Professional Documents
Culture Documents
Shop
Manual
D51EX-22
D51PX-22
CRAWLER TRACTOR
D51EX-22 B10001
SERIAL NUMBERS and UP
D51PX-22 B10001
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 D51EX/PX-22
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.
Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not
machine. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
• Always wear safety glasses when hitting parts with 3. When disassembling or assembling, support the
a hammer. machine with blocks, jacks or stands before starting
• Always wear safety glasses when grinding parts work.
with a grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00
before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or
before starting any step of the operation. Before starting hydraulic pressure measuring plugs, loosen them slowly
work, hang UNDER REPAIR signs on the controls in to prevent the oil from spurting out. Before
the operator's compartment. disconnecting or removing components of the oil, water
or air circuits, first remove the pressure completely from
5. Keep all tools in good condition and learn the correct the circuit.
way to use them.
2. The water and oil in the circuits are hot when the engine
6. Decide a place in the repair workshop to keep tools and is stopped, so be careful not to get burned. Wait for the
removed parts. Always keep the tools and parts in their oil and water to cool before carrying out any work on
correct places. Always keep the work area clean and the oil or water circuits.
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke 3. Before starting work, remove the leads from the battery.
while working. ALWAYS remove the lead from the negative (-)
terminal first.
D51EX/PX-22 00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4 D51EX/PX-22
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
OTHER
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
D51EX/PX-22 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00
REVISIONS 00
Electrical volume: Each issued as one to cover all models So that the shop manual can be of ample practical use,
Attachment volume: Each issued as one to cover all models important places for safety and quality are marked with the
following symbols.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
be available. Special safety precautions are
Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00
10-5
00-6 D51EX/PX-22
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the
symbol.
Rope diameter Allowable load 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
mm kN tons
two or more ropes, the force subjected to each rope will
10 9.8 1.0 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
11.2 13.7 1.4
hoisting is made with two ropes, each of which is
12.5 15.7 1.6 allowed to sling up to 1000 kg vertically, at various
hanging angles. When two ropes sling a load vertically,
14 21.6 2.2
up to 2000 kg of total weight can be suspended. This
16 27.5 2.8 weight becomes 1000 kg when two ropes make a 120°
hanging angle. On the other hand, two ropes are subject
18 35.3 3.6
to an excessive force as large as 4000 kg if they sling a
20 43.1 4.4 2000 kg load at a lifting angle of 150°.
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
D51EX/PX-22 00-7
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
TYPE 1 00
DISCONNECTION 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not
hold the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
CONNECTION 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-8 D51EX/PX-22
FOREWORD PUSH PULL COUPLER
TYPE 2 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a
of the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the
right - clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
D51EX/PX-22 00-9
FOREWORD PUSH PULL COUPLER
12
TYPE 3 00
DISCONNECTION 00
1. Hold the connector of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3)
contacts surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the connector of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of
the hexagonal portion at the male end to connect it.
00-10 D51EX/PX-22
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
EXPLANATION OF MAINTENANCE STANDARD TERMS 00
Example:
Standard size Tolerance
–0.022
120
–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:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
3. Standard Interference
• When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference
between these sizes is called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the shaft
to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard
interference”.
• After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in
the standard range.
D51EX/PX-22 00-11
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
4. Repair Limit And Allowable Value
• The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the
“repair limit”.
• If a part is worn to the repair limit must be replaced or repaired.
• The performance and function of a product lowers while it is used. A value below which the product can be used
without causing a problem is called the “allowable value”.
• If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated
from various tests or experiences in most cases, however, it must be judged after considering the operating condition
and customer's requirement.
5. Clearance Limit
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts
cannot be used is called the “clearance limit”.
• If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6. Interference Limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called
the “interference limit”.
• The interference limit shows the repair limit of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
00-12 D51EX/PX-22
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
● 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 Figure A.
Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
Figure A Figure B
D51EX/PX-22 00-13
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00
00-14 D51EX/PX-22
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm (lbf ft)) Face seal type
type
Nominal Width Nominal thread
size of hose across flats Thread size size - Threads per Root diameter (mm)
Range Target
(mm) inch, Thread (Reference)
series
34 - 54 (25.0 - 39.8) 44 (32.4) - 9/16 - 18UN 14.3
02 19
34 - 63 (25.0 - 46.4) 44 (32.4) 14 - -
22 54 - 93 (39.8 - 68.5) 74 (54.5) - 11/16 -16UN 17.5
03
24 59 - 98 (43.5 - 72.2) 78 57.5) 18 - -
04 27 84 - 132 (61.9 - 97.3) 103 (75.9) 22 13/16 - 16UN 20.6
05 32 128 - 186 (94.4 - 137.1) 157 (115.7) 24 1 - 14UNS 25.4
06 36 177 - 245 (130.5 - 180.7) 216 (159.3) 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 (130.5 - 180.7) 216 (159.3) 33 - -
(12) 46 197 - 294 (145.3 - 216.8) 245 (180.7) 36 - -
(14) 55 246 - 343 (181.4 - 252.9) 294 (216.8) 42 - -
D51EX/PX-22 00-15
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of strand Cross section Applicable circuit
number (mm) rating (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yellow & Green &
Color — Red & Black Blue & Red
Black Yellow Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yellow & Green & Blue &
Color — Black & Red
Blue Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 D51EX/PX-22
FOREWORD ELECTRIC WIRE CODE
12
HOW TO READ ELECTRIC WIRE CODE 00
★ 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.
(Table 1)
Using
Type Symbol Material temperature Example of use
range °C (°F)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for AV appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
–30 to +60
Thin-cover Annealed copper for electric (-22 to +140)
Conductor
low-voltage appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold
low-voltage appliance –50 to +110
AEX district, wiring at high-temperature
wire for Heat-resistant crosslinked (-58 to +230)
Insulator place
automobile polyethylene
D51EX/PX-22 00-17
FOREWORD ELECTRIC WIRE CODE
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/
20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
Diameter of
Conductor strand
Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cover D
AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
00-18 D51EX/PX-22
FOREWORD ELECTRIC WIRE CODE
12
3. Color Codes Table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
● 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.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
D51EX/PX-22 00-19
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-20 D51EX/PX-22
FOREWORD CONVERSION TABLES
12
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
D51EX/PX-22 00-21
FOREWORD CONVERSION TABLES
12
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-22 D51EX/PX-22
FOREWORD CONVERSION TABLES
12
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
D51EX/PX-22 00-23
FOREWORD CONVERSION TABLES
12
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-24 D51EX/PX-22
FOREWORD CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
D51EX/PX-22 00-25
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber cushions
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 ● Used for plastics (except polyethylene,
(2 pes.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three bond Polyethylene ● Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container ● Used mainly for adhesion of metals, rubbers,
plastics and woods.
● Quick hardening type adhesive.
Aron-alpha Polyethylene ● Quick cure type (max. strength after 30 minutes).
790-129-9130 50 g
201 container ● Used mainly for adhesion of rubbers, plastics
and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tempera-
648-50 container
ture.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
Gasket sealant
00-26 D51EX/PX-22
FOREWORD COATING MATERIALS
LG-5 790-129-9080 1 kg
tainer ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
● Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case, etc.
● Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube ● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three bond ● Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
● Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
Molybdenum
squeaking).
disulphide
lubricant
D51EX/PX-22 00-27
FOREWORD COATING MATERIALS
12
MEMORANDUM
00-28 D51EX/PX-22
01 GENERAL
D51EX/PX-22 01-1
GENERAL SPECIFICATION DRAWING
12
SPECIFICATION DRAWING
D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB
D51EX-22 D51PX-22
Item Unit 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
12,600
Machine weight kg 13,100 13,000
(12,695)
Engine model --- Komatsu SAA6D107E-1 diesel engine
Engine rated horsepower kW {HP} /rpm 97 {130} / 2,200
A Overall length mm 7,800 4,820
Values in (_) are for the machines equipped with wide blade.
01-2 D51EX/PX-22
GENERAL SPECIFICATION
12
SPECIFICATION
D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
Serial No. B10001 and up
Operating weight
● Bare tractor with ROPS cab 11,100 11,500 11,400
12,600 13,100 13,000
Weight
Gradeability deg 30 30 30
Stability (front, rear, left, right) deg 35 35 35
Quick shift mode
Forward (1st/2nd/3rd) km/h 3.4/5.6/9.0 3.4/5.6/9.0 3.4/5.6/9.0
Performance
mm
Power angle tiltdozer 3,045 3,350 3,350
Dimensions
(3,350)
To tip of exhaust pipe 2,885 2,885 2,905
To top of operator's compartment with ROPS
Overall
height
cab/canopy mm
(not including antenna) 2,997 2,997 3,015
(including antenna) 3,117 3,177 3195
Track gauge 1,790 1,880 1,880
Length of track on ground 2,745 2,745 2,745
Values in (_) are for the machines equipped with wide blade.
D51EX/PX-22 01-3
GENERAL SPECIFICATION
12
D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
Serial No. B10001 and up
--- SAA6D107E-1
Model --- 4-cycle, water-cooled, in-line vertical type, 6 cylinders,
Type direct injection, with turbocharger, air-cooled after cooler
No. of cylinders - bore x stroke mm 6-107x124
Piston displacement L {cc} 6.69 {6,690}
Discharge amount
(main pump) cm3/rev 95
Power train system
(charge pump) 55
Set pressure MPa
(main pump) {kg/cm2} 41.2 {420}
(charge pump) 3.6 {35}
Type, number --- Variable displacement angled piston type
HST motor
01-4 D51EX/PX-22
GENERAL SPECIFICATION
12
D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
Serial No. B1001 and up
control Hydraulic
φ50
Angle
Cylinder bore mm
Ripper
D51EX/PX-22 01-5
GENERAL SPECIFICATION
12
D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
Serial No. B10001 and up
Type --- Hydraulic type angle tilt dozer
Blade support method --- Hydraulic cylinder type
Dimensions Performance
Type Parallelogram
Beam length mm 700
Number of shanks 3
Ripper
depth)
Adjustment of digging depth Changeable for 2 level
Max. digging depth mm 430
Max. lift mm 375
Shank interval mm 700
Values in (_) are for the machines equipped with wide blade.
01-6 D51EX/PX-22
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
★ This Weight Table is for reference when handling components or when transporting the machine.
Unit: kg (lb)
Machine weight
with ROPS cab 12,600 (27,800) 13,100 (28,900)
with ROPS Canopy 12,240 (26,985) 12,740 (28,087)
Engine, damper assembly (not including water or oil) 585 (1,290) 585 (1,290)
● Engine assembly (including mount bracket, starter, alternator etc.) 548 (1,210) 548 (1,210)
● Damper assembly 37 (81.6) 37 (81.6)
Fan support bracket assembly (include fan, motor, guard and bracket) 67 (148) 67 (148)
Cooling core
● Radiator 36 (79.4) 36 (79.4)
● Oil cooler 25 (55.1) 25 (55.1)
● Charge air cooler 25 (55.1) 25 (55.1)
Hydraulic pump assembly (including fittings on pumps) 193 (425) 193 (425)
● HST pump 160 (353) 160 (353)
● Work equipment pump 26 (57.3) 26 (57.3)
Final drive assembly (including motor and sprockets) 496 (1,090) 496 (1,090)
● HST motor (each side) 180 (397) 180 (397)
● Final drive (each side) (including sprocket, bolts and nuts) 316 (697) 316 (697)
● Sprocket (each side) 5.6 (12.3) x9 5.6 (12.3) x9
Frame assembly (including plumbing mount brackets 1,498 (3,300) 1,498 (3,300)
● Main frame 1439 (3,170) 1439 (3,170)
● Underguard (inspection covers) 48 (106) 48 (106)
Hydraulic tank (not including hydraulic oil) (include washer tank) 173 (381) 173 (381)
Control valve
● 4-spool valve (including fittings and mount plate) 25 (55.1) 25 (55.1)
● 5-spool valve (with ripper) (include fittings and mount plate) 28 (61.7) ---
D51EX/PX-22 01-7
GENERAL WEIGHT TABLE
Unit: kg (lb)
Power angle tilt dozer assembly (include center ball, pitch link and pins) 1,415 (3,120) 1,513 (3,340)
● Blade 713 (1,570) 811 (1,790)
● Dozer frame 464 (1,020) 464 (1,020)
● Tilt cylinder assembly 37 (81.6) 37 (81.6)
● Angle cylinder assembly 32 (70.5) x 2 32 (70.5) x 2
ROPS cab assembly (Include floor, seat, air conditioner) 1,176 ( (2,590) 1,176 ( (2,590)
ROPS canopy assembly (Include floor, seat) 814 (1,790) 814 (1,790)
Operator’s seat
● Standard seat 64 (141) 64 (141)
● Hi-back seat 67 (148) 67 (148)
74 (163) 74 (163)
● Air suspension seat
Rear mask assembly (include linkage) 78 (172) 78 (172)
Engine hood assembly (include doors, muffler, pre-cleaner, exhaust tubes) 252 (556) 252 (556)
01-8 D51EX/PX-22
GENERAL WEIGHT TABLE
12
MEMORANDUM
D51EX/PX-22 01-9
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
12
TABLE OF FUEL, COOLANT AND LUBRICANTS
Ambient Temperature Recommended
Fluid
Reservoir -22 -4 14 32 50 68 86 140 122 °F Komatsu
Type
-30 -20 -10 0 10 20 30 40 50 °C Fluids
Komatsu
SAE 0W30EOS and HTHS 3.5min. (Note 1) EOS0W30
Komatsu
SAE 5W40EOS and HTHS 3.5min. (Note 1) EOS5W40
Engine oil pan
Engine oil
Komatsu
SAE 10W30DH EO10W30DH
Komatsu
SAE 15W40DH EO15W40DH
Power
Final drive case train oil TO 30 (SEA30) TO30
(Note 2)
Hydraulic
oil TOS5W30 (SEA5W30) TOS5W30
(synthetic
type oil)
Power
train TO 10 TO10
Hydraulic system oil
SAE10W30DH EO10W30DH
Engine SAE15W40DH EO15W40DH
oil
SAE10WDH EO10DH
Grease
LM-G (NLGI NO. 2) GO-L1
Lithium LM-G (NLGI NO. 2) G2-L1
grease
LM-G (NLGI NO. 2) G2-L1-S
01-10 D51EX/PX-22
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
REMARK
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine
mounted on this machine uses an electronically controlled high-pressure fuel injection device.
This device requires high precision parts and lubrication, so if low viscosity fuel with low
lubricating ability is used, the durability may drop markedly.
Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS (High-Temperature High-Shear Viscosity
150°C [302°F]) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
If these oils are not available, contact your Komatsu Distributor.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
1) The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see "CLEAN INSIDE OF COOLING SYSTEM (4-
26)" of your Operation and Maintenance Manual.
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant
(AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F). (never dilute with water)
3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
D51EX/PX-22 01-11
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
01-12 D51EX/PX-22
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
ENGINE RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
COOLING FAN PUMP - SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP) . . . 10-8
COOLING FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
OIL COOLER BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
CHARGE SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
PATH OF POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
UNDER CARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
TRACK FRAME AND RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
HYDRAULIC SYSTEM 1 (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
HST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
SAFETY-SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
TOWING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
HST MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
MOTOR CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE . . . . . . . . . . . 10-70
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
CHARGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
UNLOAD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
LS BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
WORK EQUIPMENT AND FAN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
SERVO VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
QUICK DROP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
BLADE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
RIPPER/WINCH PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
HYDRAULIC TANK, FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127
D51EX/PX-22 10-1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
CUTTING EDGE AND END BIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
WORK EQUIPMENT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
ANGLE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
PISTON VALVE FOR ANGLE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
CAB AND ITS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
STEERING AND BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
WORK EQUIPMENT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
CAB DAMPER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147
AIR CONDITIONER AND FLOOR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
ENGINE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
COOLING CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
HST CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
GEAR SHIFT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
GEAR SHIFTING BY OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED . . . . . . . . . . . . 10-160
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
PARKING BRAKE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
KOMTRAX SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
HST CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
ELECTRIC LEVER (FOR TRAVEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
KOMTRAX TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
BRAKE OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
HYDRAULIC OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
HST CIRCUIT OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
DECELERATOR PEDAL POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
BRAKE PEDAL POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
CHARGE FILTER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
ENGINE ROTATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
BOOST PRESSURE AND TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
WIF SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
HST MOTOR SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
10-2 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
ENGINE AND COOLING SYSTEM
D51EX/PX-22 10-3
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Outline
1. Cooling cores and fan located at rear end of machine. Charged air and coolant water are directed to the rear of the machine
through pipes.
2. Compressor for air conditioner is located at the front of the engine and is driven by the alternator belt.
3. The air cleaner, pre-cleaner, muffler and exhaust pipe are located on or near the engine hood.
10-4 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
COOLING SYSTEM
2. Radiator cap 8. After cooler outlet port 14. Cooler fan motor
3. Oil cooler 9. Radiator inlet port hose 15. Air bleeder of engine block
Total heat dissipation area m2 (ft2) 27.9 (300) 18.6 (200) 14.0 (151)
D51EX/PX-22 10-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
10-6 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
3. Coolant flow past lubricating oil cooler 9. Coolant flow back to radiator
5. Coolant flow from cylinder block to cylinder head 11. Coolant bypass in cylinder head
6. Coolant flow between cylinders 12. Coolant flow to water pump inlet
1. The coolant flow thermostat opens and coolant flows through the return line to the radiator.
2. Coolant flows through coolant bypass in cylinder head back to water pump inlet.
D51EX/PX-22 10-7
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
COOLING FAN PUMP - SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT
AND FAN PUMP)
10-8 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
COOLING FAN MOTOR
Type: LMF16
Specifications
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LMF16
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.0 cc/rev
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,500 rpm
Rated flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 L/min (6.3 gal/min)
Cracking pressure of check valve . . . . . . . . . . . . . . 0.13 kg/cm2 (1.84 psi)
D51EX/PX-22 10-9
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installation Installation
Free length × Installation
load Free length load
12 Spool return spring Outside diameter length
(N {kg}) (N {kg}) If damaged or
deformed, replace
58.8 N 47.1 N spring.
44.84 × 12 33 —
{6 kg} {4.8 kg}
3.04 N 2.45 N
13 Check valve spring 29.27 × 6.5 19.1 —
{0.31 kg} {0.25 kg}
10-10 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
1. Hydraulic motor
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 one side of the (Y – Y) line connecting the
top dead center of the stroke of piston (4).
● The oil sent to one side of cylinder block (5) presses piston (4) and
generates force (F1) [F1 = P × xD2/4].
● This force is applied to thrust plate (2). Since thrust plate (2) is fixed to
the angle of (a°) to the output shaft (1), the force is divided into com-
ponents (F2) and (F3).
● The radial component (F3) generates torque [T = F3 × ri] against the
(Y-Y) line connecting the top dead center and bottom dead center.
● The result of this torque [T = ∑(F3 × ri)] rotates cylinder block (5)
through the piston.
● Since this cylinder block (5) is splined to the output shaft, the output
shaft revolves to transmit the torque.
D51EX/PX-22 10-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
2. Suction valve
Function
● If the fan pump stops, the pressurized oil does not flow into the motor. Since the motor continues revolution because of the
force of inertia, however, the pressure on the outlet side of the motor rises.
● When the oil stops flowing in from inlet port (P), the suction valve sucks in the oil on the outlet side and supplies it to port
(MA) where there is not sufficient oil to prevent cavitation.
Operation
A. When starting
● If the pressurized oil from the pump is supplied to port (P)
and the pressure on (MA) side rises and starting torque is
generated in the motor, the motor starts revolution. The oil on
motor outlet (MB) side of the motor returns through port (T)
to the tank.
B. When stopping
● If the engine is stopped and the input revolution of the fan
pump lowers to 0 rpm, the pressurized oil from the pump is
not supplied to port (P) any more. As the pressurized oil is
not supplied to (MA) side of the motor, the motor speed
lowers gradually to stop.
● If the motor shaft is revolved by the force of inertia while the
oil flow in port (P) is reducing, the oil in port (T) on the outlet
side is sent by suction valve (1) to (MA) side to prevent
cavitation.
10-12 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
3. Operation of reversible valve
D51EX/PX-22 10-13
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
MEMORANDUM
10-14 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
OIL COOLER BYPASS VALVE
★ This valve consists of oil cooler bypass valve and charge safety valve
.
P1: From charge filter 1. Oil cooler bypass valve
P2: From fan motor 2. Charge safety valve
C1: To oil cooler inlet 3. Torque ........................ 147 - 186.3 Nm (108 - 137 lbf ft)
C2: From oil cooler outlet 4. Torque ........................ 49 - 59 Nm (36.0 - 43.5 lbf ft)
T: To hydraulic tank
Ts: To HST pump T1
D51EX/PX-22 10-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Oil cooler bypass valve
10-16 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Function
● The oil cooler bypass valve controls the maximum pressure in the oil cooler to protect the oil cooler.
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length × Installed Free
load load Replace spring if damaged or
6 Cooler bypass valve spring Outside diameter length length
N {kg} N {kg} deformed
86.1 N 68.9 N
43.8 × 13.2 30.8 —
{8.78 kg} {7.0 kg}
D51EX/PX-22 10-17
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
CHARGE SAFETY VALVE
10-18 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Function
● The charge safety valve is installed to the oil cooler bypass valve and controls the maximum pressure in the charge circuit
to protect the charge circuit.
Operation
● Port (A) is connected to the charge circuit, port (B) to the drain circuit,
and port (C) to the tank drain circuit through the oil cooler. The oil
also fills chamber (D) through orifice (a) of valve (3A). Poppet (3D) is
fitted to valve seat (3C).
D51EX/PX-22 10-19
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
POWER TRAIN
Outline
● The power generated by engine (1) has its torsional vibration reduced by damper (2), and is then transmitted to the input
shaft of the HST pump.
● HST pump (3) consists of swash plate type piston pumps for the left travel and right travel joined in tandem. The
hydraulic power passes from each pump through high-pressure hoses (4) and is transmitted to left and right HST motors
(5).
● HST pump (3) changes the discharge direction and discharge amount continuously in accordance with the movement of
the swash plate of each pump to match the movement of the steering, direction, and speed lever. This changes the
direction of rotation and speed of the left and right HST motors and controls the forward and reverse travel and turning of
the machine.
● The hydraulic power transmitted to HST motor (5) is output from the motor output shaft as mechanical power, and is
transmitted to final drive (6).
● Final drive (6) is a 2-stage planetary gear mechanism. It reduces the speed and rotates sprocket (7) to drive track shoe (8).
REMARK
HST is an abbreviation for Hydrostatic Transmission.
10-20 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN SYSTEM
D51EX/PX-22 10-21
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
DAMPER
Unit: mm
No. Check item Criteria Remedy
Coupling
3.
4. Boss
5. HST pump input shaft
6. Cover
7. Flywheel
Outline
● The damper reduces the torsional vibration caused by variations in the engine torque, and acts to protect the engine and
downstream drive system from the torsional vibration.
● The power from the engine is transmitted from flywheel (7) to coupling (3). Coupling (3) absorbs the torsional vibration
and transmits the power through boss (4) to the HST pump.
10-22 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
FINAL DRIVE
Outline
● The final drive is a planetary gear, 2-stage reduction type. It provides splash lubrication when the gear rotates.
● It is also possible to remove or install the final drive as a single unit.
● A floating seal is installed to the rotating and sliding portion of the sprocket to prevent the entry of sand or soil from
outside and to prevent leakage of lubricating oil.
Specifications
D51EX/PX-22 10-23
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
10-24 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Unit: mm
No. Check item Criteria Remedy
Backlash of No. 1 sun gear and No. Standard clearance Clearance limit
15
1 planetary pinion 0.13 – 0.35 1.00
Backlash of No. 1 planetary pinion
16 0.17 – 0.53 1.10
and ring gear
Backlash of No. 1 planetary carrier Replace
17 0.27 – 0.49 1.00
and No. 2 sun gear
Backlash of No. 2 sun gear and No.
18 0.14 – 0.38 1.00
2 planetary pinion
Backlash of No. 2 planetary pinion
19 0.17 – 0.53 1.10
and ring gear
D51EX/PX-22 10-25
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
PATH OF POWER TRANSMISSION
● The power from the HST motor goes from No. 1 sun gear (1) through No. 1 planetary pinion (2), is reduced and rotates in
the opposite direction from the rotation of the HST motor, and is then transmitted to ring gear (6).
● When this happens, No. 1 planetary pinion (2) forms one unit with No. 1 planetary carrier (3), and the power from No. 1
planetary carrier (3) is transmitted to No. 2 sun gear (4).
● The power transmitted to No. 2 sun gear (4) passes through No. 2 planetary pinion (5), has its speed reduced, and is
transmitted to ring gear (6).
● The rotating power undergoes two-stage reduction, is transmitted to ring gear (6), passes through hub (7), and is
transmitted to sprocket (8).
10-26 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
UNDER CARRIAGE AND FRAME
MAIN FRAME
1. Engine mount
2. Frame assembly
3. Rear underguard
4. Middle underguard
5. Engine underguard
6. Oil drain guard
Outline
● A hull frame structure with the main frame, track frame, and underguard forming one unit is used.
D51EX/PX-22 10-27
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
TRACK FRAME AND RECOIL SPRING
1. Idler 9. Rod
2. Carrier roller 10.Recoil spring
3. Track frame 11. Wear ring
4. Sprocket teeth 12. U-packing
5. Track roller end guard 13. Nut
6. Track roller center guard (if equipped) 14. Lubricator
7. Track roller 15. Cylinder
8. Seal 16. Bushing
17. Holder
10-28 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Unit: mm
No. Check item Criteria Remedy
Check item Repair limit
18 Deformation of track frame 7(in length of 3,000) Repair
Bend, twist, opening of idler section 3(in length of 300)
5
Standard size Repair limit
Free length x Installed Installed Free Installed
19 Recoil spring O.D. length load length load
Replace
110.2 kN 99.2 kN
563 x ∅196 438 551
11,238 kg 10,114 kg
Outline
● Recoil spring (10) is used to adjust the track shoe tension by supplying grease through lubricator (14) or discharge
existing grease and moving rod (9) forward or in reverse. It also damps sudden shocks applied to idler (1)
D51EX/PX-22 10-29
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
SUSPENSION
10-30 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
13. 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).
D51EX-22 D51PX-22
Displacement at center Upward 46.1 49.4
of equalizer bar side pin
(mm) Downward 46.1 49.4
D51EX/PX-22 10-31
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Unit: mm
No. Check item Criteria Remedy
10-32 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
MEMORANDUM
D51EX/PX-22 10-33
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
IDLER
10-34 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Unit: mm
No Check Item Criteria Remedy
D51EX/PX-22 10-35
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
TRACK ROLLER
D51EX/PX-22
Single flange type
10-36 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange (outside)
ø213 —
2 Outside diameter of flange (inside) ø205 —
3 Outside diameter of tread ø185 ø160
4 Thickness of tread ø42.5 30
Repair by
5 Width of flange (outside) 18 13 buildup weld-
6 Width of flange (inside) 15 10 ing or replace
Width of tread
7 42 —
(Single-flange type)
Width of tread
8 44.5 —
(Double-flange type)
9 Overall width 208 —
Tolerance Standard Clearance
Standard size
Clearance between shaft and Shaft Hole clearance limit
10
bushing –0.250 +0.074 0.250 –
ø54 —
–0.280 0 0.344
Replace
–0.250 –0.160 0.044 –
11 Clearance between shaft and collar ø53.7 —
–0.300 –0.206 0.140
Standard clearance Clearance limit
12 Axial play of roller
0.43 – 0.72 —
D51EX/PX-22 10-37
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
CARRIER ROLLER
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
ø170 —
2 Outside diameter of tread ø150 ø126 Rebuild or
3 Thickness of tread 17.5 5.5 replace
4 Width of tread 42 47
5 Width of flange 15 10
Tolerance Standard Clearance
Standard size
Clearance between shaft and Shaft Hole clearance limit
6
support –0.100 +0.250 0.100 –
ø41 —
–0.200 0 0.450
Tolerance Standard Clearance
Standard size Replace
Interference between shaft and seal Shaft Hole clearance limit
7
guard +0.170 +0.025 0.115 –
ø41.5 —
+0.140 0 0.170
Standard clearance Clearance limit
8 Play in axial direction of shaft
0 – 0.50 —
10-38 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
MEMORANDUM
D51EX/PX-22 10-39
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
SPROCKET
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Wear of tooth root Rebuild or
74 65
replace
2 Thickness of tooth root 22.7 13.7
10-40 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Full-scale drawing of sprocket tooth profile
★ Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
D51EX/PX-22 10-41
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
TRACK SHOE
D51EX/PX-22
10-42 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch
175.3 178.3
Turning over Turn over or
Standard size
2 Outside diameter of bushing Light load Heavy load replace
63 52.8 55.4
3 Thickness of bushing 13.1 2.9 5.5
Standard size Repair limit Repair or
4 Height of link
106 95 replace
Thickness of link
5 32 21 Replace
(Bushing fitting part)
a. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Shoe bolt Regular link 196 ± 20 {20 ± 2} 120 ± 10
6 (Single shoe) Retighten
(Swamp shoe) b. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Master link 196 ± 20 {20 ± 2} 180 ± 10
Tolerance
Standard size Standard clearance
Interference between bushing and Shaft Hole
7
link +0.304 +0.074
ø59 0.190 – 0.304
+0.264 0
Adjust or
Interference between regular pin +0.372 +0.062
8 ø36.2 0.210 – 0.372 replace
and link +0.272 0
Standard clearance
9 Clearance of link mating face Each side Both sides
1.2 2.4
D51EX/PX-22 10-43
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
Single shoe
D51EX/PX-22
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height of grouser Rebuild or
55 25
replace
2 Thickness of grouser 67 37
D51PX-22
Swap shoe
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height of grouser Rebuild or
83 70
replace
2 Thickness of grouser 20 7
10-44 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
HYDRAULIC SYSTEM 1 (HST)
D51EX/PX-22 10-45
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
HST PUMP
★ HST: Abbreviation for HydroStatic Transmission
Type: HPV95 + 95
10-46 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
Outline
This pump consists of a variable displacement swash plate tandem piston pump, servo valve, EPC valve and safety-suction
valve.
1. EPC valve
2. Piston pump
3. Servo valve
4. Safety-suction valve
D51EX/PX-22 10-47
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
10-48 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
Outline
● The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged
according to the load.
● It is possible to change the delivery by changing the swash plate angle (normal ↔ 0 ↔ reverse discharge).
Structure
● Cylinder block (7) is supported to front shaft (1) by spline (15). Front shaft (1) is supported by front and rear bearings (12)
and (16).
● The tip of piston (13) is a concave ball, and shoe (14) is caulked to it to form one unit. Piston (13) and shoe (14) form a
spherical bearing.
● Rocker cam (3) has flat surface (A), and shoe (14) is always pressed against this surface while sliding in a circular
movement. Rocker cam (3) positions cradle bearing (2) between front case (4) and cylindrical surface (B), and rocks.
● Piston (13) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
● Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that
the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is
sucked in and discharged through valve plate (8).
D51EX/PX-22 10-49
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
Operation
1. Operation of pump
● Cylinder block (7) rotates together with shaft (1), and shoe (5)
slides on flat surface (A).
● When this happens, rocker cam (4) moves along cylindrical
surface (B), so angle (a) between center line (X) of rocker cam (4)
and the axial direction of cylinder block (7) changes.
● (a) is named the swash plate angle.
● With center line (X) of rocker cam (4) at a swash plate angle (a) in
relation to the axial direction of cylinder block (7), flat surface
(A) acts as a cam in relation to shoe (5).
● In this way, piston (6) slides on the inside of cylinder block (7), so
a difference between volumes (E) and (F) is created inside
cylinder block (7).
● A single piston suctions and discharges the oil by the amount
(F) – (E).
● As cylinder block (7) rotates and the volume of chamber (E)
becomes smaller, the pressurized oil is discharged.
● On the other hand, the volume of chamber (F) grows larger and,
in this process, the oil is suctioned.
● As center line (X) of rocker cam (4) matches the axial direction of
cylinder block (7) (swash plate angle (a) = 0), the difference
between volumes (E) and (F) inside cylinder block (7) becomes 0.
● Suction and discharge of pressurized oil is not carried out in this
state. Namely pumping action is not performed. (Actually,
however, the swash plate angle is not set to 0)
10-50 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
2. Control of delivery
● If swash plate angle (a) becomes larger, the difference between
volumes (E) and (F) becomes larger and delivery (Q) increases.
Swash plate angle (a) is changed by servo piston (5).
● Servo spool (7) moves according to the command of the EPC
valve. Servo piston (5) is reciprocated by the command pressure
output from servo spool (7).
● This straight line movement is transmitted through slider (6) to
rocker cam (4). Rocker cam (4), which is supported by the
cylindrical surface to cradle bearing (3), then rocks on the
cylindrical surface.
● For the pump, swash plate angle (a) is a maximum of ± 16°.
D51EX/PX-22 10-51
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
3. Operation of servo valve
10-52 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
A. When lever is operated
D51EX/PX-22 10-53
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
SAFETY-SUCTION VALVE
10-54 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
1. When it is high-pressure relief valve
Function
It restricts the maximum pressure inside the HST circuit to protect the
circuit.
Operation
Function
● This ensures the oil flow in the HST closed circuit. It prevents the
charge oil flow from flowing to the pump high-pressure side
(discharge side).
Operation
D51EX/PX-22 10-55
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
B. When HST pump delivery is being discharged from port (PA)
Operation
10-56 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
TOWING VALVE
Function
● These valves are built into the top surface of the pump. There are two valves: the F valve (for the left track) and the R
valve (for the right track).
● If there is a failure on the machine, it is possible to tow the machine by connecting the HST circuit.
● However, it is necessary to cancel the shaft brake of the motor at the same time.
Operation
● To actuate the towing valves, loosen the two valves a maximum of 4.5 mm (3 turns).
D51EX/PX-22 10-57
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
HST MOTOR
● HST: Abbreviation for HydroStatic Transmission
Type: KMV160
★ Sections C-C and E-E of the illustration are shown in "Shuttle valve".
10-58 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
1. Drive shaft MA: (High pressure when traveling in reverse) Discharge port
2. Variable bent axis piston motor (L.H.) MB: (High pressure when traveling forward) Discharge port
3. Speed sensor PB: Parking brake cancel signal port
4. Charge relief valve P: Displacement control signal pressure port
T: Drain
D51EX/PX-22 10-59
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
2. Right HST motor
Direction of rotation (as seen facing drive shaft)
Flows in from (MA): Clockwise rotation
Flows in from (MB): Counterclockwise rotation
★ Sections C-C and E-E of the illustration are shown in "Shuttle valve".
10-60 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
1. Drive shaft MA: (High pressure when traveling in reverse) Discharge port
2. Variable bent axis piston motor (R.H.) MB: (High pressure when traveling forward) Discharge port
3. Speed sensor PB: Parking brake cancel signal port
4. Charge relief valve P: Displacement control signal pressure port
T: Drain
D51EX/PX-22 10-61
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
3. Operation of piston motor
Principle
● Let us assume that the shaft of a disc is supported to allow the disc to
rotate freely. If force (F) is applied to this disc at an angle, this force
(F) can be divided into force (F1) applied at a right angle to the face of
the disc and force (F2) applied in the direction of the circumference of
the disc. Force (F1) pushes the disc in the axial direction, and force
(F2) rotates the disc in a clockwise direction.
● If force (F') is applied to the disc instead of force (F), the force can be
divided in the same way into forces (F'1) and (F'2), and force (F'2) will
rotate the disc in a counterclockwise direction.
Structure
● Seven pistons (2) are installed with a spherical connection to the disc
portion of output shaft (1). Pistons (2) are at a certain angle to drive
shaft (1) and are fitted inside cylinder block (3).
● The angle of cylinder block (3) and piston (2) is determined by the
displacement control signal pressure to port (P). The relationship
between the signal pressure and displacement is shown in the
following figure.
Operation
● The oil sent under pressure from the main piston pump enters from the
piston motor inlet port. Oil pressure is formed at the rear face of piston
(2), and drive shaft (1) is rotated by angle (Q) of piston (2) and the
cylinder block.
10-62 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
4. Change of displacement of continuous variable displacement motor
Function
Operation
● The servo mechanism section has chambers (A), (B) and (C).
● The self-pressures on the chamber (A) side and chamber (C) side are
applied to their respective pressure receiving areas and the main piston is operated by the load balance on those areas.
● When the EPC pressure is 0 kg/cm2, the main piston is on the maximum side.
● If some EPC pressure is supplied, it is supplied to chamber (C) to push out the displacement selector valve spool. The
displacement selector valve spool supplies the self-pressure to chamber (C) according to the balance between the load
generated by the pressure supplied by the EPC and the load received from the displacement control spring until the set
displacement is obtained.
D51EX/PX-22 10-63
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
Specifications
Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KMV160
Type: . . . . . . . . . . . . . .Variable displacement, bent axis type piston pump
Charge relief valve set pressure: . . . . . . . . . 25 - 26 kg/cm2 (355 - 370 psi)
Parking brake release pressure: . . . . . . . . . .11 – 18 kg/cm2 (157 - 257 psi)
Theoretical capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 - 160 cm3/rev
10-64 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
5. Shuttle valve
★ For sections C-C and E-E of the illustration, see the general view.
1. Check valve
2. Shuttle valve
3. Main piston
Function
● The pressure at the high-pressure side is selected at HST main pressures (MA) and (MB), and is supplied to main piston
(3).
● A shuttle valve is provided to select the pressure from the low-pressure side and supply it to the charge relief valve.
Operation
● The higher one of pressures (MA) and (MB) is supplied to chamber (A) of the main piston by 2 check valves (1).
● In section E-E, when (MA) > (MB), the shuttle valve leans to the right and (MB) is selected as the low-pressure side and
supplied to the charge relief valve.
● When (MB) > (MA), the shuttle valve leans to the left and (MA) is selected as the low-pressure side and supplied to the
charge relief valve.
D51EX/PX-22 10-65
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
6. Charge relief valve
1. Valve 4. Poppet
2. Spring 5. Spring
3. Valve seat 6. Adjustment screw
Function
● The charge relief valve is installed inside the motor end cover. It prevents the pressure at the HST main low-pressure side
(charge pressure) selected by the shuttle valve from going above the set pressure. At the same time, it relieves the
determined oil flow inside the motor case and prevents the motor from overheating.
● In addition, it discharges the dirtiest oil inside the HST main circuit to the outside and acts to keep the inside of the HST
main circuit clean.
Operation
● Port (A) connects the pressure at the HST main low-pressure side
(charge circuit) selected by the shuttle valve.
● In addition, ports (B) and (D) are connected to the tank drain circuit
through the HST motor case.
● The pressure oil passes through orifice (g) in valve (1) and fills
chamber (C). Poppet (4) is fitted tightly to valve seat (5).
10-66 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
● If abnormal pressure is generated inside the circuit, and the oil
pressure in port (A) and chamber (C) rises to the pressure set by spring
(5), poppet (4) is pushed to the right, and the oil in chamber (C) is
relieved to port (D), so the oil pressure in chamber (C) goes down.
D51EX/PX-22 10-67
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
7. Actuation of parking brake
10-68 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
8. Speed sensor
Function
● The speed sensor is installed to the end cover of the motor. It senses revolution pulses from the drive shaft spline in the
motor and transmits electric signals to the HST controller.
● This sensor is of Hall IC type. Unlike a common speed sensor of coil type, the specified gap and angle between this sensor
and spline are maintained.
D51EX/PX-22 10-69
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
MOTOR CONTROL VALVE
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE
10-70 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
P: From HST pump CPA
T: To hydraulic tank
A1: To work equipment PPC valve
A2: To accumulator
A3: To right HST motor P
A4: To left HST motor P
A5: Plug
A6: To right and left HST motor B
2. Right HST motor gear shift EPC valve 12. Nut 20. Block
3. Left HST motor gear shift EPC valve 13. Plunger 21. Body
11. Block
Outline
● In block (11), 3 solenoid valves, 2 EPC valves, towing valve and brake
pressure sensor are installed.
● Parking brake solenoid valve (5) transmits a signal generated by the
potentiometer which operates when the brake pedal is pressed or a
signal of the limit switch connected to the parking brake lever through
the HST controller to drain the changeover oil and operate the parking
brakes built in the HST motors.
● Upon receiving a signal generated by the limit switch which operates
when the brake pedal is pressed fully or a signal from the limit switch
connected to the parking brake lever, slow brake solenoid valve (4)
drains the changeover oil slowly through the orifice in it to operate the
parking brakes built in the HST motors.
● Right HST motor gear shift EPC valve (2) and left HST motor gear shift EPC valve (3) transmit the shift switch signals of
the steering/directional/gear shift lever through the HST controller and output the oil pressure according to the signals to
change the HST motor capacity.
● Work equipment lock solenoid valve (1) is installed between HST pump CPA and control valve. If the work equipment
lock lever is set in the "Free" position, the work equipment lock solenoid is linked with the work equipment lock switch
and opens the work equipment control circuit, and then the work equipment can be operated.
● Towing valve (7) is installed between the parking brake solenoid valve and HST motor. When the parking brake cannot be
released because of an engine trouble, etc., the parking brake can be released by removing towing plate (9) and tightening
towing valve (7) to apply parking brake release pressure from outside.
★ For the procedure of releasing the parking brake, see Testing and adjusting, Procedure for releasing parking brake.
D51EX/PX-22 10-71
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
SOLENOID VALVE
4. Connector 8. Block
Operation
● The signal current does not flow from the controller, so coil (3) is
de-energized.
● For this reason, spool (7) is pushed fully to the left by spring (6).
● As a result, port (A) closes and the flow of pressurized oil from the
pump does not flow to actuator (9).
● At the same time, the oil from actuator (9) flows from port (B) to port
(C) and then, it is drained.
● When the signal current flows to the solenoid valve, coil (3) is
energized, and propulsion force to the right is generated in plunger (2).
● For this reason, spool (7) is pushed to the right by push pin (5).
● As a result, the pressurized oil from the pump flows from port (A)
through port (B), and goes to actuator (9).
● At the same time, port (C) closes, so the oil is not drained.
10-72 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
MEMORANDUM
D51EX/PX-22 10-73
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
EPC VALVE
10-74 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installed Installed Free Installed Replace EPC valve assembly
7 Return spring Outside diameter length load length load if there is damage or deforma-
3.14 N 2.55 N tion
9.0 8.4 —
{0.32 kg} {0.26 kg}
Function
D51EX/PX-22 10-75
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
Operation
10-76 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
3. When signal current is maximum (When coil is energized)
● If the signal current flows in coil (5), coil (5) is energized.
● Since the signal current at this time is maximum, the thrust of
plunger (6) becomes maximum.
● Rod (4) presses spool (2) to the left.
● The maximum oil flows from port (P) to port (C) and the pressure
in the circuit between the EPC valve and control valve becomes
maximum.
● Since port (T) is closed, the oil does not flow to the tank.
D51EX/PX-22 10-77
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
CHARGE PUMP
5. Seal gland and retainer 10. Snap ring 15. Driven gear
10-78 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
Outline
● The HST charge pump is attached to the engine flywheel housing and is driven by the pump drive assembly.
● The HST charge pump supplies pilot pressure oil to the low pressure side of the HST main circuit, charge safety valve,
motor control solenoid valve, and work equipment PPC valve.
● The charge pump sucks in the oil from the hydraulic tank.
Specifications
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Theoretical discharge amount . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 cc/rev
Operation
● The charge pump is connected to the drive assembly by coupling and rotates the drive gear. The drive gear then rotates the
driven gear.
D51EX/PX-22 10-79
STRUCTURE, FUNCTION AND
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12
MEMORANDUM
10-80 D51EX/PX-22
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12
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
Feature
CLSS stands for Closed center Load Sensing System, and has the following features.
● Fine control not influenced by load.
● Control enabling digging even with fine control.
● Ease of compound operation ensured by flow divider function using area of opening of spool during compound
operations.
● Energy saving using variable pump control.
Structure
● The CLSS consists of a variable capacity single piston pump, control valve, and actuator.
● The pump body consists of the main pump, PC valve and LS valve.
D51EX/PX-22 10-81
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Basic principle
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12
2. Pressure compensation control
● A pressure compensation valve is installed to the outlet port side of the control valve spool to balance the load.
When two actuators are operated together, this valve acts to make pressure difference (ΔP) between the upstream
(inlet port) and downstream (outlet port) the same, regardless of the size of the load (pressure). In this way, the flow
of oil from the pump is divided (compensated) in proportion to the area of opening (S1) and (S2) of each valve when
it is operated.
D51EX/PX-22 10-83
STRUCTURE, FUNCTION AND
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12
Hydraulic circuit diagram and the name of valves
10-84 D51EX/PX-22
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12
UNLOAD VALVE
1. Spool
2. Spring
Function
● When the control valve is at neutral, pump delivery (Q) discharged by the minimum swash plate angle is released to the
tank circuit. When this happens, pump discharge pressure (PP) is set at 22 kg/cm2 (312 psi) by spring (2) inside the valve:
[LS pressure (PLS): 0 kg/cm2 (0 psi)].
Operation
● Pump discharge pressure (PP) is acting on the left end of spool, and LS pressure (PLS) is acting on the right end.
● When the control valve is at neutral, LS pressure (PLS) is 0, so only pump discharge pressure (PP) has any effect, and
(PP) is set only by the load of spring (2).
● As pump discharge pressure (PP) rises, and reaches the load of spring (2) (22 kg/cm2 [312 psi]), spool (1) is moved to the
right in the direction of the arrow. Pump discharge pressure (PP) then passes through the notch (a) of spool (1) and is
connected to tank circuit (T).
● In this way, pump discharge pressure (PP) is set to 22 kg/cm2 [312 psi]
D51EX/PX-22 10-85
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12
2. When control valve is in fine control
1. Spool
2. Spring
Function
● When the control valve is in the fine control mode, if the demand flow for actuator is less than the value corresponding to
the minimum swash plate angle of the pump, pump pressure (PP) is set to LS pressure (PLS) + 22 kg/cm2 (312 psi). If the
differential pressure between pump pressure (PP) and LS pressure (PLS) becomes equal to the load of spring (2)
22 kg/cm2 (312 psi), the unload valve opens. Accordingly, LS differential pressure (PLS) is 22 kg/cm2 (312 psi) at this
time.
Operation
When fine control is carried out on the control valve, LS pressure (PLS) is generated and acts on the right end of spool (1).
● When this happens, the area of the opening of the control valve spool is small, so there is a big difference between LS
pressure (PLS) and pump discharge pressure (PP).
● When the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) reaches the load of spring
(2) 22 kg/cm2 (312 psi), spool (1) moves to the right in the direction of the arrow, and pump circuit (PP) and tank circuit
(T) are connected.
● In other words, pump discharge pressure (PP) is set to a pressure equal to the spring force 35 kg/cm2 (497 psi) + LS
pressure (PLS), and LS differential pressure (PLS) becomes 22 kg/cm2 (312 psi).
10-86 D51EX/PX-22
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12
3. When control valve is being operated (work equipment)
1. Spool
2. Spring
3. Actuator circuit
Function
● When the control valve is operated, if the demand flow for actuator exceeds the value corresponding to the minimum
swash plate angle of the pump, the outflow to tank circuit (T) is shut off and all of pump delivery (Q) is sent to the
actuator circuit.
Operation
● When the control valve is operated to a bigger stroke, LS pressure (PLS) is generated and acts on the right end of spool
(1). When this happens, the area of the opening of the control valve spool is large, so the difference between LS pressure
(PLS) and pump discharge pressure (PP) is small.
● For this reason, the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) does not reach the
load of spring (2) 22 kg/cm2 (312 psi), so spool (1) is pushed to the left by spring (2).
● As a result, pump circuit (PP) and tank circuit (T) are shut off, and all the pump delivery (Q) flows to the actuator circuit
(3).
D51EX/PX-22 10-87
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Work equipment operated
● When the lift is operated to LOWER, spool (1) moves to the right from the HOLD position, and the oil from the
pump enters bridge circuit (C), passes through cylinder port (B), and enters the cylinder bottom.
● When this happens, the oil at the cylinder head passes through cylinder port (A) and is drained.
10-88 D51EX/PX-22
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2. When lift is operated to FLOAT
● When the lift is operated to FLOAT, spool (1) moves further to the right. The oil from the pump does not enter bridge
circuit (C).
● The oil at cylinder port (B) is connected to the drain circuit through bridge circuit (C), opening (a), and cylinder port
(A).
D51EX/PX-22 10-89
STRUCTURE, FUNCTION AND
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12
Introduction of LS pressure
Function
● The LS pressure is the actuator load pressure at the outlet port end of the control valve.
● It actually reduces pump pressure (PP) at pressure reducing valve (3) of the pressure compensation valve to the same
pressure as actuation circuit pressure (A), and sends it to the LS circuit (PLS).
Operation
● When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) and notch (a) in spool (1)
through bridge passage (b) to actuator circuit (A).
● At the same time, pressure reducing valve (3) also moves to the right, so pump pressure (PP) has its pressure reduced by
the pressure loss at notch (C). It is introduced to LS circuit (PLS), and then goes to spring chamber (PLS1).
● When this happens, LS circuit (PLS) is connected to tank circuit (TS) from LS bypass plug (4). (See the section on the LS
bypass plug).
● Actuator circuit pressure (PA) [(=(A)] acts on the left end of pressure reducing valve (3); the reduced pump discharge
pressure (PP) acts on the other end.
● As a result, pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure of
spring chamber (PLS1) are the same. Pump discharge pressure (PP) is reduced at notch (C), becomes actuator circuit
pressure (A), and is taken to LS circuit (PLS).
10-90 D51EX/PX-22
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PRESSURE COMPENSATION VALVE
Function
● During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to increase,
compensation is received. [When this happens, the other actuator being used for compound operation (right side) is at a
higher load than the actuator on this side (left side).]
Operation
● If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in actuator
circuit (A) on this side (left side) tries to increase.
● If this happens, the LS pressure (PLS) of the other actuator acts on spring chamber (PLS1), and pressure reducing valve
(1) and flow control valve (2) are pushed to the left.
● Flow control valve (2) throttles the area of opening between pump circuit (PP) and spool upstream (PPA), and pressure
loss is generated between (PP) and (PPA).
● Flow control valve (2) and pressure reducing valve (1) are balanced in position where the difference in pressure between
(PLS) and (PA) acting on both ends of pressure reducing valve (2) and the pressure loss between (PP) and (PPA) on both
sides of flow control valve (2) are the same.
● In this way, the pressure difference between upstream pressure (PPA) and downstream pressure (PA) of both spools used
during compound operations is the same, so the pump flow is divided in proportion to the area of opening of notch (a) of
each spool.
D51EX/PX-22 10-91
STRUCTURE, FUNCTION AND
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LS BYPASS VALVE
1. LS bypass valve
2. Valve cover
Function
● This releases the residual pressure of LS pressure (PLS).
● It makes the speed of the rise in pressure of LS pressure (PLS) more gentle. In addition, with this discarded throttled flow,
it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the stability by lowering the effec-
tive LS differential pressure.
Operation
● The pressurized oil for LS circuit (PLS) passes from filter (a) of bypass plug (1) through orifice (b) and flows to the tank
circuit (T).
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WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM
4. Lift cylinder 8. Oil filter 12. Work equipment and fan pump
D51EX/PX-22 10-93
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
WORK EQUIPMENT AND FAN PUMP
Type: LPV45
10-94 D51EX/PX-22
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D51EX/PX-22 10-95
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Function
● The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is
discharged according to the load.
● It is possible to change the delivery amount by changing the swash plate angle.
Structure
● Cylinder block (7) is supported to shaft (1) by spline (a), and shaft (1) is supported by the front and rear bearings.
● The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a
spherical bearing.
● Rocker cam (4) has flat surface (A). Shoe (5) is kept pressed against the flat surface (A) and it slides circularly on flat
surface (A). Rocker cam (4) slides around ball (11).
● Piston (6) carries out relative movement in the axial direction inside each cylinder chamber or cylinder block (7).
● Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that
the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is
sucked in and discharged through valve plate (8).
● Hole number of cylinder block (7) is an odd number. So, it is suited to groove of valve plate (8).
10-96 D51EX/PX-22
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Operations
● Shaft (1) and cylinder block (7) rotate together and shoe (5) slides on
the flat surface (A). Since the rocker cam (4) leans around ball (11) at
this time, the angle (a) between the center line (X) of rocker cam (4)
and axis of cylinder block (7) changes. The angle (a) is called the
swash plate angle.
● When the center line (X) of the rocker cam (4) maintains the swash
plate angle (a) in relation to the axial direction of the cylinder block
(7), the flat surface (A) acts as a cam for the shoe (5).
● By this, the piston (6) slides on the inside of the cylinder block (7),
creates a difference between capacities (E) and (F), then suction and
discharge of oil for the amount of this difference (F) – (E) will be
carried out.
● In other words, oil is discharged as the capacity of the chamber (E)
decreases when the cylinder block (7) rotates.
● In the mean time, the capacity of the chamber (F) increases, and the oil
is sucked at this process. (The figure shows the state of the pump when
suction of the chamber (F) and discharge of the chamber (E) have
completed.)
● When the center line (X) of the rocker cam (4) becomes in line with
the axial direction of the cylinder block (7) (swash plate angle = 0), the
difference between capacities of (E) and (F) inside the cylinder block
(7) becomes 0, so the pump does not carry out any suction or
discharge action of oil. (In actual fact, the swash plate angle never
becomes 0.)
● In other words, delivery of the pump is directly proportional to the
swash plate angle (a).
D51EX/PX-22 10-97
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
● As the swash plate angle (a) becomes larger, difference between the
capacities (E) and (F) becomes larger, so the pump delivery (Q)
increases.
● The swash plate angle (a) is changed by the servo piston (10).
● Servo piston (10) is reciprocated straight by the signal pressure of the
PC and LS valves. This reciprocation is transferred to rocker cam (4).
Rocker cam (4) supported on ball (11) rocks around ball (11).
● The output pressure (PE) of the LS valve is applied to the pressure
chamber of servo piston (10).
● As output pressure (PE) rises, rocker cam (4) moves to reduce the
swash plate angle (a), so the pump delivery (Q) decreases.
10-98 D51EX/PX-22
STRUCTURE, FUNCTION AND
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SERVO VALVE
D51EX/PX-22 10-99
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12
Function
1. LS valve
● The LS valve controls the discharge of the pump according to the
stroke of the control lever, or the demand flow for the actuator.
● The LS valve calculates the demand flow for the actuator from
differential pressure (PLS) between pump discharge pressure
(P1L) and control valve outlet pressure (PLS) and controls pump
delivery (Q).
● [(P1L) is called the pump discharge pressure, (PLS) called the LS
pressure, and (PLS) called the LS differential pressure.]
● That is, the pump discharge is controlled according to the demand
flow for the actuator by the following method; The pressure loss
made when the oil flows through the opening of the control valve
spool [LS differential pressure (PLS)] is sensed and pump
delivery (Q) is so controlled that the pressure loss will be
constant.
2. PC valve
● When pump discharge pressure (P1L) rises, the stroke of the
control valve spool is increased and the opening area is increased
and pump delivery (Q) is increased. At this time, the PC valve
limits pump delivery (Q) according to discharge pressure (P1L) so
that the pump absorption horsepower will not exceed the engine
horsepower. In other words, the PC valve performs approximate
constant-horsepower control.
● That is, if the load on the actuator is increased and pump
discharge pressure (P1L) rises during operation, the PC valve
reduces pump delivery (Q). If the pump discharge pressure
lowers, the PC valve increases pump delivery (Q).
● The relationship between pump discharge pressure (P1L) and
pump delivery (Q) is shown below.
10-100 D51EX/PX-22
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12
MEMORANDUM
D51EX/PX-22 10-101
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
CONTROL VALVE
General view
10-102 D51EX/PX-22
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12
Outline
● This external view diagram shows the ripper valve.
● The standard valve does not have the ripper section.
A1 : To fan pump
A2 : To lift cylinder head
A3 : To tilt cylinder head
A4 : To angle cylinder
A5 : To ripper cylinder bottom
B1 : To fan pump
B2 : To lift cylinder bottom
B3 : To tilt cylinder bottom
B4 : To angle cylinder
B5 : To ripper cylinder head
LS : To LS valve of hydraulic pump
P : From work equipment pump
PA2 : From lift raise PPC valve
PA3 : From tilt left PPC valve
PA4 : From angle left PPC valve
PA5 : From ripper lower PPC valve
PB1 : —
PB2 : From lift lower PPC valve
PB3 : From tilt right PPC valve
PB4 : From angle right PPC valve
PB5 : From ripper raise PPC valve
PEPC : From solenoid valve
PP : To LS valve of hydraulic pump
T : To tank
TS : To tank
D51EX/PX-22 10-103
STRUCTURE, FUNCTION AND
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12
Sectional view (1/5)
10-104 D51EX/PX-22
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12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installation Installation Installation
Free length
8 Suction valve spring Outside diameter length load load If damaged or
2.65 N 2.16 N deformed,
36.3 × 4.45 33.3 —
{0.27 kg} {0.22 kg} replace spring.
5.1 N 4.12 N
9 Check valve spring 39.2 × 4.45 33.5 —
{0.52 kg} {0.42 kg}
D51EX/PX-22 10-105
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12
(2/5)
10-106 D51EX/PX-22
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1. Spool (Fan)
2. Spool (Lift)
3. Spool (Tilt)
4. Spool (Angle)
5. Spool (Ripper)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installation Installation Installation
Free length
6 Spool return spring Outside diameter length load load
180 N 144 N
29 × 17.5 25 —
{18.4 kg} {14.7 kg}
50 N 40.0 N
7 Spool return spring 19.92 × 16.8 18.2 —
{5.1 kg} {4.08 kg}
39.2 N 31.4 N
8 Spool return spring 14.02 × 12.1 8.73 —
{4 kg} {3.2 kg} If damaged or
55.9 N 44.7 N deformed,
9 Spool return spring 31.98 × 17.4 28.5 — replace spring.
{5.7 kg} {4.56 kg}
77.5 N 62.0 N
10 Spool return spring 33.34 × 17.2 26.8 —
{7.9 kg} {6.32 kg}
75.4 N 60.0 N
11 Spool return spring 29.27 × 17.6 26.9 —
{7.69 kg} {6.12 kg}
45.9 N 36.7 N
12 Spool return spring 17.05 × 17.2 15.2 —
{4.68 kg} {3.74 kg}
189 N 151 N
13 Spool return spring 40.73 × 17.4 28.5 —
{19.25 kg} {15.4 kg}
D51EX/PX-22 10-107
STRUCTURE, FUNCTION AND
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12
(3/5)
10-108 D51EX/PX-22
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12
1. Unload valve 8. Pressure compensation valve R (Angle)
2. Pressure compensation valve F (Fan) 9. Pressure compensation valve R (Tilt)
3. Pressure compensation valve F (Lift) 10. Pressure compensation valve R (Lift)
4. Pressure compensation valve F (Tilt) 11. Pressure compensation valve R (Fan)
5. Pressure compensation valve F (Angle)
6. Pressure compensation valve F (Ripper) F: Flow control valve
7. Pressure compensation valve R (Ripper) R: Pressure reducing valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installation Installation Installation If damaged or
Free length
12 Unload valve spring Outside diameter length load load deformed,
91.2 N 73.0 N replace spring.
28.64 × 18.6 18 —
{9.3 kg} {7.44 kg}
D51EX/PX-22 10-109
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12
(4/5)
10-110 D51EX/PX-22
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12
1. Unload valve 9. Pressure compensation valve R (Lift)
2. Main relief valve 10. Pressure compensation valve F (Lift)
3. Fan relief valve 11. Spool (Tilt)
4. Spool (Fan) 12. Pressure compensation valve R (Tilt)
5. Pressure compensation valve R (Fan) 13. Pressure compensation valve F (Tilt)
6. Pressure compensation valve F (Fan)
7. Suction valve (Lift) F: Flow control valve
8. Spool (Lift) R: Pressure reducing valve
D51EX/PX-22 10-111
STRUCTURE, FUNCTION AND
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(5/5)
10-112 D51EX/PX-22
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12
1. Suction valve 8. Spool (Ripper)
2. Suction valve 9. Pressure compensation valve R (Ripper)
3. Spool (Angle) 10. Pressure compensation valve F (Ripper)
4. Pressure compensation valve R (Angle) 11. Safety valve
5. Pressure compensation valve F (Angle) 12. Pressure bleed plug
6. Suction valve
7. Suction valve F: Flow control valve
R: Pressure reducing valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installation Installation Installation If damaged or
Free length
13 Check valve spring Outside diameter length load load deformed,
1.98 N 1.57 N replace spring.
21.9 × 5 15.8 —
{0.2 kg} {0.16 kg}
D51EX/PX-22 10-113
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12
QUICK DROP VALVE
10-114 D51EX/PX-22
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12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installation Installation Free Installation
8 Piston spring Outside diameter length load length load
25.5 N 20.4 N If damaged or
27.3 × 12 20 —
{2.6 kg} {2.08 kg} deformed, replace
46.1 N 36.9 N spring.
9 Valve spring 53.24 × 34.8 18 —
{4.7 kg} {3.76 kg}
52.5 N 42.0 N
10 Valve spring 26.35 × 23 25 —
{5.35 kg} {4.28 kg}
Outline
● The quick drop valve is installed between the control valve and lift cylinder. When the control lever is operated to
"LOWER" the blade, this device prevents a vacuum in the cylinder bottom and shortens the time lag in starting digging.
● 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
● If the blade control lever is set in the "LOWER" position, the oil from
the control valve flows in port (VB), and then flows through ports
(CB1) and (CB2) to the cylinder bottom side and pushes the piston to
the left.
● The oil on the cylinder head side is pushed out by the piston, and then
it enters ports (CH1) and (CH2) and flows through port (VH) and
control valve to the hydraulic tank.
D51EX/PX-22 10-115
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BLADE PPC VALVE
★ PPC: Abbreviation for Proportional Pressure Control
10-116 D51EX/PX-22
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D51EX/PX-22 10-117
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Operation
1. At neutral
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12
C. For blade angle
● Ports (PA) and (PB) of the blade angle control valve and
ports (P5) and (P6) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) of spool (1).
D51EX/PX-22 10-119
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12
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 (P4) 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 (P4) is relieved.
● If the pressure at port (P4) goes down too far, spool (1) is pushed
down by metering spring (2). Fine control hole (f) is shut off from
drain chamber (D), and at almost the same time, it is connected to
pump pressure chamber (PP). Pump pressure is supplied until the
pressure at port (P4) recovers to a pressure equivalent to the
position of the lever.
● When the control valve spool returns, the oil at drain chamber (D)
flows in from fine control hole (f') in the valve on the side that is
not moving. It passes through port (P3), is taken to chamber (PA),
and the oil fills the chamber.
10-120 D51EX/PX-22
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5. When blade is operated to FLOAT
● When piston (4) at the port (P4) LOWER side is pushed by disc
(5) and moves down, ball (11) contacts protrusion (a) of the piston
during the stroke. (Detente starts to act.)
● When piston (4) pushed in further, ball (11) pushes up collar (12),
which is being held by detente spring (13). While pushing up col-
lar (12), it escapes to the outside and passes over protrusion (a) of
the piston.
● 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 (P4), so more or less the same pressure is
applied as is applied to port (P4).
● 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.
D51EX/PX-22 10-121
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RIPPER/WINCH PPC VALVE
(If equipped)
10-122 D51EX/PX-22
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12
P : From charge pump 1. Spool
P1 : To ripper valve 2. Piston
P2 : To ripper valve 3. Lever
T : To tank 4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installation Installation Installation
Free length
8 Centering spring Outside diameter length load load If damaged or
125 N 100 N deformed,
33.9 × 15.3 28.4 —
{12.7 kg} {10.2 kg} replace spring.
16.7 N 13.3 N
9 Metering spring 22.9 × 8.10 22.0 —
{1.70 kg} {1.36 kg}
D51EX/PX-22 10-123
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Operation
1. At neutral
● Ports (A) and (B) of the control valve and ports (P1) and (P2) of
the PPC valve are connected to drain chamber (D) through fine
control hole (f) on spool (1).
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3. During fine control
(when control lever is returned)
● As lever (5) starts returning, spool (1) is pushed up by force of
centering spring (3) and port (P1) pressure. By this move, fine
control hole (f) is connected to drain chamber (D) and relieves
pressurized oil of port (P1) to it.
● If port (P1) pressure goes excessively low, spool (1) is pushed
down by metering spring (2), and passage between fine control
hole (f) and drain chamber (D) is shut down. And, almost at the
same time, the hole is connected to pump pressure chamber (PP)
and starts supplying pump the pressure. This supply continues
until port (P1) pressure is recovered to the level equivalent to the
lever position.
● When the control valve spool returns, oil in drain chamber (D)
flows in through fine control hole (f') on the not moving side
valve. Oil is then conducted via port (P2) to chamber (B) to fill it
up.
4. At full stroke
● When disc (5) pushes down piston (4) and retainer (7) pushes
down spool (1), connection of fine control hole (f) is switched
from drain chamber (D), to pump pressure chamber (PP).
● Thus, pilot pressurized oil from the control pump passes through
fine control hole (f) and conducted to chamber (A) through port
(P1) to push the control valve spool.
● Return oil from chamber (B) is conducted from port (P2) to drain
chamber (D) through fine control hole (f').
D51EX/PX-22 10-125
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12
HYDRAULIC TANK, FILTER
1. Hydraulic tank
2. Hydraulic oil filter
3. Oil filler cap
4. Sight gauge
5. Strainer
6. Drain plug
7. Bypass valve
Specifications
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12
ACCUMULATOR
(for PPC circuit)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nitrogen gas
Amount of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 cc
Max. operating pressure . . . . . . . . . . . . . . . . . . . . . .70 kg/cm2 (995.6 psi)
Charge pressure . . . . . . . . . . . . . . . . . . . . . . 12 kg/cm2 (170.6 psi) at 80°C
Outline
● A accumulator is installed between the charge valve and the work
equipment valve. In the case the engine is stopped with the work
equipment raised, the compressed nitrogen gas pressure in the
accumulator feeds the pilot oil pressure to the work equipment control
valve so that the work equipment will lower by its weigh.
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MEMORANDUM
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WORK EQUIPMENT
WORK EQUIPMENT
D51EX/PX-22 10-129
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10-130 D51EX/PX-22
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D51EX/PX-22 10-131
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10-132 D51EX/PX-22
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Unit: mm
No. Check item Criteria Remedy
D51EX/PX-22 10-133
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12
CUTTING EDGE AND END BIT
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height of cutting edge
204 110
2 Height of end bit 204 110 Replace
D51EX-22 379.6 ---
3 Width of end pit
D51PX-22 379.6 ---
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RIPPER
(If equipped)
Unit: mm
No. Check item Criteria Remedy
3. Support
4. Ripper cylinder
5. Shank
6. Point
7. Beam
D51EX/PX-22 10-135
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12
WORK EQUIPMENT CYLINDER
LIFT CYLINDER
TILT CYLINDER
10-136 D51EX/PX-22
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ANGLE CYLINDER
RIPPER CYLINDER
(If equipped)
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Unit: mm
No. Check item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
–0.025 +0.152 0.020 –
Lift ø50 0.516
–0.064 –0.005 0.216
Clearance between piston rod and –0.030 +0.151 0.024 –
1 Tilt ø55 0.527
bushing –0.076 –0.006 0.227
–0.025 +0.152 0.020 –
Angle ø50 0.516
–0.064 –0.005 0.216
–0.030 +0.151 0.024 –
Ripper ø60 0.527
–0.076 –0.006 0.227
–0.025 +0.142 0.105 –
Lift ø50 1.0
–0.064 +0.080 0.206
–0.025 +0.039 0.025 – Replace
Tilt ø40 1.0 bushing
Clearance between piston rod –0.064 0 0.103
2
support shaft and bushing –0.025 +0.039 0.025 –
Angle ø40 1.0
–0.064 0 0.103
–0.030 +0.174 0.130 –
Ripper ø70 1.0
–0.076 +0.100 0.250
–0.025 +0.142 0.105 –
Lift ø50 1.0
–0.064 +0.080 0.206
–0.025 +0.039 0.025 –
Tilt ø40 1.0
Clearance between cylinder bottom –0.064 0 0.103
3
support shaft and bushing –0.025 +0.025 0.025 –
Angle ø40 1.0
–0.064 0 0.089
–0.030 +0.174 0.130 –
Ripper ø70 1.0
–0.076 +0.100 0.250
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PISTON VALVE FOR ANGLE CYLINDER
Outline
● The piston valve is installed to the piston section of the angle 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
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.
D51EX/PX-22 10-139
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CAB AND ITS ATTACHMENTS
ROPS CAB
1. ROPS cab
2. Door
3. Front wiper
4. Rear wiper
5. Door wiper
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MEMORANDUM
D51EX/PX-22 10-141
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STEERING AND BRAKE CONTROL
★ PCCS: Abbreviation for Palm Command Control System
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1. Parking brake lever
2. Joystick (PCCS lever)
3. Electric lever
4. Parking brake limit switch 1
5. Parking brake limit switch 2
6. HST controller
7. Center brake proximity switch
8. Brake pedal potentiometer
9. Brake pedal
Outline
● Electric lever (3) sends electric signals to HST controller (6) according to the stroke of joystick (PCCS lever) (2). Upon
receiving these signals, HST controller (6) sends signals to the EPC valve of HST pump to change the flow in HST pump
and control the HST motor.
● If the joystick (PCCS lever) (2) is leaned to the left a little while it is leaned to the forward position, the machine turns to
the left gradually. If it is leaned to the left stroke end, the machine makes a counter-rotation.
● Brake pedal potentiometer (8) sends electric signals to HST controller (6) according to the stroke of brake pedal (9). Upon
receiving these signals, HST controller (6) sends signals to the EPC valve of HST pump to decelerate the right and left
HST motors simultaneously.
● If brake pedal (9) is pressed fully while parking brake lever (1) is in the FREE position, HST controller (6) receives
electric signals from brake pedal potentiometer (8) and operates the right and left HST brakes simultaneously. After the
machine stops, HST controller (6) stops sending signals to the parking brake solenoid valve. At this time, the signal of
center brake proximity switch (7) operates the relay to stop the signal to the slow brake solenoid valve. If the signal to the
parking brake solenoid valve or slow brake solenoid valve is stopped, the parking brakes built in the right and left HST
motors operate.
● If the parking brake lever (1) is set in the LOCK position, the HST controller receives electric signals from parking brake
limit switch 1 (4) and stops sending signals to the parking brake solenoid valve. At this time, parking brake limit switch 2
(5) stops sending signals to the slow brake solenoid valve. If the signal to the parking brake solenoid valve or slow brake
solenoid valve is stopped, the parking brakes built in the right and left HST motors operate.
D51EX/PX-22 10-143
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WORK EQUIPMENT CONTROL
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1. Work equipment lock lever
2. Blade PPC valve
3. Blade control lever
4. Ripper control lever (If equipped)
5. Ripper PPC valve (If equipped)
6. PPC lock limit switch
Outline
● 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, the PPC lock limit switch stops the signal to the PPC lock
solenoid valve and the operator can move blade control lever (3) and ripper control lever (4) but cannot operate the work
equipment.
● 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.
D51EX/PX-22 10-145
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CAB DAMPER MOUNT
Cab mount and ROPS stopper
Outline
● The mounts are installed to 2 places on each of the front side and rear side to fix the cab (with the floor frame).
● The oil-filled damper mounts absorb vibrations.
● The ROPS stoppers are installed 2 places on each of the front side and rear side to fix the cab (having the ROPS in it)
when the machine overturns.
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AIR CONDITIONER
AIR CONDITIONER AND FLOOR HEATER
D51EX/PX-22 10-147
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AIR CONDITIONER PIPING
1. Compressor
2. Refrigerant discharge piping
3. Refrigerant suction piping
4. Hot water outlet
5. Hot water return piping
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ELECTRICAL SYSTEM
MONITOR SYSTEM
● The monitor system notifies the operator of the machine condition. It monitors the machine condition with the sensors
installed to the machine and processes and displays the obtained information on the monitor panel immediately.
The contents displayed on the panel are roughly classified as shown below.
● Travel direction, gear speed, shift mode (Display panel A)
● Coolant temperature, HST oil temperature, and fuel level (Gauge section)
● Machine trouble alarm (Monitor section)
● Current, voltage, error code, of each sensor and solenoid (Display panel B)
● 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.
D51EX/PX-22 10-149
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Processing in monitor panel (Common to all specifications)
★ For details of the operating method, see Testing and adjusting, "Special functions of monitor panel (EMMS)".
Other items
Contents and conditions of processing Method Flow of signals
1. Filter and oil maintenance mode (User)
2. Maintenance interval change mode (Service)
3. Electric system failure code display mode
4. Mechanical system failure code display mode
5. Adjustment mode (Service) Each sensor/solenoid
6. Real-time monitoring mode ↓
7. Reduced cylinder mode (Service) CAM signal Controller
8. No-injection cranking mode (Service) ↓
9. Phone No. setting mode (Service) Monitor panel
10. Machine model selection mode (Service)
11. Option selection mode (Service)
12. Initialization mode (Service)
13. Luminance and brightness adjustment mode (User)
★ For details of the operating method, see Testing and adjusting, "Special functions of monitor panel (EMMS)".
10-150 D51EX/PX-22
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ENGINE CONTROL
e. Neutral signal
Function
● A limit switch is installed to the linkage of the parking brake. HST controller permits the engine to start only when the
parking brake is in the “lock” position and the steering/directional/gear shift lever is in the “N (Neutral)” position.
D51EX/PX-22 10-151
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ENGINE CONTROL SYSTEM
a. No. 1 throttle signal (fuel control dial signal) f. Engine speed signal
c. N0. 3 throttle signal (controller control signal) h. Engine oil pressure signal
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ENGINE SPEED CONTROL MECHANISM
● The engine controller receives the No. 1 throttle signal (fuel control dial signal) and No. 2 throttle signal (decelerator
pedal signal) and then selects the lower command signal and controls the fuel supply pump and injector.
● 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.
● If the starting switch is set in the OFF position, the starting switch ACC signal to the engine controller is turned OFF.
● The engine controller stops supplying fuel to the engine to stop the engine.
D51EX/PX-22 10-153
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COOLING CONTROL SYSTEM
2. Battery relay 7. Work equipment and cooling fan pump 12. Hydraulic oil temperature sensor
5. Monitor panel 10. Fan EPC valve 15. Coolant temperature sensor
10-154 D51EX/PX-22
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Outline
The HST controller monitors the coolant and hydraulic oil temperatures and controls the fan speed according to those
temperatures.
Function
● The HST controller controls the oil flow to the cooling fan motor to set the fan speed properly according to the informa-
tion from the coolant and hydraulic oil temperature sensors.
● The HST controller selects the maximum target fan speed obtained from the coolant and hydraulic oil temperatures and
output it as the fan speed control signal to the fan EPC valve.
● The fan EPC valve changes the open area of the fan spool in the work equipment valve to control the oil flow to the cool-
ing fan motor.
● The HST controller monitors the actual fan speed with the fan speed sensor and controls it to the target fan speed.
While the starting switch is in the “on” position and the engine is stopped, one of the following fan rotation modes can be
selected with the fan rotation selector switch.
Fan rotation mode includes;
2. Cleaning mode
In this mode, the fan rotates in reverse at high speed to blow off dirt from the radiator fins, regardless of the temperature
sensor signals. If this mode is used periodically, the cleaning interval of the radiator fins can be expanded.
While in the “Cleaning mode”, the machine does not move for the radiator protection even if the PCCS lever is shifted to
“forward” or “reverse” position. The starting switch needs to be turned from “off” to “on” to restart the machine under the
“forward rotation mode”.
According to the selected mode, HST controller operates the reverse solenoid valve of the cooling fan motor to change the
rotation direction of the fan.
If the rotation direction of the fan is changed while the fan is rotating, the fan drive circuit is broken. To prevent this, the fan
rotation selector switch signal is ignored while the engine is running. In this case, the fan operation pilot lamp on the monitor
panel flashes for 3 seconds.
D51EX/PX-22 10-155
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HST CONTROL SYSTEM
★ HST: Abbreviation for HydroStatic Transmission
1. Battery 9. Fuel control dial potentiometer 17. RH HST pump reverse EPC valve
2. Battery relay 10. Monitor panel 18. LH HST circuit oil pressure sensor
3. Engine controller 11. Reverse travel speed setting switch 19. RH HST circuit oil pressure sensor
4. Fuse box 12. Shift mode switch 20. LH HST motor speed sensor
5. HST controller 13. Engine speed sensor 21. RH HST motor speed sensor
6. Decelerator pedal potentiometer 14. LH HST pump forward EPC valve 22. LH HST motor EPC valve
7. Brake pedal potentiometer 15. RH HST pump forward EPC valve 23. RH HST motor EPC valve
8. Electric lever (for steering) 16. LH HST pump reverse EPC valve
10-156 D51EX/PX-22
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GEAR SHIFT CONTROL SYSTEM
GEAR SHIFTING BY OPERATOR
Function
● Upon receiving the gear shift signal from the shift-up or shift-down switch of the steering/directional/gear shift lever, the
HST controller decides the capacity of the HST pump and HST motor and shift the gear.
● The operator can select the quick shift mode or the variable shift mode with the shift mode switch.
● If the steering/directional/gear shift lever is leaned forward (for forward travel), a set travel speed is decided according to
the gear speed of broken line (B) in the above graph.
● If the steering/directional/gear shift lever is leaned backward (for reverse travel), a set travel speed corresponding to the
gear speed of settings (A) – (E) of the reverse travel speed setting switch is decided according to the above graph.
● When the steering/directional/gear shift lever is in the neutral position, the set travel speed is 0 km/h.
The figure to the right shows setting of reverse travel speed (C) in the 1st
gear speed (default).
D51EX/PX-22 10-157
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SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS
★ The values of bold-face type are for the quick shift mode.
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● If the fuel control dial or decelerator pedal is operated, a deceleration command is lowered according to the deceleration
command map.
● The deceleration command of fuel control dial is higher than that of the decelerator pedal. Accordingly, even if the fuel
control dial is returned from the "FULL SPEED" position, higher output is secured.
● The deceleration command means the ratio to the set travel speed.
Example:
● When the fuel control dial is at the "FULL SPEED" position and the decelerator pedal is not pressed:
● The deceleration command is 100%, and the command travel speed is equal to the set travel speed.
● When the fuel control dial or the decelerator pedal is set in the "MEDIUM SPEED" position:
● The travel speed is limited according to the formula of Command travel speed = Deceleration command x Set travel speed
/ 100.
Example:
● When the brake pedal is pressed halfway:
● The travel speed is limited according to the formula of Command
travel speed = Brake command x Set travel speed / 100.
D51EX/PX-22 10-159
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CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED
10-160 D51EX/PX-22
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STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM
Function
● The HST controller monitors the operating conditions of each lever and each pedal and constantly controls the swash plate
angle of the HST pump, or the delivery of the HST pump, so that the output speed of the right and left HST motors will be
the same.
● While the machine is traveling straight forward, if the right HST motor speed is higher than the left HST motor speed, the
HST controller lowers the control signal of the right HST motor forward EPC valve so that the machine will always travel
straight.
● Conditions for resetting straight travel correction control system
A. The steering/directional/gear shift lever is set in the RIGHT or LEFT steering position.
B. The steering/directional/gear shift lever is set in the NEUTRAL travel direction position.
C. A pedal or the fuel control lever is operated and the travel speed sensed by the HST motor speed sensor is 0.15 km/h
or lower.
D. The HST motor speed sensor is judged defective because of disconnection, etc.
D51EX/PX-22 10-161
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PARKING BRAKE CONTROL SYSTEM
1. Battery
2. Battery relay
3. Fuse box
4. HST controller
5. Engine
6. HST pump
7. Brake pedal
8. Brake pedal potentiometer
9. Center brake proximity switch
10. Parking brake lever
11. Parking brake limit switch 1
12. Parking brake limit switch 2
13. Center brake relay
14. Slow brake solenoid valve
15. Parking brake solenoid valve
16. Towing valve
17 Brake oil pressure sensor
18. HST motor
18a. Parking brake
10-162 D51EX/PX-22
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Function
● Parking brake limit switches 1 (11) and 2 (12) are installed and connected to parking brake lever (10) so that parking brake
(18a) will be released only when parking brake lever (10) is in the FREE position.
● Center brake proximity switch (9) is installed and connected to brake pedal (7) so that slow brake solenoid valve (14) will
be de-energized and parking brake (18a) will be applied when brake pedal (7) is pressed fully.
D51EX/PX-22 10-163
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KOMTRAX SYSTEM
KOMTRAX terminal system
● The KOMTRAX terminal sends various information on the machine by a wireless communication.The KOMTRAX
operator refers to this information in the office, and various services can be provided for the customer.
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MEMORANDUM
D51EX/PX-22 10-165
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SYSTEM COMPONENTS
MONITOR PANEL
Outline
The monitor panel consists of the monitor section which outputs an alarm when the machine has any trouble and the gauge
section and display panel which display the machine condition constantly.
The monitor panel has a microcomputer, which processes and displays the signals from the sensors, solenoids, and controllers.
The items displayed on the monitor section and gauge section are shown in DISPLAY OF MONITOR PANEL.
Operation
After the operation performed when the power is turned ON, if there is any abnormal one in the check-before-starting items,
the lamp of that item flashes or the contents of the abnormality are displayed on display panel B.
Caution items
The caution items are checked constantly while the engine is running.
If any item is abnormal, it and alarm lamp flash synchronously. The alarm buzzer may sound at this time.
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Buzzer cancel switch
● 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.
● The lamp lights up and goes off at the intervals of about 0.8 seconds.
● The flashing intervals of the lamp may change a little when the temperature is low (below about –10°C). This does not
indicate a trouble.
D51EX/PX-22 10-167
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Monitor panel display
★ The following figure shows an example of display in the quick shift mode.
10-168 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
Alarm Alarm Dis-
Display
No. Display item Display range Display method lamp buzzer play Remarks
section
output output color
Below corresponding segment
1a Gauge See figure at left — — Black LCD
All light up
Coolant
Below 102°C OFF OFF OFF
temperature
1b Caution 102°C – 105°C Flashing Flashing OFF Red LED
Above 105°C Flashing Flashing ON
Below corresponding segment
2a Gauge See figure at left — — Black LCD
All light up
HST oil
Below 100°C OFF OFF OFF Red LED
temperature
2b Caution 100°C – 110°C Flashing Flashing OFF
Above 110°C Flashing Flashing ON
Below corresponding segment
3 Gauge Fuel level See figure at left — —
All light up
P: Parking brake lever in LOCK
Travel direction N: Joystick in NEUTRAL
4a
(P, N, F, R) F: Joystick in FORWARD
Indicator R: Joystick in REVERSE OFF OFF
1: Joystick gear shift switch in 1st
[*3]
4b 2: Joystick gear shift switch in 2nd
Display panel A Gear speed (1, 2, 3) 3: Joystick gear shift switch in 3rd
(Travel direction,
[*1]
gear speed, shift
4c Forward gear speed Black LCD
mode)
(See figure at left) Below corresponding segment
Gauge — —
[*1] All light up
4d Reverse gear speed
(See figure at left)
4e Variable shift mode ON — —
Pilot
4f Quick shift mode ON — —
[*2]
Character Display panel B 0 – 99999.9 h/ Time is counted while engine is running
5 — —
display (Service meter/ 0 – 9999 rpm (alternator is generating)
Engine speed)
When charge is OFF (While engine is stopped) OFF OFF
6 Charge level
defective (Below 12 V) Flashing (While engine is running) Flashing OFF
Engine oil Below specified value OFF (While engine is stopped) OFF OFF
7
pressure (49 kPa {0.5 kg/cm2}) Flashing (While engine is running) Flashing ON
Caution Red
Charge filter Above specified value OFF (While engine is stopped) OFF OFF
8
clogging (200 kPa {2.0 kg/cm2}) Flashing (While engine is running) Flashing ON
HST charge oil Below specified value OFF (While engine is stopped) OFF OFF
9
pressure (785 kPa {8.0 kg/cm2}) Flashing (While engine is running) Flashing ON
10 Pilot Preheating In preheating mode ON OFF OFF Green
Before 30 h or more OFF
11 Maintenance Before 30 h – Replace- ON for 30 seconds after starting switch is OFF OFF Red
ment time turned ON LED
12 Warning lamp See the “warning lamp output” column of this table — — Red
Air cleaner Below specified value
13 Flashing OFF OFF Red
clogging (–7.47 kPa)
When fan speed selec-
Caution
tor switch is operated Flashing (several times)
Fan operation while engine is running
14 OFF OFF Orange
check In fan cleaning
ON
(reverse) mode
In fan forward mode OFF
Coolant level in When coolant level in
15 Flashing OFF OFF Red
fuel filter water separator rises
D51EX/PX-22 10-169
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ENGINE CONTROLLER
CN-CE01 CN-CE01
Input/
Pin No. Signal name Pin No. Signal name Title panel
output
1 Electric power supply for lift pump 18 NC(*)
2 Electric power supply for IMA 19 NC(*)
3 Atmosphere sensor 20 NC(*)
4 NC(*) 21 NC(*)
5 NC(*) 22 Engine brake drive D
6 CAN(ñ) 23 Boost temperature sensor B
7 NC(*) 24 NC(*)
8 CAN(+) 25 Common rail pressure sensor B
9 NC(*) 26 G sensor (+) B
10 NC(*) 27 NE sensor (+) B
11 Lift pump return 28 Engine brake return
12 NC(*) 29 NC(*)
13 NC(*) 30 NC(*)
14 NC(*) 31 NC(*) D
15 Coolant temperature sensor 32 IMA return C
16 5V electric power supply for sensor 33 5V electric power supply for sensor
17 Oil pressure switch 34 NC(*)
*: Never connect to NC or malfunctions or failures will occur. *: Never connect to NC or malfunctions or failures will occur.
10-170 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
CN-CE01 CN-CE02
Pin No. Signal name Title panel Pin No. Signal name Input/output
35 NC(*) A 20 NC(*)
36 NC(*) 21 NC(*)
37 5V electric power supply for sensor A 22 Fuel control dial (+5V)
38 GND C 23 Fuel control dial (ñ)
39 NC(*) 24 NC(*)
40 NC(*) 25 NC(*)
41 NC(*) 26 NC(*)
42 NC(*) C 27 NC(*)
43 NC(*) 28 NC(*)
44 Boost pressure sensor B 29 NC(*)
45 Injector #1 (+) D 30 NC(*)
46 Injector #5 (+) D 31 NC(*)
47 G sensor (ñ) C 32 NC(*)
48 Ne sensor (ñ) C 33 GND
49 NC(*) 34 NC(*)
50 NC(*) 35 NC(*)
51 Injector #2 (ñ) C 36 NC(*)
52 Injector #3 (ñ) C 37 NC(*)
53 Injector #1 (ñ) C 38 NC(*)
54 Injector #2 (+) D 39 Key switch (ACC)
55 Injector #3 (+) D 40 Electrical intake air heater relay drive
56 Injector #4 (+) D 41 NC(*)
57 Injector #6 (+) D 42 Electrical intake air heater relay return
58 Injector #4 (ñ) C 43 NC(*)
59 Injector #6 (ñ) C 44 NC(*)
60 Injector #5 (ñ) C 45 NC(*)
*: Never connect to NC or malfunctions or failures will occur. 46 CAN(+)
47 CAN(ñ)
CN-CE02 48 NC(*)
Pin No. Signal name Input/output 49 PWM OUTPUT
1 NC(*) 50 NC(*)
2 NC(*) *: Never connect to NC or malfunctions or failures will occur.
3 NC(*)
4 NC(*) CN-CE03
5 NC(*) Pin No. Signal name Input/output
6 NC(*) 1 GND
7 NC(*) 2 NC(*)
8 NC(*) 3 Electric power supply (+24V constantly)
9 Fuel control dial (+) 4 NC(*)
10 NC(*) *: Never connect to NC or malfunctions or failures will occur.
11 NC(*)
12 NC(*)
13 NC(*)
14 NC(*)
15 NC(*)
16 NC(*)
17 NC(*)
18 NC(*)
19 NC(*)
*: Never connect to NC or malfunctions or failures will occur.
D51EX/PX-22 10-171
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
HST CONTROLLER
10-172 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
Input and output signals
DEUTSCH-24P [CN-ST1] DEUTSCH-40P (1) [CN-ST2] DEUTSCH-40P (2) [CN-ST3]
Pin Input/Output Pin Input/Output Pin Input/Output
Signal name Signal name Signal name
No. signal No. signal No. signal
1 Joystick position FR4 Input 1 NC — Power source
1 Input
Fuel control dial 2 NC — (Controller)
2 Input
potentiometer 3 NC — 2 Power source (Solenoid) Input
Brake pedal 4 NC — GND
3 Input 3 —
potentiometer Parking brake limit (Solenoid, common)
5 Input
4 GND (Signal) — switch 1 (NC) 4 For driving battery relay Output
Charge filter clogging 6 NC — Left HST pump forward
5 Input 5 Output
sensor 7 Fan forward switch Input EPC valve
6 NC — 8 Neutral safety relay Output Left HST pump reverse
6 Output
7 Joystick position ST2 Input 9 NC — EPC valve
Brake oil pressure 10 Fan speed sensor Input 7 Fan reverse solenoid Output
8 Input
sensor 11 NC — 8 NC —
HST oil temperature 12 NC — Parking brake limit
9 Input 9 Input
sensor 13 Immobilize signal Input switch 2 (NO)
10 GND (Signal) — 14 NC — 10 Key cylinder C signal Input
11 NC — Parking brake limit Power source
15 Input 11 Input
12 Shift-up switch (NC) Input switch 1 (NO) (Controller)
13 Joystick position FR3 Input 16 NC — 12 Power source (Solenoid) Input
L.H. HST circuit oil Fan cleaning reverse GND
14 Input 17 Input 13 —
pressure sensor switch (Solenoid, common)
15 Alternator (R) Input 18 NC — 14 Starting switch (ACC) Input
16 NC — 19 NC — Right HST motor
15 Output
17 NC — L.H. HST motor speed forward EPC valve
20 Input
18 Shift-down switch (NO) Input sensor Right HST motor
16 Output
19 Joystick position ST1 Input 21 NC — reverse EPC valve
R.H. HST circuit oil 22 CAN0 (L) Input/Output 17 NC —
20 Input
pressure sensor 23 NC — 18 Back-up alarm Output
21 GND (Analog) — Flash ROM write 19 NC —
24 Input
Sensor power source permission signal 20 NC —
22 Output
(+5 V) Reverse travel speed 21 GND (Power source) —
25 Input
23 Shift-up switch (NO) Input setting switch (Up) 22 Power source (Solenoid) Input
24 Shift-down switch (NC) Input 26 NC — GND
23 —
Mode selector switch (Solenoid, common)
27 Input
(VARIABLE) 24 Starting switch (ACC) Input
28 NC — 25 Fan control EPC Output
29 GND (Pulse) — Left HST motor EPC
26 Output
R.H. HST motor speed valve
30 Input
sensor Parking brake solenoid
27 Output
31 GND (Communication) — valve
32 CAN0 (H) Input/Output 28 NC —
33 NC — 29 NC —
34 GND (Communication) — 30 NC —
Reverse travel speed 31 GND (Power source) —
35 Input
setting switch (Down) 32 GND (Power source) —
36 NC — 33 GND (Power source) —
Mode selector switch Sensor power source 1
37 Input 34 Output
(QUICK) (+5V)
38 NC — 35 NC —
39 GND (Pulse) — Right HST motor EPC
36 Output
40 NC — valve
Slow brake solenoid
37 Output
valve
38 NC —
39 NC —
40 NC —
D51EX/PX-22 10-173
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ELECTRIC LEVER (FOR TRAVEL)
★ Do not disassemble the electric lever. If it is disassembled, the output voltage characteristics and operating effort
characteristics will need to be adjusted.
10-174 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
D51EX/PX-22 10-175
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
KOMTRAX TERMINAL
Outline
● The KOMTRAX controller can send information via wireless communication antenna, acquiring various information of
the machine from the network signal in the machine and the input signal. Also, the controller incorporates CPU (Central
Processing Unit) and provide the wireless communication function and the GPS function.
● There are the LED lamp and the 7-segment indicator lamp in the display area, and these lamps are used for the testing and
the troubleshooting.
● The information of the LED lamp and the 7-segment indicator lamp can be checked on the monitor panel by EMMS.
10-176 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
SENSORS
The signals from the sensors are input through the controllers to the monitor panel.
Category of When
Sensor method When normal
display abnormal
D51EX/PX-22 10-177
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
BRAKE OIL PRESSURE SENSOR
(HST charge oil pressure sensor)
A. Sensor
B. Connector
Function
This sensor is installed to the parking brake solenoid valve piping. It senses
the changes of the brake circuit pressure as the changes of voltage with the
semiconductor in it, and then generates signals according to the measured
pressure.
Operation
● The oil pressure is applied to the diaphragm of the oil pressure sensor
from the pressure intake part, the diaphragm is deformed.
● The deformation in the diaphragm causes the resistance of the gauge
to change. This causes a change in the output voltage, which is
transmitted to the amplifier (voltage amplifier).
10-178 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
HYDRAULIC OIL TEMPERATURE SENSOR
1. Thermistor
2. Plug
3. Connector
Function
This sensor is installed to the pump suction piping. It senses the changes of the temperature as the changes of the resistance of
thermistor in it, and then generates signals according to the measured temperature.
D51EX/PX-22 10-179
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
HST CIRCUIT OIL PRESSURE SENSOR
1. Sensor
2. Connector
Function
This sensor is installed to the HST pump. It senses the changes of the right and left HST circuit pressures as the changes of
voltage with the semiconductor in it, and then generates signals according to the measured pressure.
Operation
The relationship between the pressure applied to sensor (P) and output
voltage (E).
10-180 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
AIR CLEANER CLOGGING SENSOR
1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector
D51EX/PX-22 10-181
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
DECELERATOR PEDAL POTENTIOMETER
BRAKE PEDAL POTENTIOMETER
1. Potentiometer
2. Connector
Function
● The potentiometer is connected to the decelerator pedal, brake pedal,
and fuel control lever and its shaft is rotated according to the operating
angle of the pedal and lever.
● The movement of the shaft operates the internal variable resistor,
which generates a signal voltage by changing the source voltage of 5
V according to the operating angle.
10-182 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
FUEL CONTROL DIAL
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
● The fuel control dial is installed to the left side of the operator's seat.
● If knob (1) is turned, the shaft of potentiometer (5) is turned to change
the resistance of the variable resistor and send a throttle signal to the
engine controller.
● The hatched areas in the following graph is the abnormality detection
areas. In those areas, the engine speed is reduced to a half.
D51EX/PX-22 10-183
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
FUEL LEVEL SENSOR
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
The fuel level sensor is installed to the side of the fuel tank. Its float moves up and down according to the fuel level.
The movement of the float operates the variable resistor through the arm. As a result, signals of change in resistance are
generated.
10-184 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
CHARGE FILTER CLOGGING SENSOR
Function
The charge filter clogging sensor is installed to the charge filter and its contact senses the pressures before and after the filter.
If the difference between those pressures exceeds the set level, the switch is turned ON.
1. Sensor
2. O-ring
3. Connector
D51EX/PX-22 10-185
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ENGINE OIL PRESSURE SWITCH
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
10-186 D51EX/PX-22
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
BOOST PRESSURE AND TEMPERATURE SENSOR
1. Connector
2. Sensor
3. O-ring
WIF SENSOR
(WATER-IN-FUEL)
1. Connector
2. Tube
3. Sensor
4. O-ring
D51EX/PX-22 10-187
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
HST MOTOR SPEED SENSOR
See HST motor, this section page 10-70.
10-188 D51EX/PX-22
20 STANDARD VALUE TABLES
★ Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from the
factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has
been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of
various tests. It is used for reference together with the state of repair and the history of operation to judge if there
is a failure.
3. These standard values are not the standards used in dealing with claims.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on
level ground, insert the safety pins, and use blocks to prevent the machine from
moving.
WARNING! When carrying out work together with other workers, always use signals and do
not let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
D51EX/PX-22 20-1
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR ENGINE
12
STANDARD VALUE TABLE FOR ENGINE
20-2 D51EX/PX-22
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS
N → Forward/Reverse 29 ± 6 29 ± 6
reverse ● Center of lever grip
● Engine: Stopped
Steering N - Sharp turn to right/left 50 ± 10 50 ± 10
● Center of lever knob
● Engine: stopped 1st stage 52 ±10 52 ±10
Brake pedal
● Center of pedal 2nd stage 75 ± 10 75 ± 10
mm
Stroke
● Engine: Stopped
Decelerator pedal 50 ±10 50 ±10
● Center of pedal
Neutral - Raise 47 ± 10 47 ± 20
● Engine: Stopped Neutral - Lower 46 ± 10 46 ± 20
Work equipment ● Center of lever knob
Neutral - Float 71 ± 10 71 ± 20
control lever ● Angle: Twisting angle of
lever Neutral - Left/Right tilt 52 ± 10 52 ± 20
Neutral - Left/Right angle ° 15 ± 3 15 ± 6
Forward and 55.9 ±9.8 55.9 ±11.8
N - Forward/Reverse
reverse (5.7 ±1.0) (5.7 ±1.2)
PCCS lever
D51EX/PX-22 20-3
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
Machine model D51EX-22, D51PX-22
Serial No. B10001 and up
Cate- Standard
Item Measurement conditions Unit value for new Service limit value
gory machine
● Engine: Stopped 70 ± 14 9.8
Decelerator pedal
● Center of pedal (7.1 ±1.4 (10)
22.5 ± 10 39.2
Neutral - Raise
(2.3 ± 1.0) (4.0)
Operating effort
N 25.5 ± 10 39.2
Neutral - Lower (kg) (2.6 ± 1.0) (4.0)
Work equipment ● Engine: Low idling 70 ± 22 118
Neutral - Float
control lever ● Center of lever knob (7.1 ± 2.2) (12.0)
25.5 ± 10 39.2
Neutral - Left/Right tilt
(2.6 ± 1.0) (4.0)
Neutral - Left/Right Nm 2.9 - 5.4 8.3
angle (kgm) (0.3 - 0.55) (0.9)
● Engine: High idling Forward - Left 40.2 - 44.1 39.2 - 45.1
(410 - 450) (400 - 460)
● HST oil temperature
(hydraulic oil 40.2 - 44.1 39.2 - 45.1
Forward - Right
Main circuit temperature): Within (410 - 450) (400 - 460)
pressure operating range (40 - 40.2 - 44.1 39.2 - 45.1
60°C) Reverse - Left (410 - 450) (400 - 460)
HST oil pressure
20-4 D51EX/PX-22
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
Machine model D51EX-22, D51PX-22
Serial No. B10001 and up
Cate- Standard
Item Measurement conditions Unit value for new Service limit value
gory machine
● Engine: High idling 1st 3.4 ± 0.2 3.4 ± 0.4
● Quick shift mode Forward 2nd 5.6 ± 0.3 5.6 ± 0.6
● Reverse travel speed: Set to
3rd 9.0 ± 0.5 9.0 ± 0.8
center
● HST oil temperature 1st 4.1 ± 0.2 4.1 ± 0.4
(hydraulic oil temperature): 2nd 6.5 ± 0.3 6.5 ± 0.6
Within operating range (40 - Reverse
60°C)
3rd 9.0 ± 0.5 9.0 ± 0.8
● Measure on flat place.
Travel speed km/h
● Engine: High idling MIN 0.8 ±0.2 0.8 ±0.3
● Variable shift mode Forward
MAX 8.5 ± 0.5 8.5 ± 0.8
● Reverse travel speed: Set to
center MIN 0.8 ±0.2 0.8 ±0.3
● HST oil temperature
(hydraulic oil temperature): Reverse
Within operating range (40 - MAX 9.0 ± 0.5 9.0 ± 0.8
60°C)
● Measure on flat place.
HST
D51EX/PX-22 20-5
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
Machine model D51EX-22, D51PX-22
Serial No. B10001 and up
Cate- Standard
Item Measurement conditions Unit value for new Service limit value
gory machine
● HST oil temperature
● (hydraulic oil temperature):
Raise 2.5 ± 0.2 3.0
● Within operating range(40 -
Blade lifting 60°C)
speed ● Between max. lifting height
● and ground
Lower 1.9 ± 0.2 2.3
● For measuring posture, see
"Work equipment 1".
● Engine: High idling
Work equipment speed
20-6 D51EX/PX-22
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
D51EX/PX-22 20-7
STANDARD VALUE TABLES PERFORMANCE MEASURING POSTURE AND METHOD
12
PERFORMANCE MEASURING POSTURE AND METHOD
Travel 1: Travel deviation
20-8 D51EX/PX-22
STANDARD VALUE TABLES PERFORMANCE MEASURING POSTURE AND METHOD
12
Work equipment 3: Blade angling speed
D51EX/PX-22 20-9
STANDARD VALUE TABLES PERFORMANCE MEASURING POSTURE AND METHOD
12
MEMORANDUM
20-10 D51EX/PX-22
30 TESTING AND ADJUSTING
D51EX/PX-22 30-1
TESTING AND ADJUSTING
ITEMS TO BE ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
PM-CLINIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
PM-CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
PM-CLINC INSPECTION SHEET (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136
PM-CLINC INSPECTION SHEET (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
PM-CLINC UNDERCARRIAGE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
UNDERCARRIAGE TROUBLESHOOTINF REPORT (IMPACT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140
30-2 D51EX/PX-22
TESTING AND ADJUSTING LIST OF TOOLS
12
LIST OF TOOLS
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
-101 - 200 kPa
Measuring intake air pressure 799-201-2202 Boost gauge kit 1
A (-760 - 1,500 Hg)
(boost pressure)
799-401-2220 Hose 1 I-coupler type (if necessary)
Measuring exhaust
B 799-101-1502 Digital thermometer 1 -99.9 - 1,299°C
temperature
Handy smoke
1 799-201-9001 1
checker
Measuring exhaust gas color C Bosch index: 0 - 9
Commercially
2 Smoke meter 1
available
1 795-799-1131 Gear 1 For 107 Series engine
Adjusting valve clearance D Commercially
2 Feeler gauge 1
available
1 795-502-1590 Compression gauge 1
D51EX/PX-22 30-3
TESTING AND ADJUSTING LIST OF TOOLS
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
799-101-5002 Hydraulic tester 1
1 Digital hydraulic ❈ Same as G1
790-261-1203 1
tester
Measuring motor control 799-401-3100 Adapter 1 Size: 02
K
valve output pressure for HST 2
799-401-3200 Adapter 1 Size: 03
799-101-5230 Nipple 1
3 Size: 14 x 1.5 mm
07002-11423 O-ring 1
1 790-190-1500 Pump assembly 1 ---
Method of releasing parking
brake (Procedure for M 799-101-5220 Nipple 4
emergency escape) 2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
30-4 D51EX/PX-22
TESTING AND ADJUSTING LIST OF TOOLS
12
MEMORANDUM
D51EX/PX-22 30-5
TESTING AND ADJUSTING ENGINE
12
ENGINE
ENGINE SPEED
★ Measure the engine speed under the following condition.
• Engine coolant temperature: Within operating range
• HST oil (Hydraulic oil) temperature: Within operating range (40 – 60°C)
1. Preparation work
Turn the starting switch ON and set the monitor panel in the "Real-time monitoring mode" to prepare for measurement of
the engine speed.
★ For the operating method, see "Special functions of monitor panel
(EMMS)".
• Controller: ENGINE
• Monitoring code: 01002-ENG SPEED
• The engine speed is displayed in rpm.
30-6 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
AIR INTAKE BOOST PRESSURE
2. Install nipple (1) of boost gauge kit A and connect it to gauge [2].
3. Run the engine at the rated output and test the air boost pressure.
• When testing with the engine mounted on the machine, test on the
condition described in the shop manual for the machine.
4. After finishing testing, remove the measuring tools and return the
removed parts.
D51EX/PX-22 30-7
TESTING AND ADJUSTING ENGINE
12
EXHAUST TEMPERATURE
1. Open the right engine side cover and remove exhaust temperature pickup plug (1) from the exhaust pipe.
30-8 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
C. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and measure the
exhaust temperature.
★ If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST
stops.
D51EX/PX-22 30-9
TESTING AND ADJUSTING ENGINE
12
EXHAUST GAS COLOR
★ If an air source and an electric power source are not available in the field, use handy smoke checker C1. When recording
official data, use smoke meter C2.
★ Measure the exhaust gas color under the following condition.
• Engine coolant temperature: Within operating range
30-10 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
VALVE CLEARANCE
1. Remove cylinder head cover (1).
2. Remove cap (2) from flywheel housing and install barring tool D1.
3. Rotate the crankshaft forward using barring tool D1 until the stamped
“1.6TOP” line (a) of the crankshaft pulley faces upward and set the
No. 1 cylinder to the compression top dead center.
★ When the No. 1 cylinder is at the compression top dead center, the
rocker arm of the No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm cannot be moved, rotate
the crankshaft one more turn. (Alternatively, adjust the valve
clearance indicated by ❍ of the valve layout plan in the next
section without rotating the crankshaft.)
D51EX/PX-22 30-11
TESTING AND ADJUSTING ENGINE
12
4. Adjust the valve clearance of No. 1 cylinder according to the
following procedure.
★ When the No. 1 cylinder is at the compression top dead center, the
valve clearance indicated by ● of the valve layout plan can be
adjusted.
• Valve layout plan
A. Insert clearance gauge D2 into the clearance between rocker arm
(3) and crosshead (4).
B. Loosen locknut (5) and adjust valve clearance using adjustment
screw (6).
★ With the filler gauge inserted, turn the adjustment screw to a
degree that you can move the filler gauge lightly.
C. Fix adjustment screw (6) and tighten locknut (5). 3Locknut:
30-12 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
MEMORANDUM
D51EX/PX-22 30-13
TESTING AND ADJUSTING ENGINE
12
COMPRESSION PRESSURE
1. Remove the engine hood and remove cylinder head cover (1).
★ Since the breather connector on the rear side of the cylinder head
cover is connected to the flywheel housing through the O-ring,
pull it together with the cylinder head cover.
2. Remove the mounting bolts of rocker arm assembly (2) on the exhaust
side, and then remove rocker arm assembly (2).
★ When removing the injector, you do not need to remove the
rocker arm assembly on the intake side.
3. Remove fuel tube (3), and then remove inlet connector (7) in the
cylinder head.
★ The inlet connector is connecting the fuel tube to the injector.
5. Install adapter E3 to the injector mounting part with the injector clamp
and connect compression gauge E1.
★ Install the gasket to the adapter end without fail.
6. Install rocker arm assembly (2) on the exhaust side and adjust the
valve clearance.
★ See “Adjusting valve clearance”.
30-14 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
7. Disconnect CN-117 connector (5) of the engine controller.
8. Rotate the engine with the starting motor and measure the
compression pressure.
★ Read the gauge when the pointer is stabilized.
★ Tighten the bolts and nuts other than the injector and inlet connector to the following torque.
★ Adjust the valve clearance. For details, see “Adjusting valve clearance”.
D51EX/PX-22 30-15
TESTING AND ADJUSTING ENGINE
12
BLOW-BY PRESSURE
★ Measure the blow-by pressure under the following condition.
• Engine coolant temperature: Within operating range
• HST oil (Hydraulic oil) temperature: Within operating range (40 -
60°C)
1. Open the left engine side cover and pull out blow-by hose (1).
2. Install nozzle tool F2 to blow-by hose (1) and connect it to gauge [1]
of blow-by checker F1.
3. Turn the starting switch ON, set the monitor panel in the "Adjustment
mode", and prepare for stalling the HST.
★ When performing this operation, set the parking brake lever in the
LOCK position and the PCCS lever in the neutral position.
★ For the operating method, see "Special functions of monitor panel
(EMMS)".
★ Adjustment code: 3016-STALL CHECK
4. While keeping the parking brake lever in the LOCK position, set the
work equipment lock lever in the FREE position and raise the blade to
the stroke end.
★ Stall the HST with the parking brake lever in the LOCK position.
5. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and relieve the blade
circuit by raising the blade, and then measure the blow-by pressure.
★ If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST
stops.
30-16 D51EX/PX-22
TESTING AND ADJUSTING ENGINE
12
ENGINE OIL PRESSURE
1. Remove right engine side covers.
4. Connect the hose of the hydraulic tester G1 to the nipples and gauge
G4.
5. Run the engine at the rated output and low idle and test the oil
pressure.
★ When testing with the engine mounted on the machine, test on the
condition described in the shop manual for the machine.
6. After finishing testing, remove the measuring tools and return the
removed parts.
D51EX/PX-22 30-17
TESTING AND ADJUSTING HANDLING CONTROLLER HIGH-VOLTAGE
12
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT
2. When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting switch OFF.
3. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start
the engine.
★ You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
30-18 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL SYSTEM
WARNING! Before checking the fuel system or removing its parts, wait at least 30 seconds after
stopping the engine until the residual pressure in the fuel circuit is released. (Do not start
the work just after stopping the engine since there is residual pressure.)
D51EX/PX-22 30-19
TESTING AND ADJUSTING FUEL SYSTEM
12
BLEEDING AIR FROM FUEL CIRCUIT
★ If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following
procedure.
Remark
Item 2 is the water separator.
3. Loosen knob (1) of the feed pump and pull it out, and then operate it
forward and backward.
★ Move the knob until it becomes stiff.
★ The plug at the top of the fuel main filter does not need to be
removed.
30-20 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
★ Air bleeding route of fuel circuit
Fuel tank ➡ Pre-filter ➡ Feed pump ➡ Main filter ➡ Metering unit ➡ Fuel tank
D51EX/PX-22 30-21
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL PRESSURE
WARNING! Stop the machine on a level ground and lower the work equipment to the ground.
★ Measure only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply
pump and the return circuit from the supply pump/common rail/injector to fuel tank.
WARNING! Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it cannot be measured.
30-22 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
2. Measuring pressure in fuel return circuit.
A. Disconnect the fuel return elbow (2) from the check valve at the
rear of the head.
B. Install adapter [F4] between fuel return hose and check valve.
C. Install nipple [1] of hydraulic tester F1 and connect to pressure
gauge.
Nipple [3]: . . . . . . . . . . . . . . . . . . . . . . 790-301-1181, 07002-11223
D. Run the engine at low idle and measure the pressure in the fuel
return circuit.
★ If the pressure in the fuel return circuit is in the following
range, it is normal.
E. After finishing measurement, remove the measuring tools and return the removed parts.
D51EX/PX-22 30-23
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL RETURN RATE AND LEAKAGE
★ Since some fuel flows out during check, prepare an oil (receiving) pan of about 20 liters.
B. Install connector I3 and cap nut [1] of tester kit I1 to the return
hose to stop the fuel from flowing out.
C. Connect test hose [2] of tester kit I1 to the supply pump.
★ Lay the test hose so that it will not slacken and put its end in
the oil (receiving) pan.
D. Run the engine at low idle and measure the return rate in 1 minute
with measuring cylinder I4.
★ If the return rate from the supply pump is in the following
range, it is normal.
At low idle 1,000 cc/min
During cranking 140 cc/min
E. After finishing measurement, remove the measuring tools and return the removed parts.
★ When measuring the leakage from the pressure limiter or finishing the measurement: Return the removed parts to
their original positions.
★ When measuring the leakage from the injector: Leave the removed parts as they are and keep the hose end in the
oil pan.
30-24 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
2. Measuring leakage from pressure limiter.
A. Open the engine hood and disconnect return hose (2) of the
pressure limiter.
★ Install the seal washer to the connector bolt.
B. Install removed connector bolt -3 and cap nut [I1] of tester kit I1
to the return hose to stop the fuel from flowing out.
C. Install connector I3 to the common rail and connect test hose [2]
of tester kit I1.
★ Lay the test hose so that it will not slacken and put its end in
the oil (receiving) pan.
D. Run the engine at low idle and measure the return rate in 1 minute
with measuring cylinder I4.
★ If the leakage from the pressure limiter is in the following
range, it is normal.
WARNING! The fuel returning from the supply pump flows out during measurement of the return rate
from the injector. Accordingly, keep the test hose end in the oil pan.
D51EX/PX-22 30-25
TESTING AND ADJUSTING FUEL SYSTEM
B. Disconnect return hose (4) of the return block.
★ Install the seal washer to the return hose.
D. Run the engine at low idle and measure the return rate in 1 minute
with measuring cylinder I4.
★ If the return rate from the injector is in the following range, it
is normal.
At low idle 180 cc/min
During cranking 90 cc/min
E. After finishing measurement, remove the measuring tools and return the removed parts.
30-26 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL CIRCUIT FOR LEAKAGE
WARNING! Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After checking the fuel system or removing its parts, check it for fuel leakage according to
the following procedure.
WARNING! Stop the machine on a level ground and lower the work equipment to the ground.
★ Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage.
1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure
piping.
2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
D51EX/PX-22 30-27
TESTING AND ADJUSTING FAN (WORK EQUIPMENT) PUMP PRES-
12
FAN (WORK EQUIPMENT) PUMP PRESSURE
Remark
If the HST oil temperature is below 45°C and the engine coolant temperature is below 60°C, the fan EPC
command current is set to 1,000 mA and the fan speed lowers below 200 rpm even in the fan 100% mode.
In this case, increase the oil temperature to above 55°C and the coolant temperature to above 65°C and
then check again.
• HST oil (Hydraulic oil) temperature: 50 - 60°C.
FAN SPEED
MEASURING FAN SPEED
Remark
If the HST oil temperature is below 45°C and the engine coolant temperature is below 60°C, the fan EPC
command current is set to 1,000 mA and the fan speed lowers below 200 rpm even in the fan 100% mode.
In this case, increase the oil temperature to above 55°C and the coolant temperature to above 65°C and
then check again.
★ Measure the fan speed under the following conditions.
• HST oil (Hydraulic oil) temperature: 50 - 60°C.
1. Preparation work
★ Measure the fan speed in the "Fan 100% mode".
A. Turn the starting switch ON and set monitor panel in the "Tuning mode" and select the "Fan 100% mode".
★ For operation method, see "Special functions of monitor panel (EMMS)".
• Tuning code: 3022 FAN MODE
B. Set monitor panel in the: Real time monitoring mode" to prepare
for measurement of the fan speed.
★ For operation method, see "Special functions of monitor
panel (EMMS)".
• Controller: HST
• Monitor code: 10007 FAN SPEED
• The fan speed is displayed in rpm.
30-28 D51EX/PX-22
TESTING AND ADJUSTING FAN SPEED
12
FAN SPEED SENSOR
ADJUSTING
★ If the fan speed sensor has been removed and installed or its signal
contains an error, adjust it according to the following procedure.
★ Remove fan speed sensor (1) before adjusting it and check that its tip
is free from steel chips.
The fan speed sensor is installed to the left top of the fan motor.
To install sensor:
4. If sensor wire lies in "Zone A" after adjustment, rotate sensor counterclockwise until wire is in the "Required position
range".
5. If sensor wire lies in "Zone B" after adjustment, rotate sensor clockwise until wire is in the "Required position range".
D51EX/PX-22 30-29
TESTING AND ADJUSTING FAN SPEED
6. If sensor wire lies in "Zone C" after adjustment, no further rotation is required.
7. After finishing adjustment, check that the monitor panel displays the fan speed normally in the "Real-time monitoring
mode".
★ For the operating method, see "Special functions of the monitor panel (EMMS)".
• Controller: HST
• Monitoring code: 10007-FAN SPEED
30-30 D51EX/PX-22
TESTING AND ADJUSTING DECELERATOR PEDAL
12
DECELERATOR PEDAL
ADJUSTING
★ When adjusting the decelerator pedal, remove the dashboard cover, dashboard undercover and pedal assembly.
Place the removed pedal assembly on the floor and connect the wiring harness connector between floor and pedal.
D51EX/PX-22 30-31
TESTING AND ADJUSTING DECELERATOR PEDAL
12
2. Measuring decelerator pedal pressing effort
A. Press the decelerator pedal with the foot to check that it operates smoothly.
B. If the decelerator pedal does not operate smoothly, supply grease through grease fitting (4) and apply grease to spring
(5).
Grease fitting (4): . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease (G2-LI)
Spring (5): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease (G2-LI)
C. Using push-pull scale, measure the full-stroke pressing effort of the decelerator pedal.
Full-stroke pressing effort: . . . . . . . . . . . . . . . . . . . . . 71 N {7.3 kg}
Decelerator pedal
Decelerator pedal
operating degree
Released 100%
Pressed (Fully) 0%
30-32 D51EX/PX-22
TESTING AND ADJUSTING HST OIL PRESSURE
12
HST OIL PRESSURE
MEASURING
WARNING! If the HST is stalled while the bypass valve (tow valve) of the parking brake circuit is
closed, the HST equipment may be damaged or it may move beyond your expectations.
Accordingly, do not stall the HST out of the "Tuning mode".
A. Turn the starting switch ON, set the monitor panel in the "Tuning mode", and prepare for stalling the HST.
• When performing this operation, set the parking brake lever in the LOCK position and the PCCS lever in the
neutral position.
• For the operating method, see "Special functions of monitor panel (EMMS)".
• Tuning code: 3016-STALL CHECK
• If the HST main circuit pressure is selected in the tuning
mode, it is displayed in 0.1 MPa.
(The figure shows the item displayed first (engine speed)
when the mode is selected.)
B. Start the engine and keep the parking brake lever in the LOCK
position.
• Stall the HST with the parking brake lever in the LOCK
position.
C. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and measure the HST
main circuit pressure.
• If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST stops.
WARNING! While the HST is stalled, the oil temperature rises sharply and locally. Accordingly, do not
stall the HST continuously for more than 30 seconds.
WARNING! The HST charge circuit pressure needs to be measured while the machine is stopped
and while the machine is actually traveling. Accordingly, measure it on a level ground
where there are no obstacles.
i. Turn the starting switch ON and display the "Real-time monitoring mode" on the monitor panel to prepare for
measuring the brake pressure.
• For the operating method, see "Special functions of monitor panel (EMMS)".
• Controller: HST
• Monitoring code: 91902-BRAKE PRESS
D51EX/PX-22 30-33
TESTING AND ADJUSTING HST OIL PRESSURE
12 • The brake pressure is displayed in 0.01 MPa.
ii. Start the engine and set the parking brake lever in the FREE
position.
iii. While running the engine at high idle, measure the brake
pressure with the PCCS lever in the neutral position and in
the forward or reverse position.
• While the machine is stopped, only the charge safety valve
on the oil cooler bypass valve side operates. While the
machine is traveling, the charge relief valve on the HST
motor side operates, also.
B. When measuring the HST charge circuit pressure directly for troubleshooting of the brake pressure sensor, parking
brake solenoid or slow brake solenoid, apply the following method.
WARNING! The HST charge circuit pressure needs to be measured while the machine is stopped
and while the machine is traveling actually. Accordingly, measure it on a level ground
where there are no obstacles.
WARNING! Loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the
tank.
WARNING! Turn the starting switch ON, set the work equipment lock lever in the FREE position, and
lower the blade to the ground. Move the work equipment control lever until it is not held in
the FLOAT position to release the residual pressure in the accumulator. After the residual
pressure is released, set the work equipment lock lever in the LOCK position and turn
starting switch OFF.
30-34 D51EX/PX-22
TESTING AND ADJUSTING HST OIL PRESSURE
ii. Install nipple [1] of hydraulic tester J1 and connect it to oil
pressure gauge [2].
• Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}.
iii. Start the engine and set the parking brake lever in the FREE
position.
iv. While running the engine at high idle, measure the HST
charge circuit pressure with the PCCS lever in the neutral
position and in the forward or reverse position.
WARNING! Since the machine will be stopped and driven actually to measure the EPC valve output
pressure, work on a flat place where there is not an obstacle.
WARNING! Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure in the
hydraulic tank.
A. Remove the cover at the floor, and then remove EPC valve output
pressure pickup plugs (2) – (5) at the top of the HST pump.
Plug (2): For left forward EPC valve
Plug (3): For left reverse EPC valve
Plug (4): For right forward EPC valve
Plug (5): For right reverse EPC valve
D51EX/PX-22 30-35
TESTING AND ADJUSTING HST OIL PRESSURE
After finishing measurement, remove the measuring instruments and return the removed parts.
ADJUSTING
★ The HST main circuit pressure and the HST pump EPC valve output
pressure cannot be adjusted.
1. Adjusting HST charge circuit pressure (on oil cooler bypass valve
side)
★ If the HST charge circuit pressure (only when the HST is in
neutral) is abnormal, adjust charge safety valve (6) of the oil
cooler bypass valve according to the following procedure.
★ When adjusting charge safety valve (6) of the oil cooler bypass
valve, remove the cooling core undercover.
30-36 D51EX/PX-22
TESTING AND ADJUSTING HST OIL PRESSURE
12
2. Adjusting HST charge circuit pressure (on motor side)
★ If the HST charge circuit pressure (only when traveling) is
abnormal, adjust charge relief valve (9) of the HST motor
according to the following procedure.
★ When adjusting charge relief valve (9) of the HST pump, remove
the HST motor covers (right and left).
D51EX/PX-22 30-37
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-
12
MOTOR CONTROL VALVE OUTLET PRESSURE
★ Measure the solenoid valve outlet pressure under the following
condition.
• HST oil (Hydraulic oil) temperature: Within operating range (40 –
60°C)
1. Preparation work
★ If the pressures in the parking brake solenoid valve and slow
brake solenoid valve are not measured simultaneously, the
operation cannot be checked.
30-38 D51EX/PX-22
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-
★ For the operating method, see "Special functions of monitor
panel (EMMS)".
• Controller: HST
• Monitoring code: 91902-BRAKE PRESS
2. Measuring Right HST motor EPC valve and Left HST motor EPC
valve
WARNING! Since the machine will be stopped and driven actually to measure the right HST motor
EPC valve and left HST motor EPC valves, work on a flat place where there is no
obstacles.
A. Start the engine and set the travel mode in the quick shift mode, then set the reverse speed setting "B".
B. While running the engine at high idle, change the travel speed and measure the solenoid valve output pressure.
★ If the output pressure is as shown in Table 1, the solenoid valve is normal.
C. After finishing measurement, remove the measuring instruments and return the removed parts.
D. Initialization of HST motor EPC valve
If the EPC valve is replaced, initialize the items related to it in the tuning mode of the monitor panel. The EPC valve
does not need to be adjusted, however, in this case.
★ For the operating method, see "Special functions of monitor panel (EMMS)".
• Tuning code: 3024-MOTOR LINE
D51EX/PX-22 30-39
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-
Table 1. Output pressures of right HST motor EPC valve and left HST motor EPC valve (when normal)
Travel speed and Output pressure of right HST motor EPC valve
Travel mode
travel condition and left HST motor EPC valve
Quick shift mode Traveling in 2nd 1.47 ± 0.49 MPa {15 ± 5 kg/cm2}
Table 2. Output pressures of parking brake solenoid valve and slow brake solenoid valve
(when normal and abnormal)
Parking brake Output pressure of parking Output pressure of slow
Brake pedal Condition of each solenoid
lever brake solenoid valve brake solenoid valve
3.23 ± 0.49 MPa 3.23 ± 0.49 MPa
Both are normal
{33 ± 5 kg/cm2} {33 ± 5 kg/cm2}
0 MPa 3.23 ± 0.49 MPa Parking brake has trouble
{0 kg/cm2} {33 ± 5 kg/cm2} (Sticking, etc.)
FREE Released
Slow brake has trouble
0 MPa 0 MPa (Sticking, etc.).
{0 kg/cm2} {0 kg/cm2} or charge pressure is
abnormal
0 MPa 0 MPa
Both are normal
{0 kg/cm2} {0 kg/cm2}
LOCK Pressed (fully)
0 MPa 3.23 ± 0.49 MPa Slow brake has trouble
{0 kg/cm2} {33 ± 5 kg/cm2} (Sticking, etc.)
★ The operation state (ON/OFF) of the solenoid valve can be checked in the monitoring mode of the monitor panel (For the
operating method, see “Special functions of monitor panel (EMMS)”).
• Controller: HST
• Monitoring code: 40914 D-OUT
[10]: Parking brake solenoid valve
[11]: Slow brake solenoid valve
Remark
Output from HST controller to the slow brake solenoid is always "ON".
Table 3. Output pressure of work equipment lock solenoid valve (Normal values)
Work equipment lock lever Output pressure of work equipment lock solenoid valve
Lock 0 MPa {0 kg/cm2}
Free 3.23 ± 0.49 MPa {33 ± 5 kg/cm2}
Stop engine with lever in free position and
turn starting switch ON immediately Decreases gradually from 3.23 MPa {33 kg/cm2}.
30-40 D51EX/PX-22
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-
12
TRAVEL DEVIATION
1. Start the engine and raise the blade to about 300 mm above the ground
and set the machine in the measuring posture.
2. Set the travel speed to the 1st in the quick shift mode.
3. After running up for 10 m with the engine speed at high idle, measure
the deviation in the travel of 20 m.
★ While measuring the travel deviation, check the HST main circuit
pressures on the right and left sides.
• Controller: HST
• Monitoring code: 52503-HST L PRESS
• Monitoring code: 52501-HST R PRESS
D51EX/PX-22 30-41
TESTING AND ADJUSTING PARKING BRAKE LEVER
12
PARKING BRAKE LEVER
★ If any part related to the parking brake lever was removed and installed or replaced, adjust the parking brake lever
according to the following procedure.
1. Set parking brake lever (1) in free position (A) and adjust installed height (b) of stopper bolt (2) so that dimension (a) of
lever (1) will be 30.7 mm.
• Standard installed height (b) of stopper bolt = 4 mm
2. Set parking brake lever (1) in lock position (B) and adjust installed height (c) of stopper bolt (3).
• Standard installed height (c) of stopper bolt: 4 mm
3. Set parking brake lever (1) in free position (A) and adjust clearance (d) between lever (4) and 2 limit switches (5).
• Clearance (d) between lever and limit switch = 0 mm
• When adjusting, do not operate the limit switch.
4.Check that limit switch (5) operates 2.5 – 3 mm when parking brake lever (1) is operated.
• When lever is lock position (B): Switch is ON
• When lever is free position (A): Switch is OFF
★ The operating condition (ON/OFF) of limit switch (5) can be checked in the "real-time monitoring mode" of the monitor.
★ For the operating method, see "Special functions of monitor panel (EMMS)".
★ Controller: HST
★ Real-time monitoring code:
40911-D-IN--8-----15
40912-D-IN-16-----22
30-42 D51EX/PX-22
TESTING AND ADJUSTING PARKING BRAKE LEVER
12
If the parking brake lever is adjusted normally, the following is displayed.
D51EX/PX-22 30-43
TESTING AND ADJUSTING BRAKE PERFORMANCE
12
BRAKE PERFORMANCE
★ Carry out the simple test of the brake performance under the following condition.
• HST oil (Hydraulic oil) temperature: Within operating range (40 - 60°C)
• Check point:
Since the test will be carried out while the machine is traveling, work on a sufficiently wide place so that you can
avoid an accident even if there is a trouble.
1. Start the engine and raise the blade to about 300 mm above the ground
and set the machine in the measuring posture.
2. Set the parking brake lever in the FREE position and set the gear speed
to the 1st.
3. Run the engine at high idle and set the PCCS lever in the forward
travel position to drive the machine forward straight.
4. While the machine is traveling, press the brake pedal and check the
stopping condition of the machine.
★ If the machine stops securely, the brake is normal.
30-44 D51EX/PX-22
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
12
BRAKE PEDAL LINKAGE
★ When adjusting the brake pedal, remove the dashboard cover, dashboard undercover and pedal assembly.
Place the removed pedal assembly on the floor and connect the wiring harness connector between floor and pedal.
D51EX/PX-22 30-45
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
12
2. Adjusting proximity switch
A. Adjust clearance (c) between proximity switch (3) and brake pedal (1).
• Clearance (c) = 2 ± 0.5 mm
B. Check that the lamp in proximity switch (3) lights up when brake pedal (1) is between the neutral position and 2-stage
spring operating point (d).
C. Check that the lamp in proximity switch (3) does not light up when brake pedal (1) is pressed to the stroke end.
C. Using push-pull scale, measure the pressing effort of the brake pedal at 2-stage spring operating point (d).
• Pressing effort at 2-stage spring operating point (d): 148 N {15.1 kg}
D. Using push-pull scale, measure the full-stroke pressing effort of the brake pedal.
• Full-stroke pressing effort: 234 N {23.8 kg}
30-46 D51EX/PX-22
TESTING AND ADJUSTING EMERGENCY RELEASE OF PARKING
12
EMERGENCY RELEASE OF PARKING BRAKE
★ If the engine cannot be started and the parking brake of the HST motor cannot be released, release it according to the
following procedure.
WARNING! If the following work is performed while the pressure of the pump assembly is abnormal,
the brake piston of the HST motor may be damaged. Accordingly, be sure to test the
pump assembly.
D51EX/PX-22 30-47
TESTING AND ADJUSTING EMERGENCY RELEASE OF PARKING
3. Connecting pump assembly M1
★ If the supply pressure becomes the specified relief pressure, the parking brake is released.
B. Remove the block of the track shoe and tow the machine at speed lower than 2 km/h.
WARNING! If the supply pressure lowers below 1.5 MPa {15 kg/cm2}, the parking brake is not
released completely (it works partially). Accordingly, keep checking oil pressure gauge [4]
while towing the machine. If the oil pressure lowers, operate the handle to maintain the oil
pressure in the range of 1.5 – 3.1 MPa {15 – 32 kg/cm2}.
C. After towing the machine to a safe place, open the valve of volume pump [1] to release the pressure supplied to the
parking brake circuit.
30-48 D51EX/PX-22
TESTING AND ADJUSTING EMERGENCY RELEASE OF PARKING
12
5. Remedy to take after towing machine
★ After towing the machine to a safe place, take the following remedy without fail to return the machine to the
condition before towing.
A. Remove pump assembly M1 and nipple M2 and install plug (8).
B. Loosen plug (5) of the 5-spool valve and return lock plate (7) and
then tighten plug (5) and bolt (6) to fix lock plate (7).
C. Install the inspection cover to the right of the floor.
D. Return plugs (4) of towed valves (1) and (2) of the HST pump and
secure them with locknuts (3).
D51EX/PX-22 30-49
TESTING AND ADJUSTING IDLER CLEARANCE
12
IDLER CLEARANCE
TESTING
★ If the lateral guide and vertical guide of the idler are so worn that the idler runs out or slants, adjust the clearance of the
idler according to the following procedure.
1. Lateral adjustment
A. Drive the machine forward slowly by 1 - 2 m onto flat ground, and then stop it.
B. Measure clearance (a) between track frame (1) and guide plate (2).
★ Measure clearance (a) on inside and outside of the right and left idlers.
Clearance limit (a): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. 4 mm
ADJUSTING
★ If the clearance exceeds the limit, adjust it according to the following procedure.
A. Loosen mounting bolt (3) of guide plate (2).
★ Since 2-piece shims are used, the guide plate does not need to be removed.
B. Remove the shims between guide plate (2) and support (4) and
adjust clearance (a).
Adjusted clearance (a): . . . . . . . . . . . . . . . . . . . . . . . 0.5 - 1.0 mm
Thickness shim x quantity for new machine: . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm x 4 pieces (for each place)
Bolts: 245 - 309 Nm [25 - 31.5 kgm] (180.7 - 227.9 lbf ft)
30-50 D51EX/PX-22
TESTING AND ADJUSTING IDLER CLEARANCE
12
2. Vertical adjustment
A. Measure clearance b, subtract 2 mm from it, and record the result (quantity of adjustment).
• Example: When clearance b is 5 mm. The quantity of adjustment is 5 -2 = 3 mm.
B. Loosen bolts (5) (4 pieces on inside and outside) until the reaction force of the spring is lost.
C. Loosen bolt (6). Do not loosen more than 3 turns.
D. Pull up vertical guide (7) with a bar and pull out shim (8) by quantity of adjustment obtained in step A.
E. Add shim (8) pulled out onto shim (9).
Remark
8 pieces in total on both sides, inside and outside.
Remark
The total number of shims (5) and (6) before adjustment must be the same as that after adjustment.
Shim thickness: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm
F. Tighten bolts (5) of spring set.
Bolts: 245 - 309 Nm [25 - 31.5 kgm] (180.7 - 227.9 lbf ft)
Bolts: 245 - 309 Nm [25 - 31.5 kgm] (180.7 - 227.9 lbf ft)
D51EX/PX-22 30-51
TESTING AND ADJUSTING TRACK SHOE TENSION
12
TRACK SHOE TENSION
TESTING
1. Drive the machine forward slowly on a level place, and then stop it.
★ Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler and carrier roller and
measure clearance (a) between the bottom of the steel bar and shoe
grouser.
★ As the steel bar, use an L-shape steel, etc. which will be deflected
less.
Standard clearance (a): . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 30 mm
ADJUSTING
B. If the grease does not come out, move the machine forward and in
reverse slowly.
C. Tighten valve (1).
30-52 D51EX/PX-22
TESTING AND ADJUSTING WORK EQUIPMENT
12
WORK EQUIPMENT
OIL PRESSURE
MEASURING
3. Run the engine at high idle and relieve the blade lift and tilt cylinders
one by one at the stroke end and measure the work equipment oil
pressure.
★ The relief pressure of the main relief valve of the control valve is
indicated when each of the above operation is performed. The oil
pressure in the angle circuit is low at the stroke end, because it has
piston valves.
D51EX/PX-22 30-53
TESTING AND ADJUSTING WORK EQUIPMENT
12
ADJUSTING
★ If the oil pressure is abnormal, adjust main relief valve (2) of the
control valve according to the following procedure.
★ Remove the panel on the right hand side of the operator’s seat.
30-54 D51EX/PX-22
TESTING AND ADJUSTING WORK EQUIPMENT
12
LOCK LEVER ADJUSTMENT
★ If any part related to the work equipment lock lever was removed and installed or replaced, adjust the work equipment
lock lever according to the following procedure.
2. Set work equipment lock lever (2) in lock position (B) and adjust clearance (b) between lever (3) and limit switch (4).
• Clearance (b) between lever and limit switch = 0 mm
• When adjusting, do not operate the limit switch.
3. Check that limit switch (4) operates 2.5 – 3 mm when work equipment lock lever (1) is operated.
• When lever is lock position (B): Switch is OFF
• When lever is free position (A): Switch is ON
D51EX/PX-22 30-55
TESTING AND ADJUSTING WORK EQUIPMENT
12
CYLINDER LEAKAGE
★ Measure the leakage in the work equipment cylinder under the following condition.
• HST oil (Hydraulic oil) temperature: Within operating range (40 - 60°C)
WARNING! Raise the front part of the machine to a height where the blade will not touch the ground
when the blade lift cylinder is extended to the lowering stroke end.
WARNING! Set the parking brake lever in the LOCK position and put a block to the rear of the track
shoe.
B. Extend the lift cylinder to the lowering stroke end and stop the engine.
WARNING! Operate the blade control lever in the lifting direction several times within 15 seconds
after stopping the engine, and then loosen the oil filler cap of the hydraulic tank slowly to
release the residual pressure in the cylinder and tank.
30-56 D51EX/PX-22
TESTING AND ADJUSTING WORK EQUIPMENT
12
2. Measuring leakage in blade tilt cylinder.
A. Remove guard on blade above tilt cylinder and cylinder cover.
B. Start the engine and raise the blade to about 1 m above the ground.
C. Fully extend the tilt cylinder to the stroke end and stop the engine.
D. Disconnect hose (2) on the head side, and block the hose side with
a plug.
★ Plug used to block hose: 07376-70210 (# 02)
E. Run the engine at high idle and move the blade control lever to
the right position and hold the tilt cylinder at relief.
D51EX/PX-22 30-57
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
3. Operate the blade control lever in each direction to the stroke end
several times within 15 seconds after stopping the engine to release the
residual pressure in the circuit.
4. Loosen oil filler cap (1) of the hydraulic tank slowly to release the
residual pressure in the tank.
★ Once the residual pressure is released, tighten the oil filler cap to
prevent dirt from entering the tank.
30-58 D51EX/PX-22
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
BLEEDING AIR
★ If any hydraulic equipment/piping of the HST circuit or work equipment circuit was removed/disconnected and installed/
connected, bleed air according to the following procedure after finishing the work.
★ Before and after bleeding air, check that the oil level in the hydraulic tank is normal and no bubbles are contained in the
oil.
2. Starting engine.
Start the engine and run it at low idle for 10 minutes.
A. Warm up the engine until the HST oil temperature (hydraulic oil temperature) reaches 80°C.
★ Air is bled more effectively when the HST oil temperature (hydraulic oil temperature) is high.
B. Set the shift mode switch in the variable shift mode position.
C. While the 1st gear speed is selected, press the shift-up switch twice.
D. Set the reverse travel speed set switch to the left once to set the reverse travel speed equal -to the forward travel
speed.
E. Set the parking brake lever in the FREE position and set the PCCS lever in the forward and reverse travel positions at
least 20 times.
• Forward ➟ Neutral ➟ Reverse ➟ Neutral
★ Repeat the operation cycle of setting the PCCS lever in the forward and reverse positions at least 20 times.
5. Operating machine.
A. After bleeding air, stop the engine and leave it for 5 minutes.
★ By this operation, the bubbles in the oil in the hydraulic tank are discharged.
B. Check for oil leakage. If no oil is leaking, operate the machine.
D51EX/PX-22 30-59
TESTING AND ADJUSTING BLADE CENTER BALL ADJUSTMENT
12
BLADE CENTER BALL ADJUSTMENT
★ If the blade was disassembled and assembled or transported, adjust the play of the center ball according to the following
procedure.
1. Tentatively assemble trunnion and cap (1) to bearing attached to the blade using bolts (2) without shims and tighten.
2. Set clearance a equal around the entire rim and measure value a.
3. Install 0.5 mm shim and 1.0 mm shim so that the total thickness of
shims equals the value of a+0.5 mm.
★ Include at least one pair of 0.5 mm shims.
2. Set clearance b equal around the entire rim and measure value b.
Bolt: 823 ~ 1029 Nm {84 ~ 105 kgm} (607 ~ 758 lbf ft)
30-60 D51EX/PX-22
TESTING AND ADJUSTING DIODES
12
DIODES
D51EX/PX-22 30-61
TESTING AND ADJUSTING DIODES
12
2. When using analog circuit tester.
A. Set the tester in the resistance range.
B. Apply the leads of the tester as shown below and check the movement of the pointer.
i. Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (-) lead to the cathode
(N) side.
ii. Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (-) lead to the anode
(P) side.
C. Judge the condition of the diode by the movement of the pointer.
• The pointer does not move in i) but moves in ii): The diode is normal (The moving range (resistance) depends on
the type and selected range of the tester, however).
• The pointer moves in both i) and ii): The diode is defective (Internal short circuit).
• The pointer moves in neither of i) and ii): The diode is defective (Internal disconnection).
30-62 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS
★ EMMS: Equipment Management Monitoring System
1. Buzzer cancel switch (Used to change, select or confirm modes in this chapter)
2. Information switch (Used to move the cursor or input values in this chapter)
D51EX/PX-22 30-63
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
30-64 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
D51EX/PX-22 30-65
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
Remark
The following Nos. correspond to those in the table on the previous page. Each No. in the table is put in [_]
in the title of each item in the text.
Operator mode
All the display operation of the monitor panel is operated by the buzzer
cancel switch (1) and information switch (2).
Each switch of [◊], [■], [>], [<] is assigned to the following function.
◊: Determine and execute
■ To cancel, release, and determine (only YES and NO screen)
>: To right, to next, to proceed, to increase (only when inputting Arabic
numbers)
<: To left, to previous, to return, to decrease (only when inputting Arabic
numbers)
30-66 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
■ Operator mode (Outline)
D51EX/PX-22 30-67
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3] Error code display mode
By pressing the [>] switch once while the action code is displayed on
the monitor panel, the present error code is displayed.
• [>]: To display error code.
★ The error codes which have been detected in the past are
separated into electrical and mechanical systems and recorded as
failure history (refer to service mode for a detail).
★ If there are several failures, other error codes are displayed by
pressing the [>] switch.
★ After displaying all the error codes by pressing the [>] switch,
press [>] switch further to return to the service meter display
screen.
★ Press the [>] switch again, and the error code is displayed from
the beginning.
★ If there is no switch operation for longer than 10 seconds in the
service meter display screen, it automatically switches to the
action code display screen.
★ The following information is displayed in the service code display
function.
A: Error code
B: Controller code
MON:Monitor panel
ENG:Engine controller
HST:HST controller
C: Trouble occurring system
★ Refer to "Error code table" for details of displayed error codes.
★ Be careful of the partial difference in the displayed information for the error code display mode and the failure history
display mode (service mode).
30-68 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
Error code table
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Mechanical
6091NX HST charge filter element Clogging HST – – ● ●
system
Mechanical
AA10NX Air cleaner Clogging MON – – – –
system
Mechanical
AB00MA Alternator Malfunction MON – – ● –
system
Mechanical
B@BAZG Engine oil Lowering of oil pressure ENG – – ● ●
system
Mechanical
B@BCNS Coolant Overheating ENG – – ● ●
system
Mechanical
B@CRNS HST oil Overheating HST – – ● ●
system
Mechanical
B@CRZG HST oil Lowering of oil pressure HST – – ● ●
system
CONTROLLER Electrical
CA111 Engine controller Internal defect ENG E04 ● ●
R system
Engine Ne/Bkup speed Electrical
CA115 Abnormal ENG E04 ENG SPEED ● ●
sensor system
Excessively high voltage Electrical
CA122 Charge pressure sensor ENG E03 ENGINE ● ●
detected system
Electrical
CA123 Charge pressure sensor Excessively low voltage detected ENG E03 ENGINE ● ●
system
Excessively high voltage Electrical
CA131 Throttle sensor ENG E03 DECEL PEDAL ● ●
detected system
Electrical
CA132 Throttle sensor Excessively low voltage detected ENG E03 DECEL PEDAL ● ●
system
Excessively high voltage Electrical
CA144 Coolant temperature sensor ENG E02 WATER TEMP ● ●
detected system
Electrical
CA145 Coolant temperature sensor Excessively low voltage detected ENG E02 WATER TEMP ● ●
system
Excessively high voltage Electrical
CA153 Charge temperature sensor ENG E01 ENGINE – –
detected system
Electrical
CA154 Charge temperature sensor Excessively low voltage detected ENG E01 ENGINE – –
system
SENSOR Electrical
CA187 Sensor power supply 2 Excessively low voltage detected ENG E03 ● ●
VOLTAGE system
Atmospheric pressure Excessively high voltage Electrical
CA221 ENG E03 ENGINE ● ●
sensor detected system
Atmospheric pressure Electrical
CA222 Excessively low voltage detected ENG E03 ENGINE ● ●
sensor system
Excessively high voltage SENSOR Electrical
CA227 Sensor power supply 2 ENG E03 ● ●
detected VOLTAGE system
Mechanical
CA234 Engine Excessively high speed ENG – – ● ●
system
Ne speed sensor power Electrical
CA238 Excessively low voltage detected ENG E03 ENG SPEED ● ●
supply system
Electrical
CA271 IMV/PCV1 Short circuit ENG E03 ENGINE ● ●
system
Electrical
CA272 IMV/PCV1 Disconnection ENG E03 ENGINE ● ●
system
Electrical
CA322 Injector # 1 Disconnection or short circuit ENG E03 ENGINE ● ●
system
D51EX/PX-22 30-69
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Electrical
CA323 Injector # 5 Disconnection or short circuit ENG E03 ENGINE ● ●
system
Electrical
CA324 Injector # 3 Disconnection or short circuit ENG E03 ENGINE ● ●
system
Electrical
CA325 Injector # 6 Disconnection or short circuit ENG E03 ENGINE ● ●
system
Electrical
CA331 Injector # 2 Disconnection or short circuit ENG E03 ENGINE ● ●
system
Electrical
CA332 Injector # 4 Disconnection or short circuit ENG E03 ENGINE ● ●
system
Electrical
CA342 Engine controller Defective matching of data ENG E04 ENGINE ● ●
system
Electrical
CA351 Injector system Abnormal circuit ENG E03 ENGINE ● ●
system
SENSOR Electrical
CA352 Sensor power source 1 Excessively low voltage detected ENG E03 ● ●
VOLTAGE system
Excessively high voltage SENSOR Electrical
CA386 Sensor power source 1 ENG E03 ● ●
detected VOLTAGE system
Excessively high voltage Electrical
CA428 Coolant sensor ENG E01 FUEL FILTER – –
detected system
Electrical
CA429 Coolant sensor Excessively low voltage detected ENG E01 FUEL FILTER – –
system
ENG OIL Electrical
CA435 Engine oil pressure switch Abnormal signal circuit ENG E02 ● ●
PRESS SW system
BATTERY Electrical
CA441 Power supply voltage Excessively low voltage detected ENG E04 ● ●
VOLTAGE system
Excessively high voltage BATTERY Electrical
CA442 Power supply voltage ENG E04 ● ●
detected VOLTAGE system
Excessively high pressure Electrical
CA449 Common rail pressure 2 ENG E03 ENGINE ● ●
detected system
Common rail pressure Excessively high voltage Electrical
CA451 ENG E03 ENGINE ● ●
sensor detected system
Common rail pressure Electrical
CA452 Excessively low voltage detected ENG E03 ENGINE ● ●
sensor system
Exceeded upper control limit of CAC Electrical
CA488 Charge temperature ENG E03 ● ●
temperature OVERHEAT system
Excessively high pressure Electrical
CA553 Common rail pressure 1 ENG E02 ENGINE ● ●
detected system
Electrical
CA559 Supply pump 1 No pressure feeding detected ENG E02 ENGINE ● ●
system
Electrical
CA689 Engine Ne speed sensor Abnormality in signal ENG E03 ENG SPEED ● ●
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03 ENG SPEED ● ●
system
CONTROLLER Electrical
CA757 Engine controller Loss of data ENG E04 ● ●
R system
Electrical
CA778 Engine Bkup speed sensor Abnormal signal ENG E03 ENG SPEED ● ●
system
CAN communication
Electrical
CA1633 (Engine controller - HST Abnormal communication ENG E03 DATA LINK ● ●
system
controller)
Excessively high voltage Electrical
CA2185 Decelerator pedal sensor ENG E03 DECEL PEDAL ● ●
detected system
30-70 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Electrical
CA2186 Decelerator pedal sensor Excessively low voltage detected ENG E03 DECEL PEDAL ● ●
system
Electrical
CA2249 Supply pump 2 No pressure feeding detected ENG E03 ENGINE ● ●
system
Electrical
CA2311 IMV solenoid Abnormal resistance ENG E03 ENGINE ● ●
system
HEATER Electrical
CA2555 Air intake heater relay Disconnection ENG E01 – –
RELAY system
HEATER Electrical
CA2556 Air intake heater relay Short circuit ENG E01 – –
RELAY system
N SAFETY Electrical
D130KA Neutral safety relay Disconnection HST E02 ● ●
RELAY system
N SAFETY Electrical
D130KB Neutral safety relay Short circuit HST E02 ● ●
RELAY system
CAN communication Defective communication
Electrical
DAFRKR (Monitor panel - HST (Abnormality in objective MON E03 DATA LINK ● ●
system
controller) component system)
CAN communication Defective communication
Electrical
DAFRMC (Monitor panel - Engine (Abnormality in objective MON E03 DATA LINK ● ●
system
controller) component system)
Electrical
DAJ000 HST controller Memory error HST – – – –
system
BATTERY Electrical
DAJ0KK HST controller Lowering of source voltage HST E04 ● ●
VOLTAGE system
MACHINE Electrical
DAJ0KQ HST controller Machine code error HST E03 ● ●
CODE system
CONTROLLER Electrical
DAJ0KT HST controller Memory error HST E03 ● ●
R system
HST controller sensor 5V SENSOR Electrical
DAJ5KK Lowering of source voltage/Input HST E04 ● ●
power supply No.1 VOLTAGE system
HST controller sensor 5V SENSOR Electrical
DAJ6KK Lowering of source voltage/Input HST E03 ● ●
power supply No.2 VOLTAGE system
Defective communication
CAN communication (HST Electrical
DAJRKR (Abnormality in objective HST E03 DATA LINK ● ●
controller - Monitor panel) system
component system)
CAN communication (HST Defective communication
Electrical
DB2RKR controller - Engine (Abnormality in objective HST E03 DATA LINK ● ●
system
controller) component system)
Electrical
DD12KA Shift up switch Disconnection HST E02 SHIFT UP SW ● ●
system
Electrical
DD12KB Shift up switch Short circuit HST E02 SHIFT UP SW ● ●
system
SHIFT DOWN Electrical
DD13KA Shift down switch Disconnection HST E02 ● ●
SW system
SHIFT DOWN Electrical
DD13KB Shift down switch Short circuit HST E02 ● ●
SW system
Electrical
DD14KB Travel lock SW 1 Short circuit HST E03 TRAVEL LOCK ● ●
system
Disagreement of ON/OFF Electrical
DD1NL4 Fan rotation selector switch HST E01 FAN SW – –
signals system
Reverse travel speed Electrical
DDDCKB Short circuit HST E01 R SPEED SW – –
switch system
Electrical
DDP6KA Brake oil pressure sensor Disconnection HST E02 BRAKE PRESS ● ●
system
D51EX/PX-22 30-71
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Electrical
DDP6KB Brake oil pressure sensor Short circuit HST E02 BRAKE PRESS ● ●
system
Electrical
DDP6MA Brake oil pressure sensor Malfunction HST E02 BRAKE PRESS ● ●
system
Electrical
DDQ2KA Travel lock SW 1 Disconnection HST E03 TRAVEL LOCK ● ●
system
Disagreement of ON/OFF SHIFT MODE Electrical
DDT0L4 Shift mode SW HST E01 – –
signals SW system
Travel lock limit switches 1 Electrical
DDU1FS Fixing HST E03 TRAVEL LOCK ● ●
and 2 system
Electrical
DDU1KA Travel lock limit switch 2 Disconnection HST E03 TRAVEL LOCK ● ●
system
Short circuit with power supply Electrical
DDU1KY Travel lock limit switch 2 HST E03 TRAVEL LOCK ● ●
line system
Hydraulic tank oil Electrical
DGS1KA Disconnection HST E01 OIL TEMP – –
temperature sensor system
Hydraulic tank oil Electrical
DGS1KX Out of input signal range HST E01 OIL TEMP – –
temperature sensor system
Electrical
DHH5KA LH pump pressure sensor Disconnection HST E02 HST PRESS ● ●
system
Electrical
DHH5KB LH pump pressure sensor Short circuit HST E02 HST PRESS ● ●
system
Electrical
DHH6KA RH pump pressure sensor Disconnection HST E02 HST PRESS ● ●
system
Electrical
DHH6KB RH pump pressure sensor Short circuit HST E02 HST PRESS ● ●
system
Electrical
DK10KA Fuel dial sensor Disconnection HST E03 FUEL DIAL ● ●
system
Electrical
DK10KB Fuel dial sensor Short circuit HST E03 FUEL DIAL ● ●
system
Electrical
DK30KA Steering angle sensor 1 Disconnection HST E03 ST LEVER ● ●
system
Electrical
DK30KB Steering angle sensor 1 Short circuit HST E03 ST LEVER ● ●
system
Electrical
DK30KX Steering angle sensor Out of input signal range HST E04 ST LEVER ● ●
system
Electrical
DK30KZ Steering angle sensor Disconnection or short circuit HST E04 ST LEVER ● ●
system
Electrical
DK30L8 Steering angle sensor Disagreement of analog signals HST E03 ST LEVER ● ●
system
Electrical
DK31KA Steering angle sensor 2 Disconnection HST E03 ST LEVER ● ●
system
Electrical
DK31KB Steering angle sensor 2 Short circuit HST E03 ST LEVER ● ●
system
Electrical
DK40KA Brake pedal sensor Disconnection HST E03 BRAKE PEDAL ● ●
system
Electrical
DK40KB Brake pedal sensor Short circuit HST E03 BRAKE PEDAL ● ●
system
Electrical
DK55KX Directional potentiometer Out of input signal range HST E04 FR LEVER ● ●
system
Electrical
DK55KZ Directional potentiometer Disconnection or short circuit HST E04 FR LEVER ● ●
system
Electrical
DK55L8 Directional potentiometer Disagreement of analog signals HST E03 FR LEVER ● ●
system
30-72 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Electrical
DK56KA Directional potentiometer 1 Disconnection HST E03 FR LEVER ● ●
system
Electrical
DK56KB Directional potentiometer 1 Short circuit HST E03 FR LEVER ● ●
system
Electrical
DK57KA Directional potentiometer 2 Disconnection HST E03 FR LEVER ● ●
system
Electrical
DK57KB Directional potentiometer 2 Short circuit HST E03 FR LEVER ● ●
system
TRAVEL Electrical
DLM0KX HST motor speed sensor Out of input signal range HST E03 ● ●
SPEED system
Left HST motor speed TRAVEL Electrical
DLM1KA Disconnection HST E01 – –
sensor SPEED system
Left HST motor speed TRAVEL Electrical
DLM1KB Short circuit HST – – –
sensor SPEED system
Left HST motor speed Electrical
DLM1MA Malfunction HST – – – –
sensor system
Right HST motor speed TRAVEL Electrical
DLM2KA Disconnection HST E01 – –
sensor SPEED system
Right HST motor speed TRAVEL Electrical
DLM2KB Short circuit HST – – –
sensor SPEED system
Right HST motor speed Electrical
DLM2MA Malfunction HST – – – –
sensor system
Electrical
DLM3KA Fan speed sensor Disconnection HST E01 FAN SPEED – –
system
Electrical
DLM3KB Fan speed sensor Short circuit HST E02 FAN SPEED ● ●
system
Brake pedal and proximity Electrical
DN21FS Fixing HST E03 BRAKE PEDAL ● ●
switch system
Electrical
DV00KB Caution buzzer: Short circuit MOM E01 BUZZER – –
system
Electrical
DV20KB Back alarm buzzer Short circuit HST E01 BACK ALARM – –
system
Parking brake solenoid Electrical
DW4BKA Disconnection HST E04 P BRAKE SOL ● ●
valve system
Parking brake solenoid Electrical
DW4BKB Short circuit HST E04 P BRAKE SOL ● ●
valve system
Parking brake solenoid Short circuit with power supply Electrical
DW4BKY HST E03 P BRAKE SOL ● ●
valve line system
Electrical
DW7BKA Fan reverse solenoid valve Disconnection HST E01 FAN CLN SOL – –
system
Electrical
DW7BKB Fan reverse solenoid valve Short circuit HST E01 FAN CLN SOL – –
system
Short circuit with power supply Electrical
DW7BKY Fan reverse solenoid valve HST E03 FAN CLN SOL ● ●
line system
SLOW BRAKE Electrical
DW7EKA Slow brake solenoid valve Disconnection HST E04 ● ●
SOL system
SLOW BRAKE Electrical
DW7EKB Slow brake solenoid valve Short circuit HST E04 ● ●
SOL system
Short circuit with power supply SLOW BRAKE Electrical
DW7EKY Slow brake solenoid valve HST E03 ● ●
line SOL system
Fan pump EPC solenoid Electrical
DWN5KA Disconnection HST E01 FAN EPC – –
valve system
Fan pump EPC solenoid Electrical
DWN5KB Short circuit HST E01 FAN EPC – –
valve system
D51EX/PX-22 30-73
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
Error code table (Continued)
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Fan pump EPC solenoid Short circuit with power supply Electrical
DWN5KY HST E02 FAN EPC ● ●
valve line system
LF HST pump EPC HST PUMP Electrical
DXA4KA Disconnection HST E03 ● ●
solenoid valve EPC system
LF HST pump EPC HST PUMP Electrical
DXA4KB Short circuit HST E03 ● ●
solenoid valve EPC system
LF HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA4KY HST E04 ● ●
solenoid valve line EPC system
LR HST pump EPC HST PUMP Electrical
DXA5KA Disconnection HST E03 ● ●
solenoid valve EPC system
LR HST pump EPC HST PUMP Electrical
DXA5KB Short circuit HST E03 ● ●
solenoid valve EPC system
LR HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA5KY HST E04 ● ●
solenoid valve line EPC system
RF HST pump EPC HST PUMP Electrical
DXA6KA Disconnection HST E03 ● ●
solenoid valve EPC system
RF HST pump EPC HST PUMP Electrical
DXA6KB Short circuit HST E03 ● ●
solenoid valve EPC system
RF HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA6KY HST E04 ● ●
solenoid valve line EPC system
RR HST pump EPC HST PUMP Electrical
DXA7KA Disconnection HST E03 ● ●
solenoid valve EPC system
RR HST pump EPC HST PUMP Electrical
DXA7KB Short circuit HST E03 ● ●
solenoid valve EPC system
RR HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA7KY HST E04 ● ●
solenoid valve line EPC system
Left HST motor EPC HST MOTOR Electrical
DXK1KA Disconnection HST E02 ● ●
solenoid valve EPC system
Left HST motor EPC HST MOTOR Electrical
DXK1KB Short circuit HST E02 ● ●
solenoid valve EPC system
Left HST motor EPC Short circuit with power supply HST MOTOR Electrical
DXK1KY HST E04 ● ●
solenoid valve line EPC system
Right HST motor EPC HST MOTOR Electrical
DXK2KA Disconnection HST E02 ● ●
solenoid valve EPC system
Right HST motor EPC HST MOTOR Electrical
DXK2KB Short circuit HST E02 ● ●
solenoid valve EPC system
Right HST motor EPC Short circuit with power supply HST MOTOR Electrical
DXK2KY HST E04 ● ●
solenoid valve line EPC system
★ Error codes:
The error code table is written in alphabetical order and also starting from small number.
The error code in parentheses is not recorded in the failure history for both electrical system and mechanical system.
★ Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON: Monitor panel system
ENG: Engine controller system
HST: HST controller system
★ Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
★ History classification:
History classification indicates in which system, either electrical system or mechanical system in the failure history
display function, a failure has been recorded.
30-74 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[4] Oil/filter maintenance mode (MAINTENANCE MONITOR)
1. If buzzer cancel switch [◊] is pressed on the normal display screen, the
maintenance mode is selected and the filter/oil maintenance mode
screen is displayed first.
* Unused on D51.
D51EX/PX-22 30-75
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[5] Brightness adjustment mode (BRIGHTNESS)
In this mode, the display condition of the monitor panel can be
adjusted on the character display portion.
The following items are displayed in the brightness adjustment mode.
Order Display Item
30-76 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
■ Service mode
D51EX/PX-22 30-77
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
5. Selection of the service menu.
If the [>] switch or [<] switch is pressed on the service menu selection screen, the service menu is displayed endlessly in
the order of the following table, then select the menu that is used.
• [>]: To proceed to next service menu.
• [<]: To return to previous service menu.
30-78 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[6] Electrical system failure history display mode (ELECTRIC FAULT)
The monitor panel retains the data for problems that occurred in the electrical system in the past as failure history. They
can be displayed as follows.
D51EX/PX-22 30-79
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
5. Deleting individual failure history data.
A. With the failure history data to be deleted displayed, press the [◊]
switch and display the individual deletion screen.
• [◊]: Display the deletion screen
B. When the individual deletion screen is displayed, operate each
switch of [<], [>] and [◊].
• [<]: Select YES (move cursor)
• [>]: Select NO (move cursor)
• [◊]: Execute YES or NO
• An information which is active currently (display is flashing)
cannot be deleted.
D. The screen changes to the fault history screen. Check that the
number of records in ** is "0".
30-80 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[7] Mechanical system failure history display mode (MACHINE
FAULT)
The monitor panel retains the data for problems that occurred in the
mechanical system in the past as failure history. They can be displayed
as follows.
D51EX/PX-22 30-81
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[8] Real time monitoring mode (REAL-TIME MONITOR)
The monitor panel can monitor the condition of the machine in real
time through the signals from the sensors installed to various parts of
the machine. In the real time monitoring mode, the following 2 types
of display can be shown.
• 1 item independent display (for each controller)
• 2 items simultaneous display (code input)
30-82 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
3. Setting 1 item individual monitoring.
A. In the monitoring system and mode selection screen, select the
monitoring system (example: ENGINE) to be used.
B. With the monitoring system selected, press the [◊] switch and
display the monitoring display and item selection screen.
• [◊]: Implement 1 system individual monitoring
D51EX/PX-22 30-83
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
5. Setting 2 items simultaneous monitoring
A. Select 2 items simultaneous monitoring (2 ITEMS) in the
monitoring system and function selection screen.
B. With 2 items simultaneous monitoring selected, press the [◊]
switch to display the monitoring code input screen.
• [◊]: Implement 2 system individual monitoring
C. In the monitoring code input screen, operate the switches [>], [<],
[◊] and [■], to input two monitoring codes directly.
• [>]: Number at the cursor increases.
• [<]: Number at the cursor decreases
• [◊]: Number at the cursor is determined
• [■]:Cursor moves to the left end / To return to the monitoring
system and function selection screen.
30-84 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
Monitoring code table
MONITOR PANEL [Monitor panel system]
Display Monitoring
Monitoring item Item display Data display range Unit
order code
D51
1 Machine model code MACHINE CODE 00205 –
(Example of display)
01010101
2 Monitor panel input signal 1 D–IN––0––––––7 40921 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
3 Monitor panel input signal 2 D–IN––8–10 40922 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
4 Fuel sensor voltage FUEL SENSOR 04200 0 – 500 mV
5 Alternator R signal input voltage R SIGNAL 04303 0 – 500 mV
****
6 Application ver. 1 VERSION (APP) 20221 –
(8 digits/symbols)
****
7 Application data ver. 1 VERSION (DATA) 20222 –
(8 digits/symbols)
****
8 Program No. VERSION 20228 –
(8 digits/symbols)
****
9 Assembly No. PART NUMBER 20227 –
(8 digits/symbols)
*******
10 Serial No. SERIAL NUMBER 20402
(7 digits)
D51EX/PX-22 30-85
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
HST CONTROLLER [HST controller system]
Display Monitoring
Monitoring item Item display Data display range Unit
order code
D51
1 Machine model code MACHINE CODE 00204 –
(Example of display)
2 HST oil temperature HST TEMP 04401 -99.9 – 999.9 °C
3 HST oil temperature sensor voltage HST TEMP 04402 0 – 5.00 V
4 Travel speed (Faster one of right and left) VEHICLE SPEED 40010 0 – 99.9 km/h
5 Right travel speed R SPEED 40002 0 – 99.9 km/h
6 Left travel speed L SPEED 40003 0 – 99.9 km/h
7 Right travel speed R SPEED 40963 0 – 9999 Hz
8 Left travel speed L SPEED 40964 0 – 9999 Hz
9 HST right circuit pressure HST R PRESS 52501 0 – 99.9 MPa
10 HST left circuit pressure HST L PRESS 52503 0 – 99.9 MPa
11 HST right circuit pressure sensor voltage HST R PRESS 52500 0 – 5.00 V
12 HST left circuit pressure sensor voltage HST L PRESS 52502 0 – 5.00 V
13 Brake pressure BRAKE PRESS 91902 0.00 – 9.99 MPa
14 Brake pressure sensor voltage BRAKE PRESS 91903 0 – 5000 mV
15 FR lever stroke FR LEVER 50204 -100.0 – 100.0 %
16 FR potentiometer 1 voltage FR LEVER 1 50202 0 – 5.00 V
17 FR potentiometer 2 voltage FR LEVER 2 50203 0 – 5.00 V
18 Steering stroke S/T LEVER 50303 -100.0 – 100.0 %
19 Steering potentiometer 1 voltage S/T LEVER 1 50300 0 – 5.00 V
20 Steering potentiometer 2 voltage S/T LEVER 2 50301 0 – 5.00 V
21 Brake pedal stroke BREAK PEDAL 50401 0.0 – 100.0 %
22 Brake potentiometer voltage BREAK PEDAL 50400 0 – 5.00 V
23 Throttle dial command speed FUEL DIAL 03003 0 – 9999 rpm
24 Throttle dial voltage FUEL DIAL 03002 0 – 5.00 V
25 Right forward pump capacity command value RF PUMP 52404 0.0 – 95.0 CC/r
26 Left forward pump capacity command value LF PUMP 52405 0.0 – 95.0 CC/r
27 Right reverse pump capacity command value RR PUMP 52406 0.0 – 95.0 CC/r
28 Left reverse pump capacity command value LR PUMP 52407 0.0 – 95.0 CC/r
Right forward pump output current command
29 RF PUMP 52400 0 – 9999 mA
value
30 Left forward pump output current command value LF PUMP 52401 0 – 9999 mA
Right reverse pump output current command
31 RR PUMP 52402 0 – 9999 mA
value
32 Left reverse pump output current command value LR PUMP 52403 0 – 9999 mA
33 Right forward pump output current sensed value RF PUMP FB 52408 0 – 9999 mA
34 Left forward pump output current sensed value LF PUMP FB 52409 0 – 9999 mA
35 Right reverse pump output current sensed value RR PUMP FB 42410 0 – 9999 mA
36 Left reverse pump output current sensed value LR PUMP FB 52411 0 – 9999 mA
37 Motor capacity command value MOTOR 52300 0 – 160 CC/r
38 Right motor output current command value R MOTOR 52301 0 – 9999 mA
39 Left motor output current command value L MOTOR 52302 0 – 9999 mA
40 Right motor output current sensed value R MOTOR FB 52303 0 – 9999 mA
41 Left motor output current sensed value L MOTOR FB 52304 0 – 9999 mA
42 Theoretical traction force TRACTION 60000 0 – 99.9 ton
43 Fan speed FAN SPEED 10007 0 – 9999 rpm
30-86 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
D51EX/PX-22 30-87
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
Detailed information of 40910 (D–IN––0 –––––– 7)
[0] Travel lever shift-up switch (NO): ON
[1] (Unused)
[2] (Unused)
[3] HST filter switch: ON (Filter is clogged)
[4] Travel lever shift-down switch (NC): OFF
[5] Travel lever shift-down switch (NO): ON
[6] Travel lever shift-up switch (NC): OFF
[7] (Unused)
Examples of display of bit information
★ The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
★ In case of no use, displayed "0".
★ The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
★ In case of no use, displayed "0".
★ The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
★ In case of no use, displayed "0".
30-88 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
Detailed information of 40913 (D–IN–24 ––––– 31)
[24] Shift mode switch: Quick shift mode (Right)
[25] Shift mode switch: Variable shift mode (Left)
[26] Fan rotation selector switch: Reverse (Right)
[27] Fan rotation selector switch: Forward (Left)
[28] (Unused)
[29] (Unused)
[30] (Unused)
[31] (Unused)
Examples of display of bit information
★ The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
★ In case of no use, displayed "0".
★ The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
★ In case of no use, displayed "0".
★ The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
★ In case of no use, displayed "0".
D51EX/PX-22 30-89
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
ENGINE [Engine controller system]
Display Monitoring
Monitoring item Item display Data display range Unit
order code
1 Engine speed 1 ENG SPEED 01002 0 – 4000 rpm
2 Engine coolant temperature COOLANT TEMP 04107 -40 – 210 °C
3 Engine coolant temperature sensor voltage COOLANT TEMP 04105 0.00 – 5.00 V
4 Decelerator pedal operating degree DECEL PEDAL 31701 0 – 100 %
5 Decelerator pedal sensor voltage DECEL PEDAL 31702 0.00 – 5.00 V
6 Selected machine model name MACHINE ID 00201 – –
7 Build version BUILD VER 20216 – –
8 Calibration data version CAL VER 20217 – –
9 Controller internal temperature ECMINT TEMP 18900 -40 – 210 °C
10 Hardware serial No. ECM S/N 20400 0 – 49999999 –
11 Converted torque TORQUE RATIO 36700 0 – 100 %
12 Engine mode selection POWER MODE 17500 0–4 –
13 Common rail pressure RAIL PRESS 36400 0 – 400 MPa
14 Common rail pressure sensor voltage RAIL PRESS 36401 0.00 – 5.00 V
15 Final common rail pressure command PFIN PRESS COMMAND 36200 0 – 400 MPa
16 Final injection timing command TFIN INJECT TIMING 36300 -180.0 – 180.0 CA
17 Ambient pressure AMBIENT PRESS 37400 -99.9 – 999.9 kPa
18 Ambient pressure sensor voltage AMBIENT PRESS 37401 0.00 – 5.00 V
19 Boost pressure 1 CHG PRESS-A 36500 -99.9 – 99.9 kPa
20 Boost pressure sensor voltage 1 CHG PRESS-A 36501 0.00 – 5.00 V
21 Battery voltage POWER PATE 03203 0.0 – 480.0 V
22 Momentary fuel consumption FUEL RATE 37300 0.0 – 999.9 L/h
23 Final accelerator pedal operating degree FINAL THROTTLE 31706 0 – 100 %
24 Intake air temperature INTAKE TEMP 18400 -50 – 200 °C
25 Intake air temperature sensor voltage INTAKE TEMP 18401 0.00 – 5.00 V
26 Boost temperature CHG TEMP 18500 -50 – 200 °C
27 Boost temperature sensor voltage CHG TEMP 18501 0.00 – 5.00 V
28 Idle validation switch 1 IVS 1 18300 0 or 1 –
29 Idle validation switch 2 IVS 2 18301 0 or 1 –
30 Final injection command (Weight unit) INJECT COMMAND 18600 0 – 1000 mg
31 Engine output torque OUTPUT TORQUE 18700 -24000 – 24000 Nm
32 WIF sensor state WATER IN FUEL 18800 0 or 1 –
30-90 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[9] Cylinder cut-out mode (CYLINDER CUT-OUT)
As one method of troubleshooting for the engine, the monitor panel
has a reduced cylinder mode that can set the desired cylinder to the no
injection condition.
1. Starting engine.
Use this function while the engine is running, because a defective
cylinder is determined depending on the engine speed in the reduced
cylinder mode.
D51EX/PX-22 30-91
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[10] No injection cranking mode
(NO INJECTION)
The monitor panel has the mode of no injection cranking, which is used for cranking after long-term storage, stopping fuel
injection of all the cylinders without starting the engine.
★ The mode of no injection cranking must be operated under the condition that the engine is stopped.
30-92 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[11] Tuning mode (TUNING)
Various devices can be set and tuned with this mode. The changes of the screen in this mode are outlined below.
D51EX/PX-22 30-93
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
B. While the tuning mode (TUNING) screen is displayed, press the
[◊] switch to display the ID input (ID INPUT) screen.
• [◊]: Display ID input (ID INPUT) screen.
C. If the [■] switch is pressed on the screen, the screen returns to the
tuning mode (TUNING) screen.
• [■]: Return to tuning mode (TUNING) screen.
30-94 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
3. Changing display pattern.
A. When changing the display pattern on the ID input (ID INPUT),
tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen, press the
[>] or [<] switch, and the 3 patterns are selected in order.
★ For the switches to be pressed and the changing order, see the
figure.
ii. After inputting tuning item ID, press the [◊] switch, and the
ID is confirmed and the selected item screen appears.
★ The displayed contents of the tuning screen are as
follows.
a: Tuning item ID
b: Tuning item name
c: Value
D51EX/PX-22 30-95
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
★ If a tuning item ID which has not been set is input, the
message is displayed. In this case, input another tuning
item ID.
iii. If the [■] switch is pressed on each tuning item screen, the screen returns to the tuning item ID input (ID = 0000)
screen.
• [■] Return to tuning item ID input (ID = 0000) screen.
B. When selecting a tuning item on tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen.
★ The selecting procedure is the same on the tuning 1 (TUNING 1) and tuning 2 (TUNING 2) screens, but
selectable items on those screens are different.
★ An example of display in tuning 1 (TUNING 1) is shown below.
i.Press the [◊] switch on the tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen, and the top item of the set
tuning items is displayed.
• [◊]: Display top item of set tuning items.
★ In tuning 2 (TUNING 2), "ID: 3001 F-PUMP LINE" is
displayed.
ii.
Press the [>] or [<] switch, and the set items are displayed in order.
• [>]: Display set items in normal order.
• [<]: Display set items in reverse order.
★ For the displayable items, see "Tuning mode table".
• <Normal display order> (For the symbols, see "Tuning mode table") Tuning 1 (TUNING 1): A1 ➔ A2 ➔ A3
➔ A4 ➔ A5 ➔ A6 ➔ A7 ➔ A1 --- (Repeated continuously).
• Tuning 2 (TUNING 2): B1 ➔ B2 ➔ B3 ➔ B1 --- (Repeated continuously).
iii. If the [■] switch is pressed on each tuning screen, the screen returns to the tuning 1 (TUNING 1) or tuning 2
(TUNING 2) screen.
• [■]: Return to tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen.
30-96 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
5. Tuning mode table and adjustment procedure
Tuning Automatic selection
No. Display Item Related information
item ID TUNING1 TUNING2
1 0005 BRAKE N-SET Brake potentiometer neutral set Potentiometer voltage A6
Steering lever left counter-rotation set
2 1010 S/T H.L-SET Potentiometer voltage A2
(Operating effort difference)
Steering lever right counter-rotation set
3 1011 S/T H.R-SET Potentiometer voltage A4
(Operating effort difference)
4 1012 S/T N-SET Steering lever neutral set Potentiometer voltage A1
5 1013 S/T M.L-SET Steering lever left max. set Potentiometer voltage A3
6 1014 S/T M.R-SET Steering lever right max. set Potentiometer voltage A5
Forward pump set
7 3001 F-PUMP LINE Command current B1
(For running track shoe idle)
Reverse pump set
8 3002 R-PUMP LINE Command current B2
(For running track shoe idle)
Forward pump start/max. capacity set
9 3003 F-PUMP RUN1 Command current
(For travel)
Reverse pump start/max. capacity set
10 3004 R-PUMP RUN1 Command current
(For travel)
11 3005 F-PUMP RUN2 Forward pump medium capacity set (For travel) Command current
12 3006 R-PUMP RUN2 Reverse pump medium capacity set (For travel) Command current
13 3007 BRAK END Brake potentiometer max. set Potentiometer voltage A7
Engine speed
EST oil temperature
14 3016 STALL CHECK Stall pressure test mode (Hydraulic oil temperature)
Right HST main circuit pressure
Left HST main circuit pressure
15 3019 SHIFT LIMIT Gear speed limit mode Limit gear speed
16 3024 MOTOR LINE Motor set (For running track shoe idle) Command current B3
17 3032 FAN MODE Fan test mode selection Mode name
18 3033 FAN AMP SET Fan set Command current
Forward pump start adjustment value change Adjustment direction
19 3035 F-PUMP MAP1
(For right and left separately) adjustment value
Reverse pump start adjustment value change Adjustment direction
20 3036 R-PUMP MAP1
(For right and left separately) adjustment value
Forward pump start adjustment value change
21 3037 F-PUMP MAP2 Travel speed adjustment value
(For right and left simultaneously)
Reverse pump start adjustment value change
22 3038 R-PUMP MAP2 Travel speed adjustment value
(For right and left simultaneously)
23 -- -- Service meter set (*) Service meter value
D51EX/PX-22 30-97
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
• When hydraulic fan, fan motor, work equipment valve, fan EPC or work equipment pump is replaced: ID INPUT: Items
of [3033]
• When PCCS lever assembly is replaced: ID INPUT: [1012] [1010] [1013] [1011] [1014]
• When brake linkage is adjusted or brake potentiometer is replaced: ID INPUT [0005] [3007]
ii.
Set buzzer cancel switch in the [◊] position and check that the
caution buzzer sounds.
★ The display of the lower line does not change after
adjustment.
★ Even if this code is turned OFF, the setting is effective.
★ This adjustment is performed to make the HST controller recognize the neutral position of the brake pedal
potentiometer. It is not performed to adjust the effect of the brake.
ii. Set buzzer cancel switch in the [◊] position and check that the
caution buzzer sounds.
★ The display of the lower line does not change after
adjustment.
★ Even if this code is turned OFF, the setting is effective.
★ This code is not used to adjust the steering performance, etc.
★ The adjustment value cannot be adjusted higher than 2,000 mV to prevent wrong setting (The caution buzzer
does not sound).
30-98 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[1011] Steering lever right counter-rotation set
(Operating effort difference) (Changed in normal order: A4)
• This code is used to adjust the right counter-rotation (operating effort
difference) position of the steering potentiometer of the PCCS lever.
• The signal output of the steering potentiometer is displayed by voltage
on the lower line (Display range: 0 – 5000).
• Adjustment method:
ii. Set buzzer cancel switch in the [◊] position and check that the
caution buzzer sounds.
★ The display of the lower line does not change after
adjustment.
★ Even if this code is turned OFF, the setting is effective.
★ This code is not used to adjust the steering performance, etc.
★ The adjustment value cannot be adjusted lower than 3,000 mV to prevent wrong setting (The caution buzzer does
not sound).
ii. Set buzzer cancel switch in the [◊] position and check that the
caution buzzer sounds.
★ The display of the lower line does not change after adjust-
ment.
★ Even if this code is turned OFF, the setting is effective.
★ This code is not used to adjust the steering performance, etc.
★ The adjustment value cannot be adjusted lower than 2,000 mV or higher than 3,000 mV to prevent wrong setting
(The caution buzzer does not sound).
D51EX/PX-22 30-99
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[1013] Steering lever left max. set
(Changed in normal order: A3)
• This code is used to adjust the left maximum position of the steering
potentiometer of the PCCS lever.
• The signal output of the steering potentiometer is displayed by voltage
on the lower line (Display range: 0 – 5000).
• Adjustment method:
ii. Set buzzer cancel switch in the [◊] position and check that the
caution buzzer sounds.
★ The display of the lower line does not change after
adjustment.
★ Even if this code is turned OFF, the setting is effective.
★ This code is not used to adjust the steering performance, etc.
★ The adjustment value cannot be adjusted higher than 2,000 mV to prevent wrong setting (The caution buzzer
does not sound).
ii. Set buzzer cancel switch in the [◊] position and check that the
caution buzzer sounds.
★ The display of the lower line does not change after
adjustment.
★ Even if this code is turned OFF, the setting is effective.
★ This code is not used to adjust the steering performance, etc.
★ The adjustment value cannot be adjusted lower than 3,000 mV to prevent wrong setting (The caution buzzer does
not sound).
30-100 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3001] Forward pump set
(For running track shoe idle) (Changed in normal order: B1)
• This code is used to adjust the command current of the forward pump
while the track shoe is running idle.
• The command current of the forward pump is displayed on the lower
line.
• Adjustment method:
i. Jack up the rear frame bottom of the machine and brace the
blade in the lowering direction to float the whole track shoe
so that it can run idle.
iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.
iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.
WARNING! If adjustment starts, the pump command current increases and the track shoe starts
running automatically. (The track shoe starts running idle, then stops and starts again.
Take care.)
WARNING! The command current of the forward pump increases to 805 mA, then the track shoe
stops.
WARNING! When stopping (interrupting) the track shoe during adjustment, return the PCCS lever to
the neutral position. (Operations of steering with the PCCS lever, brake pedal, fuel
control dial, and decelerator pedal are not accepted during adjustment. Take care.)
D51EX/PX-22 30-101
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3002] Reverse pump set (For running track shoe idle) (Changed in normal
order: B2)
• This code is used to adjust the command current of the reverse pump
while the track shoe is running idle.
• The command current of the reverse pump is displayed on the lower
line.
• Adjustment method:
i. Jack up the rear frame bottom of the machine and brace the
blade in the lowering direction to float the whole track shoe
so that it can run idle.
iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.
iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.
WARNING! If adjustment starts, the pump command current increases and the track shoe starts
running automatically. (The track shoe starts running idle, then stops and starts again.
Take care.)
WARNING! The command current of the reverse pump increases to 805 mA, then the track shoe
stops.
WARNING! When stopping (interrupting) the track shoe during adjustment, return the PCCS lever to
the neutral position. (Operations of steering with the PCCS lever, brake pedal, fuel
control dial, and decelerator pedal are not accepted during adjustment. Take care.)
30-102 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3003] Forward pump start/maximum capacity set (For travel)
• This code is used to adjust the command current of the start and
maximum capacity of the forward pump while the machine is
traveling.
• The command current of the forward pump is displayed on the lower
line.
• Adjustment method:
i. Move the machine to a wide and flat place where it can travel
straight for at least 30 m.
iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.
iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.
WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)
WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.
WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.
D51EX/PX-22 30-103
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
[3004] Reverse pump start/maximum capacity set (For travel)
• This code is used to adjust the command current of the start and
maximum capacity of the forward pump while the machine is
traveling.
• The command current of the forward pump is displayed on the lower
line.
• Adjustment method:
i. Move the machine to a wide and flat place where it can travel
straight for at least 30 m.
iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.
iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.
WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)
WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.
WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.
30-104 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
[3005] Forward pump medium capacity set (For travel)
• This code is used to adjust the command current of the medium
capacity of the forward pump while the machine is traveling.
• The command current of the forward pump is displayed on the lower
line.
• Adjustment method:
i. Move the machine to a wide and flat place where it can travel
straight for at least 15 m.
iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.
iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.
WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)
WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.
WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.
★ When moving the machine after interrupting adjustment, operate it as usually. The travel speed at the time of
interruption is kept, however.
v.After adjustment is finished, set the PCCS lever in the neutral position and set the parking brake lever in the
LOCK position.
★ When starting adjustment again after interrupting it, perform the procedures from i).
★ Even if this code is turned OFF, the setting is effective.
D51EX/PX-22 30-105
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3006] Reverse pump medium capacity set (For travel)
• This code is used to adjust the command current of the medium
capacity of the forward pump while the machine is traveling.
• The command current of the forward pump is displayed on the lower
line.
• Adjustment method:
i. Move the machine to a wide and flat place where it can travel
straight for at least 15 m.
iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.
iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.
WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)
WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.
WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.
★ When moving the machine after interrupting adjustment, operate it as usually. The travel speed at the time of
interruption is kept, however.
v.After adjustment is finished, set the PCCS lever in the neutral position and set the parking brake lever in the
LOCK position.
★ When starting adjustment again after interrupting it, perform the procedures from i).
★ Even if this code is turned OFF, the setting is effective.
30-106 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3007] Brake potentiometer maximum set (Changed in normal order: A7)
• This code is used to adjust the maximum position of the brake pedal
potentiometer.
• The signal output of the brake pedal potentiometer is displayed by
voltage on the lower line.
(Display range: 0 – 5000)
• Adjustment method:
ii.
Set buzzer cancel switch in the [◊] position and check that the
caution buzzer sounds.
★ The display of the lower line does not change after
adjustment.
★ Even if this code is turned OFF, the setting is effective.
★ This code is used to make the HST controller recognize the maximum position of the brake pedal potentiometer.
It is not used to adjust the brake performance.
D51EX/PX-22 30-107
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3016] Stall pressure test mode
• This code is used to test the engine speed, HST oil temperature
(hydraulic oil temperature), and right and left HST main circuit
pressures while the HST is stalled.
• The engine speed, HST oil temperature, right HST main circuit
pressure, or left HST main circuit pressure is displayed on the lower
line.
• How to use:
WARNING! Before selecting this code, check that the parking brake lever is in the LOCK position and
the PCCS lever is in the neutral position.
★ If this code is selected, the HST is stalled automatically. (The HST is stalled only when the PCCS lever is set in the
FORWARD or REVERSE position, however.)
• Travel speed: 3rd (Min. delivery of HST motor)
• Parking brake solenoid valve: OFF
• Slow brake solenoid valve: OFF
WARNING! The following errors are set in this code for safety. If one of them is turned ON, the
command current to the HST pump EPC valve is stopped.
No. 1: When the machine is set in this mode, it is moving.
No. 2: The parking brake lever is not in the LOCK position.
No. 3: After the machine is set in this mode, it is moving.
No. 4: The parking brake release pressure is increased.
No. 0: The above errors are reset.
i. While the engine is running, select an item to be displayed by operating information switch (5).
• [>]: Next code
• [<]: Previous code
★ The following items can be displayed.
No. Display Item Unit
1 ENG-REV Engine speed rpm
2 HST TEMP HST oil temperature °C
3 R PRESS Right HST main circuit pressure MPa
4 L PRESS Left HST main circuit pressure MPa
ii. Check that the parking brake lever is in the LOCK position.
★ Stall the HST while the parking brake lever is in the LOCK position.
iii. Set the PCCS lever in the FORWARD or REVERSE position to stall the HST and test the necessary items.
• If the PCCS lever is set in the FORWARD or REVERSE position, the HST stalls. If the PCCS lever is
returned, stalling of the HST stops.
• The displayed item can be changed even while the HST is stalled.
WARNING! While the HST is stalled, the oil temperature rises sharply and locally. Accordingly, do not
stall the HST continuously for more than 30 seconds. Accordingly, the following restric-
tion function is installed.
30-108 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
★ If stalling of the HST starts, the gauge displays gear speed, set travel speed and the shift indicator section
cycles one cell at a time. If stalling is stopped, the gauges are lit one cell at a time.
If all the gauges are out, stalling of the HST is stopped automatically. When you start the stalling again,
return the PCCS lever to the neutral position once. Then start the stalling again.
ii.
Set the buzzer cancel switch in the [◊] position to enter the
setting.
★ If the gear speed is limited, it is not shifted to the 3rd
position, even if the shift-up switch is operated.
★ The setting becomes effective when the starting switch is turned OFF and ON.
★ The setting is effective in both quick shift mode and variable shift mode.
D51EX/PX-22 30-109
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3024] Motor set (For running track shoe idle) (Changed in normal order:
B3)
• This code is used to adjust the command current of the motor while
the track shoe is running idle.
• The command current of the motor is displayed on the lower line.
• Adjustment method:
i. Jack up the rear frame bottom of the machine and brace the
blade in the lowering direction to float the whole track shoe
so that it can run idle.
iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.
iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.
WARNING! If adjustment starts, the motor command current increases and the track shoe starts
running automatically. Take care.
WARNING! The motor command current changes from 248 mA ➡ 448 mA ➡ 605 mA ➡.... and the
track shoe stops finally.
★ If adjustment stops automatically and an error is displayed, check the following items.
• When track shoe does not move: HST pump
• When track shoe moves:
1) HST motor speed sensor
2) Hose between motor EPC of 5-spool valve and motor
3) Connector between motor EPC of 5-spool valve and wiring harness
4) Is hydraulic oil temperature abnormally low?
• Display example of error
★ The arrowed letters indicate the abnormal sides.
R: Right side
L: Left side
LR: Both right and left sides
30-110 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3032] Fan test mode selection
• This code is used to select the normal control mode, fan 100% mode
or fan 70% mode.
• The mode to be selected is displayed on the lower line.
• How to select
i. Start the engine, set the fuel control dial to the high idle
position, and set the decelerator pedal in neutral (release it).
iii. Set buzzer cancel switch in the [◊] position to settle the
setting.
• The following modes can be selected.
Order Display Item
1 OFF Normal control mode
2 100% Fan 100% operation mode
3 70% Fan 70% operation mode
• Use this code while the engine coolant temperature is above 65°C and the HST oil temperature is above 55°C.
• Even if this code is turned OFF, the setting is effective as long as the starting switch is in the ON position.
• Accordingly, set the fan in the normal control mode before turning this code OFF.
i. Start the engine, set the fuel control dial in the high idle position, and set the decelerator pedal in neutral (release
it).
ii. Set the buzzer cancel switch in the [◊] position, and adjustment starts.
iii. The fan command current changes from 800 mA to 300 mA and adjustment is finished.
★ When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.
D51EX/PX-22 30-111
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3035] Forward pump start adjustment value change (For right and left
separately)
• This code is used to adjust the forward pump command value finely
when the right and left track shoes do not start forward simultaneously
(the machine swings in either direction) after performing adjustments
of [B1], or [3003] and [3005].
• The correction value of the right or left side to be adjusted is displayed
on the lower line.
• Adjustment method
ii. Set the buzzer cancel switch in the [◊] position to settle the selected correction direction.
If the selection is settled, [AD:***] is added next to [RIGHT/LEFT] on the lower line.
Once adjustment is completed, it cannot be returned. Accordingly, be sure to record the value on the right side of
[DA:***] before starting iii).
iii. Operate the information switch to decrease the value by 1. (Decrease the value by 1)
• [>]: Increase value (Start earlier)
• [<]: Decrease value (Start later)
WARNING! If the value is increased, the machine starts sharply. Take care.
WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.
iv. Check that the right and left track shoes start forward simultaneously.
v. Repeat steps iii) and iv) until the right and left track shoes start simultaneously.
vi. Set the buzzer cancel switch in the [◊] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
★ Even if this code is turned OFF, the setting is effective.
30-112 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3036] Reverse pump start adjustment value change (For right and left
separately)
• This code is used to adjust the reverse pump command value finely
when the right and left track shoes do not start reverse simultaneously
(the machine swings in either direction) after performing adjustments
of [B2], or [3004] and [3006].
• The correction value of the right or left side to be adjusted is displayed
on the lower line.
• Adjustment method
ii.
Set the buzzer cancel switch in the [◊] position to settle the selected side.
If the selection is settled, [AD:***] is added next to [RIGHT/LEFT] on the lower line.
★ Once adjustment is completed, it cannot be returned. Accordingly, be sure to record the value on the right side of
[DA:***] before starting iii).
WARNING! If the value is changed largely, the track shoe starts sharply. Take care.
WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.
iv. Check that the right and left track shoes start reverse simultaneously.
v. Repeat steps iii) and iv) until the right and left track shoes start simultaneously.
vi. Set the buzzer cancel switch in the [◊] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
★ Even if this code is turned OFF, the setting is effective.
D51EX/PX-22 30-113
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3037] Forward pump start adjustment value change (For right and left
simultaneously)
• This code is used to adjust the forward pump command value finely
when remarkably large shocks are made at the starting and stopping
moments of forward travel after performing adjustments of [B1], or
[3003] and [3005].
• The travel speed and correction value are displayed on the lower line.
• Adjustment method
WARNING! If the value is changed largely, the track shoe starts sharply. Take care.
WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.
ii. Check that shocks are not made at the moments when the machine starts and stops forward travel.
iv. Select the variable gear shift mode, set the gear speed display to the minimum (2 gauge segments), drive the
machine, and check that the travel speed is "0.6 km/h" or higher (the value on the right of [SPD:1] on the lower
line, is 600 or higher).
If the travel speed is below "0.6 km/h", time lag in start and other negative effects are made. Accordingly, return
the adjusted value until the travel speed lowers below "0.6 km/h".
v. Set the buzzer cancel switch in the [◊] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
★ Even if this code is turned OFF, the setting is effective.
★ This code is not used to adjust the starting acceleration performance but used to adjust the shocks made at the
moments when the machine starts and stops.
[_-_] Service meter set: Refer to Parts and Service News (PSN) AA07024.
30-114 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[3038] Reverse pump start adjustment value change (For right and left
simultaneously)
• This code is used to adjust the forward pump command value finely
when remarkably large shocks are made at the starting and stopping
moments of forward travel after performing adjustments of [B2], or
[3004] and [3006].
• The travel speed and correction value are displayed on the lower line.
• Adjustment method
WARNING! If the value is changed largely, the track shoe starts sharply. Take care.
WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.
ii. Check that shocks are not made at the moments when the machine starts and stops forward travel.
iv. Select the variable gear shift mode, set the gear speed display to the minimum (2 gauge segments), drive the
machine, and check that the travel speed is "0.6 km/h" or higher (the value on the right of [SPD:1] on the lower
line, is 600 or higher).
If the travel speed is below "0.6 km/h", time lag in start and other negative effects are made. Accordingly, return
the adjusted value until the travel speed lowers below "0.6 km/h".
v. Set the buzzer cancel switch in the [◊] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
★ Even if this code is turned OFF, the setting is effective.
★ This code is not used to adjust the starting acceleration performance but used to adjust the shocks made at the
moments when the machine starts and stops.
[_-_] Service meter set: Refer to Parts and Service News (PSN) AA07024.
D51EX/PX-22 30-115
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[12] Maintenance interval change mode (MAINTENANCE
MONITOR)
Monitor panel can set the maintenance intervals for various filters and
oil which become the base of replacement time display for filter and
oil. Also the monitor panel can activate or deactivate the display
function.
* Unused on D51.
★ The maintenance items which have their respective codes
are changed separately and the functions which have no
codes are used to change all the items simultaneously.
★ The item and function is displayed in the [*] section.
30-116 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
3. Display contents of the maintenance item (Items with code No.)
If the maintenance item for filter or oil is selected, the following
contents are displayed.
1: Code (2 digits)
A: Filter and oil replacement time set item
2: Remaining time to set replacement time
3: Number of times of replacement up to present
4. Changing the interval time by maintenance item (Items with code No.)
A. With the item to change the interval time (ex: P FUEL FILT)
selected on the maintenance item and the function selection
screen, press the [◊] switch to display the interval change screen.
• [◊]: Execute the function to change maintenance item.
★ The current set interval is displayed on the screen.
★ With this screen displayed, if the [>] switch or the [<] switch is
operated, the screen switches to the setting screen for enable or
disable the maintenance item.
B. On the interval change screen, operate the switches [>], [<], [◊]
and [■] to input the interval time.
• [>]: Number at the cursor increases.
• [<]: Number at the cursor decreases.
• [◊]: Number at the cursor is determined.
• [■]:To return to the service menu selection screen.
★ The time must always be input with 4 digits. For the time
with less than 4 digits, input 0s in place of the vacant number.
C. When the interval time is completely determined, the screen to
confirm the changes is displayed. Then, operate the switches [<],
[>] and [◊].
• [<]: Select YES (move cursor)
• [>]: Select NO (move cursor)
• [◊]: Execute YES or NO
D51EX/PX-22 30-117
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
B. After the screen to input intervals is displayed, press the [>]
switch or the [<] switch to display the activation or deactivation
setting screen.
• [>]: Switch the setting screen.
• [<]: Switch the setting screen
★ If the function is activated, it is displayed like the upper line.
And if it is deactivated, it is displayed like the lower line.
C. After the activate or deactivate setting screen is displayed, check
the present setting status and the contents of change. Then operate
the switches [◊] or [■].
• [◊]: Switch to the change confirmation screen
• [■]:To return to the maintenance item and function selection
screen.
• [<]: Switch to the interval change screen.
D. When the change confirmation screen is displayed, operate each
[<], [>] and [◊] switches.
• [<]: Select YES (move cursor)
• [>]: Select NO (move cursor)
• [◊]: Execute YES or NO
★ If the timer which has been OFF is turned ON, the interval is
set to the value before it was turned OFF and the rest of set
time of the timer is reset. The number of resetting times is set
to the value before it was turned OFF.
B. After the all item default value setting screen is displayed operate
[<], [>] and [◊] switches.
• [<]: Select YES (move cursor)
• [>]: Select NO (move cursor)
• [◊]: Execute YES or NO
★ All the items are set to their respective default values,
regardless of the ON or OFF state of each item.
★ The rest of the set time of the timer is set to the [default
value/elapsed time after the previous replacement].
★ The number of resetting times is kept at the value before the
default was set.
★ Each item is set turned ON.
30-118 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
7. Setting the function activation or deactivation for all the items (ALL
ITEMS).
A. With the activation or deactivation setting for all items selected
(ALL ITEMS) on the maintenance item and function selection
screen, press the [◊] switch to display the all items activation or
deactivation setting screen.
• [◊]: Implement the function to set activation or deactivation
of all the items.
B. After the all items activation or deactivation setting screen is
displayed, press the [>] switch or the [<] switch to display the
activation setting or deactivation setting screen.
• [>]: Switch the setting screen.
• [<]: Switch the setting screen
★ To deactivate all the items, display the upper line setting screen (OFF), and to activate all the items, display the
lower line setting screen (ON).
C. Confirm the setting screen, press the [◊] switch or the [■] switch
to display the change confirmation screen.
• [◊]: To switch to the change confirmation screen.
• [■]:To return to the maintenance item and function selection
screen.
★ If deactivation of all the items (OFF) is set, it will stop the
maintenance function of all the items, regardless of the
setting of each maintenance item.
★ If activation of all the items (ON) is set, the maintenance
function of all the items starts to work regardless of the
setting of each maintenance item and the interval is set to the
previous time before the interval has been deactivated.
★ The timer is reset simultaneously and it restarts to count from
0 h.
The number of resetting times is set to the value before it was turned OFF.
D. When the change confirmation screen is displayed, operate each
[<], [>] and [◊] switches.
• [<]: Select YES (move cursor)
• [>]: Select NO (move cursor)
• [◊]: Execute YES or NO
D51EX/PX-22 30-119
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
30-120 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[13] Telephone number input function (TEL)
The phone No. set in the monitor panel can be input, corrected or reset
with switches.
• When action code "E03" or "E04" is displayed, the phone No. is
displayed together with "CALL".
A. Press buzzer cancel switch [◊] on the above screen to display the
phone No. input screen.
• Once the phone No. is input, it is displayed after next time.
• Up to 12 digits can be input as the phone No. Input them in
order from the left most one.
B. The cursor is displayed on the position to input the next digit.
Select the next digit with information switches [>] and [<]. To
leave a position blank, select "*".
C. After inputting the digit, press the [◊] switch to move the cursor to
the next position.
• Repeat steps B and C until the right most digit is input.
• To change an input digit, press the [■] switch, and the screen
returns to the previous screen.
D. To finish the inputting operation, press the [■] switch twice.
• The inputting operation can be also finished by turning the starting switch OFF.
D51EX/PX-22 30-121
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
[14] Model selection mode (MACHINE).
This mode is used to make the monitor panel and HST controller recognize a machine model.
WARNING! If an input is settled carelessly in this mode, the memory in the controller is initialized.
Accordingly, use this mode only when it is necessary.
★ If a machine model different from the one which the HST controller has recognized is settled, perform all the
initialization work again.
WARNING! If the actual machine model is different from that set in the controller, the machine may
move unexpectedly or an error may be made. Accordingly, be sure to set the correct
machine model in the controller.
★ The machine model currently recognized by the monitor panel and HST controller can be checked in the real-time
monitoring mode.
Controller: MONITOR PANEL
Code: 00204 MACHINE CODE
Controller: HST
Code: 00205 MACHINE CODE
Display Model
D51 D51 (Default)
D39 D39
D37 D37
D31 D31
30-122 D51EX/PX-22
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
2. Storing data in controller
A. After determining the model selection setting, check that the
display automatically returned to the service menu screen and the
selected model is surely displayed.
B. Turn the starting switch OFF and keep that condition for longer
than 15 seconds.
★ Unless the starting switch is turned off for longer than 15
seconds, the new data is not memorized in the controller.
C. Turn the starting switch ON again.
★ After this operation, the model setting becomes effective.
D51EX/PX-22 30-123
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRI-
CAL SYSTEM
★ When carrying out troubleshooting for an electric circuit related to the
monitor panel and HST controller, expose the related connectors
according to the following procedure.
1. Monitor panel
A. Pull out the starting key (1), remove the 4 mounting bolts (3) of
each side of plastic panel (2), and move plastic panel (2) toward
the operator's seat.
B. Remove the 7 connectors of panel switches (4) and remove the
plastic panel (2).
C. Remove 7 panel switches (4) from the plastic panel (2) and insert
them in their respective connectors correctly.
D. Remove 6 mounting bolts (6) of monitor panel mounting bracket
(5) and move the bracket toward the operator's seat.
E. Remove connectors CN-P1, CN-P2 and CN-P3 and remove the
monitor panel mounting bracket (5).
30-124 D51EX/PX-22
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
2. HST controller
A. Perform steps A – C for the "monitor panel".
B. Insert or connect the diagnostic T-adapters in connectors CN-ST1,
CN-ST2 and CN-ST3 of HST controller (1).
★ If it is difficult to remove and install the connectors, remove
the controller for the ease of work.
★ Since each connector is fixed with a screw, loosen the screw
before disconnecting it.
★ When returning each connector, tighten its screw to the
specified torque to fix it.
D51EX/PX-22 30-125
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
12
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED
ITEMS TO BE ADJUSTED
★ If any of the following electrical/hydraulic devices are adjusted or replaced, perform the following system adjustment.
WARNING! If the system is not adjusted, the machine may not operate normally but may move
unexpectedly. Accordingly, be sure to adjust system.
System adjustment
Device
Tuning item Mode ID No. Display Reference
HST pump Forward HST pump set 3001 F-PUMP LINE page 30-103
TUNING 2
HST pump EPC Reverse HST pump set 3002 R-PUMP LINE page 30-104
HST motor HST motor set TUNING 2 3024 MOTOR LINE page 30-112
5-spool valve
HST motor EPC
Travel lever Steering lever neutral set 1012 S/T N-SET page 30-101
Steering lever left pivot turn 1010 S/T H. L-SET page 30-100
Steering lever left max. set TUNING 1 1013 S/T M.L-SET page 30-102
Steering lever right pivot turn set 1011 S/T H. R-SET page 30-101
Steering laver right max. set 1014 S/T M.R-SET page 30-102
Brake pedal Brake potentiometer neutral set 0005 BRAKE N-SET page 30-100
TUNING 1
Brake potentiometer Brake potentiometer max. set 3007 BRAKE END page 30-107
Fan Fan set ID INPUT 3033 FAN AMP SET page 30-113
Fan motor
Fan EPC
Work equipment valve
Work equipment pump
★ For system adjustment, use "Tuning mode" in the service mode of monitor panel (EMMS) special function.
• For usage of monitor panel (EMMS) special function , see page 30-65.
• For usage of service mode, see page 30-79
• For usage of tuning mode, see page 30-95.
• For usage of each tuning item, see the corresponding ID number.
30-126 D51EX/PX-22
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
★ For system adjustment, use "Model selection mode", "Tuning mode" or "Electrical system failure history display mode" in
the service mode of "Monitor panel (EMMS) special function".
• For usage of monitor panel (EMMS) special function , see page 30-65.
• For usage of selection mode, see page 30-124
• For usage of tuning mode, see page 30-95.
• For usage of each tuning item, see the corresponding ID number.
• For usage of electrical system failure history display mode, see page 30-81
D51EX/PX-22 30-127
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
12
1. Selecting machine model.
A. Turn the starting switch ON, set the monitor panel in "Machine
model selection mode" in the service mode, and select the
machine model.
B. Turn the starting switch OFF.
A. Jack up the rear part of the machine frame and brace the blade
against the ground to float all the track shoes above the ground so
that the tracks can be rotated with no load.
30-128 D51EX/PX-22
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
4. Initializing fan.
A. Adjust the HST oil temperature (hydraulic oil temperature) to 50
– 60 °C.
B. Run the engine at high idle.
C. Set the monitor panel in "Tuning mode" in the service mode,
select "ID INPUT", select fan initialization (3033), and adjust the
fan.
D. Turn the starting switch OFF.
D51EX/PX-22 30-129
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
12
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT
★ When the monitor panel is replaced, adjust the system according to the following procedure.
30-130 D51EX/PX-22
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
3. Setting phone No.
Set the monitor panel in "Telephone number input mode" in the
service mode and set the phone No.
D51EX/PX-22 30-131
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC
PM-CLINIC SERVICE
30-132 D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
Pm-clinic measuring points for D51EX/PX-22 (1/2)
D51EX/PX-22 30-133
TESTING AND ADJUSTING PM-CLINIC
12
Pm-clinic measuring points for D51EX/PX-22 (2/2)
30-134 D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC INSPECTION SHEET (1/2)
D51EX/PX-22 30-135
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC INSPECTION SHEET (2/2)
30-136 D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC UNDERCARRIAGE CHECK SHEET
D51EX/PX-22 30-137
TESTING AND ADJUSTING PM-CLINIC
12
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
30-138 D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
D51EX/PX-22 30-139
TESTING AND ADJUSTING PM-CLINIC
30-140 D51EX/PX-22
40 TROUBLESHOOTING (GENERAL)
D51EX/PX-22 40-101
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check to be sure the blocks, and parking brake are
in place.
WARNING! When carrying out operation with two or more workers, strictly agreed to a set of
signals to use, and do not allow any unauthorized person to come near during repairs.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, wait for the engine to cool down before starting any troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the error, to carry out repairs swiftly, and to prevent reoccurrence
of the error.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However,
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the
error that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a error occurs:
• Parts that have no connection with the error or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the error.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the error occurred?
C. Did the error occur suddenly, or were there problems with the machine condition before this?
E. Had any repairs been carried out before the error? When were these repairs carried out?
40-102 D51EX/PX-22
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
3. Check before troubleshooting.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
A. Confirm the extent of the error yourself, and judge whether to handle it as a real error or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the error, then use the
troubleshooting flowchart to locate the position of the error exactly.
A. Even if the error is repaired, if the root cause of the error is not repaired, the same error will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
D51EX/PX-22 40-103
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLE-
40-104 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent errors or other troubles before they occur, cor-
rect operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly
with correct repair procedures for electronics and is aimed at improving the quality of repairs. For this purpose, it gives
sections on 'Handling electric equipment' and 'Handling hydraulic equipment' (particularly hydraulic oil).
D51EX/PX-22 40-105
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
B. Defective compression or soldering of connectors:
The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.
C. Disconnections in wiring:
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring
still connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.
40-106 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
4. Removing, Installing, And Drying Connectors And Wiring
Harnesses.
A. Disconnecting connectors:
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.
D51EX/PX-22 40-107
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
B. Connecting connectors:
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.
40-108 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
D. Drying wiring harness:
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
D51EX/PX-22 40-109
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
HANDLING ELECTRONIC CONTROL UNIT
1. The electronic control unit contains a microcomputer and electronic
circuits.
★ This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control unit.
6. Do not place the control unit on oil, water, or soil, or in any hot
place, even for a short time.
★ Place it on a suitable dry stand.
40-110 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL
CIRCUITS
1. Always turn power OFF before disconnecting or connecting connectors.
2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3. Always connect any disconnected connectors before going on to the next step.
★ If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
D51EX/PX-22 40-111
TROUBLESHOOTING ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
number (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
40-112 D51EX/PX-22
TROUBLESHOOTING ELECTRIC WIRE CODE
12
HOW TO READ ELECTRIC WIRE CODE
★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational infor-
mation of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric
wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal
No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Type Symbol Material temperature Example of use
range (°C)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for auto- AV appliance
(Nominal No. 5 and above)
mobile Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric –30 to +60
Conductor
low-voltage appliance General wiring
AVS
wire for auto- (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
mobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold dis-
low-voltage appliance
AEX –50 to +110 trict, wiring at high-temperature
wire for auto- Heat-resistant crosslinked poly-
Insulator place
mobile ethylene
D51EX/PX-22 40-113
TROUBLESHOOTING ELECTRIC WIRE CODE
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f
(1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cover D
AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
40-114 D51EX/PX-22
TROUBLESHOOTING ELECTRIC WIRE CODE
12
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of error is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.
D51EX/PX-22 40-115
TROUBLESHOOTING ELECTRIC WIRE CODE
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
40-116 D51EX/PX-22
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
10. Check for looseness, corrosion of starting motor terminal, wiring ⎯ Tighten or replace
18. Check for water leaking on wiring terminals or connections ⎯ Disconnect connector
and dry
19. Check for blown or corroded fuse links or fuses ⎯ Replace
20. Check alternator voltage (engine running at 1/2 throttle speed or above After running for several minutes: 27.5 - Replace
29.5V
21. Check operating sound of battery relay
⎯ Replace
(when switch is turned ON/OFF)
D51EX/PX-22 40-117
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS
1. Categories of troubleshooting codes
★ If the machine monitor displays a error code, the name of the controller is also displayed at the same time, so the trou-
bleshooting codes are categorized according to the name of each controller. (This may also includes some error codes
for the electrical system that are not displayed)
★ errors of the hydraulic and mechanical system that the machine monitor cannot display are categorized as H mode.
Troubleshooting Code Troubleshooting system
ERROR CODES Troubleshooting when error codes are displayed
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine system
• Troubleshooting procedures
When any symptom supposed to be a error appeared on the machine, select a troubleshooting No. according to the procedures
below and proceed to the text of the relevant troubleshooting:
1. Troubleshooting procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display an error code in the error code display mode (electrical
system, mechanical system) on the monitor display (EMMS).
Carry out the troubleshooting of the relevant [error code] in accordance with the displayed error code.
★ Since an error code flashes when a error is detected, the error has not always been corrected even if it lights when
the starting switch is set to ON. (For some codes, errors can be detected by only turning the starting switch ON.)
★ When an error code has been recorded, be sure to perform the duplication operation corresponding to the error
code and confirm if the error has still remained or has been already corrected. (For the duplication method, refer
to the troubleshooting relevant to the error code.)
3. Troubleshooting procedures when no action code is displayed and an error code has not been recorded:
When an error code has not been recorded in the monitor panel (EMMS), a error that the machine cannot diagnose by
itself is supposed to have occurred in the electrical system or the hydraulic and mechanical system.
In this case, check again a symptom supposed to be a error and select the relevant symptom out of the table of “Symptom
supposed to be error and troubleshooting No.” Then, carry out the troubleshooting in the [E-Mode], [H-Mode] or [S-
Mode] related to the symptom.
40-118 D51EX/PX-22
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS
This method is also displayed at the beginning of each electrical system troubleshooting mode. It is important to follow each
step in the troubleshooting chart. Do not skip steps, jump ahead or stop when a problem is found. It is important to complete all
steps due to the fact that there may be several other problems causing the error code. The chart is set-up to start with the most
likely problem first down to the least likely
Action code Error code
Display on Trouble Trouble in machine
Display on panel
panel
Contents of
• Condition at the time when the monitor panel or controller detects the trouble
trouble
Action of • The action taken by the monitor panel or controller to protect the system or devices when the monitor panel or controller
controller detects the trouble
Problem that
appears on • The problem that appears on the machine as a result of the action taken by the monitor panel or controller (shown above)
machine
Related
• Information related to the detected trouble or troubleshooting
information
<Contents of description>
1 • Standard value in normal state to judge possible causes
• Remarks on judgment
Wiring harness which is not connected to power source (24 V) circuit is in contact with power
source (24 V) circuit.
Possible causes of trouble • Short circuit
(Given numbers are Independent wiring harnesses are in contact with each other abnormally.
3
reference numbers, which do not
indicate priority) <Precautions for troubleshooting>
D51EX/PX-22 40-119
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Related circuit diagram
40-120 D51EX/PX-22
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
Chart Use
• When using this chart in a repair shop environment where you have access to a copier it is advised to remove the
pages of the fault codes displayed on the machine monitor and copy these pages. After copping the needed pages,
return the original pages back to the Shop Manual for future use. On the copied pages in the right hand column of the
chart you can record your findings for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.
• When using this chart while on a road service call where a copier is not available it is advised to use a blank piece of
paper and number it from #1 through the last number listed in conjunction with the Shop Manual. Record your
readings by each number on the paper for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.
Chart Tips
D51EX/PX-22 40-121
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
40-122 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
D51EX/PX-22 40-123
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
16 799-601-7320
40-124 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
M Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
D51EX/PX-22 40-125
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
8 799-601-7340
S Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
8 799-601-7140
10 (white) 799-601-7150
12 (white) 799-601-7350
40-126 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
16 (white) 799-601-7330
S Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
10 (blue) —
— —
12 (blue) 799-601-7160
16 (blue) 799-601-7170
D51EX/PX-22 40-127
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
MIC Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 (Quantity: 5 pieces) (Quantity: 5 pieces) —
5 799-601-2710
9 799-601-2950
13 799-601-2720
40-128 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
17 799-601-2730
21 799-601-2740
8 799-601-7180
D51EX/PX-22 40-129
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12 799-601-7190
16 799-601-7210
20 799-601-7220
10 799-601-7510
40-130 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
L Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
D51EX/PX-22 40-131
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
2 —
— —
PA Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
9 —
— —
40-132 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
10 799-601-3460
— —
D51EX/PX-22 40-133
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
40-134 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
8 —
Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
D51EX/PX-22 40-135
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
5 799-601-7360
— —
6 799-601-7370
— —
4 —
— —
40-136 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9210
799-601-9210
799-601-9220
799-601-9220
D51EX/PX-22 40-137
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9230
799-601-9230
799-601-9240
799-601-9240
40-138 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9250
799-601-9250
799-601-9260
799-601-9260
D51EX/PX-22 40-139
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9270
799-601-9270
799-601-9280
799-601-9280
40-140 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9290
799-601-9290
D51EX/PX-22 40-141
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
40-142 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
D51EX/PX-22 40-143
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
★ The pin No. is also marked on the connector (electric wire insertion end)
DTM Series connector
Number of
Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9010
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
40-144 D51EX/PX-22
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
DRC26 Series connector
No. of
pins T-adapter Part
Number
Body (plug) Body (receptacle)
24 799-601-9360
40
799-601-9350
(A)
40
799-601-9350
(A)
50 799-601-4210
⎯ ⎯
D51EX/PX-22 40-145
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
★ The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker
assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
40-146 D51EX/PX-22
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
D51EX/PX-22 40-147
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
40-148 D51EX/PX-22
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
D51EX/PX-22 40-149
TROUBLESHOOTING MODE CHART
12
MODE CHART
Troubleshooting mode
No. Error or possible phenomena Code
E-mode H-mode S-mode
display
1 Action codes are displayed on machine monitor Check error code
2 If error code display function is checked, error codes are displayed ●
Engine related problems
3 Engine does not start easily (Engine starting always takes time) S-1
4 Engine does not crank E-1 S-2a)
5 Engine does not start Engine cranks but no smoke comes out stack S-2b)
6 Smoke comes out stack but engine does not start S-2c)
7 Engine does not pickup smoothly (Poor follow up performance) S-3
8 Engine stops during operation S-4
9 Engine does not run smoothly (Hunts) S-5
10 Engine output is poor (lacks power) S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is excessive (exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Coolant contains oil (blows back or reduces) S-11
16 Oil pressure drops S-12
17 Oil level rises (Coolant or fuel in oil) S-13
18 Coolant temperature is too high (overheating) S-14
19 Abnormal noise is heard S-15
20 Vibration is excessive S-16
21 Preheat does not operate E-2
Power train related problems
Right and left travel systems do not operate in forward or reverse
22 H-1 S-6
(no travel system operates)
Right and left travel systems do not operate in forward or reverse
23 H-2
(only right or left travel system does not operate)
Right and left travel system do not operate in forward or reverse
24 H-3
(only one system does not operate)
25 Speed or power of travel is low H-4
26 Gear is not shifted H-5
27 Large shocks are felt when machine starts and stops travel H-6
28 Machine deviates greatly during travel H-7
29 Hydraulic drift of travel is great H-8
30 Engine stalls or engine speed lowers extremely during travel H-9
31 Abnormal sound comes out from around HST pump and motor H-10
32 HST oil temperature rises too high H-20
40-150 D51EX/PX-22
TROUBLESHOOTING MODE CHART
Troubleshooting mode
No. Error or possible phenomena Code
E-mode H-mode S-mode
display
Work equipment related problems
33 Work equipment does not operate at all E-21 H-11
34 Speed or power of all work equipment is low H-12
35 Speed or power of lifting the blade is low H-13
36 Speed or power of tilting the blade is low H-14
37 Speed or power of angling the blade is low H-15
38 Time lag in lifting the blade is great H-16
39 Hydraulic drift of lifting the blade is great H-17
40 Hydraulic drift of tilting the blade is great H-18
Abnormal sound comes out from around work equipment pump and
41 H-19
control valve
42 Hydraulic oil temperature raises too high H-20
Monitor panel related problems
43 When ignition switch is turned ON, nothing lights up E-3
44 Charge level caution lamp flashes while engine is running E-4
45 Emergency warning items flash while engine is running E-5
46 Preheat pilot lamp does not light up during preheat operation E-6
47 The coolant temperature gauge does not indicate correctly E-7
48 The HST oil temperature gauge does not indicate correctly E-8
49 Fuel level gauge does not indicate properly E-9
50 Travel lever speed shift mode indicator does not display correctly E-10
51 Multi-information unit does not display correctly E-11
52 Caution lamp does not flash or does not go off E-12
53 Caution buzzer does not sound or will not stop sounding E-13
54 Reverse travel speed setting switch does not function E-14
55 Shift mode switch does not function E-15
56 Buzzer cancel switch does not function E-16
57 Information switch does not function E-17
Other related items
58 Fan speed is abnormal (High, low or 0 rpm) H-21
59 The fan cleaning does not operate or cannot be reset E-18
60 Backup alarm does not sound E-19
61 The horn does not sound or does not stop sounding E-20
62 Head lamp or rear lamp does not light up E-22
63 Foot heater does not operate E-23
64 Air conditioner does not operate (Cab specification) E-24
65 Windshield wipers and washers do not operate (Cab specification) E-25
66 KOMTRAX system does not operate correctly E-26
D51EX/PX-22 40-151
40 TROUBLESHOOTING (BY ERROR CODE)
D51EX/PX-22 40-201
TROUBLESHOOTING
40-202 D51EX/PX-22
TROUBLESHOOTING
D51EX/PX-22 40-203
TROUBLESHOOTING
40-204 D51EX/PX-22
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
Action Buzzer
Error codes Defective part Trouble Mode Message Lamps History
code ON
ON
CA115 Abnormal engine NE, Bkup speed Abnormal speed sensor signal ENG E04
ENG
SPEED
• • Electrical
system
CA122 Charge pressure sensor too high Excessively high voltage detected ENG E03 ENGINE • • Electrical
system
CA123 Charge pressure sensor too low Excessively low voltage detected ENG E03 ENGINE • • Electrical
system
CA131 Decelerator pedal sensor too high Excessively high voltage detected ENG E03
DECEL
PEDAL
• • Electrical
system
CA132 Decelerator pedal sensor too low Excessively low voltage detected ENG E03
DECEL
PEDAL
• • Electrical
system
CA144
Coolant temperature sensor too
high
Excessively high voltage detected ENG E02
WATER
TEMP
• q
Electrical
system
CA145
Coolant temperature sensor too
low
Excessively low voltage detected ENG E02
WATER
TEMP
• • Electrical
system
Charge temperature sensor too Electrical
CA153 Excessively high voltage detected ENG E01 ENGINE — —
high system
D51EX/PX-22 40-205
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
CA187 Sensor power source 2 too low Excessively low voltage detected ENG E03
SENSOR
VOLTAGE
• • Electrical
system
CA221
Atmospheric pressure sensor too
high
Excessively high voltage detected ENG E03 ENGINE • • Electrical
system
CA222
Atmospheric pressure sensor too
low
Excessively low voltage detected ENG E03 ENGINE • • Electrical
system
CA227 Sensor power source 2 too high Excessively high voltage detected ENG E03
SENSOR
VOLTAGE
• • Electrical
system
CA238
Abnormal power source for Ne
speed sensor
Excessively low voltage detected ENG E03
ENG
SPEED
• • Electrical
system
CA271 IMV/PCV1 short circuit Short circuit ENG E03 ENGINE • • Electrical
system
CA322
Open and short circuit in injector
#1
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA323
Open and short circuit in injector
#5
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA324
Open and short circuit in injector
#3
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA325
Open and short circuit in injector
#6
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA331
Open and short circuit in injector
#2
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA332
Open and short circuit in injector
#4
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA342
Abnormal engine controller data
matching consistency
Matching inconsistency ENG E04 ENGINE • • Electrical
system
CA351
Abnormal circuit for injector sys-
tem
Abnormal circuit ENG E03 ENGINE • • Electrical
system
CA352 Sensor power source 1 too low Excessively low voltage detected ENG E03
SENSOR
VOLTAGE
• • Electrical
system
CA386 Sensor power source 1 too high Excessively high voltage detected ENG E03
SENSOR
VOLTAGE
• • Electrical
system
FUEL FIL- Electrical
CA428 Water detection sensor too high Excessively high voltage detected ENG E01 — —
TER system
FUEL FIL- Electrical
CA429 Water detection sensor too low Excessively low voltage detected ENG E01 — —
TER system
CA435
Abnormal engine oil pressure
switch
Abnormal signal circuit ENG E02
ENG OIL
PRESS SW
• • Electrical
system
CA441 Power supply voltage too low Excessively low voltage detected ENG E04
BATTERY
VOLTAGE
• • Electrical
system
CA442 Power supply voltage too high Excessively high voltage detected ENG E04
BATTERY
VOLTAGE
• • Electrical
system
CA449 Common rail pressure too high 2 Excessively high pressure detected ENG E03 ENGINE • • Electrical
system
CA451
Common rail pressure sensor too
high
Excessively high voltage detected ENG E03 ENGINE • • Electrical
system
CA452
Common rail pressure sensor too
low
Excessively low voltage detected ENG E03 ENGINE • • Electrical
system
CAC
CA488
Charge temperature too high
torque derated
Exceeded upper control limit of
temperature
ENG E03 OVER- • • Electrical
system
HEAT
40-206 D51EX/PX-22
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
CA553 Common rail pressure too high 1 Excessively high pressure detected ENG E02 ENGINE • q•
Electrical
system
CA559 Supply pump no pressure 1 No pressure feeding detected ENG E02 ENGINE • • Electrical
system
CA731
Abnormal engine Bkup speed sen-
sor phase
Abnormal phase ENG E03
ENG
SPEED
• • Electrical
system
CA757
Loss of all data of engine control-
ler
Loss of all data ENG E04
CON-
TROLLER
• • Electrical
system
CA778
Abnormal engine Bkup speed sen-
sor
Abnormal Bkup signal ENG E03
ENG
SPEED
• • Electrical
system
Abnormal CAN communication
CA1633 (Engine controller – HST control- Abnormal communication ENG E03
DATA
LINK
• • Electrical
system
ler)
CA2185
Decelerator pedal sensor power
source too high
Excessively high voltage detected ENG E03
DECEL
PEDAL
• • Electrical
system
CA2186
Decelerator pedal sensor power
source too low
Excessively low voltage detected ENG E03
DECEL
PEDAL
• • Electrical
system
CA2249 Supply pump no pressure 2 No pressure feeding detected ENG E03 ENGINE • • Electrical
system
CA2311 Abnormal IMV solenoid Abnormal resistance ENG E03 ENGINE • • Electrical
system
HEATER Electrical
CA2555 Open in air intake heater relay Open ENG E01 — —
RELAY system
Short circuit in air intake heater HEATER Electrical
CA2556 Short circuit ENG E01 — —
relay RELAY system
DAJ5KK
HST controller sensor 5V power
supply No. 1
Lowing of source voltage/Input HST E04
SENSOR
VOLTAGE
• • Electrical
system
DAJ6KK
HST controller sensor 5V power
supply No. 2
Lowing of source voltage/Input HST E03
SENSOR
VOLTAGE
• • Electrical
system
“Defective communication
DAJRKR
CAN communication (HST con-
troller – Monitor panel)
(Abnormality in objective compo- HST E03
DATA
LINK
• • Electrical
system
nent system)”
“Defective communication
DB2RKR
CAN communication (HST con-
troller – Engine controller)
(Abnormality in objective compo- HST E03
DATA
LINK
• • Electrical
system
nent system)”
D51EX/PX-22 40-207
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
DHH5KB Left HST pump pressure sensor Short circuit HST E02
HST
PRESS
• • Electrical
system
DHH6KB Right HST pump pressure sensor Short circuit HST E02
HST
PRESS
• • Electrical
system
DK30KB Steering angle sensor 1 Short circuit HST E03 ST LEVER • • Electrical
system
DK30KX Steering angle sensor Out of input signal range HST E04 ST LEVER • • Electrical
system
DK30KZ Steering angle sensor Open or short circuit HST E04 ST LEVER • • Electrical
system
DK30L8 Steering angle sensor Disagreement of analog signals HST E03 ST LEVER • • Electrical
system
40-208 D51EX/PX-22
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
DK31KB Steering angle sensor 2 Short circuit HST E03 ST LEVER • • Electrical
system
DK55KX Directional potentiometer Out of input signal range HST E04 FR LEVER • • Electrical
system
DK55KZ Directional potentiometer Open or short circuit HST E04 FR LEVER • • Electrical
system
DK55L8 Directional potentiometer Disagreement of analog signals HST E03 FR LEVER • • Electrical
system
DLM0KX HST motor speed sensor Out of input signal range HST E03
TRAVEL
SPEED
• • Electrical
system
TRAVEL Electrical
DLM1KA Left HST motor speed sensor Open HST E01 — —
SPEED system
Electrical
DLM1KB Left HST motor speed sensor Short circuit HST — — — —
system
Electrical
DLM1MA Left HST motor speed sensor Malfunction HST — — — —
system
TRAVEL Electrical
DLM2KA Right HST motor speed sensor Open HST E01 — —
SPEED system
Electrical
DLM2KB Right HST motor speed sensor Short circuit HST — — — —
system
Electrical
DLM2MA Right HST motor speed sensor Malfunction HST — — — —
system
FAN Electrical
DLM3KA Fan speed sensor Open HST E01 — —
SPEED system
D51EX/PX-22 40-209
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
SLOW
DW7EKA Slow brake solenoid valve Open HST E04 BRAKE • • Electrical
system
SOL
SLOW
DW7EKB Slow brake solenoid valve Short circuit HST E04 BRAKE • • Electrical
system
SOL
SLOW
DW7EKY Slow brake solenoid valve
Short circuit with power supply
line
HST E03 BRAKE • • Electrical
system
SOL
Electrical
DWN5KA Fan EPC solenoid valve Open HST E01 FAN EPC — —
system
Electrical
DWN5KB Fan EPC Solenoid valve Short circuit HST E01 FAN EPC — —
system
DXA4KA
LF HST pump EPC solenoid
valve
Open HST E03
HST PUMP
EPC
• • Electrical
system
DXA4KB
LF HST pump EPC solenoid
valve
Short circuit HST E03
HST PUMP
EPC
• • Electrical
system
DXA4KY
LF HST pump EPC solenoid
valve
Short circuit with power supply
line
HST E04
HST PUMP
EPC
• • Electrical
system
DXA5KA
LR HST pump EPC solenoid
valve
Open HST E03
HST PUMP
EPC
• • Electrical
system
DXA5KB
LR HST pump EPC solenoid
valve
Short circuit HST E03
HST PUMP
EPC
• • Electrical
system
DXA5KY
LR HST pump EPC solenoid
valve
Short circuit with power supply
line
HST E04
HST PUMP
EPC
• • Electrical
system
DXA6KA
RF HST pump EPC solenoid
valve
Open HST E03
HST PUMP
EPC
• • Electrical
system
DXA6KB
RF HST pump EPC solenoid
valve
Short circuit HST E03
HST PUMP
EPC
• • Electrical
system
DXA6KY
RF HST pump EPC solenoid
valve
Short circuit with power supply
line
HST E04
HST PUMP
EPC
• • Electrical
system
DXA7KA
RR HST pump EPC solenoid
valve
Open HST E03
HST PUMP
EPC
• • Electrical
system
DXA7KB
RR HST pump EPC solenoid
valve
Short circuit HST E03
HST PUMP
EPC
• • Electrical
system
DXA7KY
RR HST pump EPC solenoid
valve
Short circuit with power supply
line
HST E04
HST PUMP
EPC
• • Electrical
system
HST
DXK1KA
Left HST motor EPC solenoid
valve
Open HST E02 MOTOR • • Electrical
system
EPC
HST
DXK1KB
Left HST motor EPC solenoid
valve
Short circuit HST E02 MOTOR • • Electrical
system
EPC
HST
DXK1KY
Left HST motor EPC solenoid
valve
Short circuit with power supply
line
HST E04 MOTOR • • Electrical
system
EPC
HST
DXK2KA
Right HST motor EPC solenoid
valve
Open HST E02 MOTOR • • Electrical
system
EPC
HST
DXK2KB
Right HST motor EPC solenoid
valve
Short circuit HST E02 MOTOR • • Electrical
system
EPC
HST
DXK2KY
Right HST motor EPC solenoid
valve
Short circuit with power supply
line
HST E04 MOTOR • • Electrical
system
EPC
40-210 D51EX/PX-22
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
Mechanical
AA10NX Air cleaner Clogging MON — — — —
system
CA115 Abnormal engine NE, Bkup speed Abnormal speed sensor signal ENG E04
ENG
SPEED
• • Electrical
system
CA122 Charge pressure sensor too high Excessively high voltage detected ENG E03 ENGINE • • Electrical
system
CA123 Charge pressure sensor too low Excessively low voltage detected ENG E03 ENGINE • • Electrical
system
CA131 Decelerator pedal sensor too high Excessively high voltage detected ENG E03
DECEL
PEDAL
• • Electrical
system
CA132 Decelerator pedal sensor too low Excessively low voltage detected ENG E03
DECEL
PEDAL
• • Electrical
system
CA144
Coolant temperature sensor too
high
Excessively high voltage detected ENG E02
WATER
TEMP
• • Electrical
system
CA145
Coolant temperature sensor too
low
Excessively low voltage detected ENG E02
WATER
TEMP
• • Electrical
system
Charge temperature sensor too Electrical
CA153 Excessively high voltage detected ENG E01 ENGINE — —
high system
Charge temperature sensor too Electrical
CA154 Excessively low voltage detected ENG E01 ENGINE — —
low system
CA187 Sensor power source 2 too low Excessively low voltage detected ENG E03
SENSOR
VOLTAGE
• • Electrical
system
CA221
Atmospheric pressure sensor too
high
Excessively high voltage detected ENG E03 ENGINE • • Electrical
system
CA222
Atmospheric pressure sensor too
low
Excessively low voltage detected ENG E03 ENGINE • • Electrical
system
CA227 Sensor power source 2 too high Excessively high voltage detected ENG E03
SENSOR
VOLTAGE
• • Electrical
system
CA238
Abnormal power source for Ne
speed sensor
Excessively low voltage detected ENG E03
ENG
SPEED
• • Electrical
system
CA271 IMV/PCV1 short circuit Short circuit ENG E03 ENGINE • • Electrical
system
CA322
Open and short circuit in injector
#1
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA323
Open and short circuit in injector
#5
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA324
Open and short circuit in injector
#3
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA325
Open and short circuit in injector
#6
Open or short circuit ENG E03 ENGINE • • Electrical
system
D51EX/PX-22 40-211
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
CA331
Open and short circuit in injector
#2
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA332
Open and short circuit in injector
#4
Open or short circuit ENG E03 ENGINE • • Electrical
system
CA342
Abnormal engine controller data
matching consistency
Matching inconsistency ENG E04 ENGINE • • Electrical
system
CA351
Abnormal circuit for injector sys-
tem
Abnormal circuit ENG E03 ENGINE • • Electrical
system
CA352 Sensor power source 1 too low Excessively low voltage detected ENG E03
SENSOR
VOLTAGE
• • Electrical
system
CA386 Sensor power source 1 too high Excessively high voltage detected ENG E03
SENSOR
VOLTAGE
• • Electrical
system
FUEL FIL- Electrical
CA428 Water detection sensor too high Excessively high voltage detected ENG E01 — —
TER system
FUEL FIL- Electrical
CA429 Water detection sensor too low Excessively low voltage detected ENG E01 — —
TER system
CA435
Abnormal engine oil pressure
switch
Abnormal signal circuit ENG E02
ENG OIL
PRESS SW
• • Electrical
system
CA441 Power supply voltage too low Excessively low voltage detected ENG E04
BATTERY
VOLTAGE
• • Electrical
system
CA442 Power supply voltage too high Excessively high voltage detected ENG E04
BATTERY
VOLTAGE
• • Electrical
system
CA449 Common rail pressure too high 2 Excessively high pressure detected ENG E03 ENGINE • • Electrical
system
CA451
Common rail pressure sensor too
high
Excessively high voltage detected ENG E03 ENGINE • • Electrical
system
CA452
Common rail pressure sensor too
low
Excessively low voltage detected ENG E03 ENGINE • • Electrical
system
CAC
CA488
Charge temperature too high
torque derated
Exceeded upper control limit of
temperature
ENG E03 OVER- • • Electrical
system
HEAT
CA553 Common rail pressure too high 1 Excessively high pressure detected ENG E02 ENGINE • • Electrical
system
CA559 Supply pump no pressure 1 No pressure feeding detected ENG E02 ENGINE • • Electrical
system
CA731
Abnormal engine Bkup speed sen-
sor phase
Abnormal phase ENG E03
ENG
SPEED
• • Electrical
system
CA757
Loss of all data of engine control-
ler
Loss of all data ENG E04
CON-
TROLLER
• • Electrical
system
CA778
Abnormal engine Bkup speed sen-
sor
Abnormal Bkup signal ENG E03
ENG
SPEED
• • Electrical
system
Abnormal CAN communication
CA1633 (Engine controller – HST control- Abnormal communication ENG E03
DATA
LINK
• • Electrical
system
ler)
CA2185
Decelerator pedal sensor power
source too high
Excessively high voltage detected ENG E03
DECEL
PEDAL
• • Electrical
system
CA2186
Decelerator pedal sensor power
source too low
Excessively low voltage detected ENG E03
DECEL
PEDAL
• • Electrical
system
CA2249 Supply pump no pressure 2 No pressure feeding detected ENG E03 ENGINE • • Electrical
system
CA2311 Abnormal IMV solenoid Abnormal resistance ENG E03 ENGINE • • Electrical
system
HEATER Electrical
CA2555 Open in air intake heater relay Open ENG E01 — —
RELAY system
Short circuit in air intake heater HEATER Electrical
CA2556 Short circuit ENG E01 — —
relay RELAY system
40-212 D51EX/PX-22
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
DAJ5KK
HST controller sensor 5V power
supply No. 1
Lowing of source voltage/Input HST E04
SENSOR
VOLTAGE
• • Electrical
system
DAJ6KK
HST controller sensor 5V power
supply No. 2
Lowing of source voltage/Input HST E03
SENSOR
VOLTAGE
• • Electrical
system
“Defective communication
DAJRKR
CAN communication (HST con-
troller – Monitor panel)
(Abnormality in objective compo- HST E03
DATA
LINK
• • Electrical
system
nent system)”
“Defective communication
DB2RKR
CAN communication (HST con-
troller – Engine controller)
(Abnormality in objective compo- HST E03
DATA
LINK
• • Electrical
system
nent system)”
D51EX/PX-22 40-213
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
Electrical
DGS1KA HST oil temperature sensor Open HST E01 OIL TEMP — —
system
Electrical
DGS1KX HST oil temperature sensor Out of input signal range HST E01 OIL TEMP — —
system
DHH5KB Left HST pump pressure sensor Short circuit HST E02
HST
PRESS
• • Electrical
system
DHH6KB Right HST pump pressure sensor Short circuit HST E02
HST
PRESS
• • Electrical
system
DK30KB Steering angle sensor 1 Short circuit HST E03 ST LEVER • • Electrical
system
DK30KX Steering angle sensor Out of input signal range HST E04 ST LEVER • • Electrical
system
DK30KZ Steering angle sensor Open or short circuit HST E04 ST LEVER • • Electrical
system
DK30L8 Steering angle sensor Disagreement of analog signals HST E03 ST LEVER • • Electrical
system
DK31KB Steering angle sensor 2 Short circuit HST E03 ST LEVER • • Electrical
system
DK55KX Directional potentiometer Out of input signal range HST E04 FR LEVER • • Electrical
system
DK55KZ Directional potentiometer Open or short circuit HST E04 FR LEVER • • Electrical
system
DK55L8 Directional potentiometer Disagreement of analog signals HST E03 FR LEVER • • Electrical
system
DLM0KX HST motor speed sensor Out of input signal range HST E03
TRAVEL
SPEED
• •Open Electrical
system
TRAVEL Electrical
DLM1KA Left HST motor speed sensor Open HST E01 — —
SPEED system
Electrical
DLM1KB Left HST motor speed sensor Short circuit HST — — — —
system
Electrical
DLM1MA Left HST motor speed sensor Malfunction HST — — — —
system
40-214 D51EX/PX-22
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TA-
TRAVEL Electrical
DLM2KA Right HST motor speed sensor Open HST E01 — —
SPEED system
Electrical
DLM2KB Right HST motor speed sensor Short circuit HST — — — —
system
Electrical
DLM2MA Right HST motor speed sensor Malfunction HST — — — —
system
★ Error codes:
The error code table is written in alphabetical order and also starting from small number.
The error code in parentheses is not recorded in the failure history for both electrical system and mechanical system.
★ Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON: Monitor panel system
ENG: Engine controller system
HST: HST controller system
★ Error codes:
Error codes indicate what is displayed in the operator mode when a failure is detected.
★ History classification:
History classification indicates in which system, either electrical system or mechanical system in the failure history
display function, a failure has been recorded.
INFORMATION IN TROUBLESHOOTING TABLE
D51EX/PX-22 40-215
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TA-
<Contents of description>
1 • Standard value in normal state to judge possible causes
• Remarks on judgment
Wiring harness which is not connected to power source (24 V) circuit is in contact with power
source (24 V) circuit.
Possible causes of trouble • Short circuit
(Given numbers are Independent wiring harnesses are in contact with each other abnormally.
3
reference numbers, which do not
indicate priority) <Precautions for troubleshooting>
40-216 D51EX/PX-22
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TA-
Related circuit diagram
D51EX/PX-22 40-217
TROUBLESHOOTING ERROR CODE [6091NX]
12
ERROR CODE [6091NX]
Contents of • When the HST oil temperature reached 50°C or above, the HST charge filter clogging switch was
trouble activated.
• Flashes the HST Charge Filter clogging caution lamp.
Action of
• Flashes the warning lamp and sounds the alarm buzzer.
controller
• If cause of the error disappears, the system resets itself.
Problem that
appears on • If machine is operated as it is, hydraulic components may be damaged.
machine
• Input state from the HST charge filter clogging switch (ON and OFF) can be checked with the monitoring mode.
Related
(Controller: HST, Code: 40910 D-IN [3])
information
• Method of reproducing error code: Start engine and increase the HST oil temperature to 50°C (122°F) or above.
40-218 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [AA10NX]
12
ERROR CODE [AA10NX]
Contents of
• Clogging of air cleaner was detected.
trouble
Action of
• Flashes the air cleaner clogging caution lamp.
controller
Problem that
appears on • If machine is operated as it is, the engine output may drop or the engine may be damaged.
machine
• Input state from the air cleaner clogging switch (ON and OFF) can be checked with the monitoring mode.
(Controller: MONITOR PANEL, Code: 40921 D-IN [6])
Related • If the air cleaner clogging monitor of the monitor panel lights up while engine stopped, air cleaner system may be defective.
information Carry out troubleshooting for Cause 2, 3 and 4 items.
• If the air cleaner clogging monitor of the monitor panel light up while engine running. Air cleaner may be clogging. Carry out
trouble shooting for Cause 1 item.
D51EX/PX-22 40-219
TROUBLESHOOTING ERROR CODE [AA10NX]
Circuit diagram related to clogged air cleaner
40-220 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [AB00MA]
12
ERROR CODE [AB00MA]
ALTERNATOR MALFUNCTION
Contents of
• Battery charge caution was detected while the engine is running.
trouble
• Flashes the Battery charge caution lamp.
Action of
• Flashes the warning lamp.
controller
• If cause of error disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, battery charging may be insufficient.
machine
• Power generation state of alternator (voltage) can be checked with the monitoring mode
Related
(Controller: MONITOR PANEL, Code: 04303 R SIGNAL).
information
• Method of reproducing error code: Start engine.
D51EX/PX-22 40-221
TROUBLESHOOTING ERROR CODE [B@BAZG]
12
ERROR CODE [B@BAZG]
Contents of
• Engine oil pressure low caution was detected while engine is running.
trouble
• Flashes the Engine oil pressure low caution lamp.
Action of
• Flashes the warning lamp and sounds the alarm buzzer.
controller
• Limits output for travel (Limit injection rate and engine speed)
Problem that
• Engine output lowers.
appears on
• If machine is operated as it is, engine may be damaged.
machine
Related
• Method of reproducing error code: Start engine.
information
40-222 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [B@BAZG]
12
ERROR CODE [B@BCNS]
COOLANT OVERHEAT
Contents of
trouble
Action of
controller
Problem that
• Engine output lowers.
appears on
• If machine is operated as it is, engine may be damaged.
machine
• Input state from the engine coolant temperature sensor (coolant temperature, sensor voltage) can be checked with the monitoring
Related
mode. (Controller: ENGINE, Code: 04107 COOLANT TEMP and code: 04105 COOLANT TEMP)
information
• Method of reproducing error code: Start engine.
D51EX/PX-22 40-223
TROUBLESHOOTING ERROR CODE [B@CRNS]
12
ERROR CODE [B@CRNS]
Contents of
• The HST oil temperature caution was indicated while the engine was running.
trouble
• Flashes the HST oil temperature caution lamp.
Action of
• Flashes the warning lamp and sounds the alarm buzzer.
controller
• If cause of error disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, HST hydraulic equipment or hydraulic equipment on the work equipment may be damaged.
machine
• Input state from the HST oil temperature sensor (oil temperature, oil temperature sensor voltage) can be checked with the moni-
Related
toring mode. (Code: 04401 HST TEMP and code: 04402 HST TEMP)
information
• Method of reproducing error code: Start engine.
40-224 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [B@CRZG]
12
ERROR CODE [B@CRZG]
Contents of trouble • When parking brake was released while the engine was running, brake pressure (charge pressure) lowered.
• Flashes the HST charge pressure caution lamp.
Action of
• Blinks the warning lamp and sounds the alarm buzzer.
controller
• If cause of error disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, HST hydraulic equipment or hydraulic equipment on the work equipment may be damaged.
machine
• Input state (oil pressure, voltage) from the brake pressure sensor can be checked with the
Related
monitoring mode. (Controller: HST, CODE: 91902 BRAKE PRESS, CODE: 91903 BRAKE PRESS)
information
• Method of reproducing error code: Start engine, operate parking brake lever (Free) and operate brake pedal (release)
D51EX/PX-22 40-225
TROUBLESHOOTING ERROR CODE [D130KA]
12
ERROR CODE [D130KA]
Contents of
• When the ground circuit of the neutral safety relay is disconnected, 24V is not generated
trouble
Action of • Flashes the warning lamp and sounds the alarm buzzer.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the engine is stopped, it can not be restarted (Disconnection).
appears on
• Engine can be started regardless of the parking lever switch position (Ground fault).
machine
• Output state to the neutral safety switch (ON and OFF, voltage) can be checked with the monitoring mode.
(Controller: HST, code: 40918 D-OUT [3], code: 50901 N-SAFETY)
Related
• Method of reproducing error code: Turn the starting switch ON and operate parking brake lever (Free).
information
• This error code is generated when the primary (coil side) of neutral safety relay has failed. A failure of the secondary cannot be
detected with this code.
Possible causes and harness Wiring harness between CN-ST2 (female) (8) – CN-11
3
(Disconnection or defective contact of (female) (2) Resistance Max. 1 Ω
standard value in
normal state connector)
Wiring harness between CN-11 (female) (1) – starting
Resistance Max. 1 Ω
switch CN-T270 (ACC)
★ Prepare with starting switch OFF and carry out troubleshooting without turning
starting switch.
Grounding fault in wiring Wiring harness between CN-ST2 (female) (8) – CN-11
Resistance Min. 1 MΩ
4 harness (Short circuit with ground (female) (2) and chassis ground
circuit)
Wiring harness between CN-11 (female) (1) – starting
switch CN-T270 (ACC), – F01 (20F) inlet and chassis Resistance Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
bleshooting.
5 Defective HST controller CN-ST2 Parking brake lever Voltage
40-226 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [D130KA]
Circuit diagram related to neutral safety relay
D51EX/PX-22 40-227
TROUBLESHOOTING ERROR CODE [D130KB]
12
ERROR CODE [D130KB]
Contents of
• Abnormal current flowed at the GND output to the neutral safety relay.
trouble
Action of • Flashes the warning lamp and sounds the alarm buzzer.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • When the engine is stopped, it can not be restarted.
machine
• Output state to the neutral safety switch (ON, OFF, and voltage) can be checked with the monitoring mode.
(Controller: HST, code: 40918 D-OUT [3], code: 50901 N-SAFETY)
Related
• Method of reproducing error code: Turn the starting switch ON and operate parking brake lever (Lock).
information
• This error code is generated when the primary (coil side) of neutral safety relay has failed. A failure of the secondary cannot be
detected with this code.
40-228 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [D130KB]
Circuit diagram related to neutral safety relay
D51EX/PX-22 40-229
TROUBLESHOOTING ERROR CODE [DAFRKR]
12
ERROR CODE [DAFRKR]
Action code Error code CAN communication (Monitor panel – HST controller): Defective communication
Trouble (Abnormality in objective component system)
E03 DAFRKR (Monitor panel system)
Contents of trouble • The monitor panel cannot recognize the HST controller in the CAN communication circuit.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly.
controller
• If cause of error disappears, system resets itself.
• The system may not work properly.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• The monitor panel does not display information.
• Method of reproducing error code: Turn the starting switch ON
• Indicate error code [DAFRMC], when the monitor panel cannot recognize the engine controller.
Related
• Indicate error code [DB2RKR], when HST controller cannot recognize the engine controller.
information
• Indicate error code [DAJRKR], when HST controller cannot recognize the monitor panel.
• Indicate error code [CA1633], when engine controller cannot recognize the HST controller.
40-230 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAFRKR]
D51EX/PX-22 40-231
TROUBLESHOOTING ERROR CODE [DAFRMC]
Action code Error code CAN communication (Monitor panel – ENGINE controller):
Trouble Defective communication (Abnormality in objective component system) (Monitor
E03 DAFRMC panel system)
Contents of trouble • The monitor panel cannot recognize the ENGINE controller in the CAN communication circuit.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly.
controller
• If cause of error disappears, system resets itself.
• The system may not work properly.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• The monitor panel does not display information.
• Method of reproducing error code: Starting switch ON.
• Indicate error code [DAFRKR], when the monitor panel cannot recognize the HST controller.
Related
• Indicate error code [DB2RKR], when HST controller cannot recognize the engine controller.
information
• Indicate error code [DAJRKR], when HST controller cannot recognize the monitor panel.
• Indicate error code [CA1633], when engine controller cannot recognize the HST controller.
40-232 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAFRMC]
D51EX/PX-22 40-233
TROUBLESHOOTING ERROR CODE [DAJ000]
Contents of trouble • The information in the HST controller ROM (non-volatile memory) is abnormal.
Action of
• Use normal data only in the main area and in the backup area.
controller
Problem that appears
on machine
Related
information
40-234 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAJ0KK]
12
ERROR CODE [DAJ0KK]
D51EX/PX-22 40-235
TROUBLESHOOTING ERROR CODE [DAJ0KK]
Circuit diagram related to HST controller power supply
40-236 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAJ0KQ]
12
ERROR CODE [DAJ0KQ]
• There is a disagreement between the selected machine model being saved on the HST controller and that on the machine.
Contents of trouble
• Do not select machine select mode.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the function partly
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The system may not work properly.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped and started again, its travel speed is limited to 50%.
• Machine model codes being recognized by the controller can be checked with the monitoring mode.
Related
(Controller: HST, Code: 00204 MACHINE CODE) and (Controller: MONITOR PANEL,
information
Code: 00205 MACHINE CODE)
Possible causes and Confirm and record the machine model that the monitor panel and the HST controller
standard value in recognize in the real monitoring mode.
normal state 1 Defective machine model selection Make appropriate setting for the machine model in the machine model selection mode.
When setting for different machine model from the one that the HST controller recog-
nizes was made, carry out all initial setting.
D51EX/PX-22 40-237
TROUBLESHOOTING ERROR CODE [DAJ0KT]
12
ERROR CODE [DAJ0KT]
Contents of • The information in the HST controller PROM (non-volatile memory) is abnormal.
trouble (Both the main area memory and backup area memory are abnormal)
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Limits the functions partly.
controller • Clear all the memory and use default values.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The system may not work properly.
Problem that
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
appears on
• Once the machine is stopped and started again, its travel speed is limited to 50%.
machine
• The setting of machine model is also cleared, and [DAJ0KQ] appears.
Related
• Method of reproducing error code: Turn the starting switch ON.
information
40-238 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAJ5KK]
12
ERROR CODE [DAJ5KK]
Action code Error code HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input
Trouble
E04 DAJ5KK (HST controller system)
• Voltage of 5 V power output No.1 circuit of the HST controller went to 4.5 V or lower or 5.5 V or higher.
Contents of trouble
• Abnormal current flowed in HST controller sensor 5 V power supply No. 1
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Stops output of 5 V power No.1 circuit.
controller • Limits the functions partly
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, it cannot be restarted.
on machine • The system may not work properly.
• If this failure occurs, individual error codes of the target components of power supply such as the pressure sensor and potentiom-
Related
eter are displayed and recorded at the same time.
information
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-239
TROUBLESHOOTING ERROR CODE [DAJ5KK]
Circuit diagram related to HST controller sensor 5 V power supply No. 1
40-240 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAJ6KK]
12
ERROR CODE [DAJ6KK]
Action code Error code HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input
Trouble
E03 DAJ6KK (HST controller system)
• Voltage of 5 V power output No.2 circuit of the HST controller went to 4.5 V or lower or 5.5 V or higher.
Contents of trouble
• Abnormal current flowed in HST controller sensor 5 V power supply No. 2
• Flashes the warning lamp and sounds the alarm buzzer.
• Stops output of 5 V power No.2 circuit.
Action of
• Stops use of the HST motor speed sensor.
controller
• Limits the functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The system may not work properly.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped and started again, its travel speed is limited to 50%.
• If this error occurs, individual error codes of the target devices of power supply such as the HST motor speed sensor are dis-
Related
played and recorded at the same time.
information
• Method of reproducing error code: Turn the starting switch ON.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
Possible causes and Grounding fault in wiring starting switch.
standard value in 2 harness Wiring harness between CN-ST3 (female) (34) – CN-
normal state (Short circuit with ground circuit) LRS2 (female) (A), – CN-RRS2 (female) (A) and chassis Resistance Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Wiring harness between CN-ST3 (female) (34) – CN-
Short circuit with power supply line
3 circuit wiring harness LRS2 (female) (A), – CN-RRS2 (female) (A) and chassis Voltage Max. 1 V
ground
(Contact with 24 V)
If the wiring harness is short circuit with power supply line circuit wiring harness, the
controller and each HST motor revolution sensor may be defective, too. Check them
after repairing wiring harness.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
4 Defective HST controller
HST controller Voltage
Between CN-ST3 (34) and CN-ST2 (39) 4.5 – 5.5 V
D51EX/PX-22 40-241
TROUBLESHOOTING ERROR CODE [DAJ6KK]
Circuit diagram related to HST controller sensor 5 V power supply No. 2
40-242 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAJRKR]
12
ERROR CODE [DAJRKR]
Disconnection in wiring Wiring harness between CN-S04 (female) (1), (6) – CN-
115 (female) (46), – CN-ST2 (female) (32), – CN-G01 Resistance Max. 1 Ω
harness
2 (female) (8), – CN-119 (female) (A), CN-DT12 (male) (3)
(Disconnection or defective contact in
Possible causes and connector) Wiring harness between CN-S04 (female) (3) – CN-115
standard value in (female) (47), – CN-ST2 (female) (22), – CN-G01
normal state Resistance Max. 1 Ω
(female) (7), – CN-119 (female) (B), CN-DT12 (male)
(10)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Wiring harness between CN-S04 (female)(1), (6) – CN-
Grounding fault in wiring 115 (female) (46), – CN-ST2 (female) (32), – CN-G01
Resistance Min. 1 M Ω
harness (female) (8), – CN-119 (female) (A), CN-DT12 (male) (3)
3
(Short circuit with ground and chassis ground
circuit)
Wiring harness between CN-S04 (female) (3) – CN-115
(female) (47), – CN-ST2 (female) (22), – CN-G01
Resistance Min. 1 M Ω
(female) (7), – CN-119 (female) (B), CN-DT12 (male)
(10) and chassis ground
D51EX/PX-22 40-243
TROUBLESHOOTING ERROR CODE [DAJRKR]
40-244 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DB2RKR]
D51EX/PX-22 40-245
TROUBLESHOOTING ERROR CODE [DB2RKR]
40-246 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DD12KA]
Contents of trouble • Both circuits in the shift up switch were turned off (set to OPEN) at the same time.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Recognizes that the shift up switch is not pressed.
controller
• Resets itself 3 seconds after if the detection conditions are unmeet.
Problem that appears
• Pressing the button does not operate the shift up.
on machine
• Both circuits of the switch are monitored, NO is used to detect the operation and NC is used to detect errors.
Related • Input state (ON/OFF) from the shift up switch can be checked with the monitoring function.
information (Controller: HST, Code: 40910 D-IN [0]: NO, [6]: NC)
• Method of reproducing error code: Turning on the starting switch and operating the shift up switch
D51EX/PX-22 40-247
TROUBLESHOOTING ERROR CODE [DD12KA]
Circuit diagram related to the shift up switch and shift down switch
40-248 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DD12KB]
12
ERROR CODE [DD12KB]
D51EX/PX-22 40-249
TROUBLESHOOTING ERROR CODE [DD12KB]
Circuit diagram related to the shift up switch and shift down switch
40-250 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DD13KA]
12
ERROR CODE [DD13KA]
Contents of trouble • Both circuits in the shift down switch were turned OFF (set to OPEN) at the same time.
Action of • Flashes the warning lamp and sounds the alarm buzzer.
controller • Recognizes that the shift up switch is not pressed.
Problem that appears
• Pressing the button does not operate the shift down.
on machine
• Both circuits of the switch are monitored, NO is used to detect the operation and NC is used to detect errors.
Related • Input state (ON/OFF) from the shift down switch can be checked with the monitoring function.
information (Controller: HST, code: 40910 D-IN [4]: NC, [5]: NO)
• Method of reproducing error code: Turning on the starting switch and operating the shift down switch
D51EX/PX-22 40-251
TROUBLESHOOTING ERROR CODE [DD13KA]
Circuit diagram related to the shift up switch and shift down switch
40-252 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DD13KB]
12
ERROR CODE [DD13KB]
Contents of trouble • Both circuits in the shift down switch were turned ON (set to CLOSE) at the same time.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Recognizes that the shift down switch is not pressed.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Pressing the button does not operate the shift down.
on machine
• Both circuits of the switch are monitored, NO is used to detect the operation and NC is used to detect errors.
Related • Input state (ON/OFF) from the shift down switch can be checked with the monitoring function.
information (Controller: HST, Code: 40910 D-IN [4]: NC, [5]: NO)
• Method of reproducing error code: Turning on the starting switch and operating the shift down switch
D51EX/PX-22 40-253
TROUBLESHOOTING ERROR CODE [DD13KB]
Circuit diagram related to the shift up switch and shift down switch
40-254 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DD14KB]
12
ERROR CODE [DD14KB]
Action code Error code Travel lock limit switch 1: Short circuit
Trouble
E03 DD14KB (HST controller system)
Contents of trouble • Both circuits in the travel lock limit switch 1 Were turned ON (set to CLOSE) at the same time.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Recognizes that the travel lock lever is set to the Free position.
controller • Limits its functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
Problem that
• Once the machine is stopped and started again, its travel speed is limited to 50%.
appears on machine
• The engine does not start.
• Both circuits of the switch are monitored, NO is used to detect the operation and NC is used to detect errors.
Related • Input state (ON/OFF) from the travel lock limit switch 1 can be checked with the monitoring mode.
information (Controller: HST, code: 40912 D-IN [18]: NO, [19]: NC)
• Method of reproducing error code: Turn the starting switch ON and operate travel lock lever.
D51EX/PX-22 40-255
TROUBLESHOOTING ERROR CODE [DD14KB]
Circuit diagram related in travel lock limit switch 1
40-256 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DD1NL4]
12
ERROR CODE [DD1NL4]
Action code Error code Fan rotation selector switch: Disagreement of ON / OFF Signals (HST controller
Trouble
E01 DD1NL4 system)
Contents of trouble • Both circuits in fan rotation selector switch were turned ON (set to CLOSE) at the same time.
Action of • Recognizes that the fan rotation selector switch is not pressed.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Fan rotation does not change, even if the fan rotation selector switch is pressed.
on machine
Related • Input state (ON/OFF) from the fan rotation selector switch can be checked with the monitoring mode.
information (Controller: HST, code: 40913 D-IN [26]: Reverse rotation (Right side), [27]: Normal rotation (Left side))
D51EX/PX-22 40-257
TROUBLESHOOTING ERROR CODE [DD1NL4]
Circuit diagram related to fan rotation selector switch
40-258 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDDCKB]
12
ERROR CODE [DDDCKB]
Action code Error code Reverse travel speed switch: short circuit
Trouble
E01 DDDCKB (HST controller system)
Contents of trouble • Both circuits in the reverse speed switch were turned ON (set to CLOSE) at the same time.
Action of • Recognizes that the reverse travel speed switch is not pressed.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Setting for reverse travel speed does not change, even if the reverse travel speed switch is pressed.
on machine
• Input state (ON/OFF) from the reverse travel speed switch can be checked with the monitoring mode.
Related
(Controller: HST, code: 40912 D-IN [16]: deceleration (Left hand), [17]: acceleration (Right hand))
information
• Method of reproducing error code: Turn the starting switch ON and operate the reverse travel speed switch
D51EX/PX-22 40-259
TROUBLESHOOTING ERROR CODE [DDDCKB]
Circuit diagram related to reverse travel speed switch
40-260 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDP6KA]
12
ERROR CODE [DDP6KA]
Contents of trouble • Input signal voltage from the brake oil pressure sensor dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
controller • Recognizes the brake pressure as 2 MPa {20 kg/cm2} when the machine stopped.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Even when the brake oil pressure lowers, the charge pressure caution lamp does not light up.
appears on machine
• Input state from the brake oil pressure sensor (brake oil pressure and brake sensor voltage) can be checked with the monitoring
Related mode.
information (Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)
• Method of reproducing error code: Turn the starting switch ON.
Grounding fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting without turning
harness starting switch.
3
(Short circuit with ground Wiring harness between CN-ST1 (female) (8) – CN-BS
circuit) Resistance Min. 1 MΩ
(female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
4 Defective HST controller CN-ST1 Voltage
Between (22) and (21) Power source 4.5 – 5.5 V
Between (8) and (21) Signal 0.4 – 0.6 V
D51EX/PX-22 40-261
TROUBLESHOOTING ERROR CODE [DDP6KA]
Circuit diagram related to brake oil pressure sensor
40-262 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDP6KB]
12
ERROR CODE [DDP6KB]
Action code Error code Brake oil pressure sensor: Short circuit
Trouble
E02 DDP6KB (HST controller system)
Contents of trouble • Input signal voltage from the brake oil pressure sensor dropped under 4.42 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
controller • Recognizes the brake pressure as 2 MPa {20 kg/cm2} when the machine stopped.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Even when the brake oil pressure lowers, the charge pressure caution lamp does not light up.
on machine
• Input state from the brake oil pressure sensor (brake oil pressure and brake sensor voltage) can be checked with the monitoring
Related mode.
information (Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-263
TROUBLESHOOTING ERROR CODE [DDP6KB]
Circuit diagram related to brake oil pressure sensor
40-264 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDP6MA]
12
ERROR CODE [DDP6MA]
Contents of trouble • The Input signal voltage from the brake oil pressure sensor detected abnormal state (sensor failure).
Action of • Flashes the warning lamp and sounds the alarm buzzer.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Even when the brake oil pressure lowers, the charge pressure caution lamp does not light up.
on machine
• Input state from the brake pressure sensor (brake pressure and brake sensor voltage) can be checked with the monitoring mode.
Related
(Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)
information
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-265
TROUBLESHOOTING ERROR CODE [DDP6MA]
Circuit diagram related to brake oil pressure sensor
40-266 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDQ2KA]
12
ERROR CODE [DDQ2KA]
Contents of trouble • Both circuits in the travel lock limit switch 1 were turned OFF (set to OPEN) at the same time.
• Flashes the centralized warning lamp and sounds the alarm buzzer.
Action of • Recognizes that the travel lock lever is set to the Free position.
controller • Limits the functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• Travel speed is reduced to 50% of the value being set from the button. Likewise, the throttle opening is reduced to 50% of the set
Problem that appears
value.
on machine
• The engine does not start.
• Both circuits of the switch are monitored, NO is used to detect the operation and NC is used to detect errors.
• Input state (ON/OFF) from the travel lock limit switch 1 can be checked with the monitoring mode.
Related
(Controller: HST, code: 40912 D-IN [18]: NO, [19]: NC)
information
• Method of reproducing error code:
Turn the starting switch ON and operate travel lock lever.
D51EX/PX-22 40-267
TROUBLESHOOTING ERROR CODE [DDQ2KA]
Circuit diagram related in travel lock limit switch 1
40-268 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDT0L4]
12
ERROR CODE [DDT0L4]
Action code Error code Shift mode switch: Disagreement of ON/ OFF Signals
Trouble
E01 DDT0L4 (HST controller system)
Contents of trouble • Both circuits in the shift mode switch were turned ON (set to CLOSE) at the same time.
Action of • Recognizes that the shift mode switch is not pressed.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Shift mode does not change, even if the shift mode switch is pressed.
on machine
• Input state (ON/OFF) from the shift mode switch can be checked with the monitoring mode.
Related
(Controller: HST, code: 40913 D-IN [24]: Quick shift mode (right side), [25]: Variable shift mode (Left side)
information
• Method of reproducing error code: Turn the starting switch ON and operate shift mode switch.
D51EX/PX-22 40-269
TROUBLESHOOTING ERROR CODE [DDT0L4]
Circuit diagram related to shift mode switch
40-270 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDU1FS]
12
ERROR CODE [DDU1FS]
Action code Error code Travel lock limit switches 1 and 2: Fixing
Trouble
E03 DDU1FS (HST controller system)
• Though the signal of travel lock limit switch 1 is set to LOCK, the output circuit to the brake solenoid valve is operating nor-
Contents of trouble
mally.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (ON/OFF) from the travel lock limit switch can be checked with the monitoring mode.
Related
(Controller: HST, code: 40911 D-IN [12]: Switch 2 (NO), code: 40912 D-IN [18]: Switch 1 (NO), [19]: Switch 1 (NC))
information
• Method of reproducing error code: Turn the starting switch ON and operate travel lock lever.
D51EX/PX-22 40-271
TROUBLESHOOTING ERROR CODE [DDU1FS]
Circuit diagram related to brake system
40-272 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDU1KA]
12
ERROR CODE [DDU1KA]
• Though the signal of travel lock limit switch 1 is set to Lock position and no current flows to output circuit of the slow brake
Contents of trouble
solenoid valve, the signal of travel lock limit switch 2 (NO) was turned OFF (set to OPEN).
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits its function partly.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (ON/OFF) from the travel lock limit switch 2 can be checked with the monitoring mode.
Related (Controller: HST, code: 40911 D-IN [12] switch 2 (NO), code: 40912 D-IN [18] switch 1 (NO), [19] switch 1 (NC))
information • Method of reproducing error code: Turn the starting switch ON and operate travel lock lever.
• If [DW7EKA] is also output, carry out troubleshooting for it first.
D51EX/PX-22 40-273
TROUBLESHOOTING ERROR CODE [DDU1KA]
Circuit diagram related to brake system
40-274 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDU1KY]
12
ERROR CODE [DDU1KY]
Action code Error code Travel lock limit switch 2: Short circuit with power supply line
Trouble
E03 DDU1KY (HST controller system)
• Though the signal of travel lock limit switch 1 is set to Free position and the output circuit of the slow brake solenoid valve out-
Contents of trouble
puts normally, the signal of travel lock limit switch 2 (NO) was turned ON (set to CLOSE).
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • When the travel lock limit switch is set to the lock position, disconnection in the slow brake solenoid may be detected.
controller • Limits the functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Once the machine is stopped, its engine speed is limited to medium (half) speed.
appears on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (ON/OFF) from the travel lock limit switch 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), code: 40912 D-IN [18]: switch 1 (NO), [19]: switch 1 (NC))
information
• Method of reproducing error code: Turn the starting switch ON and operate travel lock lever (FREE).
D51EX/PX-22 40-275
TROUBLESHOOTING ERROR CODE [DDU1KY]
Circuit diagram related to brake system
40-276 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DGS1KA]
12
ERROR CODE [DGS1KA]
• The signal of HST oil temperature sensor remains unchanged at low temperature even when the engine coolant temperature
Contents of trouble
rises.
Action of • Recognizes the HST oil temperature as 85°C.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Monitor panel HST oil temperature is not displayed normally.
on machine • The fan speed is set to over 70%.
• Input state from the HST oil temperature sensor (HST oil temperature and HST oil temperature sensor voltage) can be checked
Related with the monitoring mode.
information (Controller: HST, code: 04401 HST TEMP, and Code: 04402 HST TEMP)
• Method of reproducing error code: Turn the starting switch ON or start the engine and wait about 10 minutes.
D51EX/PX-22 40-277
TROUBLESHOOTING ERROR CODE [DGS1KA]
Circuit diagram related to HST oil temperature sensor
40-278 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DGS1KX]
12
ERROR CODE [DGS1KX]
Action code Error code HST oil temperature sensor: Out of input signal range
Trouble
E01 DGS1KX (HST controller system)
Contents of trouble • Input signal voltage from the HST oil temperature sensor dropped under 0.3 V.
Action of • Recognizes the HST oil temperature as 85°C (185°F).
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Monitor panel HST oil temperature is not displayed normally.
on machine • The fan speed is set to over 70%.
• Input state from the HST oil temperature sensor (HST oil temperature and HST oil temperature sensor voltage) can be checked
Related with the monitoring mode.
information (Controller: HST, code: 04401 HST TEMP, and Code: 04402 HST TEMP)
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-279
TROUBLESHOOTING ERROR CODE [DGS1KX]
Circuit diagram related to HST oil temperature sensor
40-280 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DHH5KA]
12
ERROR CODE [DHH5KA]
Action code Error code Left HST pump pressure sensor: Disconnection
Trouble
E02 DHH5KA (HST controller system)
Contents of trouble • Input signal voltage from the Left HST pump pressure dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
• Until the machine stops, the controller maintains the control using the pressure signal being received immediately prior to the
Action of failure.
controller
• Once the machine stops, the controller maintains the control assuming that the pump pressure is 100 kg/am2 (1,422 psi).
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• The Left HST pump oil pressure may not be monitored in the monitoring mode.
on machine
• If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly,
take extreme care when checking.
Related
• Input state from the Left HST pump pressure sensor (pressure and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 52502 HST L PRESS and code: 52503 HST L PRESS)
• Method of reproducing error code: Turn the starting switch ON or start the engine.
D51EX/PX-22 40-281
TROUBLESHOOTING ERROR CODE [DHH5KA]
40-282 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DHH5KB]
12
ERROR CODE [DHH5KB]
Action code Error code Left HST pump pressure sensor: Short circuit
Trouble
E02 DHH5KB (HST controller system)
Contents of trouble • Input signal voltage from the Left pump pressure is 4.42 V and above.
• Flashes the warning lamp and sounds the alarm buzzer.
• Until the machine stops, the controller maintains the control using the pressure signal being received immediately prior to the
Action of failure.
controller
• Once the machine stops, the controller maintains the control assuming that the pump pressure is 100kg/cm2 (1,422 psi).
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• The Left HST pump pressure may not be monitored in the monitoring mode.
on machine
• If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly,
take extreme care when checking.
Related
• Input state from the Left HST pump pressure sensor (pressure and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 52502 HST L PRESS and code: 52503 HST L PRESS)
• Method of reproducing error code: Turn the starting switch ON or start the engine.
D51EX/PX-22 40-283
TROUBLESHOOTING ERROR CODE [DHH5KB]
Circuit diagram related to Left HST pump pressure sensor
40-284 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DHH6KA]
12
ERROR CODE [DHH6KA]
Action code Error code Right HST pump pressure sensor: Disconnection
Trouble
E02 DHH6KA (HST controller system)
Contents of trouble • Input signal voltage from the Right HST pump pressure sensor dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
• Until the machine stops, the controller maintains the control using the pressure signal being received immediately prior to the
Action of failure.
controller
• Once the machine stops, the controller maintains the control assuming that the pump pressure is 100kg/cm2 (1,422 psi).
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• The Right HST pump pressure may not be monitored in the monitoring mode.
on machine
• If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly,
take extreme care when checking.
Related
• Input state from the Right HST pump pressure sensor (pressure and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 52500 HST R PRESS and code: 52501 HST R PRESS)
• Method of reproducing error code: Turn the starting switch ON or start the engine.
D51EX/PX-22 40-285
TROUBLESHOOTING ERROR CODE [DHH6KA]
Circuit diagram related to Right HST pump pressure sensor
40-286 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DHH6KB]
12
ERROR CODE [DHH6KB]
Action code Error code Right HST pump pressure sensor: Short circuit
Trouble
E02 DHH6KB (HST controller system)
Contents of trouble • Input signal voltage from the Right HST pump pressure sensor is above 4.42 V.
• Flashes the warning lamp and sounds the alarm buzzer.
• Until the machine stops, the controller maintains the control using the pressure signal being received immediately prior to the
Action of failure.
controller
• Once the machine stops, the controller maintains the control assuming that the pump pressure is 100 kg/cm2 (1,422 psi).
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• The Right HST pump pressure may not be monitored in the monitoring mode.
on machine
• If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly,
take extreme care when checking.
Related
• Input state from the Right HST pump pressure sensor (pressure and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 52500 HST R PRESS and code: 52501 HST R PRESS)
• Method of reproducing error code: Turn the starting switch ON or start the engine.
D51EX/PX-22 40-287
TROUBLESHOOTING ERROR CODE [DHH6KB]
Circuit diagram related to Right HST pump pressure sensor
40-288 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK10KA]
12
ERROR CODE [DK10KA]
Contents of trouble • Input signal voltage from the fuel dial sensor dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
• Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
Action of failure.
controller • Once the machine is stopped, the controller maintains the control assuming that the fuel dial is half position.
• Limits the functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The fuel dial operation does not work.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage and command of rotation) from the fuel dial sensor can be checked with the monitoring mode.
Related
(Controller: HST, code: 03002 FUEL DIAL and code: 03003 FUEL DIAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate fuel control lever.
D51EX/PX-22 40-289
TROUBLESHOOTING ERROR CODE [DK10KA]
Circuit diagram related to fuel dial sensor
40-290 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK10KB]
12
ERROR CODE [DK10KB]
Contents of trouble • Input signal voltage from the fuel dial sensor is above 4.5 V.
• Flashes the warning lamp and sounds the alarm buzzer.
• Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
Action of failure.
controller • Once the machine is stopped, the controller maintains the control assuming that the fuel dial is half position.
• Limits the functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The fuel dial operation does not work.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage and command of rotation) from the fuel dial sensor can be checked with the monitoring mode.
Related
(Controller: HST, code: 03002 FUEL DIAL and code: 03003 FUEL DIAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate fuel control lever.
D51EX/PX-22 40-291
TROUBLESHOOTING ERROR CODE [DK10KB]
Circuit diagram related to fuel dial sensor
40-292 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK30KA]
12
ERROR CODE [DK30KA]
Contents of trouble • Input voltage from the steering angle sensor 1 is above 4.5 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly and maintains the control using the signal from the steering angle sensor 2.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the steering angle sensor 1 can be checked with the monitoring mode.
Related
(Controller: HST, Code: 50300 S/T LEVER 1)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the steering direction)
D51EX/PX-22 40-293
TROUBLESHOOTING ERROR CODE [DK30KA]
Circuit diagram related to directional potentiometer and steering potentiometer
40-294 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK30KB]
12
ERROR CODE [DK30KB]
Contents of trouble • Input signal voltage from the steering angle sensor dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly and maintains the control using the signal from the steering angle sensor 2.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the steering angle sensor 1 can be checked with the monitoring mode.
Related
(Controller: HST, Code: 50300 S/T LEVER 1)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the steering direction)
D51EX/PX-22 40-295
TROUBLESHOOTING ERROR CODE [DK30KB]
Circuit diagram related to directional potentiometer and steering potentiometer
40-296 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK30KX]
12
ERROR CODE [DK30KX]
Action code Error code Steering angle sensor: Out of input signal range
Trouble
E04 DK30KX (HST controller system)
• In the systems 1 and 2 of the steering angle sensor, either of the error codes [DK30KA] or [DK30KB], and [DK31KA] or
Contents of trouble
[DK31KB] occurred at the same time.
• Flashes the warning lamp and sounds the alarm buzzer.
• Limits its functions partly.
Action of
• Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
controller
failure.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped, it cannot be started again.
• Input state (voltage) from the steering angle sensor 1 and 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50300 S/T LEVER 1 and Code: 50301 S/T LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the steering direction)
D51EX/PX-22 40-297
TROUBLESHOOTING ERROR CODE [DK30KZ]
12
ERROR CODE [DK30KZ]
Action code Error code Steering angle sensor: Disconnection or short circuit
Trouble
E04 DK30KZ (HST controller system)
• When the starting switch was turned ON, either of System 1 or System 2 of the steering angle sensor was defective, but, later, a
trouble occurred to the other that was normal at that time.
When the starting switch was turned ON, steering angle sensor 2 was only defective, but, later, [DK30KA] or [DK30KB]
Contents of trouble
appeared.
Or, when the starting switch was turned ON, steering angle sensor 1 was only defective, but, [DK31KA] or [DK31KB]
appeared.
• Flashes the warning lamp and sounds the alarm buzzer.
• Limits its functions partly.
Action of
• Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
controller
failure.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped, it cannot be started again.
• Input state (voltage) from the steering angle sensor 1 and 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50300 S/T LEVER 1 and Code: 50301 S/T LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the steering direction)
40-298 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK30L8]
12
ERROR CODE [DK30L8]
Action code Error code Steering angle sensor: Disagreement of analog signals
Trouble
E03 DK30L8 (HST controller system)
Contents of trouble • Total voltage of the systems 1 and 2 of the steering angle sensor is below 4.41 V or above 5.59 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Limits the functions partly.
controller • Maintains the control using the potentiometer that outputs normal signal.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the steering angle sensor 1 and 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50300 S/T LEVER 1 and Code: 50301 S/T LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the steering direction)
D51EX/PX-22 40-299
TROUBLESHOOTING ERROR CODE [DK31KA]
12
ERROR CODE [DK31KA]
Contents of trouble • Input signal voltage from the steering angle sensor dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly and maintains the control using the signal from the steering angle sensor 1.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the steering angle sensor 1 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50301 S/T LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the steering direction)
40-300 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK31KA]
Circuit diagram related to directional potentiometer and steering potentiometer
D51EX/PX-22 40-301
TROUBLESHOOTING ERROR CODE [DK31KB]
12
ERROR CODE [DK31KB]
Contents of trouble • Input signal voltage from the steering angle sensor 2 is above 4.5 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly and maintains the control using the signal from the steering angle sensor 1.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the steering angle sensor 1 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50301 S/T LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the steering direction)
40-302 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK31KB]
Circuit diagram related to directional potentiometer and steering potentiometer
D51EX/PX-22 40-303
TROUBLESHOOTING ERROR CODE [DK40KA]
12
ERROR CODE [DK40KA]
Contents of trouble • Input signal voltage from the brake pedal sensor dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
• Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
Action of
failure.
controller
• Once the machine stops, the controller maintains the control assuming that the brake pedal is at stroke 0 position.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (stroke and voltage) from the brake pedal sensor can be checked with the monitoring mode.
Related
(Controller: HST, code: 50400 BRAKE PEDAL and code: 50401 BRAKE PEDAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate the brake pedal
40-304 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK40KA]
Circuit diagram related to brake sensor
D51EX/PX-22 40-305
TROUBLESHOOTING ERROR CODE [DK40KB]
12
ERROR CODE [DK40KB]
Contents of trouble • Input signal voltage from the brake pedal sensor is above 4.5 V.
• Flashes the warning lamp and sounds the alarm buzzer.
• Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
Action of
failure.
controller
• Once the machine stops, the controller maintains the control assuming that the brake pedal is at stroke 0 position.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (stroke and voltage) from the brake pedal sensor can be checked with the monitoring mode.
Related
(Controller: HST, code: 50400 BRAKE PEDAL and code: 50401 BRAKE PEDAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate the brake pedal
40-306 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK40KB]
Circuit diagram related to brake sensor
D51EX/PX-22 40-307
TROUBLESHOOTING ERROR CODE [DK55KX]
12
ERROR CODE [DK55KX]
Action code Error code Directional potentiometer: Out of input signal range
Trouble
E04 DK55KX (HST controller system)
• In the systems 1 and 2 of the directional potentiometer, either of the error codes [DK56KA] or [DK56KB], and [DK57KA] or
Contents of trouble
[DK57KB] occurred at the same.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
controller failure.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped, it cannot be started again.
• Input state (voltage) from the directional potentiometers 1 and 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50202 FR LEVER 1 and code: 50203 FR LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (directional operation)
40-308 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK55KZ]
12
ERROR CODE [DK55KZ]
• When the starting switch was turned ON, either of System 1 or System 2 of the directional potentiometer was defective, but,
later, a trouble occurred to the other that was normal at that time.
When the starting switch was turned ON, directional potentiometer 2 was only defective, but, later, [DK56KA] or [DK56KB]
Contents of trouble
appeared.
Or, when the starting switch was turned ON, directional potentiometer 1 was only defective, but, later, [DK57KA] or
[DK57KB] appeared.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
controller failure.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, Engine speed is limited to 50% of the value.
on machine • Once the machine is stopped, it cannot be started again.
• Input state (voltage) from the directional potentiometers 1 and 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50202 FR LEVER 1 and code: 50203 FR LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (directional operation)
D51EX/PX-22 40-309
TROUBLESHOOTING ERROR CODE [DK55L8]
12
ERROR CODE [DK55L8]
Contents of trouble • Total voltage of the systems 1 and 2 of the directional potentiometer is under 4.41 V or above 5.59 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Restricts part of the functions.
controller • Maintains the control using the potentiometer that outputs normal signal.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the directional potentiometers 1 and 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50202 FR LEVER 1 and code: 50203 FR LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (directional operation)
40-310 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK56KA]
12
ERROR CODE [DK56KA]
Contents of trouble • Input signal voltage from directional potentiometer 1 dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Restricts part of the functions and maintains the control using the signal from the directional potentiometer 2.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the directional potentiometer 1 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50202 FR LEVER 1)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (directional operation)
D51EX/PX-22 40-311
TROUBLESHOOTING ERROR CODE [DK56KA]
Circuit diagram related to directional potentiometer and steering potentiometer
40-312 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK56KB]
12
ERROR CODE [DK56KB]
Contents of trouble • Input signal voltage from directional potentiometer sensor 1 is above 4.5 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly and maintains the control using the signal from the directional potentiometer 2.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the directional potentiometer 1 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50202 FR LEVER 1)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (directional operation)
D51EX/PX-22 40-313
TROUBLESHOOTING ERROR CODE [DK56KB]
Circuit diagram related to directional potentiometer and steering potentiometer
40-314 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK57KA]
12
ERROR CODE [DK57KA]
Contents of trouble • Input signal voltage from directional potentiometer 2 dropped under 0.3 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly and maintains the control using the signal from the directional potentiometer 1
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the directional potentiometer 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50203 FR LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (directional operation)
D51EX/PX-22 40-315
TROUBLESHOOTING ERROR CODE [DK57KA]
Circuit diagram related to directional potentiometer and steering potentiometer
40-316 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK57KB]
12
ERROR CODE [DK57KB]
Contents of trouble • Input signal voltage from directional potentiometer 2 is above 4.5 V.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly and maintains the control using the signal from the directional potentiometer 1.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state (voltage) from the directional potentiometer 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50203 FR LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (directional operation)
D51EX/PX-22 40-317
TROUBLESHOOTING ERROR CODE [DK57KB]
Circuit diagram related to directional potentiometer and steering potentiometer
40-318 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM0KX]
12
ERROR CODE [DLM0KX]
Action code Error code HST motor speed sensors: Out of input signal range
Trouble
E03 DLM0KX (HST controller system)
• In the Left HST motor speed sensor system and Right HST motor speed sensor system, either of the error codes [DLM1KA] or
Contents of trouble
[DLM1KB], and [DLM2KA] or [DLM2KB] occurred at the same time.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
Problem that appears
• Once the machine is stopped and started again, its travel speed is limited to 50%.
on machine
• Travel deviation occurs.
• Input state from the Left HST motor speed sensor and Right HST motor speed sensor (speed in frequency) can be checked with
Related the monitoring mode.
information (Controller: HST, code: 40002 R SPEED, code: 40003 L SPEED, code: 40963 R SPEED, and code: 40964 L SPEED)
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)
D51EX/PX-22 40-319
TROUBLESHOOTING ERROR CODE [DLM1KA]
12
ERROR CODE [DLM1KA]
Action code Error code Left HST motor speed sensor: Disconnection
Trouble
E01 DLM1KA (HST controller system)
Contents of trouble • Disconnection was detected in Left HST motor speed sensor.
Action of • Stops the straight travel correction control.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Travel deviation occurs.
on machine
• Input state from the Left HST motor speed sensor (speed and frequency) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40003 L SPEED and code: 40964 L SPEED)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)
40-320 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM1KA]
Circuit diagram related to HST motor speed sensor
D51EX/PX-22 40-321
TROUBLESHOOTING ERROR CODE [DLM1KB]
12
ERROR CODE [DLM1KB]
Action code Error code Left HST motor speed sensor: Short circuit
Trouble
– DLM1KB (HST controller system)
Contents of trouble • Signal from Left HST motor speed sensor is not input despite the travel command.
Action of • Stops the straight travel correction control.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Travel deviation occurs.
on machine
• Input state from the Left HST motor speed sensor (speed in frequency) can be checked with the monitoring mode.
(Controller: HST, code: 40003 L SPEED and code: 40964 L SPEED)
Related • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)
information • If the error code is not reproduced, improper air bleeding immediately after the assembling or modification, or false detection of
the signal being transmitted at low temperature can be suspected rather than the error of the sensor. Replacement is not
necessary.
40-322 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM1KB]
D51EX/PX-22 40-323
TROUBLESHOOTING ERROR CODE [DLM1MA]
12
ERROR CODE [DLM1MA]
Action code Error code Left HST motor speed sensor: Malfunction
Trouble
– DLM1MA (HST controller system)
Contents of trouble • Signal from Left HST motor speed sensor is entered but substantial portion of the pulses are lost during transmission.
Action of • Stops the straight travel correction control.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Travel deviation occurs.
on machine
• Input state from the Left HST motor speed sensor (speed and frequency) can be checked with the monitoring mode.
(Controller: HST, code: 40003 L SPEED and code: 40964 L SPEED)
Related • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)
information • If the error code is not reproduced, improper air bleeding immediately after the assembling or modification, or false detection of
the signal being transmitted at low temperature can be suspected rather than the error of the sensor. Replacement is not neces-
sary.
40-324 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM1MA]
Circuit diagram related to HST motor speed sensor
D51EX/PX-22 40-325
TROUBLESHOOTING ERROR CODE [DLM2KA]
12
ERROR CODE [DLM2KA]
Action code Error code Right HST motor speed sensor: Disconnection
Trouble
E01 DLM2KA (HST controller system)
Contents of trouble • Disconnection was detected in Right HST motor speed sensor.
Action of • Stops the straight travel correction control.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Travel deviation occurs.
on machine
• Input state from the Right HST motor speed sensor (speed and frequency) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40002 R SPEED and code: 40963 R SPEED)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)
40-326 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM2KA]
Circuit diagram related to HST motor speed sensor
D51EX/PX-22 40-327
TROUBLESHOOTING ERROR CODE [DLM2KB]
12
ERROR CODE [DLM2KB]
Action code Error code Right HST motor speed sensor: Short circuit
Trouble
– DLM2KB (HST controller system)
Contents of trouble • Signal from Right HST motor speed sensor is not input despite the travel command.
Action of • The straight travel correction control is stopped.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Travel deviation occurs.
on machine
• Input state from the Right HST motor speed sensor (speed in frequency) is identifiable with the monitoring mode.
(Controller: HST, code: 40002 R SPEED and code: 40963 R SPEED)
Related • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)
information • If the error code is not reproduced, improper air bleeding immediately after the assembling or modification, or false detection of
the signal being transmitted at low temperature can be suspected rather than the error of the sensor. Replacement is not neces-
sary.
40-328 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM2KB]
D51EX/PX-22 40-329
TROUBLESHOOTING ERROR CODE [DLM2MA]
12
ERROR CODE [DLM2MA]
Action code Error code Right HST motor speed sensor: Malfunction
Trouble
– DLM2MA (HST controller system)
Contents of trouble • Signal from Right HST motor speed sensor is entered but substantial portion of the pulses are lost during transmission.
Action of • The straight travel correction control is stopped.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Travel deviation occurs.
on machine
• Input state from the Right HST motor speed sensor (speed and frequency) can be checked with the monitoring mode.
(Controller: HST, code: 40002 R SPEED and code: 40963 R SPEED)
Related • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)
information • If the error code is not reproduced, improper air bleeding immediately after the assembling or modification, or false detection of
the signal being transmitted at low temperature can be suspected rather than the error of the sensor. Replacement is not neces-
sary.
40-330 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM2MA]
Circuit diagram related to HST motor speed sensor
D51EX/PX-22 40-331
TROUBLESHOOTING ERROR CODE [DLM3KA]
12
ERROR CODE [DLM3KA]
40-332 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM3KA]
Circuit diagram related to fan speed sensor
D51EX/PX-22 40-333
TROUBLESHOOTING ERROR CODE [DLM3KB]
12
ERROR CODE [DLM3KB]
Contents of trouble • While the engine is running, no signal is input from the fan speed sensor.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Stop the fan control (feedback control).
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The fan speed fails to accurately meet the specified speed.
appears on machine
Related • Input state from the fan speed sensor (speed and frequency) can be checked with the monitoring mode.
information (Controller: HST, code: 10007 FAN SPEED and code: 40965 FAN SPEED)
40-334 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM3KB]
Circuit diagram related to fan speed sensor
D51EX/PX-22 40-335
TROUBLESHOOTING ERROR CODE [DN21FS]
12
ERROR CODE [DN21FS]
Action code Error code Brake pedal and proximity switch: Fixing
Trouble
E03 DN21FS (HST controller system)
• The signal of travel lock limit switch 1 is set to Free position and the signal of travel lock limit switch 2 (NO) is set to OFF
Contents of trouble
(OPEN), but the output circuit to the slow brake solenoid valve is not operating.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Input state from the travel lock limit switch (ON and OFF) can be checked with the monitoring mode.
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), code: 40912 D-IN [18]: switch 1 (NO), [19]: switch 2 (NC))
Related • Input state from the brake pedal sensor (stroke and voltage) can be checked with the monitoring mode.
information (Controller: HST, code: 50400 BRAKE PEDAL, code: 50401 BRAKE PEDAL)
• Method of reproducing error code: Start the engine, operate the parking brake lever (Free), and operate the brake pedal (press to
the full position)
40-336 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DN21FS]
Circuit diagram related to brake system
D51EX/PX-22 40-337
TROUBLESHOOTING ERROR CODE [DV00KB]
12
ERROR CODE [DV00KB]
Contents of trouble • Abnormal current flowed at the GND output to the caution buzzer circuit.
Action of • Stops GND output from the caution buzzer circuit.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that • The caution buzzer dose not sound when the starting switch is turned ON, emergency warning items becomes abnormal, or action
appears on machine code [E02], [E03] or [E04] is displayed.
Related
• Method of reproducing error code: Turn the starting switch ON.
information
40-338 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DV20KB]
12
ERROR CODE [DV20KB]
Contents of trouble • Abnormal current flowed at the output to the back alarm buzzer circuit.
Action of • Stops output to the back alarm buzzer circuit.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• Back alarm buzzer does not sound in the reverse travel.
on machine
• Output state from the back alarm buzzer (ON, OFF and voltage) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40918 D-OUT [S], and code: 70401 BACK ALARM)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (reverse travel)
D51EX/PX-22 40-339
TROUBLESHOOTING ERROR CODE [DW4BKA]
12
ERROR CODE [DW4BKA]
Contents of trouble • No current flows at output to the parking brake solenoid valve circuit.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Stops output of the signal to the parking brake solenoid valve circuit.
controller • Limits the functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The machine is stopped as long as traveling is continued.
Problem that appears
• The machine cannot be moved as long as traveling is stopped.
on machine
• Once the machine is stopped and started again, engine speed is limited to medium (half) speed.
• Output state to the parking brake solenoid valve (ON, and OFF) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40914 D-OUT [14])
information
• Method of reproducing error code: Turn the starting switch ON and operate parking brake lever (Free).
40-340 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW4BKA]
Circuit diagram related to parking brake solenoid valve
D51EX/PX-22 40-341
TROUBLESHOOTING ERROR CODE [DW4BKB]
12
ERROR CODE [DW4BKB]
Action code Error code Parking brake solenoid valve: Short circuit
Trouble
E04 DW4BKB (HST controller system)
Contents of trouble • Abnormal current flowed at output to the parking brake solenoid valve circuit.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Stops output of the signal to the parking brake solenoid valve circuit.
controller • Limits the functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The machine is stopped as long as traveling is continued.
Problem that appears
• The machine cannot be moved as long as traveling is stopped.
on machine
• Once the machine is stopped and started again, its engine speed is limited to medium (half) speed.
• Output state to the parking brake solenoid valve (ON, and OFF) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40914 D-OUT [14])
information
• Method of reproducing error code: Turn the starting switch ON and operate parking brake lever (Free).
40-342 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW4BKB]
Circuit diagram related to parking brake solenoid valve
D51EX/PX-22 40-343
TROUBLESHOOTING ERROR CODE [DW4BKY]
12
ERROR CODE [DW4BKY]
Action code Error code Parking brake solenoid valve: Short circuit with power supply line
Trouble
E03 DW4BKY (HST controller system)
Contents of trouble • Abnormal current constantly flows to the parking brake solenoid valve circuit.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• Output state to the parking brake solenoid valve (ON, and OFF) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40914 D-OUT [14])
information
• Method of reproducing error code: Turn the starting switch ON and operate parking brake lever (Lock).
40-344 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW7BKA]
12
ERROR CODE [DW7BKA]
Contents of trouble • No current flows at output to the fan reverse solenoid valve circuit.
Action of • Stops output of the signal to the fan reverse solenoid valve circuit.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• The fan does not rotate in reverse.
on machine
• Output state to the fan reverse solenoid valve (ON, and OFF) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40914 D-OUT [8])
information
• Method of reproducing error code: Turn the starting switch ON and operate the fan rotation selector switch (CLN).
D51EX/PX-22 40-345
TROUBLESHOOTING ERROR CODE [DW7BKB]
Action code Error code Fan reverse solenoid valve: Short circuit
Trouble
E01 DW7BKB (HST controller system)
Contents of trouble • Abnormal current flowed at output to the fan reverse solenoid valve circuit.
Action of • Stops output of the signal to the fan reverse solenoid valve circuit.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• The fan does not rotate in reverse.
on machine
• Output state to the fan reverse solenoid valve (ON, and OFF) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40914 D-OUT [8])
information
• Method of reproducing error code: Turn the starting switch ON and operate the fan rotation selector switch (CLN).
40-346 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW7BKY]
12
ERROR CODE [DW7BKY]
Action code Error code Fan reverse solenoid valve: Short circuit with power supply line
Trouble
E03 DW7BKY (HST controller system)
Contents of trouble • Abnormal current constantly flows to the fan reverse solenoid valve circuit.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The fan dose not rotate in forward.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped and started again, its travel speed is limited to 50%.
• Output state to the fan reverse solenoid valve (ON, and OFF) can be checked with the monitoring mode.
Related (Controller: HST, code: 40914 D-OUT [8])
information • Method of reproducing error code: Turn the starting switch ON and start the cleaning operation and operate the fan rotation
selector switch (NOR)
D51EX/PX-22 40-347
TROUBLESHOOTING ERROR CODE [DW7EKA]
12
ERROR CODE [DW7EKA]
40-348 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW7EKA]
D51EX/PX-22 40-349
TROUBLESHOOTING ERROR CODE [DW7EKA]
Circuit diagram related to brake system
40-350 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW7EKB]
12
ERROR CODE [DW7EKB]
Action code Error code Slow brake solenoid valve: Short circuit
Trouble
E04 DW7EKB (HST controller system)
Contents of trouble • Abnormal current flowed at output to the slow brake solenoid valve circuit.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of • Stops output of the signal to the slow brake solenoid valve circuit.
controller • Limits the functions partly.
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• The machine is stopped as long as traveling is continued.
Problem that appears
• The machine is stopped, it cannot be moved again.
on machine
• The machine is stopped, engine speed is limited to medium (half) speed.
• Input state from the travel lock limit switch (ON, and OFF) can be checked with the monitoring mode.
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), and code: 40912 D-IN [18]: switch 1 (NO), [19]: switch 2 (NC))
Related • Input state from the brake pedal (stroke and voltage) can be checked with the monitoring mode.
information (Controller: HST, code: 50400 BRAKE PEDAL, and code: 50401 BRAKE PEDAL)
• Method of reproducing error code: Turn on the starting switch, operate the parking brake lever (Free) and operate the brake
pedal (Release)
D51EX/PX-22 40-351
TROUBLESHOOTING ERROR CODE [DW7EKB]
Circuit diagram related to brake system
40-352 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW7EKY]
12
ERROR CODE [DW7EKY]
Action code Error code Slow brake solenoid valve: Short circuit with power supply line
Trouble
E03 DW7EKY (HST controller system)
Contents of trouble • Abnormal current constantly flows to the slow brake solenoid valve circuit.
• Flashes the warning lamp and sounds the alarm buzzer.
Action of
• Limits the functions partly.
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
Related • Method of reproducing error code: Turn on the starting switch, operate the parking brake lever (Free) and operate the brake
information pedal (Release)
D51EX/PX-22 40-353
TROUBLESHOOTING ERROR CODE [DW7EKY]
Circuit diagram related to brake system
40-354 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DWN5KA]
12
ERROR CODE [DWN5KA]
Contents of trouble • No current flows at output to the fan EPC solenoid valve circuit.
Action of • Stops output of the signal to the fan EPC solenoid valve circuit.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• The fan speed is set to the maximum.
on machine
• Output state to the fan EPC solenoid valve can be checked with the monitoring mode.
Related
(Controller: HST, code: 31623 FAN EPC, and code: 31624 FAN EPC FB)
information
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-355
TROUBLESHOOTING ERROR CODE [DWN5KA]
Circuit diagram related to fan EPC solenoid valve
40-356 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DWN5KB]
12
ERROR CODE [DWN5KB]
Action code Error code Fan EPC solenoid valve: Short circuit
Trouble
E01 DWN5KB (HST controller system)
Contents of trouble • Abnormal current flowed at output to the fan EPC solenoid valve circuit.
Action of • Stops output of the signal to the fan EPC solenoid valve circuit.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears
• The fan speed is set to the maximum.
on machine
• Output state to the fan EPC solenoid valve can be checked with the monitoring mode.
Related
(Controller: HST, code: 31623 FAN EPC, and code: 31624 FAN EPC FB)
information
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-357
TROUBLESHOOTING ERROR CODE [DWN5KB]
Circuit diagram related to fan EPC solenoid valve
40-358 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DWN5KY]
12
ERROR CODE [DWN5KY]
Action code Error code Fan EPC solenoid valve: Short circuit with power supply line
Trouble
E02 DWN5KY (HST controller system)
Contents of trouble • Abnormal current constantly flows to the fan EPC solenoid valve circuit.
Action of • Flashes the warning lamp and sounds the alarm buzzer.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears • The fan speed is set to the minimum.
on machine • Tends to overheat.
• Output state to the fan EPC solenoid valve can be checked with the monitoring mode.
Related
(Controller: HST, code: 31623 FAN EPC, and code: 31624 FAN EPC FB)
information
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-359
TROUBLESHOOTING ERROR CODE [DXA4KA]
12
ERROR CODE [DXA4KA]
Action code Error code LF HST pump EPC solenoid valve: Disconnection
Trouble
E03 DXA4KA (HST controller system)
Contents of trouble • When the signal is output to the LF HST pump EPC solenoid valve, no current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit, too.
controller
• Limits the functions partly.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling forward, it stops.
Problem that appears • If the machine has been stopped, it cannot start forward.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%
• The output state (command current, sensed current) to the LF HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52401 – LF PUMP, Code: 52409 – LF PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the forward direction).
40-360 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA4KA]
Circuit diagram related to LF HST pump EPC solenoid valve
D51EX/PX-22 40-361
TROUBLESHOOTING ERROR CODE [DXA4KB]
12
ERROR CODE [DXA4KB]
Action code Error code LF HST pump EPC solenoid valve: Short circuit
Trouble
E03 DXA4KB (HST controller system)
Contents of trouble • When the signal is output to the LF HST pump EPC solenoid valve, an abnormal current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit, too.
controller
• Limits the functions partly.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling forward, it stops.
Problem that appears • If the machine has been stopped, it cannot start forward.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the LF HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52401 – LF PUMP, Code: 52409 – LF PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the forward direction).
40-362 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA4KY]
Action code Error code LF HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXA4KY (HST controller system)
Contents of trouble • A current is constantly flowing to the LF HST pump EPC solenoid valve circuit.
• Flashes the warning lamp and sounds the warning buzzer.
Action of
• Limits the functions partly.
controller
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• The left-hand track keeps rotating forward.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped, it cannot start again.
• The output state (command current, sensed current) to the LF HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52401 – LF PUMP, Code: 52409 – LF PUMP FB)
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-363
TROUBLESHOOTING ERROR CODE [DXA5KA]
12
ERROR CODE [DXA5KA]
Action code Error code LR HST pump EPC solenoid valve: Disconnection
Trouble
E03 DXA5KA (HST controller system)
Contents of trouble • When the signal is output to the LR HST pump EPC solenoid valve, no current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit, too.
controller
• Limits the functions partly.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling in reverse, it stops.
Problem that appears • If the machine has been stopped, it cannot start in reverse.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the LR HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52403 – LR PUMP, Code: 52411 – LR PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the reverse direction).
40-364 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA5KA]
Circuit diagram related to LR HST pump EPC solenoid valve
D51EX/PX-22 40-365
TROUBLESHOOTING ERROR CODE [DXA5KB]
12
ERROR CODE [DXA5KB]
Action code Error code LR HST pump EPC solenoid valve: Short circuit
Trouble
E03 DXA5KB (HST controller system)
Contents of trouble • When the signal is output to the LR HST pump EPC solenoid valve, an abnormal current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit, too.
controller
• Limits the functions partly.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling in the reverse, it stops.
Problem that appears • If the machine has been stopped, it cannot start in the reverse.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the LR HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52403 – LR PUMP, Code: 52411 – LR PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the reverse direction).
40-366 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA5KY]
Action code Error code LR HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXA5KY (HST controller system)
Contents of trouble A current is constantly flowing to the LR HST pump EPC solenoid valve circuit.
• Flashes the warning lamp and sounds the warning buzzer.
Action of
• Limits the functions partly.
controller
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• The left-hand track keeps rotating in the reverse.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped, it cannot start again.
• The output state (command current, sensed current) to the LR HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52403 – LR PUMP, Code: 52411 – LR PUMP FB)
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-367
TROUBLESHOOTING ERROR CODE [DXA6KA]
12
ERROR CODE [DXA6KA]
Action code Error code RF HST pump EPC solenoid valve: Disconnection
Trouble
E03 DXA6KA (HST controller system)
Contents of trouble • When the signal is output to the RF HST pump EPC solenoid valve, no current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit, too.
controller
• Limits the functions partly.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling forward, it stops.
Problem that appears • If the machine has been stopped, it cannot start forward.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the RF HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52400 – RF PUMP, Code: 52408 – RF PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the forward direction).
40-368 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA6KA]
Circuit diagram related to RF HST pump EPC solenoid valve
D51EX/PX-22 40-369
TROUBLESHOOTING ERROR CODE [DXA6KB]
12
ERROR CODE [DXA6KB]
Action code Error code RF HST pump EPC solenoid valve: Short circuit
Trouble
E03 DXA6KB (HST controller system)
Contents of trouble • When the signal is output to the RF HST pump EPC solenoid valve, an abnormal current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit, too.
controller
• Limits the functions partly.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling forward, it stops.
Problem that appears • If the machine has been stopped, it cannot start forward.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the RF HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52400 – RF PUMP, Code: 52408 – RF PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the forward direction).
40-370 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA6KY]
Action code Error code RF HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXA6KY (HST controller system)
Contents of trouble • A current is constantly flowing to the RF HST pump EPC solenoid valve circuit.
• Flashes the warning lamp and sounds the warning buzzer.
Action of
• Limits the functions partly.
controller
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• The right-hand track keeps rotating forward.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped, it cannot moved again.
• The output state (command current, sensed current) to the RF HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52400 – RF PUMP, Code: 52408 – RF PUMP FB)
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-371
TROUBLESHOOTING ERROR CODE [DXA7KA]
12
ERROR CODE [DXA7KA]
Action code Error code RR HST pump EPC solenoid valve: Disconnection
Trouble
E03 DXA7KA (HST controller system)
Contents of trouble • When the signal is output to the RR HST pump EPC solenoid valve, no current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit, too.
controller
• Limits the functions partly.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling in reverse, it stops.
Problem that appears • If the machine has been stopped, it cannot start in reverse.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the RR HST pump EPC solenoid valve can be checked in the monitoring
Related
mode. (Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)
information
• Method of reproducing error code: Start engine and operate the PCCS lever (in the reverse direction).
40-372 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA7KA]
Circuit diagram related to RR HST pump EPC solenoid valve
D51EX/PX-22 40-373
TROUBLESHOOTING ERROR CODE [DXA7KA]
12
ERROR CODE [DXA7KB]
Action code Error code RR HST pump EPC solenoid valve: Short circuit
Trouble
E03 DXA7KB (HST controller system)
Contents of trouble • When the signal is output to the RR HST pump EPC solenoid valve, an abnormal current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit, too.
controller
• Limits the functions partly.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling in the reverse, it stops.
Problem that appears • If the machine has been stopped, it cannot start in the reverse.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%.
• The output state (command current, sensed current) to the RR HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the reverse direction).
40-374 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA7KY]
Action code Error code RR HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXA7KY (HST controller system)
Contents of trouble • A current is constantly flowing to the RR HST pump EPC solenoid valve circuit.
• Flashes the warning lamp and sounds the warning buzzer.
Action of
• Limits the functions partly.
controller
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• The right-hand track keeps rotating in the reverse.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped, it cannot move again.
• The output state (command current, sensed current) to the RR HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-375
TROUBLESHOOTING ERROR CODE [DXK1KA]
12
ERROR CODE [DXK1KA]
Action code Error code Left HST motor EPC solenoid valve: Disconnection
Trouble
E02 DXK1KA (HST controller system)
Contents of trouble • When the signal is output to the Left HST motor EPC solenoid valve, no current flows.
• Flashes the warning lamp and sounds the warning buzzer.
Action of • Stops outputting to the Left HST motor EPC solenoid valve circuit.
controller • Stops outputting to the Right HST motor EPC solenoid valve circuit, too.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
Problem that appears • If the machine has been traveling at high-speed, it decelerates.
on machine • The machine cannot travel at high-speed.
• The output state (command current, sensed current) to the Left HST motor EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52302 – L MOTOR, Code: 52304 – L PUMP FB)
• Method of reproducing error code: Start engine and travel the machine at high-speed.
40-376 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXK1KB]
Action code Error code Left HST motor EPC solenoid valve: Short circuit
Trouble
E02 DXK1KB (HST controller system)
Contents of trouble • When the signal is output to the Left HST motor EPC solenoid valve, an abnormal current flows.
• Flashes the warning lamp and sounds the warning buzzer.
Action of • Stops outputting the signal to the Left HST motor EPC solenoid valve circuit.
controller • Stops outputting the signal to the Right HST motor EPC solenoid valve circuit, too.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
Problem that appears • If the machine has been traveling at high-speed, it decelerates.
on machine • The machine cannot travel at high-speed.
• The output state (command current, sensed current) to the Left HST motor EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52302 – L MOTOR, Code: 52304 – L PUMP FB)
• Method of reproducing error code: Start engine and travel the machine at high-speed.
D51EX/PX-22 40-377
TROUBLESHOOTING ERROR CODE [DXK1KY]
12
ERROR CODE [DXK1KY]
Action code Error code Left HST motor EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXK1KY (HST controller system)
Contents of trouble A current is constantly flowing to the Left HST motor EPC solenoid valve circuit.
Flashes the warning lamp and sounds the warning buzzer.
Action of
Limits the functions partly.
controller
Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
The speed of the Left-hand track becomes fast.
Problem that appears
Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
Once the machine is stopped, it cannot move again.
The output state (command current, sensed current) to the Left HST motor EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52302 – L MOTOR, Code: 52304 – L PUMP FB)
Method of reproducing error code: Turn the starting switch ON.
40-378 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXK2KA]
12
ERROR CODE [DXK2KA]
Action code Error code Right HST motor EPC solenoid valve: Disconnection
Trouble
E02 DXK2KA (HST controller system)
Contents of trouble • When the signal is output to the Right HST motor EPC solenoid valve, no current flows.
• Flashes the warning lamp and sounds the warning buzzer.
Action of • Stops outputting to the Right HST motor EPC solenoid valve circuit.
controller • Stops outputting to the Left HST motor EPC solenoid valve circuit, too.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
Problem that appears • If the machine has been traveling at high-speed, it decelerates.
on machine • The machine cannot travel at high-speed.
• The output state (command current, sensed current) to the Right HST motor EPC solenoid valve can be checked in the monitor-
Related
ing mode. (Controller: HST, Code: 52301 – R MOTOR, Code: 52303 – R PUMP FB)
information
• Method of reproducing error code: Start engine and travel the machine at high-speed.
D51EX/PX-22 40-379
TROUBLESHOOTING ERROR CODE [DXK2KB]
Action code Error code Right HST motor EPC solenoid valve: Short circuit
Trouble
E02 DXK2KB (HST controller system)
Contents of trouble • When the signal is output to the Right HST motor EPC solenoid valve, an abnormal current flows.
• Flashes the warning lamp and sounds the warning buzzer.
Action of • Stops outputting the signal to the Right HST motor EPC solenoid valve circuit.
controller • Stops outputting the signal to the Left HST motor EPC solenoid valve circuit, too.
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
Problem that appears • If the machine has been traveling at high-speed, it decelerates.
on machine • The machine cannot travel at high-speed.
• The output state (command current, sensed current) to the Right HST motor EPC solenoid valve can be checked in the monitor-
Related
ing mode. (Controller: HST, Code: 52301 – R MOTOR, Code: 52303 – R PUMP FB)
information
• Method of reproducing error code: Start engine and travel the machine at high-speed.
40-380 D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXK2KY]
12
ERROR CODE [DXK2KY]
Action code Error code Right HST motor EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXK2KY (HST controller system)
Contents of trouble • A current is constantly flowing to the Right HST motor EPC solenoid valve circuit.
• Flashes the warning lamp and sounds the warning buzzer.
Action of
• Limits the functions partly.
controller
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• The speed of the Right-hand track becomes fast.
Problem that appears
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped, it cannot move again.
• The output state (command current, sensed current) to the Right HST motor EPC solenoid valve can be checked in the monitor-
Related ing mode.
information (Controller: HST, Code: 52301 – R MOTOR, Code: 52303 – R PUMP FB)
• Method of reproducing error code: Turn the starting switch ON.
D51EX/PX-22 40-381
40 TROUBLESHOOTING (E-MODE)
12
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE) . . . . . . . . . . . . . . . . . . . 1-403
CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-403
INFORMATION IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-405
E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-406
STARTING MOTOR DOES NOT ROTATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-406
E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-409
ENGINE IS NOT PRE-HEATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-409
E-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-412
WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT . . . 1-412
E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-414
CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING . . . . . . . . 1-414
E-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-420
PRE-HEATE LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION . 1-420
E-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-422
COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY . . . . 1-422
E-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-423
HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY . . . . . . 1-423
E-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-424
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY . . . . . . . . . . . . . . . . . . . 1-424
E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-426
TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY . . . . . . . . . . . . . . . . . . 1-426
E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-426
MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY . . . . . . . . . . . . 1-426
E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-426
CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF . . . . . . . . . . . . . . . . 1-426
E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-427
CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP . . . . . . . . . . . . . . . 1-427
E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-429
REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION . . . . . . . 1-429
E-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-431
SHIFT MODE SWITCH DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-431
E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-433
BUZZER CANCEL SWITCH DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 1-433
E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-435
INFORMATION SWITCH DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-435
E-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-437
THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET . . . . . . . . 1-437
E-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-439
BACKUP ALARM DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-439
E-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-440
D51EX/PX-22 40-401
TROUBLESHOOTING
40-402 D51EX/PX-22
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOT-
12
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
Capacity of
Type of power supply Fuse No. Destination of power
fuse
1
20 A Head lamp and rear lamp
(Between terminals 1 and 1A)
2
10 A Horn
(Between terminals 2 and 2A)
3
10 A PPC lock
(Between terminals 3 and 3A)
4
30 A Air conditioner (Cab specification)
Switch power supply (Between terminals 4 and 4A)
(Battery relay terminal M) 5
10 A HST controller (Solenoid power supply)
(Between terminals 5 and 5B)
6
10 A Center brake
(Between terminals 6 and 6B)
7 Switch power supply of fuse box B
30 A
(Between terminals 7 and 7B) (Cab specification)
8 Switch power supply of fuse box B
30 A
(Between terminals 8 and 8B) (Cab specification)
9
15 A Starting switch (terminal B)
Constant power supply (Between terminals 9 and 9C)
(Battery relay terminal B) 10
30 A Engine controller (Main power supply)
(Between terminals 10 and 10C)
11
20 A Spare power supply (No destination)
(Between terminals 11 and 11D)
12
15 A pre-heat
Switch power supply (Between terminals 12 and 12D)
(Battery relay terminal M) 13
10 A Foot heater (If equipped)
(Between terminals 13 and 13D)
14
15 A Air suspension seat
(Between terminals 14 and 14D)
15
10 A HST controller (Main power supply)
(Between terminals 15 and 15E)
16
10 A Monitor panel
(Between terminals 16 and 16E)
Constant power supply 17
10 A KOMTRAX controller
(Battery relay terminal B) (Between terminals 17 and 17E)
18
10 A Service connector (CN-DT12 connector)
(Between terminals 18 and 18E)
19
10 A Constant power supply of fuse box B
(Between terminals 19 and 19E)
Switch power supply 20
5A Engine controller (ACC signal)
(Starting switch terminal ACC) (Between terminals 20 and 20F)
D51EX/PX-22 40-403
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOT-
Fuse box B (FUSE) [Cab specification]
Fuse
Type of power supply Fuse No. Destination of power
capacity
Constant power supply (Fuse 1
10A Radio (Constant power supply)
box CN-F01 (19)) (Between terminals 1 and F)
2
20A Additional working lamp
(Between terminals 2 and B)
3
20A Lighter, 12 V socket
(Between terminals 3 and B)
Switch power supply (Fuse 4
10A Room lamp, radio
box F01- (7) (8)) (Between terminals 4 and B)
5
10A Front wiper and washer, rear wiper and washer
(Between terminals 5 and B)
6
10A Left and right door wiper and washer
(Between terminals 6 and B)
40-404 D51EX/PX-22
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TA-
12
INFORMATION IN TROUBLESHOOTING TABLE
• The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before
carrying out troubleshooting, understand that information fully.
D51EX/PX-22 40-405
TROUBLESHOOTING E-1
E-1
Trouble • When starting switch is turned to START position, starting motor does not rotate.
• Since the engine starting circuit has the neutral safety function, the engine does not start unless the parking brake lever is in the
LOCK position and the travel lever is in the neutral position. (When the engine can start, [P] is lighted up on the monitor panel.)
• KOMTRAX has start lock function. If start lock is not reset, engine cannot start.
Related • If “monitor panel does not light” or “battery relay operation sound is not heard” when starting switch is turned ON, main power
information supply system may be defective. Check main power supply system.
• Since the HST controller controls the neutral safety relay with the travel lock switch signal, check that a related error code is not
displayed before carrying out troubleshooting. (If error code [D130KA], [D130KB], [DD14KB], or [DDQ2KA] is displayed, carry
out troubleshooting for it first.)
40-406 D51EX/PX-22
TROUBLESHOOTING E-1
D51EX/PX-22 40-407
TROUBLESHOOTING E-1
Circuit diagram related to engine pre-heating, starting, charging, and stopping functions
40-408 D51EX/PX-22
TROUBLESHOOTING E-2
12
E-2
D51EX/PX-22 40-409
TROUBLESHOOTING E-2
40-410 D51EX/PX-22
TROUBLESHOOTING E-2
Circuit diagram related to engine pre-heating, starting, charging, and stopping functions
D51EX/PX-22 40-411
TROUBLESHOOTING E-3
12
E-3
WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT
Trouble • When starting switch is turned ON, any item does not light up.
Related • When the starting switch is turned ON, the gear speed/Set travel speed/Shift mode indicator section, multi-information section,
information gauge section, and lamp section light up for approx 2 seconds.
40-412 D51EX/PX-22
TROUBLESHOOTING E-3
Circuit diagram related to monitor panel power supply
D51EX/PX-22 40-413
TROUBLESHOOTING E-4
12
E-4
40-414 D51EX/PX-22
TROUBLESHOOTING E-4
Circuit diagram related to engine pre-heating, starting, charging, and stopping functions
D51EX/PX-22 40-415
TROUBLESHOOTING E-5
12
E-5
40-416 D51EX/PX-22
TROUBLESHOOTING E-5
Trouble (4) The caution lamp of water level in the fuel filter lights up.
Related • The caution lamp of water level in the fuel filter lights up when the water level in the water separator located under the fuel
information pre-heater rises, and goes out by draining the water.
D51EX/PX-22 40-417
TROUBLESHOOTING E-5
40-418 D51EX/PX-22
TROUBLESHOOTING E-5
D51EX/PX-22 40-419
TROUBLESHOOTING E-6
12
E-6
Trouble • Pre-heating pilot lamp does not light up during pre-heating operation.
• This troubleshooting is for the case when the pre-heating pilot lamp does not light up during the pre-heating operation. (When the
intake air heater is not heated, carry out troubleshooting for “Engine is not pre-heated”.)
Related • pre-heating system has “automatic pre-heating function” and “manual pre-heating function”. When either of those functions oper-
information ates, pre-heater lamp lights.
• The input state (ON/OFF) from the heater relay can be checked in the monitoring mode. (Controller: MONITOR PANEL, Code:
40921 D-IN [2])
40-420 D51EX/PX-22
TROUBLESHOOTING E-6
Circuit diagram related to engine pre-heating, starting, charging, and stopping function
D51EX/PX-22 40-421
TROUBLESHOOTING E-7
12
E-7
(1)Although the coolant temperature is rising normally, the indication of the coolant temperature stays in white range (a).
Trouble
(2)Although the coolant temperature is stabilized normally, the indication of the coolant temperature rises to red range (c).
• Signals of the coolant temperature sensor are input into the engine controller and that information is transmitted to the monitor
Related panel through communication system.
information • The input state (temperature) from the coolant temperature sensor can be checked in the monitoring mode.
(Controller: ENGINE, Code: 04107 COOLANT TEMP)
(3)The coolant temperature does not match to the indication of coolant temperature gauge.
Trouble
(4)The coolant temperature gauge does not match with the indication of coolant temperature monitor.
• Signals of the coolant temperature sensor are input into the engine controller and that information is transmitted to the monitor
Related panel through communication system.
information • The input state (temperature) from the coolant temperature sensor can be checked in the monitoring mode. (Controller: ENGINE,
Code: 04107 COOLANT TEMP)
40-422 D51EX/PX-22
TROUBLESHOOTING E-8
12
E-8
(1)Although the HST oil temperature is rising normally, the indication of the HST oil temperature stays in white range (a).
Trouble
(2)Although the HST oil temperature is stabilized normally, the indication of the HST oil temperature rises to red range (c).
• Signals of the HST oil temperature sensor are input into the HST controller and that information is transmitted to the monitor panel
Related through communication system.
information • The input state (temperature) from the HST oil temperature sensor can be checked in the monitoring mode.
(Controller: HST, Code: 04401 HST TEMP)
(3)The HST oil temperature does not match to the indication of HST oil temperature gauge.
Trouble
(4)The HST oil temperature gauge does not match with the indication of HST oil temperature monitor.
• Signals of the HST oil temperature sensor are input into the HST controller and that information is transmitted to the monitor panel
Related through communication system.
information • The input state (temperature) from the HST oil temperature sensor can be checked in the monitoring mode. (Controller: HST, Code:
04001 HST TEMP)
D51EX/PX-22 40-423
TROUBLESHOOTING E-9
12
E-9
40-424 D51EX/PX-22
TROUBLESHOOTING E-9
Circuit diagram related to fuel level sensor
D51EX/PX-22 40-425
TROUBLESHOOTING E-10
12
E-10
Trouble • Gear speed, set travel speed, and shift mode indicator does not display normally.
Related • Display information of the gear speed, set travel speed, and shift mode indicator is received from the HST controller through the
information communication system.
E-11
Trouble (1) Service meter does not move forward while engine is running.
Related • Service meter starts counting when monitor panel receives engine start signal (alternator R signal).
information • While the service meter is moving forward, the hourglass mark is displayed.
E-12
40-426 D51EX/PX-22
TROUBLESHOOTING E-13
E-13
D51EX/PX-22 40-427
TROUBLESHOOTING E-13
Circuit diagram related to caution buzzer
40-428 D51EX/PX-22
TROUBLESHOOTING E-14
12
E-14
D51EX/PX-22 40-429
TROUBLESHOOTING E-14
Circuit diagram related to reverse travel speed setting switch
40-430 D51EX/PX-22
TROUBLESHOOTING E-15
12
E-15
D51EX/PX-22 40-431
TROUBLESHOOTING E-15
Circuit diagram related to shift mode switch
40-432 D51EX/PX-22
TROUBLESHOOTING E-16
12
E-16
1
Defective buzzer cancel switch Neutral, ◊ (Left) Min. 1 MΩ
(Internal disconnection or short circuit) Between (5) and (6)
t (Right) Max. 1 Ω
Neutral, t (Right) Min. 1 MΩ
Between (5) and (4)
◊ (Left) Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Wiring harness between CN-S03 (female) (17) and CN-
Disconnection in wiring harness Resistance Max. 1 Ω
BUZ (female) (6)
2 (Disconnection in wiring harness or
defective contact in connector) Wiring harness between CN-S03 (female) (16) and CN-
Resistance Max. 1Ω
BUZ (female) (4)
Wiring harness between CN-S03 (female) (5) (6)and CN-
Resistance Max. 1 Ω
BUZ (female) (5)
Possible causes and
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
standard value in
starting switch.
normal state Short circuit with chassis ground in
Between CN-S03 (female) (17) – CN-BUZ (female) (6)
3 wiring harness (Contact with ground Resistance Min. 1 MΩ
wiring harness and chassis ground
circuit)
Between CN-S03 (female) (16) – CN-BUZ (female) (4)
Resistance Min. 1 MΩ
wiring harness and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Short circuit with power source in
4 wiring harness (Contact with 24V Between CN-S03 (female) (17) – CN-BUZ (female) (6)
Voltage Max. 1 V
wiring harness and chassis ground
circuit)
Between CN-S03 (female) (16) – CN-BUZ (female) (4)
Voltage Max. 1 V
wiring harness and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
CN-S03/CN-BUZ Buzzer cancel switch Voltage
5 Defective monitor panel Between CN-503 (17) and Neutral, ◊ (Left) Max. 1 V
chassis ground t (Right) 20 – 30 V
Between CN-503 (16) and Neutral, t (Right) Max. 1 V
chassis ground ◊ (Left) 20 – 30 V
D51EX/PX-22 40-433
TROUBLESHOOTING E-16
Circuit diagram related to buzzer cancel switch
40-434 D51EX/PX-22
TROUBLESHOOTING E-17
12
E-17
D51EX/PX-22 40-435
TROUBLESHOOTING E-17
Circuit diagram related to information switch
40-436 D51EX/PX-22
TROUBLESHOOTING E-18
12
E-18
D51EX/PX-22 40-437
TROUBLESHOOTING E-18
Circuit diagram related to fan rotation selector switch
40-438 D51EX/PX-22
TROUBLESHOOTING E-19
12
E-19
D51EX/PX-22 40-439
TROUBLESHOOTING E-20
12
E-20
40-440 D51EX/PX-22
TROUBLESHOOTING E-21
E-21
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Defective work equipment lock sole-
2 noid valve CN-PSL (male) Resistance
(Internal defect) Between (1) and (2) 40 – 60Ω
Between (1), (2) and chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Work equipment lock lever
Defective work equipment lock switch CN-PSW (male) FREE LOCK
3
(Internal defect) (Upper position) (Lower position)
Between (A) and (C) Max. 1 Ω Min. 1 MΩ
Between (A), (C) and
Min. 1 MΩ Min. 1 MΩ
chassis ground
Possible causes and Defective installation of work Work equipment lock switch may be installed defectively. Check it directly (See Testing
4
equipment lock switch and adjusting).
standard value in
normal state ★ Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective diode starting switch.
5
(Internal short circuit) CN-D4 (male) Resistance (Continuity)
Between (1) and (5) Min. 1 MΩ (Broken)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Wiring harness between CN-F01 (3) and CN-PSW
Disconnection in wiring harness Resistance Max. 1 Ω
(female) (A)
6 (Disconnection in wiring harness or
defective contact in connector) Wiring harness between CN-PSW (female) (C) and CN-
Resistance Max. 1 Ω
PSL (female) (1)
Wiring harness between CN-PSL (female) (2) and chassis
Resistance Max. 1 Ω
ground (CN-T35)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Short circuit with chassis ground in
Between CN-F01 (3) – CN-PSW (female) (A) wiring har-
7 wiring harness Resistance Min. 1M Ω
ness and chassis ground
(Contact with ground circuit)
Between CN-PSW (female) (C) – CN-PSL (female) (1)
Resistance Max. 7 Ω
wiring harness and chassis ground
D51EX/PX-22 40-441
TROUBLESHOOTING E-21
Electric circuit diagram related to “work equipment does not move”
40-442 D51EX/PX-22
TROUBLESHOOTING E-22
12
E-22
D51EX/PX-22 40-443
TROUBLESHOOTING E-22
40-444 D51EX/PX-22
TROUBLESHOOTING E-22
Circuit diagram related to lamp and panel night lighting system
D51EX/PX-22 40-445
TROUBLESHOOTING E-23
12
E-23
40-446 D51EX/PX-22
TROUBLESHOOTING E-23
D51EX/PX-22 40-447
TROUBLESHOOTING E-23
Circuit diagram related to foot heater
40-448 D51EX/PX-22
TROUBLESHOOTING E-24
12
E-24
D51EX/PX-22 40-449
TROUBLESHOOTING E-24
40-450 D51EX/PX-22
TROUBLESHOOTING E-24
D51EX/PX-22 40-451
TROUBLESHOOTING E-24
40-452 D51EX/PX-22
TROUBLESHOOTING E-24
Circuit diagram related to air conditioner
D51EX/PX-22 40-453
TROUBLESHOOTING E-25
12
E-25
40-454 D51EX/PX-22
TROUBLESHOOTING E-25
D51EX/PX-22 40-455
TROUBLESHOOTING E-25
Trouble (3) Rear windshield wiper does not operate (Continuous operation is defective).
Related • If fuse (FUSE (5)) is broken, operations of both front windshield wiper and rear windshield wiper become defective.
information • Carry out troubleshooting with rear wiper switch ON.
40-456 D51EX/PX-22
TROUBLESHOOTING E-25
Trouble (4) Right door wiper does not operate (Continuous operation is defective).
Related • If fuse (FUSE (6)) is broken, operations of both right door wiper and left door wiper become defective.
information • Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF.
D51EX/PX-22 40-457
TROUBLESHOOTING E-25
12
Trouble (5) Right door wiper does not operate intermittently.
• Before carrying out troubleshooting, check that continuous operation is normal.
Related
• Carry out troubleshooting with right door wiper switch and intermittent switch ON.
information
• During intermittent operation, wiper stops for 5 seconds after each cycle of operation.
40-458 D51EX/PX-22
TROUBLESHOOTING E-25
Trouble (6) Left door wiper does not operate (Continuous operation is defective).
Related • If fuse (FUSE (6)) is broken, operations of both right door wiper and left door wiper become defective.
information • Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF.
D51EX/PX-22 40-459
TROUBLESHOOTING E-25
40-460 D51EX/PX-22
TROUBLESHOOTING E-25
Trouble (8) Water does not come out from front window washer.
Related • Before carrying out troubleshooting, check that windshield wiper operates normally.
information • If fuse (FUSE (5)) is broken, operations of both front window washer and rear window washer become defective.
D51EX/PX-22 40-461
TROUBLESHOOTING E-25
Trouble (9) Water does not come out from rear window washer.
Related • Before carrying out troubleshooting, check that windshield wiper operates normally.
information • If fuse (FUSE (5)) is broken, operations of both front window washer and rear window washer become defective.
40-462 D51EX/PX-22
TROUBLESHOOTING E-25
Trouble (10) Water does not come out from right door washer.
Related • Before carrying out troubleshooting, check that windshield wiper operates normally.
information • If fuse (FUSE (6)) is broken, operations of both right door washer and left door washer become defective.
D51EX/PX-22 40-463
TROUBLESHOOTING E-25
Trouble (11) Water does not come out from left door washer.
Related • Before carrying out troubleshooting, check that windshield wiper operates normally.
information • If fuse (FUSE (6)) is broken, operations of both right door washer and left door washer become defective.
40-464 D51EX/PX-22
TROUBLESHOOTING E-25
Circuit diagram related to windshield wiper and window washer
D51EX/PX-22 40-465
TROUBLESHOOTING E-26
12
E-26
Defective starting switch ACC signal ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting.
2
and alternator R signal CN-G01 Signal Voltage
Between (36) and Starting switch
20 – 30 V
(37), (38) ACC supply
Between (28) and
Alternator R 20 – 30 V
(37), (38)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out
Possible causes and troubleshooting.
standard value in 3 Defective starting switch C signal CN-G01 Signal Voltage
normal state
Between (27) and
Starting switch C 20 – 30 V
(37), (38)
★ Turn starting switch ON and carry out troubleshooting.
LED (4) Normal state
LED-C4 ON
4 State of CAN connection
★ Prepare with starting switch OFF and carry out troubleshooting.
CN-G01 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 Ω
★ Turn starting switch ON and carry out troubleshooting.
Number of mails not
5 LED (7) Normal state
transmitted yet
7-segment 0–9
★ Turn starting switch ON and carry out troubleshooting
LED (8) Normal state
6 State of positioning with GPS Dot ON
In an outdoor location within radio waves' penetration range, it sometimes takes more
than a minute from turning on of the starting switch to completion of the positioning.
40-466 D51EX/PX-22
TROUBLESHOOTING E-26
12
LED display unit
CK01 connector
D51EX/PX-22 40-467
40 TROUBLESHOOTING (H-MODE)
12
INFORMATION IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-503
H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-504
RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE . . . . . . . . . . . . . . . . . . . . 40-504
H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-506
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE . . . . . . . . . . . . . . . . 40-506
H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-507
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE . . . . . . . . . . . . . . . . . 40-507
H-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-508
SPEED OR POWER OF TRAVEL IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-508
H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-509
GEAR IS NOT SHIFTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-509
H-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-510
LARGE SHOCKS ARE MADE WHEN MACHINE
STARTS AND STOPS TRAVEl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-510
H-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-511
MACHINE DEVIATES LARGELY DURING TRAVEL . . . . . . . . . . . . . . . . . . . . . . 40-511
H-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-512
HYDRAULIC DRIFT OF TRAVEL IS LARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-512
H-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-513
ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEl . . . . . 40-513
H-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-514
ABNORMAL SOUND COMES OUT FROM
AROUND HST PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-514
H-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-515
WORK EQUIPMENT DOSE NOT OPERATE AT ALL . . . . . . . . . . . . . . . . . . . . . . 40-515
H-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-516
SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW . . . . . . . . . . . . . . 40-516
H-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-517
SPEED OR POWER OF LIFTING BLADE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . 40-517
H-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-518
SPEED OR POWER OF TILTING BLADE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . 40-518
H-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-519
SPEED OR POWER OF ANGLING BLADE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . 40-519
H-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-520
TIME LAG IN LIFTING BLADE IS LARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-520
H-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-521
HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE . . . . . . . . . . . . . . . . . . . . . . 40-521
H-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-522
HYDRAULIC DRIFT OF TILTING BLADE IS LARGE . . . . . . . . . . . . . . . . . . . . . . 40-522
H-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-523
D51EX/PX-22 40-501
TROUBLESHOOTING
40-502 D51EX/PX-22
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TA-
12
INFORMATION IN TROUBLESHOOTING TABLE
★ The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand
that information fully.
D51EX/PX-22 40-503
TROUBLESHOOTING H-1
12
H-1
40-504 D51EX/PX-22
TROUBLESHOOTING H-1
D51EX/PX-22 40-505
TROUBLESHOOTING H-2
12
H-2
40-506 D51EX/PX-22
TROUBLESHOOTING H-3
12
H-3
Contents of trouble • Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).
• If this trouble occurs just after the initial adjustment of the pump, the pump may be adjusted wrongly. In this case, perform the ini-
tial adjustment of the pump again.
(During idle travel: 3001-F-PUMP LINE, 3002-R-PUMP LINE)
(During actual travel: 3003-F-PUMP RUN1, 3004-R-PUMP RUN1, 3005-F-PUMP RUN2, 3006-R-PUMP RUN2)
• HST pump capacity command value and HST pump EPC current command value can be checked in the real-time monitoring
mode.
Controller: HST
Related Capacity command Current command
information
value value
Right front 52404 52400 RF PUMP
Left front 52405 52401 LF PUMP
Right rear 52406 52402 RR PUMP
Left rear 52407 52403 LR PUMP
a If each command value is 0, cause of failure is not in hydraulic system but in electrical system (on controller side).
D51EX/PX-22 40-507
TROUBLESHOOTING H-4
12
H-4
40-508 D51EX/PX-22
TROUBLESHOOTING H-5
12
H-5
D51EX/PX-22 40-509
TROUBLESHOOTING H-6
12
H-6
LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEl
Contents of trouble • Large shocks are made when machine starts and stops travel.
Related
information
40-510 D51EX/PX-22
TROUBLESHOOTING H-7
12
H-7
D51EX/PX-22 40-511
TROUBLESHOOTING H-8
12
H-8
40-512 D51EX/PX-22
TROUBLESHOOTING H-9
12
H-9
Malfunction of 5-spool valve (HST Stop and travel in 1st 0 kg/cm2 (0 psi)
4
motor EPC valve)
Travel in 2nd 15 ± 5 kg/cm2
Quick shift mode (213 ± 71 psi)
D51EX/PX-22 40-513
TROUBLESHOOTING H-10
12
H-10
ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR
Contents of trouble • Abnormal sound comes out from around HST pump and motor.
Related
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
information
40-514 D51EX/PX-22
TROUBLESHOOTING H-11
12
H-11
If the oil pressure does not become normal after adjustment, the main relief valve
may have a malfunction or a defect in it. Check the main relief valve directly.
D51EX/PX-22 40-515
TROUBLESHOOTING H-12
12
H-12
40-516 D51EX/PX-22
TROUBLESHOOTING H-13
12
H-13
D51EX/PX-22 40-517
TROUBLESHOOTING H-14
12
H-14
40-518 D51EX/PX-22
TROUBLESHOOTING H-15
12
H-15
D51EX/PX-22 40-519
TROUBLESHOOTING H-16
12
H-16
40-520 D51EX/PX-22
TROUBLESHOOTING H-17
12
H-17
D51EX/PX-22 40-521
TROUBLESHOOTING H-18
12
H-18
40-522 D51EX/PX-22
TROUBLESHOOTING H-19
12
H-19
If the oil pressure does not become normal after adjustment, the main relief valve may
have a malfunction or a defect in it. Check the main relief valve directly.
Defect in work equipment pump
5 The pump unit of the work equipment pump may have a defect in it. Check it directly.
(pump unit)
Loosening of piping between HST
6 The piping between the HST pump and HST motor may be loosened. Check it directly.
pump and HST motor
D51EX/PX-22 40-523
TROUBLESHOOTING H-20
12
H-20
If the oil pressure does not become normal after adjustment, the main relief valve may
have a malfunction or a defect in it. Check the main relief valve directly.
Defect in work equipment pump
7 The pump unit of the work equipment pump may have a defect in it. Check it directly.
(pump unit)
8 Wrong installed direction of fan See fan from rear of machine and check that its vanes are concave.
Cause Standard value in normal state/Remarks on troubleshooting
If coolant temperature is too high, fan speed may be low.
Increase oil temperature to above 50°C and check fan
1500 rpm
speed at high idle in fan 100% mode.
★ If the HST oil temperature is below 45°C and the engine coolant temperature is
below 60°C, the fan EPC command current is set to 1,000 mA and the fan speed
lowers below 200 rpm even in the fan 100% mode. In this case, increase the oil
temperature to above 55°C and the coolant temperature to above 65°C and then
check again.
40-524 D51EX/PX-22
TROUBLESHOOTING H-21
12
H-21
D51EX/PX-22 40-525
40 TROUBLESHOOTING (S-MODE)
12
METHOD OF USING TROUBLESHOOTING CHARTS ........................ 40-602
(S-1) ENGINE STARTING PERFORMANCE IS POOR . . . . . . . . . . . . . . . . . . . . . . . . . 40-606
(S-2) ENGINE DOES NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-607
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK . . . . . 40-608
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START . . . . . . . . . 40-609
(S-3) ENGINE DOES NOT RUN SMOOTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-610
(S-4) ENGINE STOPS DURING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-611
(S-5) ENGINE SPEED HUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612
(S-6) ENGINE LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-613
(S-7) EXHAUST SMOKE IS BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-615
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE . . . . . . 40-616
(S-9) OIL BECOMES CONTAMINATED QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-617
(S-10) FUEL CONSUMPTION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-618
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR . . . 40-619
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP . . . . . . . . . . . . . . . . . . . . . . . . . 40-620
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL) . . . . . . . . . . . . . . . 40-621
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING) . . . . . . . . . . . . . . . 40-622
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG . . . . . . . . . . . 40-623
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING . . . . . . . . . . . . . . . . . 40-624
D51EX/PX-22 40-601
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING
12
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 inspection
without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability
causes to make final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items in
B are items that can be obtained from the user, depending on the user’s level.
[Check Items]
The serviceman carries out simple inspection to narrow down the causes. The items under (C) in the chart on the right
correspond to this. The serviceman narrows down the causes from information (A) that he has obtained from the user and the
results of (C) that he has obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest
probability from information gained from [Questions] and [Check items].
Causes
(a) ❊
Questions
(A) (b) ❊
(c) ❊
(d) ❍
(e) ❍
(B)
Check items
(C)
i ●
Trouble-
shooting
ii ●
iii ●
40-602 D51EX/PX-22
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING
12
)
ction
that has the highest number of points is the most probable cause, so start
troubleshooting for that item to make final confirmation of the causes.
inje
*1. For [Confirm recent repair history] in the [Questions] Section, ask the
ssive
e
user, and mark the Cause column with # to use as reference for locating
ozzle
renc
(exce
the cause of the failure. However, do not use this when making calcula-
g, cy ment
ir cle er, interfe
tion n
tions to narrow down the causes.
er
tion p g
ump
d
timin
ele
*2. Use the # in the Cause column as reference for [Degree of use (Operated
n
injec
li
aner
for long period)] in the [Questions] section as reference. As a rule, do
harg
ion
ized
not use it when calculating the points for locating the causes, but it can
n rin
t
injec
injec
rboc
be included if necessary to determine the order for troubleshooting.
e
pisto
s
a
e d tu
ctive
ged,
oper
ged
Worn
Defe
Clog
Clog
I mp r
Seiz
*1 Confirm recent repair history
*2 Degree of use of machine Operated for long period Δ Δ Δ
❊
D51EX/PX-22 40-603
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING
12
• 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 causal
relationship with this problem: [Exhaust gas slowly became black], [Power slowly 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.
head
)
• Excessive injection fuel
ction
)
eized
and
pray
, plun seat
e inje
ger s
rger
tive s
valve
iv
ce
ce ss
ocha
tion ti le, defec
Legend
feren
and
x
ent
(rack
❍: Possible causes (judging from Questions and
rb
e
en tu
air cle er, inter
mp (
valve
r
n ce
uffler
elem
linde
ming
check items)
ump
nozz
leara
n pu
e
❊: Most probable causes (judging from Questions
ed m
g , cy
ct of
betw
aner
tion p
harg
ction
jectio
c
conta
and Check items)
clogg
n rin
alve
of air
injec
rboc
injec
je
■: Possible causes due to length of use (used for a
in
in
per v
pisto
ed tu
ctive
ctive
hed,
oper
ctive
age
ged
ged
long period)
Impro
W o rn
Leak
Crus
Defe
Defe
Clog
●: Items to confirm the causes.
Clog
Impr
Defe
Seiz
Confirm recent repair history
Degree of use Operated for long period Δ Δ Δ Δ
Suddenly became black ❊ ❍ ❍
❊ ❍ ❍
Questions
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Rem-
Clean
edy
40-604 D51EX/PX-22
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of ❍ and ❊ marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect:
(1) Clogged air cleaner element: ❊❍❊
(2) Air leakage between turbocharger
and head ❍❍
(3) Clogged, seized injection nozzle: ❍
(4) Defective contact of valve, valve seat: ❍
(5) Worn position 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.
D51EX/PX-22 40-605
TROUBLESHOOTING (S-1) ENGINE STARTING PERFORMANCE IS
12
(S-1) ENGINE STARTING PERFORMANCE IS POOR
Causes
Defective alternator
Clogged air clearer
may not start until the crankshaft revolves 2 turns at maximum.
Defective battery
This phenomenon does not indicate a trouble, however
1) Little or no fuel comes out even when the plug is removed from the fuel filter
2) If fuel return line to fuel tank is removed little or no fuel comes out ❊
Exhaust manifold has cold areas after start up when touched ❊
Engine pick up is poor or irregular ❍❍ ❊
There is hunting from engine (rotation is irregular) ❍❊❍
Excessive blow-by gasses ❊
When air cleaner element is inspected directly, it is found to be clogged ●
When compression pressure is measured, it is found to be low ● ●
●
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
40-606 D51EX/PX-22
TROUBLESHOOTING (S-2) ENGINE DOES NOT CRANK
3) When terminal B and terminal C of starting safety relay are connected, engine ●
cranks
4) Even if terminal B and C at safety relay are connected engine does not crank. ●
5) There is no 20 to 30V between battery relay terminal B and terminal E ●
When ring gear is inspected directly, tooth surface is found to be chipped ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
D51EX/PX-22 40-607
TROUBLESHOOTING (S-2) ENGINE DOES NOT CRANK
12
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK
General causes why engine turns but no exhaust smoke comes out Causes
Carry out troubleshooting according to the displayed code “No pressure feed by ● ●
supply pump (1)*
Carry out troubleshooting according to the displayed code. “Abnormality in supply ●
pump IMV/PCV (2)*
Inspect overflow valve directly ●
Engine can be started in reduced cylinder mode ●
Fuel flows out when pressure limiter return piping is disconnected ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
40-608 D51EX/PX-22
TROUBLESHOOTING (S-2) ENGINE DOES NOT CRANK
12
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START
General causes why exhaust smoke comes out of stack but engine does not Causes
start
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
D51EX/PX-22 40-609
TROUBLESHOOTING (S-3) ENGINE DOES NOT RUN SMOOTHLY
When a cylinder cut-out operation is made engine speed does not change ●
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Clean
40-610 D51EX/PX-22
TROUBLESHOOTING (S-4) ENGINE STOPS DURING OPERATIONS
12
(S-4) ENGINE STOPS DURING OPERATIONS
General causes why engine stops during operations Causes
• Seized parts inside engine
See (H-mode)
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
D51EX/PX-22 40-611
TROUBLESHOOTING (S-5) ENGINE SPEED HUNTS
12
(S-5) ENGINE SPEED HUNTS
General causes why engine does not idle smoothly Causes
• Air in fuel system
• Defective speed sensor (Error at degree that it is not indicating)
Remedy
Add
40-612 D51EX/PX-22
TROUBLESHOOTING (S-6) ENGINE LACKS POWER
12
(S-6) ENGINE LACKS POWER
General causes why engine lacks power Causes
• Insufficient intake air
• Insufficient supply of fuel
D51EX/PX-22 40-613
TROUBLESHOOTING (S-6) ENGINE LACKS POWER
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
(1)*See Failure Code [CA559] and [CA2249]
Adjust
Repair
Repair
Repair
Clean
Clean
Remedy
(2)*See Failure Code [CA122] and [CA123]
40-614 D51EX/PX-22
TROUBLESHOOTING (S-7) EXHAUST SMOKE IS BLACK
12
(S-7) EXHAUST SMOKE IS BLACK
General causes why exhaust smoke is black Causes
• Insufficient intake air
When cylinder cut out is performed, engine speed does not change ●
Carry out troubleshooting according to the displayed code. Abnormality in coolant
temperature sensor (2)* ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
D51EX/PX-22 40-615
TROUBLESHOOTING (S-8) OIL CONSUMPTION IS EXCESSIVE OR
with oil
When exhaust pipe is removed, inside is found to be dirty with oil ❊
There is oil in engine coolant ❊
Exhaust smoke is blue under light load ❊❊
Amount of blow-by gas Excessive ❍ ❍ ❊❊
None ❊
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
40-616 D51EX/PX-22
TROUBLESHOOTING (S-9) OIL BECOMES CONTAMINATED
12
(S-9) OIL BECOMES CONTAMINATED QUICKLY
General causes why oil becomes contaminated quickly Causes
• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper fuel
See S-7
Inspect oil filter directly ●
Oil filter bypass valve is broken ●
Inspect turbocharger drain line directly ●
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
D51EX/PX-22 40-617
TROUBLESHOOTING (S-10) FUEL CONSUMPTION IS EXCESSIVE
12
(S-10) FUEL CONSUMPTION IS EXCESSIVE
General causes why fuel consumption is excessive Causes
• Leakage fuel
• Improper condition of fuel injection
Replace
Replace
Replace
Replace
Repair
Repair
Repair
40-618 D51EX/PX-22
TROUBLESHOOTING (S-11) OIL FOUND IN COOLANT, OR COOL-
See H
mode
Remove oil pan and inspect directly ● ●
Pressure-tightness test of cylinder head shows there is leakage ●
Replace
Replace
Replace
Replace
Replace
Remedy
D51EX/PX-22 40-619
TROUBLESHOOTING (S-12) OIL PRESSURE CAUTION LAMP
12
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP
General causes why oil pressure lamp lights up Causes
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Replace
Repair
Adjust
Clean
Clean
Clean
Clean
Remedy
⎯
Add
40-620 D51EX/PX-22
TROUBLESHOOTING (S-13) OIL LEVEL RISES (COOLANT OR
Replace
Replace
Repair
Repair
Repair
Remedy
D51EX/PX-22 40-621
TROUBLESHOOTING (S-14) COOLANT TEMPERATURE TOO HIGH
Condition of overheating
Always tends to overheat ❍❊❊ ❍
Water temperature gauge Rise quickly ❍ ❊
Does not go down from red range ❊
Radiator coolant level drops under low level ❊
Engine oil level has risen, oil is milky ❊❍
Fan speed is slow ❊
Fan does not rotate ❊
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy -
Add
40-622 D51EX/PX-22
TROUBLESHOOTING (S-15) ABNORMAL NOISE IS HEARD WHEN
If exhaust manifold is touched after start up there are cold spots on manifold ❊❍
Color of exhaust smoke
Blue under light load ❊
Black ❍❊ ❍
Engine does not pick up smoothly and combustion is irregular ❊
Abnormal noise is heard when engine is accelerated ❍ ❍ ❍
Blow-by gasses are excessive ❊
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
D51EX/PX-22 40-623
TROUBLESHOOTING (S-16) EXCESSIVE VIBRATION WHEN EN-
12
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING
Causes
Remedy
40-624 D51EX/PX-22
90 OTHERS
D51EX/PX-22 90-1
OTHERS
12
90-2 D51EX/PX-22
OTHERS CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM
12
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM
CONNECTOR LIST
★ The address roughly shows the places of the connectors in the 3-dimensional connector arrangement drawing and circuit diagrams
D51EX/PX-22 90-3
OTHERS CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM
90-4 D51EX/PX-22
OTHERS CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM
D51EX/PX-22 90-5
OTHERS
12
90-6 D51EX/PX-22
OTHERS CONNECTOR LOCATION VIEW
D51EX/PX-22 90-7
OTHERS CONNECTOR LOCATION VIEW
12
90-8 D51EX/PX-22
OTHERS CONNECTOR LOCATION VIEW
12
D51EX/PX-22 90-9
OTHERS CONNECTOR LOCATION VIEW
12
90-10 D51EX/PX-22
OTHERS CONNECTOR LOCATION VIEW
12
D51EX/PX-22 90-11
OTHERS CONNECTOR LOCATION VIEW
12
90-12 D51EX/PX-22
OTHERS CONNECTOR LOCATION VIEW
12
D51EX/PX-22 90-13
OTHERS CONNECTOR LOCATION VIEW
90-14 D51EX/PX-22
OTHERS CONNECTOR LOCATION VIEW
12
D51EX/PX-22 90-15
OTHERS CONNECTOR LOCATION VIEW
90-16 D51EX/PX-22
OTHERS CONNECTOR LOCATION VIEW
12
D51EX/PX-22 90-17
OTHERS CONNECTOR LOCATION VIEW
90-18 D51EX/PX-22
OTHERS CONNECTOR LOCATION VIEW
12
D51EX/PX-22 90-19
OTHERS CONNECTOR LOCATION VIEW
12
90-20 D51EX/PX-22
OTHERS CAB ELECTRICAL ACCESSORIES
12
CAB ELECTRICAL ACCESSORIES
D51EX/PX-22 90-21
OTHERS CAB ELECTRICAL ACCESSORIES
12
90-22 D51EX/PX-22
OTHERS AIR CONDITIONER AND HEATER UNIT
12
AIR CONDITIONER AND HEATER UNIT
D51EX/PX-22 90-23
OTHERS AIR CONDITIONER AND HEATER UNIT
12
90-24 D51EX/PX-22
OTHERS HYDRAULIC SYSTEM (VIEW 1 OF 2)
12
HYDRAULIC SYSTEM (VIEW 1 OF 2)
D51EX/PX-22 90-25
OTHERS HYDRAULIC SYSTEM (VIEW 1 OF 2)
12
90-26 D51EX/PX-22
OTHERS HYDRAULIC SYSTEM (VIEW 1 OF 2)
12
VIEW (2 OF 2)
D51EX/PX-22 90-27
OTHERS HYDRAULIC SYSTEM (VIEW 1 OF 2)
12
90-28 D51EX/PX-22
OTHERS ELECTRICAL SYSTEM
D51EX/PX-22 90-29
D51EX/PX-22
OTHERS ELECTRICAL SYSTEM
12
90-30 D51EX/PX-22
OTHERS ELECTRICAL SYSTEM
D51EX/PX-22 90-31
OTHERS ELECTRICAL SYSTEM
12
90-32 D51EX/PX-22
OTHERS ELECTRICAL SYSTEM
12
ENGINE HARNESS AND CONTROLLER (VIEW 3 OF 5)
D51EX/PX-22 90-33
OTHERS ELECTRICAL SYSTEM
12
90-34 D51EX/PX-22
OTHERS ELECTRICAL SYSTEM
12
MONITOR PANEL AND SWITCHES (VIEW 4 OF 5)
D51EX/PX-22 90-35
OTHERS ELECTRICAL SYSTEM
12
90-36 D51EX/PX-22
OTHERS ELECTRICAL SYSTEM
12
KOMTRAX AND CONNECTORS (VIEW 5 OF 5)
D51EX/PX-22 90-37
OTHERS ELECTRICAL SYSTEM
90-38 D51EX/PX-22