 12 16 16 12 8 12 16 20 2
M4P M6P M8P S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P
q q q q q q
q q
10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31 24
07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31
q q q q q
D65EX, PX-15
20-371
(8)
TROUBLESHOOTING
Number of pins
T-adapter kit 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4101 q q q q q q q q 799-601-4201 Identification symbol Out of kit q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Part No.
Part name
799-601-9340 Case 799-601-9350 Adapter for DRC 799-601-9360 Adapter for DRC 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor 799-601-9430* Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV 40 24 2 3 2 3 2 2 2 3 3 3 4 3 3 3 2 3 3 4 3 3 3 2 4 4 50 60 60 121 16 16 26 2, 3, 4, DRC-40 DRC-24 G A3 P 1,2,3 S C A ITT3N FCIN FCIG FCIB 4160 4180 1,2,3L 1,2,3,4C 1,2,3A 1,2,3B 1,2,3,G 2,PA 1,2,3,4T DTP4 DRC50 DRC60 HST16A HST16B HST26A
q q q
799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor 795-799-5540* Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE, CAM Adapter for engine (CRI-T3) 799-601-4140 Atomosphere pressure 799-601-4150 Adapter for engine (CRI-T3) POIL Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA 799-601-4190* 799-601-4230* Socket for engine (CRI-T3) Commonrail pressure Socket for engine (CRI-T3) Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator 799-601-4380* Socket for engine (CRI-T3)(95) Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 799-601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280 Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9730 Adapter for controller (HST) 799-601-9890 Multi-adapter for DT2 4 and DTM2
* Shows not T-adapter but socket.
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
Action code
Troubleshooting page
Error code 1500L0 15SAL1 15SALH 15SBL1 15SBLH 15SEL1 15SELH 15SFL1 15SFLH 15SGL1 15SGLH A000N1 AB00MA AD00L2 AD00MA AD10L3 AD10MA AD10MB AD11KA AD11KB AD51KA AD51KB ADA1KA ADAZKB
Failed section Transmission clutch Forward clutch Forward clutch Reverse clutch Reverse clutch 1st clutch 1st clutch 2nd clutch 2nd clutch 3rd clutch 3rd clutch Engine Alternator Common rail Common rail Fuel supply pump Fuel supply pump Fuel supply pump Fuel supply pump solenoid 1 Fuel supply pump solenoid 1 Fuel supply pump solenoid 2 Fuel supply pump solenoid 2 No.1 injector solenoid No.1, 2, and 3 injector solenoids
Trouble See the list. (L0) See the list. (L1) See the list. (LH) See the list. (L1) See the list. (LH) See the list. (L1) See the list. (LH) See the list. (L1) See the list. (LH) See the list. (L1) See the list. (LH) Overrun (N1) Malfunction (MA) See the list. (L2) Defective function (MA) See the list. (L3) Defective function (MA) Function reduction (MB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB)
CALL E03 20-408 CALL E03 20-409 CALL E03 20-410 CALL E03 20-411 CALL E03 20-412 CALL E03 20-413 CALL E03 20-414 CALL E03 20-415 CALL E03 20-416 CALL E03 20-417 CALL E03 20-418 20-419 20-420
CALL E03 20-420 CALL E03 20-421 CALL E03 20-421 CALL E03 20-423 CALL E03 20-423 CALL E03 20-424 CALL E03 20-425 CALL E03 20-426 CALL E03 20-427 E02 20-428
CALL E03 20-429
D65EX, PX-15
20-401
(1)
TROUBLESHOOTING
Error code to display at the same time

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

Error code DB22KK DB29KQ DB2AMA DB2RKR DB2RMC DB30KK DAQ0KK DB35KK DAQ5KK DB36KK DAQ6KK DB39KQ DAQ9KQ DD11KB DD12KA DD12KB DD13KA DD13KB DD14KA DDQ2KA DD14KB DDQ2KB DDE2L6 DDN7KA DDN7KB DDQ2KA DD14KA DDQ2KB DD14KB DGE2KX DGE3L6 DGE4KX DGS1KX DH30KX DH40KX DK10KX DK12KX Failed section Engine controller load power supply Engine controller type select Trouble Source voltage reduction/input (KK) Action code
CALL E04 20-468
Type select signal inconsistency (KQ) CALL E03 20-470 E02 20-471
Fuel injection amount adjustment switch signal Malfunction (MA) Steering and transmission controller CAN communication Engine controller CAN communication Steering and transmission controller Steering and transmission controller sensor 5 V power supply Steering and transmission controller sensor 24 V power supply Steering and transmission controller type collation Starting switch Shift up switch Shift up switch Shift down switch Shift down switch Parking lever switch Parking lever switch Engine oil pressure switch Pitch control switch Pitch control switch Parking lever switch Parking lever switch Engine water temperature sensor (for high temperature) Engine water temperature sensor (for low temperature) Fuel temperature sensor Hydraulic oil temperature sensor Boost pressure sensor Common rail pressure sensor Fuel control dial Deceleration potentiometer Defective communication (KR) Defective communication (MC) Source voltage reduction/input (KK) Source voltage reduction/input (KK) Source voltage reduction/input (KK)
CALL E04 20-472 CALL E03 20-474 CALL E04 20-476 CALL E03 20-476 CALL E03 20-476
Type select signal inconsistency (KQ) CALL E04 20-476 Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Refer to table (L6) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Input signal is out of normal range (KX) See table (L6) Input signal is out of normal range (KX) Input signal is out of normal range (KX) Input is out of normal range (KX) Input is out of normal range (KX) Input is out of normal range (KX) Input is out of normal range (KX) CALL E04 20-477 E02 E02 E02 E02 20-478 20-480 20-482 20-484
CALL E03 20-486 CALL E03 20-488 E01 E02 E02 20-490 20-492 20-494
CALL E03 20-496 CALL E03 20-496 E01 E02 E01 E02 20-497 20-498 20-499 20-500 20-502
CALL E03 20-504 CALL E03 20-506 CALL E03 20-508
D65EX, PX-15
20-403
(1)
TROUBLESHOOTING
Error code DK30KA DK30KB DK30KX DK30KZ DK30L8 DK31KA DK31KB DK40KA DK40KB DK55KX DK55KZ DK55L8 DK56KA DK56KB DK57KA DK57KB DKH1KA DKH1KB DLE3LC DLF1KA DLH1LC DV00KB DW5AKA DW5AKB DW7BKA DW7BKB DWN1KA DWN1KB DWN2KA
Failed section Steering potentiometer 1 Steering potentiometer 1 Steering potentiometer Steering potentiometer Steering potentiometer 1 Steering potentiometer 2 Steering potentiometer 2 Brake potentiometer Brake potentiometer Forward-reverse potentiometer Forward-reverse potentiometer Forward-reverse potentiometer Forward-reverse potentiometer 1 Forward-reverse potentiometer 1 Forward-reverse potentiometer 2 Forward-reverse potentiometer 2 Pitch angle sensor Pitch angle sensor Engine Ne speed sensor Transmission output speed sensor Engine G speed sensor Caution buzzer Pitch control solenoid Pitch control solenoid Fan reverse solenoid Fan reverse solenoid HSS EPC solenoid right HSS EPC solenoid right HSS EPC solenoid left
Trouble Disconnection (KA) Short circuit (KB)
Action code
CALL E03 20-510 CALL E03 20-511
Input signal is out of normal range (KX) CALL E04 20-512 Disconnection or short circuit (Double trouble) (KZ) See table (L8) Short circuit (KA) Disconnection (KB) Disconnection (KA) Short circuit (KB) CALL E04 20-512 CALL E03 20-513 CALL E03 20-514 CALL E03 20-515 CALL E03 20-516 CALL E03 20-517
Input signal is out of normal range (KX) CALL E04 20-518 Disconnection or short circuit (Double trouble) (KZ) See table (L8) Short circuit (KA) Disconnection (KB) Short circuit (KA) Disconnection (KB) Short circuit (KA) Disconnection (KB) See table (LC) Disconnection (KA) See table (LC) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) CALL E04 20-518 CALL E03 20-519 CALL E03 20-520 CALL E03 20-522 CALL E03 20-524 CALL E03 20-526 CALL E03 20-528 CALL E03 20-529 CALL E03 20-530 E01 20-531
CALL E03 20-532 E02 E02 E01 E01 20-533 20-534 20-535 20-536 20-537
CALL E03 20-538 CALL E03 20-539 CALL E03 20-540
20-404
(1)
D65EX, PX-15
TROUBLESHOOTING
Error code DWN2KB DWN5KA DWN5KB DXH4KA DXH4KB DXH5KA DXH5KB DXH6KA DXH6KB DXH7KA DXH7KB DXH8KA DXH8KB
Failed section HSS EPC solenoid left Fan pump TVC solenoid Fan pump TVC solenoid 1st clutch ECMV 1st clutch ECMV 2nd clutch ECMV 2nd clutch ECMV 3rd clutch ECMV 3rd clutch ECMV Reverse clutch ECMV Reverse clutch ECMV Forward clutch ECMV Forward clutch ECMV
Trouble Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB) Disconnection (KA) Short circuit (KB)
Action code
CALL E03 20-541 E01 E01 20-542 20-543
CALL E03 20-544 CALL E03 20-545 CALL E03 20-546 CALL E03 20-547 CALL E03 20-548 CALL E03 20-549 CALL E03 20-550 CALL E03 20-551 CALL E03 20-552 CALL E03 20-553
D65EX, PX-15
20-405
(1)
TROUBLESHOOTING
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 Panel display Contents of trouble Action of monitor panel or controller Problem that appears on machine Related information Error code Controller code Panel display Trouble Trouble that appeared on machine
State where the monitor panel or controller detects the trouble Action to be taken to protect the system and equipment when the monitor panel or controller detects a trouble Problem that appears as an abnormality in the main unit by the action taken by the monitor panel or controller (above) Information related to a detected trouble or troubleshooting Cause Standard value in normal state/Remarks on troubleshooting <Described contents> Standard value in normal state required to judge the assumed cause (good or not) Remarks required to judge whether the cause is good <Phenomenon of defective harness> Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. 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.
Possible causes and standard value in normal state
Cause by which a trouble is assumed to be detected 3 (The order number indicates a serial number, 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.
20-406
(1)
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 KB KK KQ KR KT KX KZ MA MB MW NS ZG ZK Contents of trouble Disconnection in wiring Short circuit Source voltage reduction/input Type select signal inconsistency Defective communication Abnormality in controller Outside input signal range Disconnection or short circuit (Double trouble) Malfunction Performance reduction Sliding Overheat Oil pressure reduction Coolant level reduction Trouble code L0 L1 L2 L3 L4 L6 L8 LC LD LH Contents of trouble Fill signals at two or more channels which are not set as combination are turned ON at the same time. 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. rpm signals in two systems are inconsistent. Switch is pressed for usually unthinkable long time. Fill signal is OFF when command current to ECMV is ON.
D65EX, PX-15
20-407
(1)
TROUBLESHOOTING
ERROR CODE 1500L0
ERROR CODE 1500L0 (TRANSMISSION CLUTCH: SEE THE LIST. (L0))

Action code CALL E03 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]
Contents of trouble
Action of controller Problem that appears on machine Related information
20-408
(1)
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 Problem that appears on machine Related information 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F1. 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 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). Cause
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 Problem that appears on machine Related information 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to R1. 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 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). Cause
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 Problem that appears on machine Related information 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to R1. 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 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). Cause
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 Problem that appears on machine Related information 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, running is limited to F1. 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 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). Cause
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 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 F1R1 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 F1R1 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). Cause
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 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 F1R1 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 F1R1 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). Cause
20-414
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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 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 F2R2 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 F2R2 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). Cause
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 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 F2R2 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 F2R2 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). Cause
20-416
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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 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 F3R3 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 F3R3 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). Cause
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 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 F3R3 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 F3R3 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). Cause
20-418
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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 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 3 Defective engine controller Instruct the using procedure again. Check that engine speed is displayed normally.
D65EX, PX-15
20-419
(1)
TROUBLESHOOTING
ERROR CODE AB00MA, ERROR CODE AD00L2 ERROR CODE AB00MA
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA))

Action code Contents of trouble Action of controller Problem that appears on machine Related information Error code AB00MA Controller code Trouble Alternator: Malfunction (MA) (Mechanical system)
During rotation of engine, 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 Trouble Common rail: See the list. (L2) (Engine controller system)
The fuel pressure of common rail became high (level 1). 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 Cause 1 Defective related system 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.
20-420
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D65EX, PX-15
TROUBLESHOOTING
ERROR CODE AD00MA, ERROR CODE AD00MA ERROR CODE AD10L3
ERROR CODE AD00MA (COMMON RAIL: DEFECTIVE FUNCTION (MA))

Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code AD00MA Controller code Engine Trouble Common rail: See the list. (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 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 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. Cause
1 2 3 Possible causes and standard value in normal state 4 5 6 7 8 9
D65EX, PX-15
20-421
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TROUBLESHOOTING
ERROR CODE AD10L3
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.
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) 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. 90C), 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.
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
20-422
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D65EX, PX-15
TROUBLESHOOTING
ERROR CODE AD10MA, ERROR CODE AD10MA AD10MB
ERROR CODE AD10MA (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))

Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code AD10MA Controller code Engine Trouble Fuel supply pump: Defective function (MA) (Engine controller system)
An abnormal pressure occurred in the common rail fuel pressure. 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 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 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].
D65EX, PX-15
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
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 1 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 2 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. 3 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 4 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
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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. 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 Cause
2 Possible causes and standard value in normal state 3
D65EX, PX-15
20-425
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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
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 without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between EN3 (female) (13) Resistance Max. 1 z 2 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. 3 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 4 Defective engine controller Between (13) (23) 2.3 5.3 z Between (13) (23) Min. 1 Mz chassis ground
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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
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
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 Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting Defective No.1 injector solewithout 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 Cause
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 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
Defective No.1 injector solenoid (Internal short)
Defective harness ground4 ing (Contact with ground circuit)
D65EX, PX-15
20-429
(1)
TROUBLESHOOTING
ERROR CODE ADAZKB
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)
Cause
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)
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)
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)
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 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
Defective harness ground4 ing (Contact with ground circuit)
20-434
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE ADDZKB
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)
Cause
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. 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 Cause
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. 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 Cause
Circuit diagram related to No.6 fuel injector solenoid
D65EX, PX-15
20-437
(1)
TROUBLESHOOTING
ERROR CODE B@BAZG, ERROR CODE B@BCNS B@BAZG
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))

Action code Contents of trouble Action of controller Problem that appears on machine Related information Error code B@BAZG Controller code Engine Trouble Engine oil: Oil pressure reduction (ZG) (Mechanical system)
During rotation of engine, 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 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 Engine water temperature 1 overheat (When system is in normal state) Defective engine water 2 temperature caution lamp system Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing engine water temperature overheat is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of engine water temperature caution lamp system in accordance with During running of engine, emergency caution item flashes in E mode.
20-438
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE B@CENS, ERROR CODE B@HANS B@CENS
ERROR CODE B@CENS (POWER TRAIN OIL: OVERHEAT (NS))

Action code Contents of trouble Action of controller Problem that appears on machine Related information Error code B@CENS Controller code Steering Trouble Power train oil: Overheat (NS) (Mechanical system)
During rotation of engine, 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 Power train oil temperature 1 overheat (When system is in normal state) Defective power train oil 2 temperature overheat caution lamp system Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing power train oil temperature overheat is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of power train oil temperature caution lamp system in accordance with During running of engine, emergency caution 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. Cause Hydraulic oil temperature 1 overheat (When system is in normal state) Defective hydraulic oil 2 temperature caution lamp system Standard value in normal state/Remarks on troubleshooting It is suspected that problem causing hydraulic oil temperature overheat is occurring at present or occurred in past. Investigate cause and damage condition, and correct it. Carry out troubleshooting of hydraulic oil temperature caution lamp system in accordance with During running of engine, emergency caution 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. 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 Cause
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. 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 1 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 2 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 3 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 4 transmission controller ST3 (female) Continuity Between (4) chassis ground Continue Cause
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) 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 Cause
20-442
(1)
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) 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 Cause
20-444
(1)
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) 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 Cause
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 Defective back-up alarm relay (Internal disconnection) 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. BKA (male) Resistance Between (1) (2) 200 400 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ST2 (female) (18) Resistance Max. 1 z BKA (female) (2) 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. Wiring harness between ST2 (female) (18) Resistance Min. 1 Mz BKA (female) (2) with chassis ground 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. ST2 PCCS lever Voltage Neutral position 20 30 V Between (18) chassis ground Reverse position Max. 1 V
Defective disconnection in wiring harness (Disconnec3 tion in wiring or defective contact in connector)
Short circuit with chassis 4 ground in wiring harness (Contact with ground circuit)
Defective steering and transmission controller
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). 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 1 (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) 2 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 3 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 4 Defective controller Max. 1 V Between EN1 (female) When relay is driven (12) ground When relay is 20 30 V not driven Cause
20-450
(1)
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) 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. 1 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 2 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), 3 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 4 Defective engine controller OFF position Max. 1 V Between (1), (2), (21) chassis ground ON position Max. 8 V Cause
20-452
(1)
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 Problem that appears on machine Related information Error code D5ZFKA Controller code Steering Trouble Transmission neutral signal: Disconnection (KA) (Steering and transmission controller system)
Voltage is not generated when ground of transmission neutral safety relay circuit is interrupted. This signal line is for backing up (The main signal is transmitted through the CAN communication network). Stops outputting the transmission neutral signal. None in particular. 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. 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 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. 2 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 3 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. 4 Defective engine controller Between EN3 (7), (17) ground Voltage 5 11 V Cause
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 Problem that appears on machine Related information Error code D5ZFKB Controller code Steering Trouble Transmission neutral signal: Short circuit (KB) (Steering and transmission controller system)
Abnormal current flowed when ground signal of transmission neutral safety relay circuit is output. This signal line is for backing up (The main signal is transmitted through the CAN communication network). Stops outputting the transmission neutral signal. None in particular. 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. 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 Cause
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. 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) 1 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) 2 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) 3 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 4 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 pan5 defective steering and el or steering and transmission controller is defective. (Troubleshooting transmission controller cannot be carried out since it is internal defect.) Cause
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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. Standard value in normal state/Remarks on troubleshooting If any of fuses FS1-9 is broken, circuit probably has short circuit with 1 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 2 wiring or defective contact in Wiring harness between FS1-1 battery relay Resistance Max. 1 z connector) terminal C Wiring harness between ST3 (female) (21) Resistance Max. 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 3 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 4 ST3 Voltage transmission controller Between (1), (2), (11), (12), (22) 20 30 V (21), (31), (32), (33) Cause
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D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DAQ0KK DB30KK, ERROR CODE DAQ0KT
Circuit diagram related to Steering and transmission controller power supply
ERROR CODE DAQ0KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT))
Action code E02 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code DAQ0KT Controller code Steering Trouble Steering and transmission controller: Abnormality in controller (KT) (Steering and transmission controller system)
Information of ROM (nonvolatile storage) of steering and transmission controller is not normal. 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.)
D65EX, PX-15
20-459
(1)
TROUBLESHOOTING
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. 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 1 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 2 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 3 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 4 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 5 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 6 transmission controller ST1 Voltage Between (22) (21) 4.5 5.5 V Cause
20-460
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D65EX, PX-15
TROUBLESHOOTING
Circuit diagram related to steering and transmission controller 5 V power supply
D65EX, PX-15
20-461
(1)
TROUBLESHOOTING
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. 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 Cause
Circuit diagram related to steering and transmission controller 24 V power supply
20-462
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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 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 Error code Steering and transmission controller CAN communication: Defective communication (KR) DB3RKR Steering (Steering and transmission controller system) Steering and transmission controller cannot recognize monitor panel, 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. Controller code Trouble
Method of reproducing error code: Turn starting switch ON. 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) 1 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) 2 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) 3 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 4 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, 5 el, engine controller, or steering and transmission controller. (Troubledefective steering and shooting cannot be carried out since it is internal defect.) transmission controller Cause
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D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB3RKR
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 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
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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 Trouble 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 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. 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 2 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 3 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 4 ground in wiring harness FS2-7 outlet port with chassis ground (Contact with ground circuit) Wiring harness between FS2-7 inlet port Resistance Min. 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. 5 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. 6 Defective engine controller EN3 Voltage Between (1), (2), (21) 20 30 V (11), (31), (32) Cause 1 Defective fuse (FS2-7)
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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 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
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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 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.
D65EX, PX-15
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 Error code Steering and transmission controller CAN communication: Defective communication (KR) DB2RKR Steering (Steering and transmission controller system) Steering and transmission controller cannot recognize engine controller with CAN communication circuit. 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. Controller code Trouble
Method of reproducing error code: Turn starting switch ON. 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) 1 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) 2 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) 3 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 4 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 5 transmission controller, transmission controller, engine controller is defective. defective engine controller (Troubleshooting cannot be carried out since it is internal defect.) Cause
20-472
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB2RKR
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 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) ST2 (female) (32) EN2 (female) (32) CA2 Resistance Max. 1 z (female) (A) CA2 (female) (A) G01 (female) (8) 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 (female) (A) CA2 (female) (A) G01 (female) (8) with chassis ground 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 Voltage Max. 1 V (female) (A) CA2 (female) (A) G01 (female) (8) with chassis ground 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. CA2 (male), CA2 (male) Resistance Between (A) (B) 100 140 z If no problem is found in causes 1 to 4, it is suspected that engine controller, steering and transmission controller is defective. (Troubleshooting cannot be carried out since it is internal defect.)
Disconnection in wiring harness (Disconnection in 1 wiring or defective contact in connector)
Short circuit with chassis 2 ground in wiring harness (Contact with ground circuit) Possible causes and standard value in normal state
Hot short circuit in wiring 3 harness (Contact with 24 V circuit)
Defective CAN terminal resistance
Defective engine controller, 5 defective steering and transmission controller
20-474
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DB2RMC
D65EX, PX-15
20-475
(1)
TROUBLESHOOTING
ERROR CODE DB30KK DAQ0KK, ERROR CODE DB35KK DAQ5KK, ERROR CODE DB36KK DAQ6KK, ERROR CODE DB39KQ DAQ9KQ ERROR CODE DB30KK DAQ0KK
ERROR CODE DB30KK DAQ0KK (STEERING AND TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))
a See DAQ0KK.
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. 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 Cause
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. 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. Wiring harness between ST1 (female) (12) Disconnection in wiring Resistance Max. 1 z harness (Disconnection in SFTU (female) (3) 2 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) 3 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) 4 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) Cause
20-478
(1)
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. 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) Cause
20-480
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD12KB
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. 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. Wiring harness between ST1 (female) (24) Disconnection in wiring Resistance Max. 1 z harness (Disconnection in SFTD (male) (3) 2 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) 3 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) 4 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) Cause
20-482
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD13KA
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. 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) Cause
20-484
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DD13KB
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. 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 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) 2 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 3 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 4 transmission controller Between (15) Max. 1 V 5 11 V chassis ground Between (5) 5 11 V Max. 1 V chassis ground Cause
20-486
(1)
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. 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 Cause
20-488
(1)
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. 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 1 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 2 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 3 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 4 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 5 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 Cause
20-490
(1)
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. 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) 1 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 2 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 3 harness (Contact with 24 V P0A (female) (3) with chassis ground circuit) Wiring harness between ST3 (female) (20) P0A (female) (1) P0B (male) (1) with chassis Voltage Max. 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) 4 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) Cause
20-492
(1)
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. 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) Cause
20-494
(1)
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 DD14KA ERROR CODE DDQ2KA DD14KB
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 90C. 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 Defective high engine water temperature sensor (Internal 1 disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. TWH (male) Resistance Between (1) (2) 3.5 k 90 kz (10 100C) 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 EN2 (female) (27) Resistance Max. 1 z TWH (female) (1) Wiring harness between EN2 (female) (39) Resistance Max. 1 z TWH (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 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 Between (27) (39) 3.5 k 90 kz (10 100C) Between (27), (39) Min. 1 Mz chassis ground
4 Defective engine controller
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. 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 1 disconnection or short Between (A) (B) 0.3 k 9 kz (10 100C) 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 2 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. 3 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 4 Defective engine controller Between (37) (39) 0.3 k 9 kz (10 100C) Between (37), (39) Min. 1 Mz chassis ground Cause
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. 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 1 sensor (Internal disconnection or short circuit) Between (A) (B) 0.3 k 9 kz (10 100C) 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 2 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. 3 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 4 Defective engine controller Between (17) (39) 0.3 k 9 kz (10 100C) Between (17), (39) Min. 1 Mz chassis ground Cause
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. 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 1 disconnection or short Between (1) (2) 3.5 k 90 kz (10 100C) 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 2 wiring or defective contact in SDS (female) (1) connector) Wiring harness between ST1 (female) (21) Resistance Max. 1 z SDS (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 3 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. 4 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 5 transmission controller Between (9) (21) 3.5 k 90 kz (10 100C) Between (9) chassis ground Min. 1 Mz Cause
20-500
(1)
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. 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 1 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) 2 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 3 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 4 Defective engine controller Between (19) (39) 4.6 5.4 V Between (20) (39) 0.3 4.7 V Cause
20-502
(1)
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. 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 1 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) 2 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 3 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 4 Defective engine controller Between (19) (39) 4.6 5.4 V Between (40) (39) 0.7 4.5 V Cause
20-504
(1)
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 Action of controller Problem that appears on machine Related information Error code DK10KX Controller code Engine Trouble Fuel control dial: Input is out of normal range (KX) (Engine controller system)
Signal voltage of fuel control dial circuit is below 0.5 V or above 4.5 V. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of decelerator pedal potentiometer. 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. 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. 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 1 (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) 2 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 3 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) 4 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 5 Defective engine controller Between (9) (29) 4.6 5.4 V Between (10) (29) 0.5 4.5 V Cause
20-506
(1)
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 Problem that appears on machine Related information Error code DK12KX Controller code Engine Trouble Fuel control dial: Input is out of normal range (KX) (Engine controller system)
Signal voltage of deceleration potentiometer circuit is below 0.3 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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. 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 Cause
Possible causes and standard value in normal state 3
20-508
(1)
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 Action of controller Problem that appears on machine Related information Error code DK30KA Controller code Steering Trouble Steering potentiometer 1: Disconnection (KA) (Steering and transmission controller system)
Signal voltage of steering potentiometer 1 system is above 4.5 V. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer 2 system. 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. 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). 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 Action of controller Problem that appears on machine Related information Error code DK30KB Controller code Steering Trouble Steering potentiometer 1: Short circuit (KB) (Steering and transmission controller system)
Signal voltage of steering potentiometer 1 system is below 0.5 V. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer 2 system. 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. 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). 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)
D65EX, PX-15
20-511
(1)
TROUBLESHOOTING
ERROR CODE DK30KX, DK30KZ ERROR CODE DK30KX
ERROR CODE DK30KX (STEERING POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Possible causes and standard value in normal state Error code Controller code Steering potentiometer: Input signal is out of normal range Trouble (KX) (Steering and transmission controller system) DK30KX Steering Either of error codes [DK30KA] and [DK30KB] of steering potentiometer systems 1 and 2 and either of error codes [DK31KA] and [DK31KB] are displayed simultaneously. Flashes caution lamp and turns on caution buzzer. 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 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
20-512
(1)
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 Problem that appears on machine Related information Possible causes and standard value in normal state Error code Controller code Steering potentiometer 1: See table (L8) Trouble (Steering and transmission controller system) DK30L8 Steering Total signal voltage of each of steering potentiometer 1 system and 2 system is below 4.41 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. 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 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
D65EX, PX-15
20-513
(1)
TROUBLESHOOTING
ERROR CODE DK31KA
ERROR CODE DK31KA (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KA))

Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DK31KA Controller code Steering Trouble Steering potentiometer 2: Short circuit (KA) (Steering and transmission controller system)
Signal voltage of steering potentiometer 2 system is above 4.5 V. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer 1 system. 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. 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 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)
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 Action of controller Problem that appears on machine Related information Error code DK31KB Controller code Steering Trouble Steering potentiometer 2: Disconnection (KB) (Steering and transmission controller system)
Signal voltage of steering potentiometer 2 system is below 0.5 V. Flashes caution lamp and turns on caution buzzer. Continues controlling with signal of steering potentiometer 1 system. 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. 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). 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 2 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 3 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. 4 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 5 transmission controller ST1 Voltage Between (19) (21) 0.5 4.5 V Cause Defective sensor power 1 source system
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 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 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)
TROUBLESHOOTING
ERROR CODE DK55KX, DK55KZ ERROR CODE DK55KX
ERROR CODE DK55KX (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))
Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Forward-reverse potentiometer: Input signal is out of normal Trouble range (KX) (Steering and transmission controller system) DK55KX Steering Either of error codes [DK56KA] and [DK56KB] of forward-reverse potentiometer systems 1 and 2 and either of error codes [DK57KA] and [DK57KB] are displayed simultaneously. 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
ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (Double trouble) (KZ))
Action code CALL E04 Contents of trouble Action of controller Problem that appears on machine Related information Error code Controller code Forward-reverse potentiometer: Disconnection or short circuit Trouble (KZ) (Steering and transmission controller system) DK55KZ Steering When starting switch is turned ON, 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
20-518
(1)
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 Problem that appears on machine Related information Error code Controller code Forward-reverse potentiometer: See table (L8) Trouble (Steering and transmission controller system) DK55L8 Steering Total signal voltage of each of forward-reverse potentiometer 1 system and 2 system is below 4.41 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. 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 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
D65EX, PX-15
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 Problem that appears on machine Related information Error code DK56KA Controller code Steering Trouble Forward-reverse potentiometer 1: Short circuit (KA) (Steering and transmission controller system)
Signal voltage of forward-reverse potentiometer 1 system is above 4.5 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. 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 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). 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 Problem that appears on machine Related information Error code DK56KB Controller code Steering Trouble Forward-reverse potentiometer 1: Disconnection (KB) (Steering and transmission controller system)
Signal voltage of forward-reverse potentiometer 1 system is below 0.5 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. 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 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). 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
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 Problem that appears on machine Related information Error code DK57KA Controller code Steering Trouble Forward-reverse potentiometer 2: Short circuit (KA) (Steering and transmission controller system)
Signal voltage of forward-reverse potentiometer 2 system is above 4.5 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. 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 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). 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, 1 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 2 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. 3 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 4 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 5 wiring or defective contact in Wiring harness between ST1 (female) (21) Resistance Max. 1 z connector) TL2 (female) (1)
20-524
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DK57KA
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 Problem that appears on machine Related information Error code DK57KB Controller code Steering Trouble Forward-reverse potentiometer 2: Disconnection (KB) (Steering and transmission controller system)
Signal voltage of forward-reverse potentiometer 2 system is below 0.5 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. 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 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). 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
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 Controller code Steering 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. 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, 1 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 2 (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. 3 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 4 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 Controller code Steering 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. 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, 1 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 2 (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 3 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. 4 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 5 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 Defective engine Ne speed 1 sensor (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. NE (male) Resistance 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. Wiring harness between EN2 (female) (36) Resistance Max. 1 z NE (female) (1) 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. Wiring harness between EN2 (female) (36) Resistance Min. 1 Mz NE (female) (1) with chassis ground 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 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. 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 1 (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 2 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. 3 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 4 transmission controller Between (30) (29) 400 1,000 z Between (30) chassis ground Min. 1 z Cause
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. 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 1 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 2 wiring or defective contact in (female) (1) connector) Wiring harness between EN2 (female) (25) G Resistance Max. 1 z (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit with chassis Wiring harness between EN2 (female) (35) G Resistance Min. 1 Mz 3 ground in wiring harness (female) (1) with chassis ground (Contact with ground circuit) Wiring harness between EN2 (female) (25) G Resistance Min. 1 Mz (female) (2) with chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. EN2 (female) Resistance 4 Defective engine controller Between (35) (25) 1.4 k 3.5 kz Between (35), (25) Min. 1 Mz chassis ground Cause
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 Trouble 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 Defective caution buzzer (Internal short circuit) 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)
Short circuit with power 2 source in wiring harness (Contact with 24 V circuit)
3 Defective monitor panel
Circuit diagram related to caution buzzer
D65EX, 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. 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 Cause
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. 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 1 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. 2 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 har3 ness (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 4 transmission controller Between (17) (3) 20 30 z Between (17) chassis ground Min. 1 Mz Cause
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. 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 Cause
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. 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 Cause
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 Problem that appears on machine Related information Error code DWN1KA Controller code Steering Trouble HSS EPC solenoid right: Disconnection (KA) (Steering and transmission controller system)
When signal is output to HSS EPC solenoid right circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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). 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 Cause
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 Problem that appears on machine Related information Error code DWN1KB Controller code Steering Trouble HSS EPC solenoid right: Short circuit (KB) (Steering and transmission controller system)
When signal was output to HSS EPC solenoid right circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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). 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 Cause
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 Problem that appears on machine Related information Error code DWN2KA Controller code Steering Trouble HSS EPC solenoid left: Disconnection (KA) (Steering and transmission controller system)
When signal is output to HSS EPC solenoid left circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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). 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 Cause
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 Problem that appears on machine Related information Error code DWN2KB Controller code Steering Trouble HSS EPC solenoid left: Short circuit (KB) (Steering and transmission controller system)
When signal was output to HSS EPC solenoid left circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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). 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 Cause
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. 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 1 (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 2 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. 3 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 4 transmission controller ST3 (female) Resistance Between (36) (23) 5 15 z Cause
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. 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 1 (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. 2 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 har3 ness (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 4 transmission controller Between (36) (23) 5 15 z Between (36) chassis ground Min. 1 Mz Cause
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. 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 Cause
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. 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 Cause
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 Problem that appears on machine Related information Error code DXH5KA Controller code Steering Trouble 2nd clutch ECMV: Disconnection (KA) (Steering and transmission controller system)
When signal is output to 2nd clutch solenoid circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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. 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 Cause
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 Problem that appears on machine Related information Error code DXH5KB Controller code Steering Trouble 2nd clutch ECMV: Short circuit (KB) (Steering and transmission controller system)
When signal was output to transmission 2nd clutch solenoid circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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. 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 Cause
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 Problem that appears on machine Related information Error code DXH6KA Controller code Steering Trouble 3rd clutch ECMV: Disconnection (KA) (Steering and transmission controller system)
When signal is output to 3rd clutch solenoid circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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. 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 Cause
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 Problem that appears on machine Related information Error code DXH6KB Controller code Steering Trouble 3rd clutch ECMV: Short circuit (KB) (Steering and transmission controller system)
When signal was output to transmission 3rd clutch solenoid circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1 and R1. 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. 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 Cause
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 Problem that appears on machine Related information Error code DXH7KA Controller code Steering Trouble Reverse clutch ECMV: Disconnection (KA) (Steering and transmission controller system)
When signal is output to reverse clutch solenoid circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1. 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. 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. 1 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 2 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. 3 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 4 transmission controller ST3 (female) Resistance Between (37) (13) 5 25 z Cause
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 Problem that appears on machine Related information Error code DXH7KB Controller code Steering Trouble Reverse clutch ECMV: Short circuit (KB) (Steering and transmission controller system)
When signal was output to transmission reverse clutch solenoid circuit, 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. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to F1. 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. 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 1 ECMV (Internal short circuit) Between (1) (2) 5 25 z Between (1) chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 2 ground in wiring harness (Contact with ground circuit) Wiring harness between ST3 (female) (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 har3 ness (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 4 transmission controller Between (37) (13) 5 25 z Between (37) chassis ground Min. 1 Mz Cause
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 Problem that appears on machine Related information Error code DXH8KA Controller code Steering Trouble Forward clutch ECMV: Disconnection (KA) (Steering and transmission controller system)
When signal is output to forward clutch solenoid circuit, any current does not flow. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission forward clutch solenoid circuit. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to R1. Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output current of forward clutch ECMV) Method of reproducing service code: Start engine and drive machine forward. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward clutch ECMV (Internal short circuit) FSOL (male) Resistance Between (1) (2) 5 25 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in Wiring harness between ST3 (female) (27) Resistance Max. 1 z wiring or defective contact in FSOL (female) (1) connector) Wiring harness between ST3 (female) (13) Resistance Max. 1 z FSOL (female) (2) aPrepare with starting switch OFF, then turn starting switch ON and Short circuit with power carry out troubleshooting. source in wiring harness Wiring harness between ST3 (female) (27) (Contact with 24 V circuit) Voltage Max. 1 V FSOL (female) (1) with chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering and transmission controller ST3 (female) Resistance Between (27) (13) 5 25 z Cause
20-552
(1)
D65EX, PX-15
TROUBLESHOOTING
ERROR CODE DXH8KB
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB))

Action code CALL E03 Contents of trouble Action of controller Problem that appears on machine Related information Error code DXH8KB Controller code Steering Trouble Forward clutch ECMV: Short circuit (KB) (Steering and transmission controller system)
When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed. Flashes caution lamp and turns on caution buzzer. Stops outputting to transmission forward clutch solenoid circuit. Limits operation of engine and transmission. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, travel is limited to R1. Output (Current) to forward clutch solenoid can be checked in monitoring mode. (Code 31608, 31622: Output current of forward clutch ECMV) Method of reproducing service code: Start engine and drive machine forward. Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective forward clutch FSOL (male) Resistance 1 ECMV (Internal short circuit) Between (1) (2) 5 25 z Between (1) chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting Short circuit with chassis without turning starting switch ON. 2 ground in wiring harness (Contact with ground circuit) Wiring harness between ST3 (female) (27) Resistance Min. 1 Mz FSOL (female) (1) with chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring har3 ness (with another wiring Wiring harness between ST3 (female) (27) harness) Resistance Min. 1 Mz FSOL (female) (1) with wiring harness between ST3 (female) (13) FSOL (female) (2) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective steering and ST3 (female) Resistance 4 transmission controller Between (27) (13) 5 25 z Between (27) chassis ground Min. 1 Mz Cause
D65EX, PX-15
20-553
(1)
TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
Information described in troubleshooting list ........................................................................................... E- 1 The engine does not start .............................................................................................................. E- 2 The preheater does not operate. ................................................................................................... E- 3 The monitor panel does not come on at all when the starting switch is turned on. ....................... E- 4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out. ...................................................................................................................... E- 5 While the engine is operating, the battery charge level caution lamp flashes. ............................... E- 6 While the engine is operating, the emergency warning item flashes. ............................................ E- 7 While the preheater is operating, the preheating pilot lamp does not come on. ............................ E- 8 The engine water temperature gauge does not indicate normally. ................................................ E- 9 Indication of the power train temperature gauge is abnormal. ....................................................... E-10 The hydraulic oil temperature gauge does not indicate normally. .................................................. E-11 Indication of the fuel gauge is abnormal. ....................................................................................... E-12 Indications of gear speed and engine speed are abnormal. .......................................................... E-13 Indication of the preset mode service meter is abnormal. ............................................................. E-14 The warning lamp does not flash or does not go out. .................................................................... E-15 The alarm buzzer does not sound or does not stop. ...................................................................... E-16 Auto shift down is not possible or is not released. ......................................................................... E-17 The buzzer cancel switch does not work. ...................................................................................... E-18 The information switch does not work. ........................................................................................... E-19 The preset mode does not operate or cannot be reset. ................................................................. E-20 The monitor panel cannot be set in the service mode or cannot be set out of the service mode. . E-21 The back-up alarm does not sound. .............................................................................................. E-22 The head lamp and rear lamp do not light up. ............................................................................... E-23 Malfunction of wipers ..................................................................................................................... E-24 Washing water does not come out. ................................................................................................ E-25 The air conditioner does not operate. ............................................................................................
20-602 20-603 20-606 20-608 20-609 20-610 20-612 20-615 20-617 20-618 20-619 20-620 20-621 20-621 20-621 20-622 20-623 20-624 20-625 20-626 20-627 20-629 20-630 20-632 20-648 20-653
D65EX, PX-15
20-601
(1)
TROUBLESHOOTING

a Troubleshooting lists and related circuit diagrams contain the following information all together. Understand the contents carefully and troubleshoot the machine.
Trouble Related information Problem that appears on the machine. Information related to problems occurred or troubleshooting Cause Standard value in normal state/Remarks on troubleshooting <Described contents> Standard value in normal state required to judge the assumed cause (good or not) Remarks required to judge whether the cause is good 1 <Phenomenon of defective harness> Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. Grounding fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit. Defective hot short A harness not connected to the power (24 V) circuit comes into contact with the power (24 V) circuit. Defective short A harness of an independent circuit abnormally comes into contact with one of another circuit.
2 Possible causes and standard value in normal state
Cause by which a trouble is assumed to be detected (The order number indicates a serial number, not a priority <Notes on troubleshooting> sequence.) (1) Method of indicating connector numbers and handling T-junction For troubleshooting, insert or connect the T-junction adapter as shown below unless especially specified. 3 When male or female is not indicated for a connector number, disconnect the connector, and insert the T-junction adapter in both the male and female. When male or female is indicated for a connector number, disconnect the connector, and insert the T-junction adapter in only either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus () leads as shown below unless especially specified. 4 Connect the plus (+) lead to a pin or harness indicated in the front. Connect the minus () lead to a pin or harness indicated in the rear.
Related circuit diagram
This is the excerpted circuit diagram related to trouble Connector No.: Indicates (Model-No. of pins) (Color). Arrow ( ): Roughly indicates mounting place on machine.
20-602
(1)
D65EX, PX-15
TROUBLESHOOTING
E-1
E-1 THE ENGINE DOES NOT START

Trouble Related information The engine does not start. The engine start circuit has the neutral safety function, and the engine does not start unless the parking lever is set to the lock position or the travel lever is in the neutral position. If the monitor panel does not come on or the battery relay does not cause operating sound when the starting switch is set to ON, the main electric power supply system is supposed to be out of order. So, inspect the main electric power supply system. Cause 1 Insufficient battery capacity Standard value in normal state/Remarks on troubleshooting Battery voltage Battery specific gravity Min. 25 V Min. 1.26 aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Starting switch Switch position Resistance OFF Min. 1 Mz Between 250 (B) and 280 (C) START Max. 1 z aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Parking lever Free position Lock position Monitor panel Other than P is P is displayed displayed aPrepare with the starting switch OFF, then start the engine and carry out troubleshooting. If the engine starts in accordance with the engine starting arrangement after the neutral safety relay (NSF) is replaced with another one while the starting switch is set to OFF, the relay is defective. aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Alternator Voltage Between Terminal R and ground Max. 12 V aPrepare with the starting switch OFF, then start the engine and carry out troubleshooting. Starting motor Voltage Electric power supply: between 20 30 V Terminal B and ground Charge: between ST (2) and Max. 12 V ground Starting: between ST (1) and 20 30 V ground When the voltages of electric power supply, for charging and starting are normal but the starting motor does not rotate, the starting motor is defective. aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between 280 (C) and NFS (feResistance Max. 1 z male) (3) Wiring harness between NSF (female) (5) and Resistance Max. 1 z ST (female) (1) Wiring harness between NSF (female) (5) and Resistance Max. 1 z EN1 (female) (20)
Defective starting switch (internal disconnection)
Defective parking lever 3 switch (Internal trouble defect or defective adjustment)
Defective neutral safety relay (internal disconnection)
Defective alternator (internal short circuit)
Detective starting motor (internal defect)
Disconnection in wiring harness (disconnection in 7 wiring or defective contact in connector)
D65EX, PX-15
20-603
(1)
TROUBLESHOOTING
E-1
Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Hot short circuit of wiring 8 harness (Contact with 24 V Wiring harness between alternator R terminal circuit) and ST (female) (2) or ST1 (female) (15) or Voltage Max. 1 V S04 (female) (9) with ground aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between 280 (C) NSF (feResistance Min. 1 Mz Short circuit with chassis male) (3) and chassis ground 9 ground in wiring harness Wiring harness between NSF (female) (5) ST (Contact with ground circuit) Resistance Min. 1 Mz (female) (1) and chassis ground Wiring harness between NSF (female) (5) Resistance Min. 1 Mz EN1 (female) (20) and chassis ground
Cause
20-604
(1)
D65EX, PX-15
TROUBLESHOOTING
E-1
Engine start/charge-related circuit diagram
D65EX, PX-15
20-605
(1)
TROUBLESHOOTING
E-2
E-2 THE PREHEATER DOES NOT OPERATE.

Trouble The preheater does not operate. aThis troubleshooting describes the procedures to be followed when the manual preheating function cannot heat the electrical intake air heater mounting section. (When the preheating lamp only does not come on, carry out the troubleshooting of The preheating lamp does not come on.) For preheating, both the Automatic Preheating Function and the Manual Preheating Function are available. When either function is performed, the preheating lamp comes on. If the monitor panel does not come on or the battery relay does not cause operating sound hen the starting switch is turned ON, the main electric power supply system supposed to be out of order. So, inspect the main electric power supply system. Cause Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Starting switch Switch position Resistance OFF Min. 1 Mz Between 250 (B) and 280 (C) HEAT Max. 1 z If fuse is broken, circuit probably has a grounding fault, etc.
Related information
Defective starting switch (Internal disconnection)
Defective fuse (FUSE, FS1, 2)
aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective preheater relay Disconnect coolant sensor TWL with starting switch OFF and replace (Internal disconnection) preheater relay with another one, and then turn starting switch ON. If preheating is started, preheater relay RHR is defective. aPrepare with the starting switch OFF, then set the starting switch to HEAT and carry out troubleshooting. Heater relay Voltage Electric power supply: between 20 30 V Defective heater relay Terminal HT/B (B) and ground (internal defect) Signal: between Terminal 20 30 V HT/S (C) and ground When the both voltages of electric power supply and signal are normal and no operating sound is caused, the heater relay is defective. aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Defective electrical intake air Electrical intake air heater Continuity heater (internal defect) Between terminals Continue aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between starting switch 255 Resistance Max. 1 z (R1) and RHR (female) (3) and HT/S (C) Disconnection in wiring harness (Disconnection in Wiring harness between RHR (female) (5) Resistance Max. 1 z wiring or defective contact in FS1 (7) connector) Wiring harness between battery relay and CN-C Resistance Max. 1 z and ST/B and HT/B Wiring harness between heater relay HT/A (A) Resistance Max. 1 z terminal and electrical intake air heater aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between starting switch 255 Resistance Min. 1 Mz (R1) RHR (3) HT/S (C) terminal and ground Short circuit with chassis Wiring harness between RHR (female) (5) Resistance Min. 1 Mz ground in wiring harness FS1 (7) and ground (Contact with ground circuit) Wiring harness between battery relay C Resistance Min. 1 Mz ST/B terminal HT/B and ground Wiring harness between heater relay HT/A Resistance Min. 1 Mz intake air heater terminal and ground
20-606
(1)
D65EX, PX-15
TROUBLESHOOTING
E-2
Engine preheat-related circuit diagram
D65EX, PX-15
20-607
(1)
TROUBLESHOOTING
E-3
E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON.
Trouble Related information If operation sound of the battery is not heard when the starting switch is turned ON, the main power supply system may be defective. Accordingly, check the may power supply system. The monitor panel does not come on at all when the starting switch is turned ON. When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge section and the lamp section come on for approximately 2 sec. and go out. Standard value in normal state/Remarks on troubleshooting When the fuse FS2-(6) is cut off, the circuit may have possibly been Defective fuse FS2-(6) short-circuited with ground. aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection of wiring harness (Disconnection in Wiring harness between S03 (female) (1) (2) Resistance Max. 1 z wiring or defective contact in and fuse FS2-(6) connector) Wiring harness between S03 (female) (3) (4) Resistance Max. 1 z and GND01 and ground aPrepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring without turning the starting switch ON. harness (Contact with Wiring harness between S03 (female) (1), (2) ground circuit) Resistance Min. 1 Mz fuse FS2-(6) with ground aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel S03 Voltage Between (1) (2) and (3) (4) 20 30 V Cause
Circuit diagram related to ripper pin puller solenoid
20-608
(1)
D65EX, PX-15
TROUBLESHOOTING
E-4
E-4 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT.
Trouble Related information Possible causes and standard value in normal state When the starting switch is turned ON, the monitor panel completely remains lighted and does not go out. When the starting switch is turned ON, the gear speed indicator, the multi information section, the gauge section and the lamp section come on for approximately 2 sec. and go out. Cause 1 Defective monitor panel Standard value in normal state/Remarks on troubleshooting This internal defect cannot be diagnosed.
D65EX, PX-15
20-609
(1)
TROUBLESHOOTING
E-5
E-5 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES.
Trouble Related information The battery charge level caution lamp flashes. When any abnormality is detected during engine operation, the battery charge level caution lamp will flash. Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then start the engine and carry out troubleshooting. Defective alternator (insuffiAlternator Engine speed Voltage cient power generation) Between Terminal R Min. medium speed 20 30 V and ground (half) aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Disconnection of wiring harness (Disconnection in Wiring harness between S04 (female) (9) and Resistance Max. 1 z wiring or defective contact in alternator R terminal connector) Between wiring harness AL/F and GND03 and Resistance Max. 1 z ground aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring harness (Contact with Between wiring harness (between S04 (female) ground circuit) Resistance Min. 1 Mz (9) and alternator R terminal, or STC1 (1) (female) (15)) and ground aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. Defective monitor panel S04 Engine speed Voltage Between (9) and Medium speed (half) 20 30 V ground Cause
20-610
(1)
D65EX, PX-15
TROUBLESHOOTING
E-5
Engine start/charge-related circuit diagram
D65EX, PX-15
20-611
(1)
TROUBLESHOOTING
E-6
E-6 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES.
Trouble (1) The engine oil pressure caution lamp flashes. When any abnormality is detected during engine operation, the engine oil pressure caution lamp will flash and sound the alarm buzzer. The engine oil pressure switch signal is sent and received from the engine controller through communication. Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode. (Code 40900: Engine controller input signal 1) Cause Standard value in normal state/Remarks on troubleshooting Drop of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is de1 (when the system is normal) tected. aPrepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the engine. The engine oil low pressure PSL Engine Resistance 2 switch is defective. (Internal short circuit) Stop Max. 1 z Between terminal and ground Min. 600 rpm Min. 1 Mz aPrepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the engine. The engine oil high pressure PSH Engine Resistance 3 switch is defective. (Internal short circuit) Stop Max. 1 z Between terminal and ground Min. 1,300 rpm Min. 1 Mz aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Ground fault of wiring Between wiring harness (between EN1 (female) Resistance Min. 1 Mz 4 harness (Contact with (21) and PSL) and ground ground circuit) Between wiring harness (between EN1 (female) Resistance Min. 1 Mz (15) and PSH) and ground aPrepare with the starting switch OFF, then carry out troubleshooting without turning the switch ON or after starting the engine. EN1 Engine Voltage Stop Max. 1 V 5 Defective engine controller Between (21) and ground Min. 600 rpm 5 11 V Stop Max. 1 V Between (15) and ground Min. 1,300 rpm 5 11 V 6 Defective monitor panel This is an internal defect, which cannot be troubleshot.
Related information
Circuit diagram related to engine oil low pressure switch and engine oil high pressure switch
20-612
(1)
D65EX, PX-15
TROUBLESHOOTING
E-6
Trouble (2)
Related information
The engine water temperature caution lamp flashes. When any abnormality is detected during engine operation, the engine water temperature caution lamp will flash and sound the alarm buzzer. The engine water temperature caution lamp flashes or goes out as it links with indication on the engine water temperature gauge. Input state (temperature) from engine water temperature (high temperature side) sensor can be checked in monitoring mode. (Code 04102: Engine water temperature (high temperature side)) Cause Overheated engine water 1 temperature (when the system is normal) Standard value in normal state/Remarks on troubleshooting As overheated engine water was detected, check the engine water temperature. (When the water temperature is over 108C, 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.
The engine water temperature sensor system is 2 defective. (Engine controller system)
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
White range/Green range
Trouble (3)
Related information
The power train oil temperature caution lamp flashes. When any abnormality is detected during engine operation, the power tlain oil temperature caution lamp will flash and sound the alarm buzzer. The power train oil temperature caution lamp flashes or goes out as it links with indication on the power train oil temperature gauge. Input state (temperature) from power train oil temperature sensor can be checked in monitoring mode. (Code 30100: Torque converter oil temperature) Cause Standard value in normal state/Remarks on troubleshooting Overheated oil temperature As an overheated power train oil temperature was detected, check the 1 of power train (when the power train oil temperature. (When the oil temperature is over 130C, system is normal) the lamp flash and sound the buzzer, over 120C, 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
D65EX, PX-15
20-613
(1)
TROUBLESHOOTING
E-6
Trouble (4)
Related information
The hydraulic oil temperature caution lamp flashes. When any abnormality is detected during engine operation, the hydraulic oil temperature caution lamp will flash and sound the alarm buzzer. The hydraulic oil temperature caution lamp flashes or goes out as it links with indication on the hydraulic oil temperature gauge. Input state (temperature) from hydraulic oil temperature sensor can be checked in monitoring mode. (Code 04401: Hydraulic oil temperature) Cause Overheated hydraulic oil 1 temperature (when the system is normal) Standard value in normal state/Remarks on troubleshooting As an overheated hydraulic oil temperature was detected, check the hydraulic oil temperature. (When the oil temperature is over 130C, the lamp flash and sound the buzzer, over 120C, 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.
The hydraulic 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
20-614
(1)
D65EX, PX-15
TROUBLESHOOTING
E-7
E-7 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON.
Trouble Related information While the preheater is operating, the preheating pilot lamp does not come on. aThis troubleshooting describes the procedures to be followed when the preheating lamp doe not come on. (When the preheater mounting section is not heated, carry out the troubleshooting of The preheater does not work.) For preheating, both the Automatic Preheating Function and the Manual Preheating Function are available. Even when either function is performed, the preheating lamp comes on. Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then carry out troubleshooting Disconnection of wiring without turning the starting switch ON. harness (Disconnection in 1 wiring or defective contact in Wiring harness between S03 (female) (9) and Resistance Max. 1 z connector) heater relay HT/A (A) terminal aPrepare with the starting switch OFF, then carry out troubleshooting Ground fault of wiring without turning the starting switch ON. 2 harness (Contact with Wiring harness between S03 (female) (9) and ground circuit) Resistance Min. 1 Mz heater relay HT/A (A) terminal and ground aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. S03 Voltage 3 Defective monitor panel ON Max. 1 V Between (9) and ground R1 Min. 7 V Cause
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 The engine water high temperature sensor is defective. 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. TWH (male) Resistance Between (1) and (2) 3.5 k 90 kz (10 100C) Between (1) (2) and ground Min. 1 Mz aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Wiring harness between EN2 (female) (27) Resistance Max. 1 z and TWH (female) (1) Wiring harness between EN2 (female) (39) Resistance Max. 1 z and TWH (female) (2) aPrepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON. Between wiring harness (between EN2 (female) 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. Between wiring harness (between EN2 (female) Voltage Max. 1 V (27) and TWH (female) (1)) and ground 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. EN2 (female) Resistance Between (27) and (39) 3.5 k 90 kz (10 100C) This is an internal defect, which cannot be troubleshot.
Disconnection of wiring harness (Disconnection in 2 wiring or defective contact in connector) Possible causes and standard value in normal state
Ground fault of wiring 3 harness (Contact with ground circuit)
Hot short circuit of wiring 4 harness (Contact with 24 V circuit)
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. 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 1 (Internal disconnection or Between (1) and (2) 3.5 k 90 kz short circuit) 10 100C 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 2 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. 3 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) 4 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 5 Defective monitor panel S04 (female) Resistance temperature Between (12) and 10 100C 3.5 k 90 kz ground Cause
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. 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 1 (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 2 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. 3 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) 4 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 5 controller ST1 (female) Resistance Between (9) and (21) 3.5 k 90 kz 6 Defective monitor panel This is an internal defect, which cannot be troubleshot. Cause
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. 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 1 (Internal disconnection or short circuit) Full About 4 z Between (1) and (2) (ground) Empty About 85 z aPrepare with the starting switch OFF, 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 2 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. 3 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) 4 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 5 Defective monitor panel This is an internal defect, which cannot be troubleshooting. Cause
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. 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) Cause
Trouble (2) Related information Possible causes and standard value in normal state
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. 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 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.
D65EX, PX-15
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) 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.
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.
Cause
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.
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)
Cause
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.
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 1 (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) 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 3 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 4 transmission controller and ST3 (21), (31), Max. 1 V (32), (33) OFF (0) 5 11 V Between (6) and ground Max. 1 V
Cause
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.
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.
Cause
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.
Standard value in normal state/Remarks on troubleshooting Since the buzzer cancel switch system is supposed to be out of order, carry out the troubleshooting of The buzzer cancel switch does not work. Since the information switch system is supposed to be out of order, carry out the troubleshooting of The information switch does not work. When the fuse FS1 (10) is cut off, a ground fault may have possibly oc3 Defective 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 4 (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 5 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 6 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. 7 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 8 (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 9 transmission controller OFF 5 11 V Between (6) and ground ON Max. 1 V
Cause Defective buzzer cancel 1 switch system Defective information switch 2 system
D65EX, PX-15
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. 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. Cause
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.
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
Cause Defective head lamp 1 (Breakage of bulb) 2 Defective fuse (FS1-(8))
Standard value in normal state/Remarks on troubleshooting Since the head lamp may be defective, check its bulb for breakage.
Trouble (2) Related information
The rear lamp does not light up.
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
Cause Defective rear lamp 1 (Breakage of bulb) 2 Defective fuse (FS1-(8))
Standard value in normal state/Remarks on troubleshooting Since the rear lamp may be defective, check its bulb for breakage.
20-630
(1)
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. 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 Cause
1 2
20-632
(1)
D65EX, PX-15
TROUBLESHOOTING
E-23
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
Cause
D65EX, PX-15
20-633
(1)
TROUBLESHOOTING
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. 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 Cause
20-634
(1)
D65EX, PX-15
TROUBLESHOOTING
E-23
Circuit diagram related to wiper system
D65EX, PX-15
20-635
(1)
TROUBLESHOOTING
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. 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 circuit with chassis ground in CN33 (female) (3) 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 Cause
1 2
20-636
(1)
D65EX, PX-15
TROUBLESHOOTING
E-23
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
Cause
D65EX, PX-15
20-637
(1)
TROUBLESHOOTING
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. 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 Cause
20-638
(1)
D65EX, PX-15
TROUBLESHOOTING
E-23
D65EX, PX-15
20-639
(1)
TROUBLESHOOTING
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. 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 Cause
1 2
20-640
(1)
D65EX, PX-15
TROUBLESHOOTING
E-23
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
Cause
D65EX, PX-15
20-641
(1)
TROUBLESHOOTING
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
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 1 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 2 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 3 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 4 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
20-642
(1)
D65EX, PX-15
TROUBLESHOOTING
E-23
D65EX, PX-15
20-643
(1)
TROUBLESHOOTING
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. 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 Cause
1 2
20-644
(1)
D65EX, PX-15
TROUBLESHOOTING
E-23
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
Cause
D65EX, PX-15
20-645
(1)
TROUBLESHOOTING
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
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 1 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 2 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 3 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 4 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
20-646
(1)
D65EX, PX-15
TROUBLESHOOTING
E-23
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. 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 Cause
20-648
(1)
D65EX, PX-15
TROUBLESHOOTING
E-24
Circuit diagram related to washer system
D65EX, PX-15
20-649
(1)
TROUBLESHOOTING
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. 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 Cause
For the electric circuit diagram of each system, see Trouble (1).
20-650
(1)
D65EX, PX-15
TROUBLESHOOTING
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. 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 Cause
D65EX, PX-15
20-651
(1)
TROUBLESHOOTING
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. 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 Cause
20-652
(1)
D65EX, PX-15
TROUBLESHOOTING
E-25
E-25 THE AIR CONDITIONER DOES NOT OPERATE.

Trouble (1) Related information No air flow.
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.
Cause Defective circuit breaker 1 (CB2)
D65EX, PX-15
20-653
(1)
TROUBLESHOOTING
E-25
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.
Cause
20-654
(1)
D65EX, PX-15
TROUBLESHOOTING
E-25
Cooling is not possible.
Cause
1 Defective pressure switch
Defective compressor clutch relay (coil side)
Defective compressor clutch relay (contact side)
Defective condenser relay (contact side)
5 Defective thermistor Possible causes and standard value in normal state
Defective condenser blower resistor
7 Defective condenser motor
Defective compressor magnet clutch
9 Defective compressor
Disconnection of wiring harness (Disconnection in 10 wiring or defective contact in connector)
Standard value in normal state/Remarks on troubleshooting aPrepare with the starting switch OFF, then turn the starting switch ON and carry out troubleshooting. 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. 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. 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. 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. 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. Condenser blower resistor Resistance Between terminals 2.8 z 5% aTurn the starting switch on and carry out the troubleshooting. The motor is in order if it is rotating when the air conditioner is switched ON. aStart the engine and carry out the troubleshooting. The compressor magnet clutch is supposed to be out of order, so inspect it directly. aStart the engine and carry out the troubleshooting. 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 or CN-R1 (female) (8C) Wiring harness between CN-R5 (female) Resistance Max. 1 z (18A) and A/C (female) (1) 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
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.
Cause
20-656
(1)
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 ........................................................................................... H- 1 No travel power (no drawbar pull) .................................................................................................. H- 2 Machine does not move (at 2nd or 3rd speed) .............................................................................. H- 3 Machine does not move in any speed range ................................................................................. H- 4 Machine travels only in one direction forward or in reverse ........................................................... H- 5 When gear is shifted or travel direction is changed, large time lag is made .................................. H- 6 Machine does not turn (not turned rightward or leftward) .............................................................. H- 7 Steering speed or power is low ...................................................................................................... H- 8 Brake does not work ...................................................................................................................... H- 9 Overheat of power train oil temperature ......................................................................................... H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor ............ H-11 All work equipment speeds are slow .............................................................................................. H-12 Work equipment does not move .................................................................................................... H-13 Blade lift speed is slow or lacks power ........................................................................................... H-14 Blade tilt speed is slow or lacks power ........................................................................................... H-15 Ripper lift speed is slow or lacks power ......................................................................................... H-16 Excessive hydraulic drift of blade lift .............................................................................................. H-17 Excessive hydraulic drift of blade tilt .............................................................................................. H-18 Excessive hydraulic drift of ripper lift ..............................................................................................
20-702 20-703 20-704 20-705 20-706 20-707 20-708 20-708 20-709 20-709 20-710 20-710 20-711 20-711 20-712 20-712 20-713 20-713 20-714
D65EX, PX-15
20-701
(1)
TROUBLESHOOTING

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 1 Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting
2 Cause supposed to have caused failure <Contents> (The sequence shows refer- Standard values in normal state for judging possible causes ence numbers and does not Remarks for making judgment 3 mean priority.)
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. 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. Cause
7 8
D65EX, PX-15
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.) 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. Cause
3 4
20-704
(1)
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. 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 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.
20-706
(1)
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. 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. 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. Cause
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. 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. Cause
20-708
(1)
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 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.
Defective brake valve function
Defective adjustment of brake pedal linkage
3 Defective brake seal 4 Slipped or abrasive brake disk plate
H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE

Trouble Related information The oil temperature of the power train overheats. 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.) 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.) Cause
1 2
D65EX, PX-15
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 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. Cause Defective PTO (pump drive 1 unit of HSS and work equipment) Defective HSS and work 2 equipment pump Standard value in normal state/Remarks on troubleshooting The PTO pump drive unit of the work equipment is assumed to be defective; directly check it.
The pump of the HSS and work equipment is assumed to be defective; 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 {35 +14 kg/cm2} 0 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.
20-710
(1)
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. Cause Defective PTO (Pump drive 1 unit of HSS and work equipment) Defective HSS and work 2 equipment pump Standard value in normal state/Remarks on troubleshooting The PTO pump drive unit of the HSS and work equipment is assumed to be defective; directly check it.
The HSS and work equipment pump is assumed to be defective; directly check it. aPrepare with starting switch OFF, then drive the engine in high idling mode for troubleshooting. Defective unload valve func3 Work equipment lever Unload pressure tion 3.43 +1.37 MPa 0 Full neutral {35 +14 kg/cm2} 0 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 4 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 self5 pressure 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 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.
Defective PPC valve function
Defective function of blade lift operation valve (Spool)
3 Aired blade lift cylinder
D65EX, PX-15
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 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.
Defective function of blade tilt operation valve (Spool)
3 Aired blade tilt cylinder
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER

Trouble Related information Ripper lift speed is slow or lacks power. Confirm 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 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.
Defective function of ripper lift operation valve (Spool)
Defective function of ripper 3 lift operation valve (suction valve) 4 Aired ripper lift cylinder
20-712
(1)
D65EX, 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 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.
Defective seal of blade lift operation valve (Spool)
Defective seal of blade lift cylinder
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 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.
Defective seal of blade tilt operation valve (Spool)
Defective seal of blade tilt cylinder
D65EX, PX-15
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 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.
Defective seal of ripper lift operation valve (Spool)
Defective seal of ripper lift cylinder
20-714
(1)
D65EX, PX-15
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)
Method of using troubleshooting charts ................................................................................................... S- 1 Starting performance is poor (starting always takes time) ............................................................. S- 2 Engine does not start ..................................................................................................................... S- 3 Engine does not pick up smoothly (follow-up is poor) .................................................................... S- 4 Engine stops during operations ..................................................................................................... S- 5 Engine does not rotate smoothly (hunting) .................................................................................... S- 6 Engine lacks output (or lacks power) ............................................................................................. S- 7 Exhaust smoke is black (incomplete combustion) ......................................................................... S- 8 Oil consumption is excessive (or exhaust smoke is blue) .............................................................. S- 9 Oil becomes contaminated quickly ................................................................................................ S-10 Fuel consumption is excessive ...................................................................................................... S-11 Oil is in cooling water (or water spurts back, or water level goes down) ........................................ S-12 Oil pressure caution lamp lights up (drop in oil pressure) .............................................................. S-13 Oil level rises (water, fuel in oil) ...................................................................................................... S-14 Water temperature becomes too high (overheating) ...................................................................... S-15 Abnormal noise is made ................................................................................................................ S-16 Vibration is excessive .....................................................................................................................
20-802 20-806 20-807 20-810 20-811 20-812 20-813 20-814 20-815 20-816 20-817 20-818 20-819 20-820 20-821 20-822 20-823
D65EX, PX-15
20-801
(1)
TROUBLESHOOTING
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 users 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
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
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
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 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.
Causes
Confirm recent repair history Degree of use of machine Ease of starting Operated for long period Gradually became worse Starts when warm
E E
Q w w
Q Q w w Q Q Q Q w w Q Q
Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Preheating indicator lamp does not light up during preheating or in low temperatures Charging caution lamp lights up while engine is running Dust indicator lamp is red Air breather hole in fuel tank cap is clogged Leakage of fuel from fuel piping When fuel priming pump is operated, there is no response, or operation is too heavy Starting motor cranks engine slowly When engine is cranked with starting motor No fuel comes out even when fuel filter air bleed plug is removed
w w
w w w w w w Q w Q Q w w w w Q Q Q w Q Q w q q q q q q q q q
Yes No
When hose at collection portion for spill flow from fuel injector is disconnected, spill flow is small (See error code AD10L3) When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly add combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive Check air cleaner directly When compression pressure is measured, it is found to be low When air is bled from fuel line, air comes out Check fuel filter, strainer directly Check fuel feed pump strainer directly Carry out troubleshooting for error code AD10L3: Fuel supply pump non-force feed Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Intake air heater mount does not become warm during operation of preheating Is voltage 26 30 V between alternator terminal B and terminal E with engine at low idling?
w w
q q q
When specific gravity of electrolyte or voltage of battery is measured, it is found to be low 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 Condition of horn when starting switch is turned ON Operated for long period Horn does not sound Horn volume is low
E E
w w w w Q Q w w Q q q q w
When battery is checked, battery electrolyte is found to be low Battery terminal is loose 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 When starting switch is turned to START, pinion moves out, but Makes grating noise Soon disengages again Makes rattling noise and does not turn Check flywheel ring gear directly When specific gravity of electrolyte or voltage of battery is measured, it is found to be low There is no voltage (20 30 V) between battery relay terminal B and terminal E Turn the starting switch OFF, connect the cord, and carry out troubleshooting at ON When terminal B and terminal C of starting switch are connected, engine starts When terminal B and terminal C of starting motor are connected, engine starts When terminal B and terminal C of safety relay are connected, engine starts When terminal of safety switch and terminal B of starting motor are connected, engine starts Remedy
Q w w Q Q
q q q q
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 Operated for long period
E E E
Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is removed, there is no fuel in filter There is leakage from fuel piping When fuel priming pump is operated, there is no response, or operation is too heavy When engine is cranked with starting motor No fuel comes out even when fuel filter air bleed plug is removed When hose at collection portion for spill flow from fuel injector is disconnected, spill flow is small (See error code AD10L3)
w Q w w w w w w Q w Q Q Q w w w w Q Q Q w Q Q q q q q q q q q q w w w w Q Q
E
E E
When air is bled from fuel line, air comes out Check fuel filter directly Check fuel feed pump gauze filter directly Check fuel feed pump directly Carry out troubleshooting for error code AD10L3: Fuel supply pump non-force feed Carry out troubleshooting Abnormality in fuel supply pump solenoid in troubleshooting for monitor panel Check fuel overflow valve directly Possible to start in reduced cylinder mode Remedy
q q
20-808
(1)
D65EX, 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 Suddenly failed to start Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Preheating indicator lamp dies not light up during preheating or in low temperatures Dust indicator lamp is red Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained When fuel filter is removed, there is no fuel in filter There is leakage from fuel piping When fuel priming pump is operated, there is no response, or operation is too heavy Starting motor cranks engine slowly When engine is cranked, abnormal noise is heard from around cylinder head When engine is cranked with starting motor No fuel comes out even when fuel filter air bleed plug is removed Operated for long period
E E
w w w w w
w Q Q
w w Q w w w w w Q Q w w Q w w w w q q q q q q q q q q q
Remedy
When hose at collection portion for spill flow from fuel injector is disconnected, spill flow is small (See error code AD10L3) When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Check air cleaner element directly Remove head cover and check directly When compression pressure is measured, it is found to be low When air is bled from fuel line, air comes out Check fuel filter, strainer directly Check fuel feed pump strainer directly Carry out troubleshooting for error code AD10L3: Fuel supply pump non-force feed Spray condition is poor when fuel injector is tested as individual part When specific gravity of electrolyte or voltage of battery is measured it is found to be low Defective water temperature gauge display on machine Intake air heater mount does not become warm during preheating
D65EX, 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
E E
E E
Engine pick-up suddenly became poor Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Engine oil must be added more frequently Dust indicator lamp is red Air breather hole in fuel tank cap is clogged Rust and water are found when fuel is drained There is leakage from fuel piping When fuel priming pump is operated, there is no response, or operation is too heavy When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas Blue under light load Black
w w w w
Q Q w w w w w
Q w
w w w w w Q Q Q w w Q w w Q Q w q q q q q q q q q q q w w Q w Q w w w
Abnormal noise is heard from around cylinder head when engine is run Noise of interference is heard from around turbocharger High idling speed is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) Blow-by gas is excessive Check air cleaner element directly When compression pressure is measured, it is found to be low Check valve clearance directly When turbocharger is rotated by hand, it is found to be heavy When air is bled from fuel line, air comes out Check fuel filter, strainer directly Check fuel feed pump strainer directly Carry out troubleshooting for error code AD10L3: Fuel supply pump non-force feed Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Remedy
20-810
(1)
D65EX, 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 Operated for long period Abnormal noise was heard and engine stopped suddenly Condition when engine stopped Engine overheated and stopped Engine stopped slowly There was hunting and engine stopped Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Fuel level caution lamp lights up Fuel tank is found to be empty Air breather hole in fuel tank cap is clogged There is leakage from fuel piping When priming pump is operated, there is no response, or operation is too heavy Rust and water are found when fuel tank is drained Metal particles are found when oil is drained Does not turn at all When it is attempted to turn engine by hand Turns in opposite direction Moves amount of backlash Fuel supply pump shaft does not turn Engine rotates, but stops when load is applied to machine Check dynamic valve system directly Check piston and connecting rod directly Check crankshaft directly Check gear train directly Check fuel filter, strainer directly Check fuel feed pump strainer directly Check fuel feed pump directly Carry out troubleshooting for error code AD10L3: Fuel supply pump non-force feed When auxiliary equipment (Hyd. pump, air compressor) is removed, engine turns Remedy
E E
w w w w w Q w w Q Q Q Q w
Q w Q w w Q Q Q Q Q Q w
w w w w w Q Q w w Q Q
w w w w w w
w w w
q q q q q q q q q q
D65EX, 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 Operated for long period Occurs at a certain speed range Condition of hunting Occurs at low idling Occurs even when speed is raised Occurs on slopes Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Air breather hole in fuel tank cap is clogged Rust and water are found when fuel tank is drained There is leakage from fuel piping When fuel priming pump is operated, there is no response, or operation is too heavy When air is bled from fuel line, air comes out Check fuel feed pump strainer directly Check fuel filter, strainer directly Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Carry out troubleshooting for error code DLH1LC: Abnormality in Ne revolution sensor Carry out troubleshooting for error code DLE3LC: Abnormality in G revolution sensor Remedy
E E
Q w
Q Q Q Q Q Q Q Q Q w Q w w w w Q Q w w Q Q q q q q q q
Q Q Q Q
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 Operated for long period Suddenly Gradually
E E
Q Q w Q Q Q w w w Q Q Q Q Q Q Q
Q Q Q Q
Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Engine oil must be added more frequently Dust indicator lamp is red Air breather hole in fuel tank cap is clogged There is leakage from fuel piping Power is lacking after short stop in operations Color of exhaust gas Black Blue under light load
w w w w w w w Q w w Q w w q q q q q q q q q q q q q q q q Q Q Q Q Q Q w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Noise of interference is heard from around cylinder head when engine is run Abnormal noise is heard from around cylinder head when engine is run High idling speed of engine is low High idling speed is normal, but speed suddenly drops when load is applied Engine pickup is poor and combustion is irregular There is hunting from engine (rotation is irregular) Blow-by gas is excessive When air cleaner element is inspected directly, it is found to be clogged Check air intake piping directly When boost pressure is measured, it is found to be low When compression pressure is measured, it is found to be low Check valve clearance directly Check fuel filter, strainer directly Check fuel feed pump gauze filter directly Carry out troubleshooting for error code AD10L3: Fuel supply pump non-force feed Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode Check mounting of boost pressure sensor directly Carry out troubleshooting for error code DH30KX: Abnormality in boost pressure sensor Carry out troubleshooting for error code DGE4KX: Abnormality in fuel temperature sensor Remedy
D65EX, PX-15
20-813
(1)
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 Operated for long period Suddenly became black Color of exhaust gas Gradually became black Blue under light load Non-specified fuel is being used Engine oil must be added more frequently Power was lost Dust indicator lamp is red Muffler is crushed Leakage of air between turbocharger and cylinder head, loose damp Operates in low-temperature mode even at normal temperatures When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Noise of interference is heard from around turbocharger when engine is run Abnormal noise is heard from around cylinder head when engine is run Stall speed is too high (excessive injection of fuel) Exhaust noise is abnormal Engine pickup is poor and combustion is irregular Blow-by gas is excessive When hose from the injector to spill collection portion is disconnected, spill flow is found to be abnormally high (See error code AD10L3) Check air cleaner directly When turbocharger is rotated by hand, it is found to be heavy When compression pressure is measured, it is found to be low Check valve clearance directly 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 Check fuel spill piping directly Carry out troubleshooting for error code DGE3L6: Abnormality in water temperature sensor Remedy Suddenly Gradually
w w Q w
Q Q Q Q Q Q w
w Q w Q Q
Q Q w w
Q Q
Q Q Q Q w w w Q Q Q Q w Q Q Q w w q q q q q q q q q q Q Q w
20-814
(1)
D65EX, 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
E E E
Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Outside of engine is dirty with oil Loose piping clamp in air intake system Inside of turbocharger air supply pipe is dirty with oil Inside of exhaust pipe is dirty with oil There is oil in engine cooling water Oil level in clutch or damper chamber rises Exhaust smoke is blue under light load Amount of blow-by gas Excessive None
w w Q Q w w w Q w
Q Q w w w w w
w w Q q q q q q q q q q q q q q q
Remedy
Q w
w w w w
When intake manifold is removed, dust is found inside When intake manifold is removed, inside is found to be extremely dirty Excessive play of turbocharger shaft Check breather element directly When compression pressure is measured, it is found to be low Check rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage There is external leakage of oil from engine
D65EX, 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
E E E
Non-specified fuel is being used Engine oil must be added more frequently Even when oil temperature rises, oil filter caution lamp lights up When oil filter is inspected, metal particles are found Inside of exhaust pipe is dirty with oil Engine oil temperature rises quickly Color of exhaust gas Blue under light load Black Excessive None Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low Check breather, breather tube directly Check oil cooler is inspected directly Check oil filter directly Spring of oil filter safety valve catching or broken Check turbocharger drain tube directly Remedy
Q w w Q Q w w w w Q Q w w q q q q q q q q Q w Q
Amount of blow-by gas
20-816
(1)
D65EX, PX-15
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Leakage of fuel Improper condition of fuel injection (injection pressure, injection timing) Excessive injection of fuel
Causes
Confirm recent repair history Degree of use of machine Condition of fuel consumption Operated for long period More than for other machines of same model Gradually increased Suddenly increased There is external leakage of fuel from engine There is irregular combustion Engine oil level rises and smells of diesel fuel When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Low idling speed is high Engine stall speed is high Exhaust gas color Black White
E E
Q Q Q Q w w w w w Q
Q Q Q
Q Q Q Q q q q q q q q
Remedy
Q Q
Remove head cover and check directly Check fuel feed pump oil seal directly Carry out troubleshooting for error code DGE3L6: Fuel supply pump non-force feed Engine speed does not change when operation of certain cylinders is stopped in reduced cylinder mode When flow of oil from fuel injector at spill return collection portion is measured, it is found to be excessive Carry out troubleshooting for error code AD10L3: Abnormality in water low-temperature sensor Check with monitoring function on machine
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 Operated for long period Suddenly increased Gradually increased
Q Q Q Q Q Q w w
Q Q w
Hard water is being used as cooling water Engine oil level has risen, oil is cloudy white Excessive air bubbles inside radiator, spurts back Hydraulic oil, transmission oil is cloudy white When hydraulic oil, transmission oil is drained, water is found Pressure-tightness test of cylinder head shows there is leakage Check cylinder block, liner directly Check cylinder liner directly Pressure-tightness test of oil cooler shows there is leakage Remedy
w w q q q q q
20-818
(1)
D65EX, 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
Oil pressure caution lamp lights up Non-specified oil is being used Replacement of filters has not been carried out according to Operation Manual Lights up at low idling Condition when oil pressure lamp light up Lights up at low idling and high idling Lights up on slopes Sometimes lights up Oil temperature caution lamp lights up (machines equipped with lamp) Oil level in oil pan is low There is crushing, external leakage from hydraulic piping Oil is cloudy white or smells of diesel oil Metal particles are found when oil is drained Metal particles are found when oil inside oil filter is drained Metal particles are found in oil filter Check oil pan strainer pipe directly Oil pump rotation is heavy, there is play Deterioration, damage of valve, spring in oil pump relief valve Check oil filter directly Carry out troubleshooting for error code DDE2L6: Abnormality in oil pressure sensor When oil level sensor is replaces, oil pressure caution lamp goes out Remedy
Q w Q w w w
Q w Q w Q w w w Q w Q Q w w w
w w q q q
q q q q q
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) a If there is oil in the cooling water, carry out troubleshooting for Oil is in cooling water.
Causes
E E
Fuel consumption has increased Water must be added more frequently There is oil in engine cooling water Oil smells of diesel fuel Oil is cloudy white When engine is started, drops of water come from muffler When radiator cap is left open and engine is run at idling, an abnormal number of bubbles appear, or water spurts back Exhaust smoke is white Water pump drain hole (breather hole) is clogged When water pump drain hole (breather hole) is cleaned, water comes out Oil level goes down in clutch chamber or damper chamber Oil level goes down in hydraulic tank When compression pressure is measured, it is found to be low Remove head cover and check directly Check cylinder block, liner directly Check rear oil seal directly Pressure-tightness test of oil cooler shows there is leakage Remove water pump and check directly Remove thermostat cover and check directly Remove fuel supply pump and check directly Check auxiliary equipment seal directly Remedy
w Q Q w Q Q w Q w w w w Q Q w Q Q w
w q q q q q q q q q q
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 Operated for long period Suddenly overheated Always tends to overheat Rises quickly Water temperature gauge Does not go down from red range
E E
E E
Q w Q w w Q Q w w w
Q Q w
Radiator water level caution lamp lights up Engine oil level has risen, oil is cloudy white Fan belt tension is loose There is play when fan pulley is rotated Cloudy white oil is floating on cooling water Excessive air bubbles inside radiator, water spurts back When light bulb is held behind radiator, no light passes through Radiator shroud, inside of underguard are clogged with dirt or mud Water is leaking because of cracks in hose or loose clamps Cooling water flows out from radiator overflow hose Fan belt whines under sudden acceleration Power train oil temperature enters red range faster than engine water temperature When compression pressure is measured, it is found to be low Check cylinder liner directly Check oil cooler directly Temperature difference between top and bottom radiator tanks is excessive When function test is carried out on thermostat, it does not open even at cracking temperature Temperature difference between top and bottom radiator tanks is small Check radiator core directly When function test is carried out on radiator cap, cracking pressure is found to be low Check fan belt, pulley directly When water temperature is measured, it is found to be normal Remedy
w w w w w w w w w w q q q q q q q q q w
D65EX, 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 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.
Causes
Confirm recent repair history Degree of use of machine Condition of abnormal noise Operated for long period Gradually occurred Suddenly occurred
Q Q Q w w w w w w w Q
Q Q w
Non-specified fuel is being used Engine oil must be added more frequently Metal particles are found in oil drained from oil filter Leakage of air between turbocharger and cylinder head Noise of interference is heard from around turbocharger when engine is run Abnormal noise is heard from around cylinder head when engine is run Vibrating noise is heard from around muffler when engine is run When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Color of exhaust gas Blue under light load Black
w Q w Q w Q Q w q q q q q q q q q q q q Q w Q Q
Engine pickup is poor and combustion is abnormal Abnormal noise is loud when accelerating Blow-by gas is excessive When turbocharger is rotated by hand, it is found to be heavy Check dynamic valve system directly When muffler is removed, abnormal noise disappears Check valve clearance directly When compression pressure is measured, it is found to be low Remove timing gear cover and check directly 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 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 a If there is abnormal noise together with the vibration, carry out troubleshooting also for Abnormal noise is made.
Causes
Confirm recent repair history Degree of use of machine Condition of vibration Operated for long period Suddenly increased Gradually increased
Q Q Q w w Q Q w q q q q q q q q Q Q w w Q Q Q
Non-specified fuel is being used Metal particles are found in oil drained from oil filter Metal particles are found when oil pan is drained Oil pressure is low at low idling Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Check dynamic valve system directly Check main bearing, connecting rod bearing directly Check gear train directly Check cam bushing directly Check with monitoring function on machine Check engine mounting bolts directly When face runout and radial runout are inspected, they are found to be incorrect Check support spigot joint portion directly Check inside of output shaft (damper) directly Remedy
Q Q Q Q Q Q
D65EX, PX-15
20-823
(1)
DISASSEMBLY AND ASSEMBLY
30 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL ................. Removal and installation of assemblies .. Disassembly and assembly of assemblies . COATING MATERIALS LIST ...................... SPECIAL TOOL LIST ................................. SKETCHES OF SPECIAL TOOLS ............. REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY ........... Special tool .............................................. Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY ...................... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY ................... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF NOZZLE TIP ............................................... Special tool .............................................. Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL .............................. Special tool .............................................. Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY ................................ Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF ENGINE REAR SEAL ................................. Special tool .............................................. Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY .................. Special tool .............................................. Removal .................................................. Installation ............................................... 30- 4 30- 4 30- 5 30- 6 30- 8 30- 12 3030303013 13 13 14 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY ........................... 30Removal .................................................. 30Installation ............................................... 30REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY ............................ 30Removal .................................................. 30Installation ............................................... 30REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY ................................. 30Special tool .............................................. 30Removal .................................................. 30Installation ............................................... 30REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY ............ 30Removal .................................................. 30Installation ............................................... 30DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY ............ 30Disconnection ......................................... 30Connection .............................................. 30DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY ................................................ 30Special tool .............................................. 30Disassembly ............................................ 30Assembly ................................................ 30DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY ....................................... 30Special tool .............................................. 30Disassembly ............................................ 30Assembly ................................................ 30DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY ....................................... 30Disassembly ............................................ 30Assembly ................................................ 30DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY ........ 30Disassembly ............................................ 30Assembly ................................................ 30REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY ........... 30Removal .................................................. 30Installation ............................................... 30-
34 34 35 36 36 37 38 38 38 41 43 43 45 46 46 49 50 50 50 57 68 68 68 75 86 86 88 92 92 94 97 97 97
30- 17 30- 17 30- 17 30- 18 30- 18 30- 19 303030303030303022 22 22 23 24 24 24 24
30- 25 30- 25 30- 25 303030303030303026 26 26 26 29 29 29 32
D65EX, PX-15
30-1
(8)
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY ............................ Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF COOLING FAN PUMP ASSEMBLY ........... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY .............................. Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY ......................... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY ......................... Special tool ............................................. Removal .................................................. Installation ............................................... DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY ......................... Special tool ............................................. Disassembly ............................................ Assembly ................................................ REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY ..................... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF IDLER ASSEMBLY .................................... Removal .................................................. Installation ............................................... DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY .................................... Special tool ............................................. Disassembly ............................................ Assembly ................................................ REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY ................... Removal .................................................. Installation ............................................... DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY ................... Special tool ............................................. Disassembly ............................................ Assembly ................................................ REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY ................... Removal .................................................. Installation ............................................... DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY ................... Special tool ............................................. Disassembly ............................................ Assembly ................................................
30- 98 30- 98 30- 98 30- 99 30- 99 30-100
30-101 30-101 30-101 30-102 30-102 30-102 30-103 30-103 30-103 30-104 30-105 30-105 30-105 30-108 30-112 30-112 30-113 30-114 30-114 30-114 30-115 30-115 30-115 30-116 30-119 30-119 30-119 30-120 30-120 30-120 30-122 30-124 30-124 30-124 30-125 30-125 30-125 30-126
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY ................ Removal .................................................. Installation ............................................... DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY ................ Special tool .............................................. Disassembly ............................................ Assembly ................................................. EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY ........................ Check before expanding track shoe assembly ......................................... Expansion of track shoe assembly (Ordinary) ................................................ Expansion of track shoe assembly (When track frame has internal trouble) .. Installation ............................................... WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY ................................................ Special tool .............................................. Whole disassembly .................................. Whole assembly ...................................... FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK ............................................. Special tool .............................................. Disassembly ............................................ Assembly ................................................. REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY ........................ Special tool .............................................. Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY .................. Special tool .............................................. Removal .................................................. Installation ............................................... DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR SIDE BUSHING ............ Disassembly ............................................ Assembly ................................................. REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY ................. Removal .................................................. Installation ............................................... DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY ................. Assembly ............................................. DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ....... Special tool .............................................. Disassembly ............................................ Assembly .................................................
30-129 30-129 30-129 30-130 30-130 30-130 30-131 30-133 30-133 30-133 30-134 30-135
30-136 30-136 30-136 30-139 30-151 30-151 30-151 30-152 30-158 30-158 30-158 30-158 30-159 30-159 30-159 30-160 30-161 30-161 30-161 30-162 30-162 30-163 30-164 30-164 30-165 30-165 30-165 30-167
30-2
(2)
D65EX, PX-15
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY .................................... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF ROPS GUARD ........................................... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF OPERATORS CAB ASSEMBLY ................ Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF OPERATORS CAB GLASS (STUCK GLASS) ........................................ Special tool .............................................. Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY ..................... Special tool .............................................. Removal .................................................. Installation ...............................................
30-171 30-171 30-172 30-173 30-173 30-173 30-174 30-174 30-176
30-179 30-180 30-180 30-181 30-187 30-187 30-187 30-191
REMOVAL AND INSTALLATION OF STEERING AND TRANSMISSION CONTROLLER ASSEMBLY ...................... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY ....... Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY ............................ Removal .................................................. Installation ............................................... REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY ......................... Removal .................................................. Installation ...............................................
30-192 30-192 30-192 30-193 30-193 30-193 30-194 30-194 30-194 30-195 30-195 30-195
D65EX, PX-15
30-3
(2)
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
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)
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.
Category Komatsu code LT-1A Part number 790-129-9030 Q'ty 150 g Container Tube Main features and applications 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. Polyethylene Features: Resistance to heat and chemicals. container Used to fix and seal bolts and plugs. Can Used to stick and seal metal, glass, and plastics.
LT-2 LT-3 Adhesive LT-4 Holtz MH 705 ThreeBond 1735
09940-00030
50 g
790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener) 790-129-9040 790-129-9120 790-129-9140 250 g 75 g 50 g
Polyethylene Used to seal plugs. container Tube Heat-resistant seal used to repair engines. Quick-setting adhesive. Polyethylene Setting time: Within 5 sec. to 3 min. container Used mainly to stick metals, rubbers, plastics, and woods. Quick-setting adhesive. Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container Used mainly to stick rubbers, plastics, and metals. Features: Resistance to heat and chemicals. Polyethylene Used for fitted portions used at high temperacontainer tures. Tube Used to stick or seal gaskets and packings of power train case, etc.
Aron-alpha 201
790-129-9130
2g
Loctite 648-50 LG-1
79A-129-9110 790-129-9010
50 cc 200 g
LG-5
790-129-9080
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. 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. Features: Silicon-based quick-setting sealant. Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. Used to seal transfer case, etc.
Gasket sealant
LG-6
790-129-9020
200 g
Tube
LG-7 LG-8 ThreeBond 1207B
790-129-9070
1 kg
Tube
419-15-18131
100 g
Tube
30-6
(8)
D65EX, PX-15
CateKomatsu code gory LG-9 ThreeBond 1206D Gasket sealant LG-10 ThreeBond 1206E LG-11 ThreeBond 1121 ThreeBond 1211 Molybdenum disulfide lubricant
Part number
Q'ty
Container
Main features and applications 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. Used as lubricant/sealant when the radiator hoses are inserted. Can be coated with paint. Feature: Can be used together with gaskets. Used for covers of the transmission case and steering case etc. Gasket sealant used to repair engine. Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. Used to lubricate linkages, bearings, etc. 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.
790-129-9310
200 g
Tube
790-129-9320
200 g
Tube
790-129-9330 790-129-9090
200 g 100 g
Tube Tube
LM-P
09940-00040
200 g
Tube
Seizure prevention compound
LC-G NEVER-SEEZ
Can
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
Feature: Lithium grease with extreme pressure lubrication performance. General purpose type.
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. 400 g 16 kg 400 g 16 kg 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. 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. 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.
Grease
Hyper White Grease G2-T, G0-T (*)
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)
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
200 g
Tube
G2-U-S ENS grease
427-12-11871
2 kg
Can
D65EX, PX-15
30-7
(8)
CateKomatsu code gory SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER Primer SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41 SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SEAL 580 SUPER S or W Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381
Part number
Q'ty 20 ml
Container Glass container Glass container
Main features and applications Used as primer for cab side. (Using limit: 4 months after date of manufacture) Used as primer for glass side. (Using limit: 4 months after date of manufacture) 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) Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture) 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) Used as adhesive for glass. (Using limit: 6 months after date of manufacture) 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) Used to seal front window. (Using limit: 6 months after date of manufacture) Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
417-926-3910 20 ml Adhesive for cab glass Adhesive for cab glass
22M-54-27230
20 ml
Glass container
22M-54-27240
150 ml
Can
22M-54-27250
20 ml
Glass container
417-926-3910
320 ml
Polyethylene container
Adhesive
20Y-54-39850
310 ml
Polyethylene container Ecocart (Special container) Polyethylene container Polyethylene container
22M-54-27210
320 ml
417-926-3920
320 ml
Caulking material
20Y-54-55130
333 ml
22M-54-27220
333 ml
Cartridge
30-7-1
(8)
D65EX, PX-15
SPECIAL TOOL LIST
SPECIAL TOOL LIST

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).
Necessity
New/ remodel
Item
Symbol
Part No.
795-471-1800
Part name
Remover Plate Bolt Bracket Bolt Bolt
Sketch
Qty
Nature of work, remarks
1 1 1 1 3 1 Removal, installation of fuel supply pump drive gear
1 795-471-1810 Removal and installation of fuel A1 supply pump assembly 2 795-471-1820 3 795-471-1830 4 01435-01035 5 01435-01025 Removal and installation of engine front seal Removal and installation of nozzle tip A2 A3
795T-521-1140 Push tool 01010-31640 Bolt
t t t t t t t t q t q q q q t t t t t t t t t t
1 3 1 1 3 3 1 3 1
Press fitting of engine front seal
795T-471-1550 Wrench 795-931-1210 Push tool
Q Fixing of injector assembly
A4 Removal and installation of engine rear seal A5 Removal and installation of cylinder head assembly Disassembly and assembly of TORQFLOW transmission assembly A6
01050-31625 Bolt 01050-31645 Bolt 795-931-1220 Push tool
Press fitting of standard seal
01050-31645 Bolt 790-331-1110 Wrench
Press fitting of sleeved seal Tightening of cylinder head bolt
D1
799-301-1600
Oil leak tester
Check of operation of piston Removal, installation of brake and carrier assembly Removal, installation of bevel pinion nut Adjustment of preload on bevel gear shaft and bevel gear assembly
1 791T-422-1320 Hanger 2 790-302-1500 E 3 796-730-2300 Commercially 4 available or 795-630-1810 790-337-1032 Removal and installation of final drive assembly J1 791-427-1090 01010-51635 791-427-1100 2 790-101-2102 790-101-1102 Disassembly and assembly of final drive assembly J 3 792-520-2121 791-427-1200 4 790-101-2102 790-101-1102 Wrench kit Wrench assembly Torque wrench Lifting tool Plate Bolt Remover assembly Puller Pump Installer Installer assembly Puller Pump
1 1 1 1 1 1 2 1 1 1 1 1 1 1
Disassembly and assembly of HSS assembly
Lifting up of final drive assembly
Separation of sprocket hub assembly and bearing Installation of floating seal
Press fitting of sprocket hub bearing
30-8
(6)
D65EX, PX-15
SPECIAL TOOL LIST
Necessity
New/ remodel
Item
Disassembly and assembly of idler assembly Disassembly and assembly of track roller assembly Disassembly and assembly of carrier roller assembly Disassembly and assembly of idler assembly and track roller assembly
Symbol
Part No.
Part name
Installer Installer Installer
Sketch
Qty
1 791-515-1520 2 791-530-1520 L 3 796-230-1110
t t t t
1 1 1 Installation of floating seal
4 791-601-1000 791-685-8005 791-635-3160
Oil pump
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 1 1 1
Supply of oil
Compressor of type B t Extension Spacer Spacer Pump Cylinder Remover assembly Puller Pump Installer assembly Puller Pump Remover Brush Push tool Bar Guide Push tool Bar Guide Checker Installer Oil pump Push tool Bar Guide Push tool Bar Guide Installer Oil pump Frame Extension Nut Screw Screw Adapter Pusher t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
Disassembly and assembly of recoil spring assembly
790-201-2780 790-201-2790 790-101-1102 790-101-1600 791-450-1100
Disassembly, assembly of recoil spring assembly
Removal and installation of equalizer bar assembly
790-101-2102 790-101-1102 791-430-1200
Pulling out of center pin
Removal and installation of pivot shaft assembly
790-101-2102 790-101-1102 1 790-646-7531 2 791-660-7460 791-432-1110 3 791-646-7550
Press fit ring
Removal of pin plug of track link Cleaning of pin of track link Installation pin plug of track link (for large plug)
Whole disassembly and whole assembly of track shoe assembly
791-646-7560 R 791-932-1110 4 791-646-7523 791-646-7590 5 790-701-3000 6 791-432-1120 7 791-601-1000 791-432-1110 3 791-646-7550 791-646-7560 791-932-1110 4 791-646-7523 791-646-7590 6 791-432-1120
Installation pin plug of track link (for small plug) Check of track link for airtightness Installation of seal of track link Supply of track link oil Installation of pin plug of track link (for large plug)
Installation of pin plug of track link (for small plug) Installation of seal of track link Supply of track link oil
Field disassembly and assembly of one link
7 791-601-1000 791-635-3110 791-635-3160 791-635-3170 8 791-635-3180 791-635-3190 791-645-3510 791-646-3260
Pulling out of pin
D65EX, PX-15
30-9
(5)
SPECIAL TOOL LIST
Necessity
New/ remodel
Item
Symbol
9
Part No.
790-101-1102 790-101-1300 790-105-2300 790-101-1102 791-645-3520 791-432-1210
Part name
Pump Cylinder Jack Pump Adapter Spacer Guide Frame Extension Nut Screw Screw Adapter Adapter Pusher Spacer Spacer Frame Extension Nut Screw Screw Adapter Guide Pusher Guide Frame Extension Nut Screw Screw Adapter Repair stand Pump Wrench Socket Socket Socket Expander Ring Clamp Ring Clamp
Sketch
Qty

Pulling out of pin
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
1 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 1 1 4 2 1 1 1 1 1 1 1 2 1 1 1 1 1
10
Connection of link
11
Press fitting of bushing
12 791-645-3540 791-635-3110 791-635-3160 791-635-3170 791-635-3180 13 791-635-3190 791-645-3510 791-645-3520 791-645-3530 Field disassembly and assembly of one link R 791-432-1210 791-432-1220 791-635-3110 791-635-3160 791-635-3170 14 791-635-3180 791-635-3190 791-645-3520 791-645-3540 791-645-3550 15 791-646-3270 791-635-3110 791-635-3160 16 791-635-3170 791-635-3180 791-635-3190 791-645-3510 1 790-502-1003 790-101-1102
Press fitting of pin
Press fitting of bushing
Connection of link
Press fitting of pin
Disassembly, assembly of hydraulic cylinder assembly Removal, installation of cylinder head
2 790-330-1100 790-302-1270 3 790-302-1280 Disassembly and assembly of hydraulic cylinder assembly U 790-302-1340 4 790-720-1000 796-720-1650 5 07281-01029 796-720-1680 07281-01589
Removal, installation of nut
Installation of piston ring Installation of piston ring (for blade lift cylinder) Installation of piston ring (for blade tilt cylinder)
30-10
(4)
D65EX, PX-15
SPECIAL TOOL LIST
Necessity
New/ remodel
Item
Symbol
Part No.
790-201-1791
Part name
Push tool Push tool Grip Bolt Plate Plate Lifter (Suction cup)
Sketch
Qty

Press fitting of bushing (for blade lift cylinder) Press fitting of bushing (for blade tilt cylinder) Press fitting of dust seal
t t t t t t t
1 1 1 1 1 1 2
6 790-201-1811 Disassembly and assembly of hydraulic cylinder assembly U 7 790-101-5021 01010-50816 790-201-1620 790-201-1610 Removal and installation of operators cab glass (Stuck glass) X1 793-498-1210
(for blade tilt cylinder) (for blade lift cylinder) Installation of window glass
D65EX, PX-15
30-11
(8)
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

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

SPECIAL TOOL
New/ remodel Necessity
Symbol
Part No. 795-471-1800
Part name Remover Plate Bolt Bracket Bolt Bolt
1 1 1 1 3 1
1 795-471-1810 A1 2 795-471-1820 3 795-471-1830 4 01435-01035 5 01435-01025
REMOVAL
k
Disconnect the cable from the negative () terminal of the battery. 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
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. 3. Remove the engine undercover. 4. Open engine left cover (1). 5. Remove covers (2) and (3).
Sketch
7. Disconnect fuel supply pump wiring connectors PCV1 (5), PCV2 (6), and G (7).
Qty
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). 12. Remove high-pressure pipes (18) and (19). 13. Remove lubrication tube (20). *5 *6
D65EX, PX-15
30-13
(5)
14. Removal of fuel supply pump. 1) Remove cover (22).
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.
2) Remove gear mounting nut (23) and washer (24). a Take great care not to drop the nut and washer in the case.
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
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.
3 Fuel hoses (8) and (9):
14.8 19.6 Nm {1.5 2.0 kgm}
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}
8) Tighten bolt A1-2 and remove the gear and fuel supply pump (27).
a Install cover (12) with its slit on the cylinder block side. Install cover (13) with its face down.
4
k
3 Tightning torque of bolt:
Approx. 196 294 Nm {20 30 kgm}
Do 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)
a Install the fuel supply pump and the parts between it and common rail according to the following procedure.
vi) Install gear cover (22).
3 Mounting nut:
14.7 17.6 Nm {1.5 1.8 kgm}
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).
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:
3 Mounting nut:
3 Sleeve nut on supply pump side: 2 4 supply pump mounting bolts:
39.2 58.8 Nm {4 6 kgm} 39.2 49 Nm {4 5 kgm}
127 147 Nm {13 15 kgm}
iii) Tighten supply pump (27) permanently. Adhesive (LT-2)
3 Clamping bolt: 3 Clamping bolt:
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. 11.8 14.7 Nm {1.2 1.5 kgm}
vii) Tighten bracket (29), and then tighten bracket (30) permanently. 11.8 14.7 Nm {1.2 1.5 kgm}
30-16
(4)
D65EX, PX-15
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)
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY

REMOVAL
1. Remove right and left covers (1). 2. Open cover (2).
INSTALLATION
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)
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY

REMOVAL
k
Disconnect the cable from the negative () terminal 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). 7. Remove common rail cover (9).
3 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).
9
30-18
(2)
D65EX, PX-15
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.
Do not bend the high-pressure pipes before using them. k Be sure to use the genuine high-pressure 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.
INSTALLATION
1
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).
3 High-pressure pipe sleeve nut:
3 Air cleaner band:

9.8 11.76 Nm {1.0 1.2 kgm}
3 Eyebolt:
34.3 44.1 Nm {3.5 4.5 kgm}
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:
3 Hose clamp between air intake connector and turbocharger: 6.8 0.49 Nm {69 5 kgcm}
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)
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}
3 Head cover mounting bolt:

9.8 1 Nm {1.0 0.1 kgm}
10
3 Wiring harness mounting nut:

2.0 2.4 Nm {0.2 0.24 kgm}
30-20
(2)
D65EX, PX-15
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)
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 A3 Part No. 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
INSTALLATION
1. Fit tool A3 in vice [1]. a Do not pinch the injector directly in the vice.
5. Mount nozzle assembly (3) and manually tighten retaining nut (2).
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 45 (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)
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

SPECIAL TOOL
Symbol A2 Part No. 795T-521-1140 01010-31640 Part name Push tool Bolt t t 1 3 Q
INSTALLATION
1
1. Using guide bolt [1], set the crank pulley.
REMOVAL
k
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. 2. Tighten the mounting bolts. (M14): 157 196 Nm {16 20 kgm} (M16): 245 308.7 Nm {25 31 kgm}
2
3 Mounting bolt:
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 +1 mm 0
4. Remove engine front seal (5).
30-24
(2)
D65EX, PX-15
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY

REMOVAL
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
6. Remove damper assembly (3).
INSTALLATION
1
2 Mounting bolt: 3 Mounting bolt:

Liquefied adhesive (LT-2) 98.1 122.6 Nm {10 12.5 kgm}
4. Drain oil from the damper case. 6 Damper case: 1.7 l
2 Cover mounting face: 3 Mounting bolt:

Gasket sealant (LG-6) 98.1 122.6 Nm {10 12.5 kgm}
5. Using guide bolt [1], remove damper cover (2). 4 Damper cover: 35 kg
2 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.
3 Drain plug: 58.8 78.5 Nm {6 8 kgm}
5 Damper case: 1.7 l (TO30)
D65EX, PX-15
30-25
(2)
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

SPECIAL TOOL
Symbol Part No. 795-931-1210 4 01050-31625 A 5 01050-31645 795-931-1220 01050-31645 Part name Push tool Bolt Bolt Push tool Bolt t t t t t 1 3 3 1 3
INSTALLATION
1
REMOVAL
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
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. 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}
3. Remove engine rear seal (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 m 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.
30-26
(2)
D65EX, PX-15
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)
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.
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).
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:
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
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

SPECIAL TOOL
Symbol A6 Part No. 790-331-1110 Part name Wrench q 1
11. Disconnect 6 wiring connectors of the injector and move the wiring harness. 12. Remove tube (11).
5
13. Remove high-pressure pipe clamps (12), (13), and (14), 2 pieces each. 6 14. Remove bracket (15). 15. Remove filler tube (16).
REMOVAL
k

1
1. Drain cooling water. 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)
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
23. Remove high-pressure pipe (28). 24. Remove spill tubes (29) and (30). 25. Remove head cover (31).
8 9 10
29. Remove push rod (40). 30. Remove mounting bolt (41) and fuel injector assembly (42). 15
26. Remove wiring harness (32) from the injector.

11
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
27. Loosen locknut (33), and then loosen adjustment screw (34) by 2 3 turns. 12 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)
INSTALLATION
1
10
3 Mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
3 Drain plug:
11.8 17.6 Nm {1.2 1.8 kgm}
11
3 Injector wiring harness mounting nut:

2.0 2.4 Nm {0.2 0.24 kgm} a Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE.
3 Air cleaner band:

9.8 11.76 Nm {1.0 1.2 kgm}
12
13
3 Tube eyebolt (at each end):

34.3 44.1 Nm {3.5 4.5 kgm}
3 Rocker shaft mounting bolt:

58.8 73.5 Nm {6 7.5 kgm}
14
3 Hose clamp between air intake connector and turbocharger: 6.8 0.49 Nm {69 5 kgcm}
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 20 more (Angle tightening). 5) While fixing adjustment screw (39) with a flat-head screwdriver, etc., tighten locknut (38).
3 Eyebolt on cylinder block side:

24.5 34.3 Nm {2.5 3.5 kgm}
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}
3 Locknut: 58.8 73.5 Nm {6 7.5 kgm}
3 Spill tubes (29) (5 pieces from front 3 Spill tubes (30) (on both ends):
of engine): 9.8 12.7 Nm {1.0 1.3 kgm} 24.5 34.3 Nm {2.5 3.5 kgm}
15
a For the installation procedure, see REMOVAL AND INSTALLATION OF FUEL INEJCTOR ASSEMBLY.
30-32
(2)
D65EX, PX-15
16
3 Rocker housing mounting bolt:

58.8 73.5 Nm {6 7.5 kgm} 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
2. Make a punch mark (g). 3. Tighten bolt 7 to the following torque. 66.2 7.4 Nm {6.8 0.8 kgm}
3 Bolt 7 (Auxiliary bolt):
17
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) 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 90 +30 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 90 +30 by using 0 a protractor and a wrench.
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
D65EX, PX-15
30-33
(2)
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY

REMOVAL
k
3. Disconnect hose (3). 4. Remove bolt (4) and move valve (5) down. 5. Disconnect wiring connector CN-244 (6) and remove 2 wiring harness clamps. 6. Remove support (16).
Disconnect the cable from the negative () terminal of the battery. a Drain fuel, if necessary. 1. Remove cover (1).
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
8. Disconnect wiring connectors CN-247 (8) and CN-224 (9) of the rear lamp and remove the wiring harness clamp.
12. Sling the fuel tank assembly temporarily. 13. Remove 4 right and left covers (14) and mounting bolts.
9. Remove cover (10) in the rear of the operators seat.
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
30-35
(2)
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
1. Drain cooling water.
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
INSTALLATION
1
3 Drain plug:
11.8 17.6 Nm {1.2 1.8 kgm}
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
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(2)
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY

REMOVAL
k k k
4. Close the fuel feed valve. 5. Drain cooling water.

1
a a
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. Disconnect the cable from the negative () terminal of the battery. 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. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere. If refrigerant gas (R134a) gets in your eyes, you 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.
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
1. Remove right and left covers (1). 2. Remove the engine hood assembly. For details, see REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY. 3. Remove right and left covers (3). 8. Disconnect hose (9).
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D65EX, PX-15
9. Disconnect wiring connectors E21 (10) and E22 (11). 10. Disconnect hose (12). 11. Remove duct (13) and cover (14).
3
15. Disconnect heater hoses (19) and (20) and remove the clamp. 16. Remove heat insulation panel (21).
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. 19. Remove fan guard (23).
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(8)
20. Disconnect wiring connector FAR (24). 21. Remove plate (25). 22. Disconnect hoses (26), (27), and (28).
25. Remove the mounting bolt and clamp of tube (31) under the right side of the engine and lower the tube.
23. Remove plate (29).
26. Remove universal joint (32).
24. Lift off fan drive assembly (30).
4 Fan drive assembly: 110 kg
27. Loosen the elbow of the breather pipe at the damper and direct breather pipe (33) straight down. 6
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D65EX, PX-15
28. Sling the engine assembly temporarily. a Pass sling wires through the mounting bracket on the rear side. 29. Remove 8 engine mounting bolts (34).
INSTALLATION
3 Drain plug:
3
11.8 17.6 Nm {1.2 1.8 kgm}
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
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.
3 Tightening torque of air conditioner refrigerant piping:

Thread size 16 x 1.5 22 x 1.5 24 x 1.5 4 Tightening torque 11.8 14.7 Nm {1.2 1.5 kgm} 19.6 24.5 Nm {2.0 2.5 kgm} 29.4 34.3 Nm {3.0 3.5 kgm}
a Adjust the tension of the alternator belt. For details, see TESTING AND ADJUSTING, Testing and adjusting alternator belt tension.
5
Liquefied adhesive (LT-2)
98.1 122.6 Nm {10 12.5 kgm}
2 Threads of elbow:
3 Elbow: 13.7 21.6 Nm {1.4 2.2 kgm}

Gasket sealant (LG-1)
D65EX, PX-15
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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).
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D65EX, PX-15
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY

REMOVAL
k
6. Disconnect hoses (6), (7), and (8). 7. Remove suction tube (9).
Disconnect the cable from the negative () terminal of the battery. 6 Hydraulic tank: 55 l
1. Drain oil.
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.
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(2)
11. Disconnect tube (15) from the HSS pump assembly.
15. Remove universal joint (24).
12. Disconnect hoses (16), (17), and (18) from the cooling fan pump. 13. Disconnect the suction tube and hose (19) together from the rear. 1
16. Remove right and left final drive shaft covers (25).
14. Remove the cover and disconnect hoses (20), (21), (22), and (23) from the pressure pickup ports.
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.
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D65EX, PX-15
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
1
3 Hose clamp:
8.8 0.5 Nm {90 5 kgcm}

Liquefied adhesive (LT-2) 98.1 122.6 Nm {10.0 12.5 kgm}
20. Remove 4 right and left mounting bolts (31).
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
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(2)
DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY

DISCONNECTION
1. Drain oil from the power train case. 6 Power train case: 48 l 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.
2. Disconnect wiring connector TM1 (1) above the HSS case.
3. Disconnect wiring connector TMV (2) on the right side of the transmission case.
7. Remove all the pipes and hoses from each part. 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
3
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D65EX, PX-15
9. Remove HSS pump assembly (7).
4 HSS pump assembly: 75 kg
12. Remove HSS motor assembly (10). 4 HSS motor assembly: 45 kg
10. Remove cooling fan pump assembly (8).
4 Cooling fan pump assembly: 30 kg
13. Remove 13 mounting bolts and HSS assembly (11). 5 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
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(2)
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).
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(2)
D65EX, PX-15
CONNECTION
Carry out connection in the reverse order to disconnection.
1
a Using push tool [4], install oil seal (22) to retainer (15).
3 Mounting bolt of bracket (3):

98 123 Nm {10.0 12.5 kgm} a If the cable nut was loosened, adjust it. For details, see TESTING AND ADJUSTING, Adjusting parking brake lever.
2 Lip of oil seal: Grease (G2-LI) 2 Periphery of press fitting surface of

oil seal and inside wall of hole of retainer: Gasket sealant (LG-5) a Wipe off the projected gasket sealant.
a Apply gasket sealant (LG-6) to the threads of only 1 mounting bolt (21) of tube (20).
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm} Refilling with oil
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
5 Power train case: 48 l (TO30)
3 Mounting bolt:
245 309 Nm {25 31.5 kgm}
2 O-ring between coupling and shaft: 2 Mounting bolt: 3 Mounting bolt:

Grease (G2-LI) Liquefied adhesive (LT-2)
245.1 309.0 Nm {25.0 31.5 kgm}
D65EX, PX-15
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(2)
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY

SPECIAL TOOL
Symbol D1 Part No. 799-301-1600 Part name Oil leak tester q 1
4) Disconnect 10 connectors (6) of the ECMV. 5) Remove cover (7) and wiring harness (8) together.
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). 6) Remove control valve assembly (9).
2) Remove flange (4). 3) Using eyebolt [1], remove sleeve (5).
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).
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(2)
D65EX, PX-15
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).
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).
D65EX, PX-15
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(2)
7. No. 1 discs, plates, and springs 1) Remove 5 springs (32). 2) Remove 6 plate (33) and 5 discs (34).
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).
8. No. 1 housing assembly 1) Using eyebolts [4], remove No. 1 housing assembly (35). 2) Remove No. 1 piston (36) from the housing.
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).
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(2)
D65EX, PX-15
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).
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).
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).
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].
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).
2) Remove seal ring (65). 3) Drive pin (66) into shaft (67). 4) Drive out shaft (67) from No. 3 carrier side.
D65EX, PX-15
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(2)
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.
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).
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(2)
D65EX, PX-15
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).
23. Guide pin and No. 5 piston Remove 5 guide pin (100) and No. 5 piston (101).
2) Remove snap ring (95), then remove No. 4 ring gear (96) from carrier (97).
24. No. 5 discs, plates, and springs Remove 5 springs (102), 3 discs (103), and 2 plates (104).
22. No. 4 housing assembly 1) Remove No. 4 housing assembly (98). 2) Remove No. 4 piston (99).
25. No. 5 ring gear Remove No. 5 ring gear (105).
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(2)
26. Cage (For fixing No. 5 carrier) 1) Remove snap ring (106).
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).
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(2)
D65EX, PX-15
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.
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
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(2)
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
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.
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.
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).
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D65EX, PX-15
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).
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
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).
27 34 Nm {2.8 3.5 kgm}
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.
D65EX, PX-15
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(2)
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).
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(6)
D65EX, PX-15
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].
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). 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
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).
D65EX, PX-15
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(2)
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).
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D65EX, PX-15
5) Install spring (120) and valve (121).
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.
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(2)
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.
8) Install snap rings (17) and (16). 9) Install No. 2 sun gear (15) and snap ring (14).
6) Install input shaft (22) to No. 1 carrier assembly (123), and then install snap ring (24).
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).
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D65EX, PX-15
26. Front plate assembly 1) Press fit bearing (126) to front plate (125). 2) Install seal ring (127).
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 No. 1 No. 2 No. 3 No. 4 No. 5 Standard stroke (mm) 5 7 4 4 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
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(2)
29. Transmission case 1) Fit the O-ring and install transmission case (11), using eyebolts [2].
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}
5) Using eyebolt [1], fit the O-ring and install sleeve (5). 6) Install flange (4).
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:
7) Install cover (3). 31. Sleeve Install sleeve (2).
2 Cover: Gasket sealant (LG-6)
44.1 53.9 Nm {4.4 5.5 kgm}
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D65EX, PX-15
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
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(2)
DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY

SPECIAL TOOL
Symbol
Part No.
Part name Hanger Wrench kit Wrench Torque wrench
1 791-422-1320 2 790-302-1500 E 3 796-730-2300 Commercially 4 available or 795-630-1810
q q q q
1 1 1 1
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).
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Sketch
Qty
3. Cover assembly 1) Using eyebolt [1], remove cover assembly (5).
D65EX, PX-15
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).
3) Left carrier driver gear i) Remove bolt (19) and holder (20). ii) Remove gear (22).
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(2)
iii) Using gear puller [3], push out shaft (21).
4) Remove the plug, spring (30), and valve (31).
iv) Remove snap ring (23), then remove bearing (28) from cover (32). v) Remove outer race (29) from cover (32).
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).
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D65EX, PX-15
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).
11) Remove snap ring (59) and bearing (57). a Pry up the bearing from the cut of the hub.
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(2)
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).
5) Remove bushing (91) from carrier (90). 8. Sun gear 1) Remove snap ring (70) and collar (73).
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D65EX, PX-15
2) Using gear puller [8], remove sun gear (72) and bearing (98).
3) Disassembly of bevel pinion assembly i) Remove the bolt (97), plate (99), and pin (100).
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.
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).
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.
iv) Remove bearing (104). v) Remove outer races (105) and (107) from cage (103).
D65EX, PX-15
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(2)
vi) Remove bearing (106) and spacer (108) from bevel pinion (102).
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.
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.
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.
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(2)
D65EX, PX-15
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:
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 120C. 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).
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(2)
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 120C. 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.
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.
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
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}
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D65EX, PX-15
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).
3 Bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
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 Locknut: 3 Locknut:
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
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 9. 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
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(2)
If the measured backlash is out of the standard range, adjust it according to the following procedure.
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.)
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.)
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.
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(2)
D65EX, PX-15
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.
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.
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.
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.
D65EX, PX-15
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(2)
4) Install sun gear (72). 5) Install bearing (98) with the push tool. a Press fit the inner race and outer race simultaneously.
5) Set hub (92) to ring gear (52) and install snap ring (50). 6) Install hub (92) to carrier assembly (64).
6) Install collar (73) and snap ring (70). 6. Assembly of carrier assembly 1) Install bushing (91) to carrier (90).
7) Install hub and carrier assembly (64) to hub (54) and tighten bolts (89).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
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).
7. Assembly of brake assembly 1) Install stopper (56) to the hub, then install snap ring (58). 2) Install bushing (60) to hub (39).
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(2)
D65EX, PX-15
3) Install hub (39) to hub (54) with 18 mounting bolts.
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
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.
4) Install bearing (57) to hub (39). 5) Install snap ring (59).
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).
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(2)
11) Install spring (42). 12) Install guide bolt [14] to cage (51). 13) Install bearing (60) to cover (41).
18) Remove the bolts and nuts used to compress the spring, then install 4 bolts (40).
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.
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).
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(2)
D65EX, PX-15
2) Left carrier drive gear i) Press fit bearing (26) to shaft (21).
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).
3) Intermediate gear assembly i) Install bearings (17) and spacer (17a) to gear (15).
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.
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.
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(2)
iii) Install holder (13) and tighten bolt (12). 98 123 Nm {10 12.5 kgm}
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).
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) 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.
2 Mating face of cover:
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(2)
D65EX, PX-15
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 OF PTO ASSEMBLY

DISASSEMBLY
1. Lubrication tubes Remove lubrication tubes (1) and (2). 3. Cover assembly (left) 1) Remove mounting bolts, then using forcing screw [2], remove cover assembly (8).
2. Cover assembly (right) 1) Remove mounting bolts, then using forcing screw [1], remove cover assembly (3).
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).
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D65EX, PX-15
4. Idler gear 1) Remove mounting bolts, then remove plate (13).
5. Cover Remove cover (19).
2) Remove mounting bolts, and using forcing screws [3], remove shaft (14).
6. Scavenging pump drive gear 1) Remove snap ring (20) and (21). 2) Knock out gear (22) from snap ring side.
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).
3) Remove bearing (23).
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(2)
7. Input shaft bearing Remove snap ring (24), then remove bearing (25).
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).
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(2)
D65EX, PX-15
2) Hold the inner race side of bearing (23) with push tool [4] and install gear (22) to the bearing.
3) Install spacer (17). 4) Install outer race (18) to gear (15).
3) Install snap ring (20) and (21).
5) Install gear (15). 6) Install bearing (16). a Press fit inner race side.
3. Idler gear 1) Fit the O-ring to shaft (14) and install them to the case.
2 O-ring: Grease (G2-LI)
7) Fit plate (13) and tighten bolts.
2) Install bearing (16).
156.9 196.1 Nm {16.0 20.0 kgm}
D65EX, PX-15
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(2)
4. Cover assembly (left) 1) Install bearings (11) to gear (12).
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) Install O-ring to cover (10).
2 O-ring: Grease (G2-LI) 3) Install gear assembly (9) to cover (10).

4) Mesh idler gear, install cover assembly (3).
4) Mesh idler gear, and install cover assembly (8).
6. Cover Install cover (19).
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(2)
D65EX, PX-15
7. Lubrication tubes Install lubrication tubes (2) and (1).
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(2)
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).
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(2)
D65EX, PX-15
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
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(2)
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) Install cage assembly (21) to pump (22).
2 Mounting bolt (20): 3 Mounting bolt:
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.
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D65EX, PX-15
3. Case 1) Install bearing (13) to case (12).
4. Gear and input shaft 1) Press fit collar (6) and inner race (7) to input shaft (5).
2) Using push tool [5], push inner race end of bearing, then install case assembly (10) to boss portion of turbine (11).
2) Install input shaft (5) and gear (4).
58.9 73.6 Nm {6 7.5 kgm}
3) Install spacer (9). 4) Install snap ring (8).
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(2)
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: 3 Drain plug:
49.0 58.8 Nm {5.0 6.0 kgm} 2) Install drain plug. 5.9 8.8 Nm {0.6 0.9 kgm}
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(2)
D65EX, PX-15
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
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(2)
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY

REMOVAL
k
8. Lift off HSS pump assembly (7).
4 HSS pump assembly: 75 kg
1. Drain the hydraulic oil.
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).
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(2)
D65EX, PX-15
REMOVAL AND INSTALLATION OF COOLING FAN PUMP ASSEMBLY

REMOVAL
k
8. Remove 4 tube mounting bolts (8) under the HSS pump assembly.
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
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(2)
INSTALLATION
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
REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY
REMOVAL
k
5. Lift off power train and lubricating oil pump assembly (4). 1 4 Power train and lubricating oil pump assembly: 15 kg
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
1
4. Disconnect tubes (2) and (3).
3 Mounting bolt:
98 123 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 through the system. Then, check the oil level again.
D65EX, PX-15
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(2)
REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY

REMOVAL
k
INSTALLATION
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
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(2)
D65EX, PX-15
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY

SPECIAL TOOL
Symbol Part No. 790-337-1032 J1 791-427-1090 01010-51635 Part name Lifting tool Plate Bolt t t t 1 1 2
5. Remove cover (2).
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. 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
REMOVAL
1. Remove track shoe assembly. For details, REMOVAL OF TRACK SHOE ASSEMBLY. 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
1
4. Remove bracket (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
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(2)
INSTALLATION
1
2 Thread of bracket mounting bolt:

Liquefied adhesive (LT-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}
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
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D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

SPECIAL TOOL
Symbol
Part No. 791-427-1100
Part name Remover assembly Puller Pump Installer Installer assembly Puller Pump
t t t t t t t
1 1 1 1 1 1 1
2 790-101-2102 790-101-1102 J 3 792-520-2121 791-427-1200 4 790-101-2102 790-101-1102
DISASSEMBLY
1. Carrier assembly 1) Remove cover. 2) Remove mounting bolts, and using eyebolts [1], remove carrier assembly (1).
Sketch
Qty
a If gear assembly (4) remains in position when the plate is remains, use puller [3] to remove it.
4) Support dear (5), then push shaft (6) and remove bearing (7).
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).
5) Remove bearing (7) from shaft (6). 6) Remove outer race (8) from gear (5).
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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).
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).
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.
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.
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D65EX, PX-15
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.
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ASSEMBLY
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).
6) Assemble shim, the install 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 circumference. iii) Select shim to give a thickness of measured clearance a + 0 0.1 mm. a If the clearance is 0, check that the rotating torque of the pinion is at least 0.98 Nm {0.1 kgm}.
4) Install bearings (31) to pinion (30). 5) Install pinion assembly (29). a Install so that the part with the small outside diameter is facing the outside.
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2. Output shaft Install output shaft (27). 3. Gear assembly 1) Install bearing (26) to gear (25).
4) Using eyebolts [7], install cover assembly (21) to case, then tighten mounting bolts.
2) Install thrust washer (35) to case. 3) Using eyebolts [9], install gear assembly (24).
4. Cover assembly 1) Install spacer (20) to cover (36). 2) Using tool J4, press fit bearing (19). a A press can be used instead of the puller. 3) Using tool J3, install floating seal. a Remove all oil and grease from the Oring and O-ring contact surface, and dry before installing. a After installing the floating seal, check that the angle of the seal is less than 1 mm.
5. Sprocket, hub assembly 1) Install outer race (18) to hub (13). 2) Using tool J3, install floating seal (16). a Remove all oil and grease from the Oring and O-ring contact surface, and dry before installing. a After installing the floating seal, check that the angle of the seal is less than 1 mm.
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3) Check that there is no dirt or dust on sliding surface of floating seal, then coat thinly with engine oil. 4) Using eyebolts [13], set sprocket and hub assembly (15) in cover.
8) Set holder (10) in position. a The bearings are set right, so there is no need to adjust them, but in order to check that there are no defective parts, measure the preload as follows. i) With no preload given to the bearings, measure the rotating torque of the sprocket hub, and take this as (b) Nm {kgm}. a Measure the sliding resistance of the floating seal first. ii) Rotate the sprocket and tighten the plate holder bolt to 245.2 308.9 Nm {25 31.5 kgm}. iii) After tightening the bolt, check that the rotating torque is (b) + 0 61.8 Nm {0 6.3 kgm}.
5) Using tool J4, rotate sprocket and hub assembly, and press fit bearing (19). a Press fit to a point which does not give any preload.
6. Shaft Using eyebolts [4], install shaft (9). 7. Carrier assembly 1) Press fit outer race (8) to planetary gear (5). a The bearing is set right, so be careful not to change the combination when installing.
6) Set hub (13) to ring gear (14), and install snap ring (12). 7) Using eyebolts [5], install ring gear and hub assembly (11).
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2) Assemble 2 bearings (7) to gear (5), and set to carrier (17). a Center with the shaft hole. 3) Align with dowel pin and install plate (3).
3 Mounting bolt:
490.3 608 Nm {50 62 kgm}
4) Expand fit shaft (6). a Leave in dry ice for approx. 30 minutes. 5) Install lock plates (2).
3 Mounting bolt:
98 122.6 Nm {10 12.5 kgm}
6) Using eyebolts [1], install carrier assembly (1).
3 Mounting bolt:
245.2 308.9 Nm {25 31.5 kgm} 7) Install cover.
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REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY

REMOVAL
1. Remove track shoe assembly. For details, REMOVAL OF TRACK SHOE ASSEMBLY. 2. Using jack, jack up chassis, then set stands [1] and [2] under front frame and steering case. k Set the stands securely. 4. Remove pivot shaft cover (3). a The diagram shows the D65EX-15.
3. Remove tilt cylinder hose protection cover, then disconnect hoses (1) and (2). (On inside of track frame on right side of chassis).
6. Sling the track frame assembly. 7. Remove lock (5) and pull out pin (6).
1
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8. Remove bolt (7) and plate (8), then lift off track frame assembly (9). 2 a Oil will leak from the pivot shaft case, so prepare a container to catch it.
INSTALLATION
1
k
4 Track frame assembly: 1,600 kg (D65EX) 1,800 kg (D65PX) 6 Pivot shaft case: 4.5 l
When aligning the pin holes, never insert your fingers in them.
a When inserting in the pivot shaft, apply oil (EO30-CD) to face a of track frame (9).
3 Plate mounting bolt:
5 Pivot shaft case: 4.5 l (EO30-CD)
455 565 Nm {46.5 58 kgm}
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REMOVAL AND INSTALLATION OF IDLER ASSEMBLY
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY

REMOVAL
1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove lock plate (1), then remove lubricator (2). k The inside of the recoil spring cylinder is under negative pressure, so if the lubricator is not removed, the yoke will be pulled back into the cylinder when the yoke and idler support are disconnected. k To prevent danger, never stand in front of or behind the recoil spring assembly. 4. Raise idler assembly and pull out, then remove mounting bolts of support (5) and yoke (6). 5. Lift off idler assembly (7). 4 Idler: 200 kg
INSTALLATION
1
3. Remove left and right guide plate (3). 1 a Remove shim (4), check the number and thickness, and keep in a safe place.
2 Thread of guide plate mounting bolt:
a Standard shim thickness: 4 mm a Adjust the shim thickness so that clearance a between the track frame and guide plate (3) is 0.5 1.0 mm. Liquefied adhesive (LT-2)
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DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

SPECIAL TOOL
Symbol L Part No. Part name Installer Oil pump t t 1 1
5. Sling idler (3) and pull it out of shaft and support assembly (6). a Prevent the sling wires from opening with wires or ropes. 6. Remove floating seals (7) and (8) from idler (3).
1 791-515-1520 4 791-601-1000
DISASSEMBLY
1. Remove the oil filler plug and drain the oil. 6 Idler: 0.25 l
2. Remove nut (1) and drive out bolt (2) from the nut side.
7. Remove floating seal (9) from shaft and support assembly (6).
3. Using push puller [1], pull support (4) out of idler (3). 4. Remove floating seal (5) from support (4).
8. Remove nut (10) and drive out bolt (11) from the nut side. 9. Similarly to step 3, using the push puller, pull shaft (13) out of support (12).
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10. Remove 2 bushings (14) from idler (3).
ASSEMBLY
1. Using push tool [2], press fit 2 bushings (14) to idler (3).
2. Fit the O-ring to shaft (13) and install them to support (12). a When installing the shaft, match it to the groove of the support. a Install the shaft to the support, the end not having an oil filler first. 3. Drive in bolt (11) and tighten nut (10).
2 Nut: Liquefied adhesive (LT-2)
4. Using tool L1, install floating seal (9) to shaft and support assembly (6).
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a When installing floating seals, thoroughly clean, degrease, and dry the contact surfaces of the O-rings and floating seals (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces. a After installing the floating seals, check that their slant is less than 1 mm and their projection a is 7 11 mm.
8. Using tool L1, install floating seal (7) to idler (3). a For the method of installation, see step 4.
9. Using tool L1, install floating seal (5) to support (4). a For the method of installation, see step 4.
5. Fit the O-ring to the shaft. 6. Using tool L1, install floating seal (8) to idler (3). a For the method of installation, see step 4.
10. Drive in bolt (2) and tighten nut (1).
7. Sling and install idler (3) to shaft and support assembly (6). a Prevent the sling wires from opening with wires or ropes.
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11. Refilling with oil 1) Remove plug (15) from shaft (13) and add oil through the oil filler. a When evacuating the system before adding the oil, use tool L4. 5 Idler: 0.25 l (TO30) 2) Tighten plug (15).
3 Plug: 98 137.2 Nm {10 14 kgm}
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REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY

REMOVAL
1. Remove idler assembly. For details, see REMOVAL AND INSTALLATION OF IDLER ASSEMBLY. 2. Lift off recoil spring assembly (1). 4 Recoil spring assembly: 500 kg
1
INSTALLATION
1
a When assembling the recoil spring assembly (1) inside the track frame, use lever block [1] to sling the top and make it horizontal, then push in the recoil spring and set it in the frame.
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DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY

SPECIAL TOOL
Symbol Part No. 791-685-8005 791-635-3160 M 790-201-2780 790-201-2790 790-101-1102 790-101-1600 Part name Compressor of type B Extension Spacer Spacer Pump Cylinder t t t t t t 1 1 1 1 1 1
3) Using push tool [1], remove piston (11) from yoke (10) with press. a If cylinder (19) has not been damaged, or nut (16) at the tip of the shaft has not fallen off, disassemble as follows.
DISASSEMBLY
1. Remove yoke and piston assembly (2) from recoil spring assembly (1).
3. Remove holder (13) from case (12) of recoil spring. k To prevent danger, never stand in front of or behind the recoil spring assembly. 4. Disassembly of holder 1) Remove cover (14) from holder (13).
2. Disassembly of yoke, piston assembly 1) Remove snap ring (3), then remove ring (4), packing (5), rings (6). 2) Remove bolt (7), then remove plate (8) and washer (9).
2) Remove seal (15) from holder (13).
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k
5. Set recoil spring assembly (1) to tool M. k The spring is under a high installed load, so be careful to set it correctly. a Installed load of spring: 189.5 kN {19,320 kg}
If cylinder (19) has been damaged, or nut (16) at the tip of shaft has fallen off, there is danger that the recoil spring may fly off to the front when mounting bolts (21) of holder (13) are removed. For this reason, disassemble as follows. When disconnecting holder (13) and case (12), do not stand in front of or behind the recoil spring assembly until safety has been confirmed and the recoil spring has been removed.
6. Apply hydraulic pressure slowly, compress spring, and tighten nut (16) until spacer (17) comes out, then take out spacer (17) and remove nut (16).
1) Set recoil spring assembly (1) to tool M. k The spring is under a high installed load, so be careful to set it correctly. a Installed load of spring: 189.5 kN {19,320 kg}
7. Gradually release hydraulic pressure to remove tension of spring. 8. Remove spring (18) and cylinder (19) from case (12), then remove bushing (20) from cylinder (19).
2) Apply hydraulic pressure slowly and secure recoil spring assembly. 3) Maintain condition in Step 2), and remove mounting bolts (21) of holder (13). 4) Gradually release hydraulic pressure to remove tension of spring.
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ASSEMBLY
1. Press fit bushing (20) to cylinder (19), and assemble case (12), spring (18), and cylinder (19) temporarily, then set to tool M. k The spring is under a high installed load, so be careful to set all parts correctly.
3. Install nut (16), then install spacer (17).
4. Gradually release hydraulic pressure to completely remove tension of spring, then remove recoil spring assembly (1) from tool M. 5. Assembly of holder Assemble seal (15) to holder (13), then install cover (14).
2 Lip of seal: Grease (G2-LI)
6. Install holder (13) to case (12) of recoil spring.
2. Apply hydraulic pressure slowly compress spring, and set so that installed length of the spring is the standard value. a When compressing the spring, be careful not to damage the thread. Use lever block [2] and carry out centering while compressing the spring. a Installed length of spring: 634 mm
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7. Assembly of yoke, piston assembly 1) Using push tool [2], press fit piston (11) to yoke (10).
2) Assemble washer (9) and plate (8), and tighten bolt (7). a Bend the plate securely. 3) Fit ring (6), packing (5), and ring (4), and install snap ring (3).
8. Assemble yoke and piston assembly (2) to recoil spring assembly (1).
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REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY

REMOVAL
1. Loosen track shoe tension. For details, see REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY. 2. Remove mounting bolts of track roller guard (1).
1
INSTALLATION
1
2 Thread of roller guard mounting bolt:

3. Remove track roller mounting bolts (2).

2
2 Thread of track roller mounting bolt: 3 Track roller mounting bolt:

Liquefied adhesive (LT-2) 343 427 Nm {35.0 43.5 kgm} a Install so that the oil plug is on the outside of the chassis.
4. Start engine, and operate blade, and hydraulic jack to jack up machine. k After jacking up the machine, set blocks on top of the track shoes and lock the work equipment control levers and brake lock lever. 5. Remove track roller assembly (3). 4 Track roller assembly: Single flange: 55 kg Double flange: 65 kg
2
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D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY

SPECIAL TOOL
Symbol L Part No. Part name Installer Oil pump t t 1 1
5. Remove floating seal (6) from track roller assembly (1).
2 791-530-1520 4 791-601-1000
DISASSEMBLY
1. Remove the oil filler plug and drain the oil. 6 Track roller: 0.32 l
2. Set track roller assembly (1) on block [1]. 3. Using push puller [2], push in collar (3), and then remove lock (4) and collar (3). 6. Sling roller (7) and pull it out of shaft (8).
4. Remove floating seal (5) from collar (3). 7. Remove floating seal (9) and bushing (10) (1 on each side) from roller (7).
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8. Remove floating seal (11) from shaft assembly (8). 9. Remove lock pin (12), and then remove collar (14) from shaft (13).
ASSEMBLY
1. Using push tool [3], press fit 2 bushings (10) to roller (7).
10. Remove floating seal (15) from collar (14).
2. Using tool L2, install floating seal (15) to collar (14).
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3. Fit the O-ring to shaft (13) and install collar (14) and lock pin (12).
6. Sling roller (7) and install it to shaft assembly (8).
4. Using tool L2, install floating seal (11) to shaft (8). a For the method of installation, see step 2.
7. Using tool L2, install floating seal (6) to roller assembly (1). a For the method of installation, see step 2.
5. Using tool L2, install floating seal (9) to roller (7). a For the method of installation, see step 2.
8. Using tool L2, install floating seal (5) to collar (3). a For the method of installation, see step 2.
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9. Set track roller assembly (1) to block [1]. 10. Fit the O-ring to the shaft and install collar (3). Using push puller [2], push in collar (3) and install lock (4).
11. Refilling with oil 1) Remove plug (16). Using tool L4, add oil through the oil filler. 5 Track roller: 0.32 l (GO140) 2) Tighten plug (16).
3 Plug: 98 137.2 Nm {10 14 kgm}
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REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY

a The figures in this section show D65EX-15. 4. Sling carrier roller assembly (2) and pull and remove it out of support (3). 4 Carrier roller assembly: 30 kg
REMOVAL
1. Loosen the track shoe assembly. For details, see EXPANSION OF TRACK SHOE ASSEMBLY. 2. Using hydraulic jack [1], raise the track shoe.
INSTALLATION
3. Remove mounting bolts (1) of the carrier roller assembly. Carry out installation in the reverse order to removal. Adjust the track shoe assembly tension. For details, see TESTING AND ADJUSTING, Adjusting track shoe assembly tension.
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DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY

SPECIAL TOOL
Symbol L Part No. Part name Installer t 1
4. Set carrier roller assembly (6) on block [1]. 5. Using push tool [2] and a press, pull out shaft assembly (7).
3 796-230-1110
DISASSEMBLY
1. Remove oil filler plug (1) and drain the oil. 6 Carrier roller: 0.24 l
2. Remove snap ring (2) and cover (3).
6. Remove bearing (9) and 2 outer races (10) from roller (8).
3. Remove bolt (4) and spacer (5).
7. Remove collar (12), floating seal (13), and bearing (14) form shaft (11). 8. Remove floating seal (15) from collar (12).
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ASSEMBLY
1. Press fit 2 outer races (10) to roller (8).
2. Using push tool [3], press fit collar (12) to shaft (11).
4. Install floating seal (13) to the shaft. a For precautions for installation, see step 3. 5. Using push tool [4], press fit bearing (14) to the shaft.
3. Using tool L3, install floating seal (15) to collar (12).
6. Set shaft assembly (7) to block [5] and install roller (8).
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7. Using push tool [6], press fit bearing (9). a While turning roller (8), press fit the bearing.
8. Install spacer (5) and tighten bolt (4).
3 Bolt: 278 32.4 Nm {28.3 3.3 kgm}
9. Supply oil to the carrier roller.
5 Carrier roller: 0.24 l (GO140B)
10. Fit the O-ring to cover (3) and install them to the roller, and then install snap ring (2). 11. Tighten plug (1).
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EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY

CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY
k k
EXPANSION OF TRACK SHOE ASSEMBLY

(Ordinary) a If any abnormality is not detected by CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY, perform the following procedure. 1. Set master link (3) above the idler (a little after the center of the idler) moving the machine forward or in reverse. a Set blocks [1] and [2] between the front side of the idler and carrier roller so that the mating part of the master link will not open until the master bolt is pulled out.
Since it may be very dangerous to expand the track shoe assembly, check the following items in advance. Do not loosen the lubricator more than 1 turn. If the grease is not discharged well, move the machine forward and in reverse.
1. Remove cover (1) and loosen lubricator (2) of the adjustment cylinder to discharge the grease. k Do not loosen the lubricator more than 1 turn.
2. After the shoe is loosened, perform EXPANSION OF TRACK SHOE ASSEMBLY (Ordinary). 3. If the track shoe is not loosened by the above work, perform EXPANSION OF TRACK SHOE ASSEMBLY (When track frame has internal trouble). a The track frame may have an internal trouble (damage of the recoil spring or recoil spring set bolt, fall of the shaft end nut, etc.).
2. Loosen the track shoe. 1 k Do not loosen lubricator (2) more than 1 turn. a If the track shoe is not loosened after the lubricator is loosened, move the machine forward and in reverse.
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3. Remove track shoe (4). 2 a Do not loosen and pull out 4 mounting bolts (5) one by one, but loosen them by 1 2 turns each and check that they can be rotated lightly, and then pull them out. a If the bolts are rotated forcibly while they are still tight, the threads of them and master link (3) may be damaged.
EXPANSION OF TRACK SHOE ASSEMBLY

(When track frame has internal trouble) a If any abnormality is detected by CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY, perform the following procedure. k If the track shoe is removed while the track frame has an internal trouble, it may spring back. Even if the track shoe is removed, the idler may jump out, and that can cause a serious result. Accordingly, expand the track shoe according to the following procedure. 1. Loosen the track shoe. 1 Do not loosen lubricator (2) more than 1 turn. k a If the track shoe is not loosened after the lubricator is loosened, move the machine forward and in reverse. a Check that the all grease has been discharged.
4. Sling the front end of master link (3) and move the machine slowly in reverse to expand track shoe assembly (5). a Length of track shoe: Approx. 9.5 m
2. Move the machine slowly forward against large block [3] or a wall (or the blade of another machine of the similar size of the machine to be repaired, if available) to press the track shoe on the idler side. When the recoil spring and track shoe are distorted, stop and apply the brake. a Set master link (3) between the idler and front carrier roller. a For safe work, apply lever block [4] between the carrier roller support and link. 3. Remove track shoe (4) and disconnect master link (3). 2 a Do not loosen and pull out the 4 mounting bolts one by one, but loosen them by 1 2 turns each and check that they can be rotated lightly, and then pull them out. a If the bolts are rotated forcibly while they are still tight, the threads of them and master link (3) may be damaged.
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4. Move the machine slowly in reverse to expand the track shoe assembly.
INSTALLATION
Carry out installation in the reverse order to expansion (ordinary).
1
a Adjust the track shoe tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
2
2 Shoe mounting bolt: 3 Shoe mounting bolt:
a Tighten the shoe mounting bolts for the master link in the following order. a Tighten the all 4 bolts with fingers until the master link mating faces are fitted. a If the bolts are tightened forcibly before the master link mating faces are fitted, the threads of them and master link may be damaged. Seizure prevention compound (MARUZEN MOLYMAX No. 2 or equivalent)
1st time: 343 39 Nm {35 4 kgm} 2nd time: 180 0 (Angle tightening) 20
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WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY

SPECIAL TOOL
Symbol
Part No.
Part name Remover Brush Push tool Bar Guide Push tool Bar Guide Checker Installer Oil pump
1 791-646-7531 2 791-660-7460 791-432-1110 3 791-646-7550 791-646-7560 R 791-932-1110 4 791-646-7523 791-646-7590 5 790-701-3000 6 791-432-1120 7 791-601-1000
t t t t t t t t t t t
1 1 1 1 1 1 1 1 1 1 1
2. Disassembly of link 1) Set the link assembly on a link press and hit it with a hammer so that the bushing will be fitted to the jaw [1]. a If the link tread, outside of the bushing, etc. are worn, adjust the height of the jaw [1] or guide plate and align the pin and bushing with the left and right disassembly jig [2], [3] so that the link hole will not be damaged during disassembly work. a If the pin and bushing are not aligned well, the link hole may be damaged and the pin and bushing may be broken during disassembly work.
WHOLE DISASSEMBLY
1. Removal of shoe Sling the shoe assembly and set it with the shoe up on the floor and remove the shoe by using a shoe bolt impact wrench. a If a shoe bolt is not loosened after it is unscrewed by 1 turn (If its torque is not reduced to 0), loosen the other bolts first, and it will be removed smoothly. a If a shoe bolt is turned forcibly while its torque is not 0, bolt and link will adhere to each other and they will need to be repaired. a When moving the shoe assembly, take care not to damage the master link. a If it is obliged to cut a shoe nut with gas, keep the seal temperature below 80C to prevent thermal deterioration of the seal and take measures to prevent the spatters from entering through the clearances among the links.
Sketch
Qty
a Using tool R1, drive the small plug of the pin inward after the disassembly work so that the workplace will not become dirty.
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2) Operate the left cylinder to pull out the pin and bushing from the left link simultaneously. a Check the pulling out force of the pin and bushing to see if the necessary press fitting force for the pin and bushing can be obtained when reversed and assembled again.
3. Inspection Check the parts for the following items to see if they can be used for a lubricated track or a grease-filled track, then examine them generally and determine to use them for a lubricated track or grease-filled track. a For judgment of reuse of the parts, see Parts judgment guide, Undercarriage, Lubricated track. 1) Check the parts visually for damage. If a part seems to be damaged, check it by dye penetrant test or magnaflux inspection. If it has any crack, it cannot be used again. Discard it.
3) Return the left cylinder and operate the right cylinder to pull out the pin and bushing from the right link simultaneously.
4) Return the right cylinder and take out the links, pins, bushings, and spacers on both sides and feed the next 1 set of the link assembly to the jaw. a If the bushing ends and sealing surfaces are damaged, oil will leak. Accordingly, handle them carefully.
2) Measure the outside diameter of the press fitting parts of the pin and bushing and the inside diameter of the pin and bushing fitting parts of the link with a micrometer and a cylinder gauge to see if the allowable fitting allowance is obtained. When using the pin, bushing, and link for a lubricated track, however, secure the standard fitting allowance between the pin and link. a If the allowable fitting allowance is not obtained, replace the parts with new ones. a For the dimensional criteria, see STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Track shoe.
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a Precautions for storage 1) Store the seal without removing it from the link so that the counterbore portion will not be rusted and take care not to damage the seal lip. 2) Apply rust-preventive oil to the pin and bushing fitting parts, shoe mating surface, and master link mating surface of the link. 3) When storing, apply rust-preventive oil to the all surfaces of the pin, bushing, and spacer. Take care not to damage the ends of the bushing in particular.
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D65EX, PX-15
WHOLE ASSEMBLY
a Before performing the following procedure, see PARTS JUDGMENT GUIDE, UNDERCARRIAGE, PROCEDURE FOR TURNING LUBRICATED TRACK. When recycling for lubricated track 1. Preparation work 1) Cleaning seal assembly Remove the seal assembly from the link and divide it into the seal ling (1) and load ring (2), then clean them. a Since the seal ring and load ring are deteriorated easily by the cleaning liquid (trichloroethylene etc.), clean them quickly. After cleaning them, wipe off the cleaning agent from them.
3) If the link, pin, bushing, and spacer are dirty, clean them. Remove the nodules sticking to the link and bushing with the grinder, too. a Since these parts rust easily, clean them just before assembling them. a Do not polish the bushing ends. If they are polished, oil may leak. 4) If large plug (3) was pulled out of the pin, drive it in according to the following procedure. i) Using tool R2, clean the pin hole.
2) When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the nodules sticking to the press fitting parts with the grinder, too. a If the ends are worn and sharpened, they may scuff the press fitting parts and cause oil leakage.
ii) Insert large plug (3) in the plug insertion window of the guide of tool R3. a Coat the large plug with oil (GO90) and install it with the small diameter end on the pin side. iii) Push the bar of tool R3 with the hand until the large plug stops. iv) Push the large plug with the bar to press the guide against pin (4). v) Drive in the bar with a hammer. a Driving distance a from pin end: 6 2 mm a If the chamfered part of the pin hole has been worn, chamfer it with a small-sized grinder (grindstone tip angle: 45 60) so that the large plug will not be damaged.
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(2)
5) Installation of seal assembly Clean and degrease part b indicated with thick lines (the counterbore portion of the link and seal assembly) carefully. Then, using tool R6, push in the seal assembly to the bottom. a If oil or grease is sticking to the counterbore portion of the link or seal assembly, the seal will turn and its sealing performance will lower. Accordingly, do not apply any oil or grease to that portion.
6) Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. Dimension c: 3 mm d: 3 mm e: 49.7 mm a If the pin end (part f) or link sides (parts g and h) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on both sides will be even.
7) Adjust the relief pressure of the link press so that the pressing force of the press will not exceed the standard value. a If the pressing force is too strong, the spacer will be pressed forcibly against the bushing. As a result, the spacer may be broken and it and bushing may be worn abnormally. a Pushing force of pin and bushing: 539 kN {55 tons} Pushing force C 1.8 x Average pressure (Adjust the relief pressure of the link press to set the press cutting force.) 2. Assembly of link 1) Apply oil (GO90) to the mating surfaces of the pin and bushing with a clean brush and assemble them, then set them before the jaw of the link press. a When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press).
a Set the link receiving face of jaw [4] vertically. a Wear plate [5] should be a replaceable one, if possible.
2) Press fit the master links on both bushing sides to the bushing with the shoe fitting faces up. a At this time, use the master links on the pin side as supports.
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D65EX, PX-15
a Press fitting force for bushing: 98 147 kN {10 15 tons}
6) Send the master links and set the next pin and bushing. a When reusing a pin, install it so that its side hole (i) will be the link tread side similarly to a new one. a If it is not installed so, its strength may be lowered. Accordingly, indicate the direction of the side hole on the end face to prevent a mistake.
3) Using the shoe bolt hole pitch gauge, press fit the master links until the distance between the shoe bolt holes of both links is the standard value. a Remove the all steel chips caused by press fitting of the bushing with compressed air. 4) Turn over the master links and check that they are press fitted in parallel.
7) Set the right link and install the spacer to the pin. a Check that the seal surface and bushing end are free from dir t and apply oil (GO90) to them with a clean cloth or brush. a When installing the spacer, wipe it with a clean cloth.
5) Measure the projections of the bushing on both sides with a depth gauge. a Adjust the press fitting jig of the link press so that the projections on both sides will be even. 8) Set the right jig on the receiving side and the left one on the pushing side and press fit the pin and bushing simultaneously. a If the pin and bushing have play when they are press fitted, the seal may come off the link. To prevent this, press fit smoothly. a If the seal comes off the link, stop press fitting and set the seal to the link correctly, then start press fitting again.
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(2)
a Press fitting force for pin and bushing: 245 343 kN {25 35 tons}
11) Set the left jig on the receiving side and the right one on the pushing side and press fit the left link. a When press fitting, take care that both seals and spacers will not come off. Press fitting force for link: 245 343 kN {25 35 tons}
9) Using the spacer [6] for fine adjustment, press fit the pin and bushing until the pin end is fitted to the bottom of the receiving jig. a Adjust the depth of the receiving jig hole so that the projections of the pin on both sides will be even.
12) Press fit until the link, spacer, and bushing are fitted together. a Actually, you cannot see from outside if the above parts are fitted. Accordingly, control the hydraulic pressure of the link press. Set the relief pressure to a proper level and heighten the hydraulic pressure to that level. a For setting of the relief pressure, see 1. Preparation work. a Check that adjacent 2 links can turn around each other.
10) Set the left link and install the spacer to the pin. a Apply oil similarly to the right link.
13) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes and check that the result is within the standard range. a If the distance between the shoe bolt holes is longer than the standard range, disassemble and check for abnormality, then press fit again.
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a If the distance between the shoe bolt holes is shorter than the standard range and the shoe cannot be installed, the spacer or bushing end may be worn more than the allowable limit. In this case, disassemble and replace the parts.
a Supply oil so that depth j of the hollow between the top of pin (4) and top of the oil level will be in the following range when the link is left with large plug (3) side up (with the link assembly on its side) for 30 minutes. Dimension j: 50 80 mm 14) After each link is assembled, bleed air from the pin by using tool R5 and check the sealing performance. a Keep the degree of vacuum inside the pin at 91 95 kPa {680 710 mmHg} for 5 seconds and check that the pressure does not change. If the pressure changes, disassemble and check the seal. If the seal is free from abnormality, assemble again.
16) After supplying oil, drive in the small plug to the following specified position, using tool R4. a For the method of driving the small plug, see the large plug side [1. Preparation work, step 4)]. a Apply oil (GO90) around the small plug. Driving depth from end: 2.5 1 mm
15) Using tool R7, supply oil (GO90) until the oil supply pressure rises to 196 294 kPa {2 3 kg/cm2}. a In a cold or very cold district, supply Komatsu genuine oil (150-09-19270 or 19532-61990) having better low-temperature characteristics instead of GO90. a If the oil pressure is heightened too much, it has bad effects on the seal. Take care.
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17) Assemble the master link on the pin side at last. a Check that the master links on both sides are press fitted in parallel. 3. Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench.
2 Shoe bolt: 3 Shoe bolt (Master link)

Lubricant containing molybdenum disulfide (LM-P)
2 Shoe bolt:
Initial torque: 343 39 Nm {35 4 kgm} Retightening angle: 180 0 20 a Tighten the bolts in the order of 1 4.
3 Shoe bolt (Regular link)
Lubricant containing molybdenum disulfide (LM-P) Initial torque: 539 49 Nm {55 5 kgm} Retightening angle: 120 10
When recycling for grease-filled track 1. Preparation work 1) Cleaning seal assembly Remove the seal assembly from the link and divide it into the seal ling (1) and load ring (2), then clean them. a Since the seal ring and load ring are deteriorated easily by the cleaning liquid, clean them quickly. After cleaning them, wipe off the cleaning agent from them.
2) When installing a double track, place the assembled double shoes on a level place in 1 line with the shoe side up. 3) Pull pin-side master link (5) and bushingside master link (6) together and set them to each other by the mating faces. 4) Place shoe (7) on the links and fits the mating faces of the links. 5) Check that shoe bolts (8) can be tightened easily, then connect the links with the master bolts.
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2) When reusing the pin, chamfer its end corners carefully with a grinder so that it will be press fitted smoothly.
4) If the outside of the pin, surfaces of the spacer, and ends and inside of the bushing are dirty, clean them. 5) Apply grease to the outside of the pin and surfaces of the spacer.
3) Using tools R3 and R4, drive in the large and small plugs. Tool R3 (For large plug) Tool R4 (For small plug) a Although tools R3 and R4 have different shapes, use them similarly to drive in the plugs. i) Insert plug (3) in the plug insertion window of the guide of tool R3/R4. a Apply oil (GO90) to the outside of the plugs and install it with the small diameter end on the pin side. ii) Push the bar of tool R3/R4 with the hand until the plug stops. iii) Push the plug with the bar to press the guide against the pin (4). iv) Drive in the bar with a hammer. a Driving distance a from pin end: Large plug: 2.5 1 mm Small plug: 6 2 mm a If the plugs were not pulled out when the shoe was disassembled, reuse them as they are.
6) Installation of seal assembly Clean and degrease part b indicated with thick lines (the counterbore portion of the link and seal assembly) carefully. Then, using tool R6, push in the seal assembly to the bottom. a If oil or grease is sticking to the counterbore portion of the link or seal assembly, the seal will turn and its sealing performance will lower. Accordingly, do not apply any oil or grease to that portion.
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7) Adjust the dimensions of the press fitting jig of the link press to keep the projection of the pin and bushing constant and keep the installed dimensions of the seal within the standard range. Dimension c: 3 mm d: 3 mm e: 49.7 mm a If the pin end (part f) or link sides (parts g and h) are worn, add the dimensions of the worn parts when adjusting the standard dimensions so that the projections of the pins and bushings on both sides will be even.
2) Press fit the master links on both bushing sides to the bushing with the shoe fitting faces up. a At this time, use the master links on the pin side as supports. a Press fitting force for bushing: 98 147 kN {10 15 tons}
a Set the link receiving face of jaw [4] vertically. a Wear plate [5] should be a replaceable one, if possible.
3) Using the shoe bolt hole pitch gauge, press fit the master links until the distance between the shoe bolt holes of both links is the standard value. a Remove the all steel chips caused by press fitting of the bushing with compressed air. 4) Turn over the master links and check that they are press fitted in parallel.
2. Assembly of link 1) Apply lithium grease (G2-LI) to the mating surfaces of the pin and bushing and assemble them, then set them before the jaw of the link press. a When reusing (reversing) the bushing, set the worn outside surface of the bushing on the shoe fitting side of the link (set the bushing with the worn outside surface up on the link press).
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5) Measure the projections of the bushing on both sides with a depth gauge. a Adjust the press fitting jig of the link press so that the projections on both sides will be even.
7) Set both links and operate both pushing jigs to press fit the pin and bushing simultaneously. a If the pin and bushing have play when they are press fitted, the seal may come off the link. To prevent this, press fit smoothly. If the seal comes off the link, stop press fitting and set the seal to the link correctly, then start press fitting again. a Pushing force of pin and bushing: 539 kN {55 tons} Pushing force C 1.8 x Average pressure (Adjust the relief pressure of the link press to set the press cutting force.)
6) Send the master links and set the next pin and bushing. a When reusing a pin, install it so that its side hole will be the link tread side similarly to a new one. a If it is not installed so, its strength may be lowered. Accordingly, indicate the direction of the side hole on the end face to prevent a mistake. a If the outside of the pin is worn, install it so that the un-worn surface will be on the traction side. In this case, install the pin so that its side hole will be the link tread side, too.
8) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt holes. When the distance is in the standard range, stop press fitting.
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9) Assemble the master link on the pin side at last. a Check that the master links on both sides are press fitted in parallel. 3. Installation of shoe 1) Set the link assembly on the bed and install the shoe with a shoe bolt impact wrench and a torque wrench.
2 Shoe bolt:
3 Shoe bolt (Regular link)
Lubricant containing molybdenum disulfide (LM-P) Initial torque: 539 49 Nm {55 5 kgm} Retightening angle: 120 10
2) When a 2-piece track is used, place the assembled 2 shoes on a level place in 1 line with the shoe side up. 3) Pull pin-side master link (5) and bushingside master link (6) together and set them to each other by the mating faces. 4) Place shoe (7) on the links and fits the mating faces of the links. 5) Check that shoe bolts (8) can be tightened easily, then connect the links with the master bolts.
2 Shoe bolt:
3 Shoe bolt (Master link)
Lubricant containing molybdenum disulfide (LM-P)
Initial torque: 343 39 Nm {35 4 kgm} Retightening angle: 180 0 20 a Tighten the bolts in the order of 1 4.
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Assembly instructions for rotary-bushing track a Only the parts of the instructions for the rotarybushing track different from the standard track are explained below. a Disassemble and inspect the rotary-bushing track similarly to the standard track. a Apply the following procedure in the field, too. 1. Setting pin and bushing Set the sub-assembly of pin (1), rotary bushing (2), seal (3), and fixed bushing (4) to the press line.
3. Caulking ends of link 1) Set caulking jigs [1] to both ends of the link. Using pressing jigs [2], press both caulking jigs simultaneously until they are fitted to both ends of the link. a For details of caulking jig [1] and pressing jig [2], see the following page. a Set caulking jigs [1] so that the un-machined parts of the link will be deformed. a If caulking jigs [1] are pressed to strongly, the spacers will be broken. Accordingly, limit the pressing force to the following value. Max. pressing force: 588 kN {60 tons}
2. Press fitting pin and bushing to link Press fit the pin and bushing to link (5) simultaneously. a Before press fitting, check that the hole of the bushing is aligned with the hole to fit the bushing. a Press fit the pin and bushing so that projection a of the pin and projection b of the bushing will be in the following ranges. Dimension a: 4.45 0.6 mm Dimension b: 3.05 0.2 mm
2) Check that the link has been caulked correctly from c to d as shown in the following figure.
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a Caulking jig [1]
a Pressing jig [2] Dimension e: 48.2 mm f: 4.45 mm g: 3.05 mm h: 70 mm
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D65EX, PX-15
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK

a In this section, how to use the special tools is explained mainly. a For details of disassembly and assembly, see WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY.
SPECIAL TOOL
New/ remodel New/ remodel Necessity Necessity
Sketch
Symbol
Part No. 791-432-1110
Part name Push tool Bar Guide Push tool Bar Guide Installer Oil pump Frame Extension Nut Screw Screw Adapter Pusher Pump Cylinder Jack Pump Adapter Spacer Guide Frame Extension Nut Screw Screw Adapter Adapter Pusher Spacer Spacer Frame Extension Nut Screw Screw Adapter Guide Pusher Guide
Symbol
Part No. 791-635-3110 791-635-3160 791-635-3170 791-635-3180 791-635-3190 791-645-3510
Part name Frame Extension Nut Screw Screw Adapter
t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t
1 1 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 R 16
t t t t t t
1 1 4 2 1 1
3 791-646-7550 791-646-7560 791-932-1110 4 791-646-7523 791-646-7590 6 791-432-1120 7 791-601-1000 791-635-3110 791-635-3160 791-635-3170 8 791-635-3180 791-635-3190 791-645-3510 791-646-3260 9 10 11 790-101-1102 790-101-1300 790-105-2300 790-101-1102 791-645-3520 791-432-1210 791-635-3110 791-635-3160 791-635-3170 791-635-3180 13 791-635-3190 791-645-3510 791-645-3520 791-645-3530 791-432-1210 791-432-1220 791-635-3110 791-635-3160 791-635-3170 14 791-635-3180 791-635-3190 791-645-3520 791-645-3540 791-645-3550 15 791-646-3270
DISASSEMBLY
1. Pins 1) Set track shoe assembly on block. 2) Using tool R8 (frame, extension, nut, screw, adapter, pusher), and tool R9 (pump, cylinder), remove pins (1) and (2). a If the tip of the pin or the side of the link are unevenly worn, correct with a hand grinder to ensure that the part is at a right angle to tool R8.
12 791-645-3540
D65EX, PX-15
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(5)
Sketch
Qty
Qty
2. Links 1) Put tool R10 and spacer [1] (Outside diameter: 55 mm, Thickness: 47 mm) to the tread side of links (3) and (4). a Set tool R10 as close to the tip of the link as possible. 2) Apply hydraulic pressure slowly to the puller until the tip of the link opens 6 8 mm, then disconnect the link. a There is danger that the bushing will come out, so do not apply more hydraulic pressure than necessary. a If an electric pump is used, there is danger that more hydraulic pressure will be applied than necessary, so always use a hand pump.
ASSEMBLY
1. Bushing Put tool R11 in contact with the end face of link (4), and press fit bushing (7). a Bushing press fitting force: 98 147 kN {10 15 tons} a Always use a new bushing.
2. Pins 1) Using tool R3, knock a large plug into the oil hole of pin (1). a Always use a new pin.
3) Disconnect links (5) and (6) in the same way.
2) To determine the pushing pressure when carrying out the final assembly, measure the outside diameter of the pin with a micrometer and note down the measurement.
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3) Coat the press-fitting hole a for the pin in link (4) with gasket sealant (198-32-19890). a If the link is used again, finish the press fitting hole for the pin smoothly with sandpaper.
3. Seal Install seal (8) with tool R6. a Check that there is no oil on the contact surface of the link and seal.
4) Put tool R11 in contact with the end face of link (4), and press fit pin (1). a Press fit so that the side hole b in the pin is on the same side as the link tread. a Pin press fitting force: 147 kN {15 20 tons} a Always use a new pin.
4. Link sub-assembly 1) Install link sub-assembly (10). a Check that there is no dirt or dust stuck to the surface of the seal or the end face on the bushing, then coat with oil (GO140B) using a clean cloth or small brush.
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2) Install tool R12 (guide used when press fitting link) to bushing (7).
3) Install seal (8) with tool R6. a Check that there is no oil on the contact surface of the link and seal.
5. Link 1) To determine the pushing pressure when carrying out the final assembly, measure the dimensions of the press-fitting hole for the pin in link (3) with a cylinder gauge, and note down the measurement.
2) Coat the press-fitting hole a for the pin in link (3) with gasket sealant (198-32-19890). a If the link is used again, finish the pressfitting hole for the pin smoothly with sandpaper.
4) Check that there is no dirt or dust stuck to the surface of the seal or the end face of the bushing, then coat with oil (GO140B) using a clean cloth or small brush. 5) Using tool R13, press fit pin portion of link (3) to link sub-assembly (10). a Pin press fitting force: 294 392 kN {30 40 tons}
6) Using tool R14, press fit bushing portion of link (3) to link sub-assembly (10). a To prevent the use of any excessive force, press fit the pin portion and bushing portion gradually in turn.
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a Pin and bushing press fitting force: 245 343 kN {25 35 tons}
4) Using tool R6, install seals (13) and (14) to links (5) and (6). a Always use new seals. a Check that there is no oil on the contact surface of the link and seal.
6. Connecting link 1) Finish the inside surface of the press-fitting hole for the pin in link (5) and (6) smoothly with sandpaper.
2) Lower the track shoe assembly to the ground. 3) Set lever block [2] to the left and right link assemblies as shown in the fig, then put tool R10 and spacer [1] (outside diameter 55 mm, thickness 47 mm) in contact with the tread on links (5) and (6). a Set tool R10 as close to the tip of the link as possible.
5) Check that there is no dirt or dust stuck to the surface of the seal or the end face of bushing (7), then coat with oil (GO140B) using a clean cloth or small brush. 6) Apply hydraulic pressure slowly to the puller until the tips of links (5) and (6) open 6 8 mm. a There is danger that the bushing will come out, so do not apply more hydraulic pressure than necessary. a If an electric pump is used, there is danger that more hydraulic pressure will be applied than necessary, so always use a hand pump. 7) Operate lever block [2], align the centers of the link hole and bushing hole, and connect the links with tool R15 (guide pin). a Operate the lever block [2] slowly and be careful not to damage the seal or get sand stuck to the seal surface.
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(2)
7. Pin 1) Using tool R3, knock a large plug into the oil hole of pin (2). a Always use a new pin.
6) Coat the remaining press-fitting portion of pin (2) with gasket sealant (198-32-19890).
2) To determine the pushing pressure when carrying out the final assembly, measure the outside diameter of pin (2) with a micrometer, and note down the measurement. 3) Set the track shoe assembly on block again. 4) Using tool R16, press fit pin (2) to links (5) and (6). a Press fit so that the side hole in the pin is on the same side as the link tread. a Pin press fitting force: 98 147 kN {10 15 tons} 5) Temporarily stop press fitting when there is 15 20 mm left for press fitting pin (2).
7) Coat the press-fitting hole for the pin in link (6) with gasket sealant (198-32-19890), then continue to press fit pin (2).
8) Using tool R13, apply the specified pressure to links (3) and (4) and links (5) and (6). a Set pushing force of pin and bushing: 539 kN {55 tons} Set pushing force C 1.8 x average pushing force (Adjusting the relief pressure of link press to fix the set pushing force)
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8. Vacuum test Using hand vacuum pump [3], remove the air from the small plug hole at the end face of pins (1) and (2) and check the sealing performance. a Check that the airtightness is maintained for 5 seconds at a negative pressure of 92.7 1.9 kPa {695 15 mmHg}.
2) Using tool R4, drive in the small plug to the following depth quickly. a Coat the outside circumference of the small plug with oil (GO140B). Depth to drive from end face: 2.5 1 mm
9. Charging with oil 1) Using tool R7, charge with oil (GO140B) through the small plug hole in the pin. a Be careful not to raise the pressure too high when charging with oil. This will have an adverse effect on the seal. a Take into consideration the expansion of the oil under heat, and be careful not to charge with too much oil.
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REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY

SPECIAL TOOL
Symbol Part No. 791-430-1200 P 790-101-2102 790-101-1102 Part name Installer assembly Puller Pump t t t 1 1 1
INSTALLATION
1
3 Pivot shaft mounting bolt:

455 565 Nm {46.5 58 kgm} a Assemble the seal (2) as follows (see diagram on right). 1) Turn over the seal so that the embossed letters (a) on the seal are on the inside. 2) With the seal turned over, insert the seal on the pivot shaft (1). a When inserting the seal, be careful not to damage the surface.
REMOVAL
1. Remove track frame assembly. For details, see REMOVAL OF TRACK FRAME ASSEMBLY. 2. Sling pivot shaft assembly (1). 3. Remove mounting bolts, then forcing screws [1], raise pivot shaft assembly and pull out. 1 4 Pivot shaft assembly: 90 kg (D65EX) 100 kg (D65PX)
4. Remove seal (2). 5. Remove ring (3).
2 3
a Press fit ring (3) using tool P. a Press fitting force: 18.6 kN {1.9 ton}
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REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY

SPECIAL TOOL
Symbol Part No. 791-450-1100 N 790-101-2102 790-101-1102 Part name Remover assembly Puller Pump t t t 1 1 1
4. Sling equalizer bar (5) temporarily.
REMOVAL
1. Remove side pin covers (1) and (2).
5. Remove lock plate (6). Using tool N, pull out center pin (7). 2 k Do not operate the hydraulic equipment of tool N in front of or under the puller, but operate it away as much as possible. 6. Lower and remove equalizer bar (5). 4 Equalizer bar assembly: 130 kg
2. Using a jack, raise the chassis and set a stand under the front frame. k Set the stand securely. 3. Remove lock (3) and pull out pin (4).
1
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INSTALLATION
1
k
When aligning the pin holes, never insert your fingers in them. When aligning the pin holes, never insert your fingers in them. Lubricant containing molybdenum disulfide (LM-P)
2 Frame boss:
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D65EX, PX-15
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR SIDE BUSHING
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR SIDE BUSHING

DISASSEMBLY
1. Remove seal (1). 2. Remove ring (2). 3. Remove spherical bushing (3).
ASSEMBLY
1. Install ring (2) to one side. 2. Using push tool [1] and a press, press fit spherical bushing (3). a Press fitting force: 15.7 kN {1.6 ton} 3. Install ring (2) to opposite side.
4. Install seal (1).
2 Between bushing and seal:

Grease (G2-Ll)
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REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY

REMOVAL
k
Disconnect the cable from the negative () terminal of the battery. k Lower the work equipment to the ground safely and release the residual pressure in the piping. For details, see TESTING AND ADJUSTING, Releasing residual pressure in work equipment cylinder. a Plug the disconnected pipes and hoses to prevent foreign matter from entering them. a Put tags to the disconnected pipes and hoses to prevent a mistake in re-connecting them. 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. Disconnect hose (1) of the accumulator.
5. Remove the mounting bolts and control valve assembly (14). 4 Control valve assembly: 120 kg
4. Disconnect the following hoses (2) (13) of the control valve. (2): Ripper cylinder bottom (3): Ripper cylinder head (4): Lift cylinder head (5): Lift cylinder bottom (6): Tilt cylinder bottom (7): Tilt cylinder head (8), (9): HSS motor (10), (12): Hydraulic tank (11): HSS pump (13): HSS pump LS valve
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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)
Bleeding air Bleed air from the piping. For details, see TESTING AND ADJUSTING, Bleeding air from work equipment cylinder.
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DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY

In this section, only precautions for assembly of the control valve assembly are explained. For details and tightening torque of each part, see STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Hydraulic equipment - Control valve.
ASSEMBLY
a Tighten sleeve (2) so that dimension a will be in the standard range and punch (b) at the end of sleeve (2) will be directed straight up, and then tighten check valve (1). Dimension a: 19 0.75 mm
a After tightening the plug, leave it for at least 2 hours.
3 Plug: 9.8 2.9 Nm {1 0.3 kgm}
3 Check valve:
58.8 78.5 Nm {6 8 kgm}
a When tightening plug (3), thoroughly degrease and dry the female threads of the spool and apply a drop (about 0.02 g) of LOCTITE (No. 262) each to 2 places.
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DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY

SPECIAL TOOL
Symbol 1 Part No. 790-502-1003 790-101-1102 790-302-1270 3 790-302-1280 790-302-1340 4 790-720-1000 796-720-1650 U 5 07281-01029 796-720-1680 07281-01589 790-201-1791 6 790-201-1811 790-101-5021 01010-50816 7 790-201-1620 790-201-1610 Part name Repair stand Pump Wrench Socket Socket Socket Expander Ring Ring t t t t t t t 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Blade tilt cylinder
2 790-330-1100
For blade lift t Clamp cylinder t For blade tilt t Clamp cylinder t Push tool (For blade t lift cylinder) Push tool (For blade t tilt cylinder) Grip Bolt Plate (For blade tilt cylinder) Plate (For blade lift cylinder) t t t t
3. Piston rod assembly Blade lift cylinder 1) Using tool U2, disconnect cylinder head assembly (2). 2) Pull out piston rod assembly (3). a Place an oil container under the cylinder to catch the oil.
DISASSEMBLY
1. Remove tube from cylinder assembly. 2. Set cylinder assembly (1) to tool U1. Blade lift cylinder
Blade tilt cylinder 1) Remove mounting bolts, and disconnect cylinder head assembly (4). 2) Pull out piston rod assembly (5). a Place an oil container under the cylinder to catch the oil.
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4. Piston assembly, cylinder head assembly 1) Set piston rod assembly (6) to tool U1. 2) Using tool U3, remove nut (7). Width across flat of nut Blade lift cylinder: 50 mm Blade tilt cylinder: 80 mm
5. Disassembly of piston assembly Blade lift cylinder 1) Remove piston ring (10) and wear rings (11) and (12). 2) Remove retainers (13) and (14) from piston assembly. a Do not remove the piston valve and valve seat installed to the piston.
3) Remove piston assembly (8) and slider (9). a The slider is installed only to the blade lift cylinder. 4) Remove cylinder head assembly (4).
Blade tilt cylinder Remove piston ring (15) and wear ring (16).
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6. Disassembly of cylinder head assembly Blade lift cylinder 1) Remove O-ring and backup ring (17). 2) Remove snap ring (18), then remove dust seal (19). 3) Remove rod packing (20). 4) Remove bushing (21).
ASSEMBLY
a Be careful not to damage the packings, dust seals, or O-rings when assembling. 1. Assembly of cylinder head assembly Blade tilt cylinder 1) Using tool U6, press fit bushing (26) to cylinder head (4). 2) Using tool U7, assemble dust seal (24).
Blade tilt cylinder 1) Remove O-ring and backup ring (22). 2) Remove snap ring (23), then remove dust seal (24). 3) Remove rod packing (25). 4) Remove bushing (26).
3) Install snap ring (23). 4) Install rod packing (25), then install O-ring and backup ring (22).
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Blade lift cylinder 1) Using tool U6, press fit bushing (21) to cylinder head (4).
2. Assembly of piston assembly Blade tilt cylinder 1) Using tool U4, expand piston ring (15). a Set the piston ring on tool U4 and turn the handle 8 10 times to expand the ring. 2) Remove piston ring (15) from tool U4, and install to piston. 3) Using tool U5, compress piston ring (15).
2) Using tool U7, assemble dust seal (19).
4) Install wear ring (16).
3) Install snap ring (18). 4) Install rod packing (20), then install O-ring and backup ring (17).
Blade lift cylinder 1) Install retainers (14) and (13) to piston. 2) Using tool U4, expand piston ring (10). a Set the piston ring on tool U4 and turn the handle 8 10 times to expand the ring. 3) Remove piston ring (10) from tool U4, and install to piston. 4) Using tool U5, compress piston ring (10).
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5) Install wear rings (12) and (11).
3. Piston assembly, cylinder head assembly 1) Set cylinder rod to tool U1. 2) Assemble cylinder head assembly (4) to rod. 3) Fit slider (9) and install piston assembly (8), then using tool U3, tighten nut (7). a The slider (9) is installed only to the blade lift cylinder.
4. Piston rod assembly Blade tilt cylinder 1) Set cylinder to tool U1. 2) Assemble piston rod assembly (5) to cylinder. 3) Install cylinder head (4).
2 Threads of rod: 3 Nut (7):

Cylinder Blade lift cylinder Blade tilt cylinder
3 Mounting bolt:
162 14.7 Nm {16.5 1.5 kgm}
Thread tightener (Loctite No. 262 or equivalent)
Width across flats 50 mm 80 mm
Tightening torque 1.08 0.11 kNm {110 11 kgm} 3.97 0.40 kNm {405 40.5 kgm}
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Blade lift cylinder 1) Set cylinder to tool U1. 2) Assemble piston rod assembly (3) to cylinder. 3) Using tool U2, install cylinder head (2).
3 Cylinder head:
735 73.5 Nm {75 7.5 kgm}
5. Tube Install tube to cylinder assembly.
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REMOVAL AND INSTALLATION OF BLADE ASSEMBLY

REMOVAL
k
Lower the work equipment to a level place and set blocks [1] under both straight frames securely.
4. Similarly, disconnect the lift cylinder assembly on the opposite side from the blade. k After stopping the engine, release the residual pressure from the piping. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. 5. Remove step (3) and covers (4).
1. Remove cap (1) from the lift cylinder. 1 a Check the quantity and thickness of the inserted shims. 6. Disconnect hose (5). a Plug the openings so that dirt will not enter the piping. 7. Remove both trunnion caps (6).
2
2. Sling lift cylinder assembly (2) temporarily. Start the engine and retract the piston rod fully.
8. Start the engine and move the machine in reverse slowly to disconnect the blade assembly (7) from the trunnion (8). 3
3. Fix the lift cylinder assembly to machine side. a Bind the piston rod with wires so that it will not come out.
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INSTALLATION
1
a Adjust clearance a at the mating face of the cap to the following value with shims and check that the shims rotate smoothly. Standard clearance a: 0.2 0.5 mm Standard shim thickness: 5 mm a After installing the blade, adjust its tilting distance. For details, see TESTING AND ADJUSTING, Adjusting blade. Refilling with oil (Hydraulic tank) 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. Bleeding air Bleed air from the work equipment cylinders. For details, see TESTING AND ADJUSTING, Bleeding air from work equipment cylinders.
a Adjust the shims of the trunnion. For details, see TESTING AND ADJUSTING, Adjusting blade.
3
a Adjust height b and width c of both straight frames to the following values with block [2], etc. Trunnion height b: D65EX: 422 mm D65PX: 529.4 mm Frame width c: D65EX: 2,352 mm D65PX: 2,888 mm
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D65EX, PX-15
REMOVAL AND INSTALLATION OF ROPS GUARD
REMOVAL AND INSTALLATION OF ROPS GUARD

REMOVAL
1. Sling the ROPS guard temporarily and remove 8 mounting bolts (1). 1 2. Lift off ROPS guard (2). 4 ROPS guard: 260 kg
INSTALLATION
1
3 Mounting bolt:
824 1,030 Nm {84 105 kgm}
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REMOVAL AND INSTALLATION OF OPERATORS CAB ASSEMBLY

REMOVAL
k
1. Remove the ROPS guard assembly. For details, see REMOVAL AND INSTALLATION OF ROPS GUARD. 2. Remove covers (1), (2), and (3).
4. Disconnect wiring connectors (7) and (8) and remove all the wiring harness clamps fixed to the chassis. *2
5. Pull wiring harness (9) disconnected in the previous step into the operators cab.
a Before removing cover (3), disconnect wiring connectors SIG (4) and ACC (5) on the back side. *1
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6. Open cover (10).
10. Remove cooler box (16) from the front part in the operators cab.
7. Disconnect wiring connectors CN-19 (11), CN20 (12), and CN-21 (13). *3 8. Disconnect 4 hoses (14).
11. Remove bolt (17).
9. Pull grommet (15) into the operators cab. *4
12. Remove 21 operators cab mounting bolts marked with q.
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13. Lift off operators cab assembly (18). a Check that all the wires and pipes are disconnected. 4 Operators cab assembly: 410 kg
Sticking seal to air conditioner box 1) Remove dirt, oil, and grease from the top of the floor frame to which gasket sealant (32) will be applied. 2) Apply gasket sealant to the top of the floor frame. For the area to be coated with the gasket sealant, see view Z. ThreeBond 1207B 3) Fit seal (30) into the guide plate of the air conditioner box. Adhesive (LT-1A) a Pull seal (30) down and fit it, pressing the gasket sealant applied in 2). a Fill the clearance between seal (30) and the floor frame with adhesive (LT-1A). 4) Apply grease (G2-LI) to the periphery of seal (30) (sealing surface against the cab). a Apply the grease so that the cab will slide well and the seal will not be moved or deformed when the cab is installed.
2 Gasket sealant (32):
2 Inside surface of seal:
INSTALLATION
*1 , *2 , *3 a When connecting each connector, take care not to mistake its No. *4 a When connecting each connector, install the grommet securely to the through hole of the cab. Seal arrangement drawing
CJD13422
Installation of seal to cab mating face 1) Sling the cab assembly. 2) Remove dirt, oil, and grease from the seal sticking face. k Do not stand under the cab. 3) Referring to the figure, stick seals (22), (23), (24), (25), and (31). 4) Stick the seals in the order of (22), (31), (23), (24), and (25). 5) Press end face "h" of seal (22) against the air conditioner box to eliminate clearance. 6) Fit part "j" (joint) properly to eliminate clearance.
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7) Use the excessive part of seal (22) as seal (24). a The figure shows the cab seen from bottom.
8) Cut seal (22) so that it will be flush with seal (23). (See figure P.) Fit part "k" (joint) properly to eliminate clearance. 9) Stick seal (31) to the groove, and then stick seal (23). (See section A-A.)
When installing the operators cab, obey the following points. 1) Lower the operators cab assembly onto the floor frame slowly. a Since the reaction force of the seal sponge is large, lower the operators cab assembly slowly. a Check that the air conditioner duct seal on the cab side is tightly in contact with the air conditioner duct on the dashboard side and there is not clearance. a Since the clearance between the air conditioner duct on the cab side and the monitor is narrow, lower the operators cab assembly carefully. 2) Tighten the mounting bolts temporarily. 3) Check that the seal between air conditioner bracket (17) and cab (18) is fitted securely. 4) Check that there is not clearance at joint a of the seal and floor frame.
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5) Check that clearance e between cab-side air conditioner duct (26) and monitor (27) is even on both sides. At the same time, check that cab-side air conditioner duct seal f is fitted to faces C on both sides of dashboardside air conditioner duct (28) without deviating to the right or left. a If clearance e between the cab-side air conditioner duct and monitor is not even, loosen the mounting screws of the cabside air conditioner duct and move the duct so that the clearance will be even. Similarly correct the deviation of the cab and air conditioner to the right or left, if necessary. 6) Tighten the mounting bolts of the dashboard mounting bracket. 7) Measure the pressure in the cab. For details, see TESTING AND ADJUSTING, testing and adjusting operator's cab.
Parts to be installed to operators cab before installing operators cab 1) Install open lock stopper mounting grip (29).
2) Install cab mounting L-plate (10) to the cab temporarily.
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REMOVAL AND INSTALLATION OF OPERATORS CAB GLASS (STUCK GLASS)
Among the panes of window glass of the operators cab, the 3 panes of (1) and (2) on both sides are stuck. In this section, the procedure for replacing the stuck glass is explained.
(1): Front window glass (2): Left door window glass : Right door window glass (3): Both-sided adhesive tape (4): Trim seal (5): Door handle
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SPECIAL TOOL
Symbol X1 Part No. 793-498-1210 Part name Lifter (Suction cup) t 2
a If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. a Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4]. (The following figure shows the operators cab of a wheel loader.)
REMOVAL
Remove the window glass to be replaced according to the following procedure. 1. Using seal cutter [1], cut the adhesive between broken window glass (6) and operators cab (metal sheet) (7).
2. Remove the window glass.
a If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it. (The following figure shows the operators cab of a wheel loader.)
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INSTALLATION
1. Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operators cab. a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfaces. (If the painted surfaces are scratched, adhesion will be lowered.) (The following figure shows the operators cab of a wheel loader.)
a Do not remove the release tape of the bothsided adhesive tape on the glass sticking side before sticking the glass. a When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. a Take care that the both-sided adhesive tape will not float at each corner of the window frame. a Do not lap the finishing end of both-sided adhesive tape (3) over the starting end but make clearance a of about 5 mm between them.
2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (7) and window glass (8) with white gasoline. a If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the sticking surfaces, leave them for at least 5 minutes to dry.
4. Install trim seals (4) to both door window glasses (2).
3. Stick both-sided adhesive tape (3) along the inside edges of the front window glass sticking section and both door window glass sticking sections.
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a Install each trim seal (4) so that its finishing end and starting end will be jointed at position (c) and dimension (b) between the corner and position (c) will be 90 mm.
3) Cut the tapes between window glasses (1) and (2) and operators cab (7) with a knife, and then remove the window glasses. a Do not remove the tapes left on the window glasses and operators cab before installing the window glasses.
5. Position the new window glass. 1) Using tool X1, set the window glass to the sticking position. Check the clearance between the window glass and the operators cab on the right, left, upper, and lower sides, and then adjust it evenly. a Position front window glass (1) from inside of operators cab (7). Adjust it so that the difference between black coated part and the metal sheet of operators cab (7) will be even on the right, left, upper, and lower sides. a When positioning each door window glass (2), align handle holes (d) of door (9) (on the glass side and door metal sheet side) first. Then, adjust the door window glass so that the positional relationship between it and door metal sheet will be even all around the window. 2) After positioning the glasses, stick tapes [6] between front window glass (1) and operators cab (7) and the right, left, and lower parts of each door window glass (2) and each door (9), and then draw positioning line (e).
6. Apply adhesive.
2 Adhesive:
Sikaflex 256HV manufactured by Sika Japan Do not use primer. The using limit of the adhesive is 6 months after the date of manufacture. Do not use the adhesive after this limit. Keep the adhesive in a dark place where the temperature is below 25C. Never heat the adhesive higher than 30C. When reusing the adhesive, remove the all hardened part from the nozzle tip.
a a a a a
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1) Break aluminum seal (11) of the outlet of adhesive cartridge (10) and install the nozzle.
4) Remove release tape of the both-sided adhesive tape (3a) on the glass side.
2) Cut the tip of the adhesive nozzle (12) so that dimensions (f) and (g) will be as follows. Dimension (f): 10 mm Dimension (g): 15 mm
5) Apply adhesive (13) to the outside of bothsided adhesive tape (3) of the operators cab.
3) Set adhesive cartridge (10) to caulking gun [7]. a An electric caulking gun is more efficient.
a Apply adhesive (13) to dimensions (h) and (j) of both-sided adhesive tape (3) of operators cab (7). Dimension (h): 10 mm Dimension (j): 15 mm a Apply adhesive (13) higher than both-sided adhesive tape (3).
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a Apply the adhesive evenly.
4) Fill the clearance between front window glass (1) and operators cab (7) with caulking material (14) all around the window.
2 Caulking material:
SEKISUI SILICONE SEALANT a The using limit of the caulking material is 6 months after the date of manufacture. Do not use the caulking material after this limit.
7. Install the front window glass. 1) Using tool X1, match front window glass (1) to line (e) on positioning tapes [6] drawn in step 5 and install it to operators cab (7). a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking the window glass, press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of the window glass firmly.
5) After applying caulking material (14) to front window glass (1), form it with the fingers as shown in the following figure. a Use rubber spatula [9] to form the caulking material around the handrail, etc. where it is difficult to form with the fingers.
3) Mask front window glass (1) and operators cab (7) with masking tapes [8].
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8. Install both door window glasses. 1) Using tool X1, match both door window glasses (2) to lines (e) on positioning tapes [6] drawn in step 5 and install them to both doors (9). a Since the window glass cannot be removed and stuck again, stick it very carefully. a Stick the glass within 5 minutes after applying the adhesive. 2) After sticking each window glass, press all around it until it is stuck to the both-sided adhesive tape. a Press the corners of each window glass firmly.
3) Fill the clearance between each door window glass and trim in the range of dimension (k). 1] Mask the range of dimension (k) of each door window glass. 2] Fill clearance (m) between each door window glass (2) and trim seal (4) with caulking material. a The using limit of the caulking material is 6 months after the date of manufacture. Do not use the caulking material after this limit. a Apply the caulking material to joint (c) of the trim seal, too.
2 Caulking material:
SEKISUI SILICONE SEALANT
a If adhesive (13) is projected from the trim seals (4) of stuck door window glasses on both sides, remove it with rubber spatula [9].
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9. Fix the window glasses. 1) Using styrene foam blocks [10] and rubber bands [11], fix the front window glass to fit it completely. a You may use sealing tapes to fix the front window glass. (The figure shows the operators cab of a hydraulic excavator.)
2) Immediately after sticking both door window glasses, install door handles (5) and fix the glasses.
10. After installing the window glasses, remove the primer and adhesive from them and the operators cab. a Using white gasoline, wipe off the adhesive before it is dried up. a When cleaning the glasses, do not give an impact to them. 11. Protect the stuck window glasses. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20C and humidity of 65%). 2) After applying the adhesive, wait for at least 24 hours, before operating the machine actually.
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REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY

REMOVAL
k k
a a
k
Disconnect the cable from the negative () terminal of the battery. 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. Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance. Ask professional traders for collecting and filling operation of refrigerant (R134a). Never release the refrigerant (R134a) to the atmosphere.
1. Remove the engine hood assembly. For details, see REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY. 2. Remove the operators cab assembly. For details, see REMOVAL AND INSTALLATION OF OPERATORS CAB ASSEMBLY. 3. Remove the operators seat assembly. 4. Remove cover (1).
If refrigerant gas (R134a) gets in your eyes, you 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. k Lower the work equipment to the ground safely and release the residual pressure in the piping. For details, see TESTING AND ADJUSTING, Releasing residual pressure in work equipment cylinder.
5. Disconnect accumulator hose (2).
6. Disconnect PPC hoses (3), (4), and (5) from the control valve assembly. (3): Color band: Not used (4): Color band: Brown, green (5): Color band: Blue
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7. Disconnect wiring connector STB (6) above the control valve assembly and remove the wiring harness clamp.
10. Disconnect ripper hoses (11) and (12).
11. Disconnect hoses (13) and (14) from the upper side of the power train unit. 8. Disconnect wiring connector CAN (7) and remove the wiring harness clamp. 12. Disconnect brake rod (20). 1 a Before disconnecting the brake rod, check the depressing stroke of the brake pedal.
9. Disconnect PPC hoses (8), (9), and (10) from the control valve assembly. (8): Color band: Not used (9): Color band: Not used (10): Color band: Brown
13. Remove covers (15) and (16).
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14. Disconnect wiring connectors PL1 (17), PL2 (18), and P12 (19).
17. Remove the clamp and wiring harness (23). 18. Remove the clamp and disconnect terminal (24). 19. Disconnect ground wire (25). 20. Remove bracket (26).
15. Disconnect wiring connector STA (21).
21. Remove cable (27) of the parking brake lock lever from the bracket. 2
16. Remove cover (22) on the left side of the chassis. 4 Cover assembly: 55 kg
22. Disconnect wiring connectors E21 (28) and E22 (29) at the left front of the floor frame and remove the wiring harness clamp.
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23. Disconnect receiver tank hose (30) and air conditioner compressor hose (31). 3 24. Disconnect heater hoses (32) and (33). a Close the heater hose valve on the engine side. a Plug the disconnected hoses.
29. Remove brackets (41) and (42), and then remove 4 rear mounting bolts (43) each from the right and left sides.
25. Disconnect wiring connectors S13 (34), 214 (35), 215 (36), and 218 (47) at the right front of the floor frame and remove the connector bracket (37). 26. Remove cover (38).
30. Remove front 1 mounting bolt (44) each from the right and left side.
27. Disconnect wiring connector 101 (39) on the right side of the engine and remove the wiring harness clamp. 28. Disconnect terminal (40).
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31. Lift off floor frame assembly (45). a When lifting off the floor frame assembly, check that all the wires and pipes have been disconnected. 4 Floor frame assembly: 380 kg
INSTALLATION
Carry out installation in the reverse order to removal. a Adjust the brake pedal. For details, see TESTING AND ADJUSTING, Adjusting brake pedal.
2
a Adjust the parking brake lever. For details, see TESTING AND ADJUSTING, Adjusting parking brake lever.
3
a Connect the hoses without twisting them. a When installing the air conditioner hoses, take care that dirt, dust, water, etc. will not enter them. a When connecting each air conditioner hose, check that O-ring (46) is fitted to the adapter. a Apply sufficient amount of compressor oil (Showa-Shell Suniso 4G or 5G) to each Oring.
3 Tightening torque of air conditioner refrigerant piping:

Thread size 16 x 1.5 22 x 1.5 24 x 1.5 Tightening torque 11.8 14.7 Nm {1.2 1.5 kgm} 19.6 24.5 Nm {2.0 2.5 kgm} 29.4 34.3 Nm {3.0 3.5 kgm}
Filling air conditioner circuit with refrigerant (R134a) Fill the air conditioner circuit with refrigerant (R134a). 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.
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REMOVAL AND INSTALLATION OF STEERING AND TRANSMISSION CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF STEERING AND TRANSMISSION CONTROLLER ASSEMBLY

REMOVAL
k
Disconnect the cable from the negative () terminal of the battery. 4 Operators seat assembly: 70 kg
3. Remove the 4 mounting bolts and pull out steering and transmission controller assembly (3) toward you. 4. Disconnect wiring connectors ST1 (4), ST2 (5), and ST3 (6) and remove steering and transmission controller assembly (3). 1 a When disconnecting each connector, loosen the screw at the center of the wiring harness.
1. Remove operators seat assembly (1).
2. Remove left side cover (2).
INSTALLATION
1
3 Mounting screw: 2.82 Nm {0.288 kgm}
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REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY

REMOVAL
Disconnect the cable from the negative () terminal of the battery. a For the method of changing the fuel injection amount adjustment switch after replacing the engine assembly or engine controller assembly, ask your Komatsu distributor. 1. Remove operators seat assembly (1). 4 Operators seat assembly: 70 kg
k
3. Remove the 4 mounting bolts and pull out engine controller assembly (3) toward you. 4. Disconnect wiring connectors EN1 (4), EN2 (5), and EN3 (6) and remove engine controller assembly (3). 1 a When disconnecting each connector, loosen the screw at the center of the wiring harness.
INSTALLATION
2. Remove left side cover (2).
1
3 Mounting screw: 2.82 Nm {0.288 kgm}
D65EX, PX-15
30-193
(2)
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY

REMOVAL
k
7. Remove the 4 mounting bolts and lift off fan drive assembly (8), while evading the piping and frame around it. 4 Fan drive assembly: 60 kg
2. Remove the mounting bolts and open fan guard (1).
INSTALLATION
3. Remove fan guard (2). 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)
4. Disconnect wiring connector FAR (3). 5. Remove plate (4). 6. Disconnect hoses (5), (6), and (7).
30-194
(2)
D65EX, PX-15
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY

REMOVAL
1. Remove the fan drive assembly. For details, see REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY. 2. Remove the mounting bolt (1) and lock plate (2).
1
6. Remove the 4 mounting bolts and fan motor assembly (5). 3
INSTALLATION
1 2
3. Loosen nut (3). 2 a Do not remove the nut but leave it inserted by 2 3 threads.
1. Tighten nut (3) to 142 Nm {14.5 kgm}. 2. Align the mounting bolt holes on the front side and back side of lock plate (2), and then install lock plate (2) with the less adjustment amount side up and tighten nut (3). 3. Tighten mounting bolt (1). Liquefied adhesive (LT-2)
3
2 Mounting bolt:
Wipe the fan motor shaft and fan boss to remove dirt, and then degrease them.
4. Using puller [1], disconnect fan (4) from fan motor shaft. 5. Remove nut, then remove fan (4).
D65EX, PX-15
30-195
(2)
OTHERS
90 OTHERS
Hydraulic circuit diagram Power train hydraulic circuit diagram ...................................................................................................... Work equipment hydraulic circuit diagram .............................................................................................. Electrical circuit diagram Electrical circuit diagram (1/6) ................................................................................................................ Electrical circuit diagram (2/6) ................................................................................................................ Electrical circuit diagram (3/6) ................................................................................................................ Electrical circuit diagram (4/6) ................................................................................................................ Electrical circuit diagram (5/6) ................................................................................................................ Electrical circuit diagram (6/6) ................................................................................................................ Cab electrical circuit diagram .................................................................................................................
90- 2 90- 3 90- 5 90- 7 90- 9 90-11 90-13 90-15 90-17
D65EX, PX-15
90-1
OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM

Hydraulic circuit diagram
90-2
D65EX, PX-15
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
D65EX, PX-15
90-3
ELECTRICAL CIRCUIT DIAGRAM (1/6)
Electrical circuit diagram
D65EX, PX-15
90-5
D65EX, PX-15
90-7
D65EX, PX-15
90-9
D65EX, PX-15
90-11
D65EX, PX-15
90-13
(3)
D65EX, PX-15
90-15
CAB ELECTRICAL CIRCUIT DIAGRAM
D65EX, PX-15
90-17

D65ex-15 67000 Up

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SEBM029508

Machine model D65EX-15 D65PX-15 D65WX-15

Serial number 67001 and up 67001 and up 67001 and up

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

Indication Page to be newly added Page to be replaced

Action required Add Replace Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

1 2 2-1 2-2 2-3 2-4 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

01- 9 01-10 01-11

(7) (7) (7) (7) (7) (7) (7)

(7) (7) (7) (7)

(7) (7) (7)

(7) (7) (7) (7) (7) (7)

(7) (7) (5)

(7) (7) (7)

(7) (7) (7)

1 2 3 4 5 6 7 7-1 8 9 10 11 12 12-1 13 14 15 16 16-1

6 Safety check before starting work 7 8

9 Good physical condition and preparation 10

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

Tolerance 0.022 0.126

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

HOW TO READ ELECTRIC WIRE CODE

HOW TO READ ELECTRIC WIRE CODE

Heat-resistant low-voltAEX age wire for automobile

HOW TO READ ELECTRIC WIRE CODE

8 50/0.45 7.95 3.7 5.5 5.3

15 84/0.45 13.36 4.8 7.0 7.0

20 41/0.80 20.61 6.0 8.2 8.2

30 70/0.80 35.19 8.0 10.8 10.8

40 85/0.80 42.73 8.6 11.4 11.4

f of nominal No. denotes flexible.

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

PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION

METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER

STANDARD TIGHTENING TORQUE TABLE

STANDARD TIGHTENING TORQUE TABLE

Width across flats mm 10 13 14 27

STANDARD TIGHTENING TORQUE TABLE

STANDARD TIGHTENING TORQUE TABLE

STANDARD TIGHTENING TORQUE TABLE

Unit kg kW {HP}/rpm mm mm mm km/h km/h

D65PX-15 20,770 142 {190}/1,950

67001 and up 67001 and up

17,050 20,130 20,860 (22,540)

17,010 20,010 20,740 (22,420)

17,300 20,040 20,770

17,050 20,130 20,860 (22,540)